AC140 14247 Part2 - en

Index
1402000247
1
1 Safety Instructions 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Crane Chassis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Technical Data 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Dimensions, weights, axle loads for chassis / crane vehicle 1 . . . . .
2.1.2 Driving speed of crane vehicle 60 t (132 kip) 1 . . . . . . . . . . . . . . . . . .
2.1.3 Drive 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.4 Climatic Operating Conditions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.5 Tyres 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.6 Optional Equipment 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Overview of the Crane Chassis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Signs 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Preparation for Emergency Control, Superstructure 7 . . . . . . . . . . . .
2.5 Additional fuel tank (additional tank 300 l / 80 USgal) in
the crane chassis (optional) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Separate fuel tank (extra tank 300 l / 80 USgal) in the chassis
for superstructure operation (optional) 11 . . . . . . . . . . . . . . . . . . . . . . .
4 Drivers Cab 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Operators Platform 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Dashboard System 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Instrument Panel 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Function Buttons on the Steering Wheel 11 . . . . . . . . . . . . . . . . . . . . .
4.2.3 Switches on the Instrument Panel 13 . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Driver Information System 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Driver Information System (43) Display 23 . . . . . . . . . . . . . . . . . . . . .
4.3.2 Indicator Lights in the Driver Information System 37 . . . . . . . . . . . . . .
4.4 Ignitionstarter Switch (15) 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Steering Wheel Setting 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Combination switch 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 On the Left on the Steering Column 49 . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 On the Right of the Steering Column 51 . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Entry / Exit for Crane Operators Cab 53 . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Driver Door / Passenger Door 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1 Opening and Closing the Cab Door 55 . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2 Window Controls 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Drivers Seat / Passengers Seat 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1 Folding the Passenger Seat 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2 Headrest 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.3 Safety Belt 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Hinged Bed (Optional) 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.1 Procedure for Folding the Bed down 73 . . . . . . . . . . . . . . . . . . . . . . . . .
Index
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2
5 Engine (OM 502 LA) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Before Starting the Engine 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Starting Aid with External Batteries 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Ignitionstarter switch (see section 4 Drivers cab) 9 . . . . . . . . . . .
5.4 Starting Procedure (Engine Start) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Starting the Engine in the Drivers Cab 9 . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 Starting the Engine at the Outrigger Controls
(External Engine Start) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 After Starting the Engine 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Before Switching Off the Engine 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Switching Off (Engine Stop) in Normal Circumstances 15 . . . . . . . . .
5.7.1 Switching off the Engine in the Drivers Cab 15 . . . . . . . . . . . . . . . . . .
5.7.2 Switching Off the Engine on the Outrigger Control 15 . . . . . . . . . . . . .
5.8 Switching Off the Engine in an Emergency 17 . . . . . . . . . . . . . . . . . . .
5.8.1 Switching Off Procedure Quick Stop (Optional Equipment) 17 . . . .
5.8.2 Quick Stop with Air Shutoff Valve 17 . . . . . . . . . . . . . . . . . . . . . . . . .
5.9 Electronic Engine Management 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.1 Engine Control 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.2 Idle Speed 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.3 Cruise Control 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.4 Limiter (for Limiting the Maximum Speed) 27 . . . . . . . . . . . . . . . . . . . .
5.9.5 Monitoring the Engine 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.6 Reading Off the Fault Memory 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.7 Evaluation of the Displayed Faults 35 . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Driving the Crane 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Instructions for all Types of Driving 1 . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Checks Before Driving the Crane 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Transport Safety Locks 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Axle Loads / Speeds / Tyres 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1 Possible Axle Loads / Permitted Speeds 13 . . . . . . . . . . . . . . . . . . . . .
6.4.2 Driving with Uneven Axle Loads 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.3 Driving with Reduced Axle Loads 25 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.4 Driving with axle loads exceeding 12 t (26.4 kip) 29 . . . . . . . . . . . . . .
6.4.5 Shorter maintenance intervals for axle loads above 12.5 t
(27.6 kip) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Driving on Public Roads 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Driving with axle loads of 12 t (26.4 kip) 39 . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Driving in the United Kingdom (UK Approval) 39 . . . . . . . . . . . . . . . . .
6.5.3 Checks Always Done before Driving on the Road 41 . . . . . . . . . . . . .
6.6 Defined Driving Conditions 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.1 Driving with total weight 60 t (132.3 kip) 45 . . . . . . . . . . . . . . . . . . . . . .
6.6.2 Driving with total weight 35.4 t (78 kip) 49 . . . . . . . . . . . . . . . . . . . . . . .
6.6.3 Driving with total weight 73.8 t (162.7 kip) 53 . . . . . . . . . . . . . . . . . . . .
6.7 Driving Downhill 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Driving over Hill Summits 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index
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3
6.9 Checking the Operation Functions During the Journey 59 . . . . . . . . .
6.9.1 Monitoring Elements in the Instrument Controls 59 . . . . . . . . . . . . . . .
6.9.2 Indicator Lights on the Display (43)
Driver Information System 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.3 Displays on the Transmission Information
Displays (75) 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10 Driving on the Construction Site 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.1 Driving in the Transport Condition 67 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11 Driving in the Configured Condition
Driving in Erect Mode (with Erected Main Boom / Equipment) 69 . .
6.11.1 Instructions on Driving in Erect Mode 69 . . . . . . . . . . . . . . . . . . . . . . .
6.11.2 Driving Tables with Metric Dimension Units 77 . . . . . . . . . . . . . . . . . . .
6.11.3 Driving Tables with English / American Dimensions 95 . . . . . . . . . . . .
6.11.4 Driving the Crane with a Load 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12 Driving with dolly 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12.1 Important instructions for Dolly operation 115 . . . . . . . . . . . . . . . . . . .
6.12.2 Dolly equipment for the towing vehicle (optional) 117 . . . . . . . . . . . . . .
6.12.3 Measures for Dolly operation 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12.4 Dolly not contained in crane manufacturers scope of supply 135 . . . .
6.12.5 Dolly contained in the manufacturers scope of supply 135 . . . . . . . . .
6.13 Dolly Coupling / Supply Connections (Optional) 137 . . . . . . . . . . . . . . .
6.13.1 Coupling and uncoupling a dolly 137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14 Attaching and Removing the Spare Wheel (Spare Wheel Holder,
Hoist Arrangement, Optional) 143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Drive gearbox / distributor gear 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Drive gearbox: 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Description of the System 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 System Design 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3 Shifting Gears 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.4 (75) Transmission information display (Z 51 348) 11 . . . . . . . . . . . .
7.1.5 (43) Driver information system display 13 . . . . . . . . . . . . . . . . . . . . . .
7.1.6 Driving and Shifting Gears 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.7 Change transmission mode: Manual / automatic 17 . . . . . . . . . . . . . .
7.1.8 Changing Gears 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.9 Reverse driving / changing the driving direction 23 . . . . . . . . . . . . . . .
7.1.10 Stopping 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.11 Shutting off the engine and vehicle 27 . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.12 Manoeuvring (Distance < 1m) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.13 Towing 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.14 Towing start 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.15 Rolling down a downhill slope 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.16 Exhaust brake 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.17 Clutch protection 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.18 Overspeed protection 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.19 Roller dynamometer 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Hydraulic Retarder (System ZF Intarder) 37 . . . . . . . . . . . . . . . . . . . .
Index
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7.3 System malfunctions / error diagnosis 39 . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Fault messages 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Reading off the fault code
43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 Error list 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Distributor gear 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Operating the distributor gear 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Driving stuck cranefree 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Brakes 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Emergency pressure supply braking system 3 . . . . . . . . . . . . . . . .
8.2 Service Brake 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1 Wear indicator for brake linings (disc brake) 7 . . . . . . . . . . . . . . . . . .
8.3 Parking brake 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Brake Pressure Limit
(Optional equipment / national regulations) 11 . . . . . . . . . . . . . . . . . . .
8.5 Retarder Brakes 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.1 Engine Brake (Exhaust Brake and Constant Throttle) 15 . . . . . . . . . .
8.5.2 Hydraulic Retarder (System ZF Intarder) 17 . . . . . . . . . . . . . . . . . . . .
8.5.3 Function SustainedAction Brake Cruise Control 19 . . . . . . . . . . . . .
8.6 AntiBlockingSystem (ABS) 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.1 ABS: Full function / offroad mode 25 . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.2 ABS Functions Check / Fault Display 25 . . . . . . . . . . . . . . . . . . . . . . . .
8.6.3 Braking with ABS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.4 ABS with Dolly Operation 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Steering 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 General System Description 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Safety Instructions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1 Safety instructions for protecting the system 3 . . . . . . . . . . . . . . . . . .
9.2.2 Safety instructions for the protection of life and limb for
maintenance / service work 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Monitoring functions for all steering programs 7 . . . . . . . . . . . . . . . . .
9.3.1 Monitoring the steering / emergency steering pump 9 . . . . . . . . . . . .
9.3.2 Monitoring the electrohydraulic rear axle steering 11 . . . . . . . . . . . . .
9.4 Steering programs 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1 Selection of the Steering Programme Road Travel or
Construction Site Operation 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2 Steering program road travel 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3 Steering program construction site mode 19 . . . . . . . . . . . . . . . . . . .
9.4.4 Synchronising the wheels when changing program 33 . . . . . . . . . . . .
9.4.5 Raising/Lowering the Lift Axle 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Steering Computer / Fault Diagnosis / Fault List 37 . . . . . . . . . . . . . . .
9.5.1 Operating functions 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Registration of a fault 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.3 error memory / fault codes 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.4 Fault categories / fault reaction 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.5 Fault list (following) 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Manual emergency steering 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index
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5
10 Differentials / Differential Locks 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Differentials 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Differential Locks 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Activating the Differential Locks 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 Activating the Longitudinal Locks 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 Activating the Transverse Locks 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Hydraulic Suspension 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Distribution of the suspension circuits / assignment of the
pressure gauge 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.1 In normal situations: Fourcircuit System 5 . . . . . . . . . . . . . . . . . . . . .
11.1.2 Exception: Threecircuit System 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Setting for Driving in the Transport Position 7 . . . . . . . . . . . . . . . . . . .
11.2.1 General 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.2 Automatic setting road travel level 7 . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.3 Manual Setting of the Level 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Monitoring the Hydraulic Suspension 13 . . . . . . . . . . . . . . . . . . . . . . . .
11.3.1 Monitoring the Pressure 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.2 Level Control, Level Indicator 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 to lock the suspension 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4.1 Activating the Suspension Block
. . . Before Driving in an Erect Mode 17 . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 Height Adjustment 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6 Raising Axles 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.7 Hold axles 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.8 Lowering Brake Valves in the Basic Suspension Block 23 . . . . . . . . .
11.9 Selecting the Operating Modes
(Axle loads 12 t / 26.5 kip or Reduced axle loads) 25 . . . . . . . . . . .
12 Outriggers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 Notes on Outriggers: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 Arrangement of Outrigger Controls 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Information System for the Outrigger Controls 9 . . . . . . . . . . . . . . . .
12.3.1 Indicators on the Display 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3.2 Functions 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3.3 Support Pressure Display 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3.4 Inclination Indicator 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Automatic Levelling 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5 Hold Axles / Raise Axles Functions 29 . . . . . . . . . . . . . . . . . . . . . . .
12.5.1 Hold Axles Function 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5.2 Raise Axles Function 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.6 Measures before Stabilising: 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7 Supporting the Outrigger Plates 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7.1 Permitted Ground Pressures 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.8 Safe Distance to Slopes and Pits 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.8.1 Pinning positions of the outrigger struts 49 . . . . . . . . . . . . . . . . . . . . . .
Index
1402000247
6
12.9 Stabilising Procedure 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.9.1 Extend support (outrigger support area 8.23 m x
7.50 m/27 ft x 24.6 ft) 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.9.2 Checking the Level at the Chassis 61 . . . . . . . . . . . . . . . . . . . . . . . . . .
12.9.3 Retracting the Outriggers 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.10 Levelling with the Counterweight 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.11 Supporting Spans 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.11.1 Normal Outrigger Span 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.11.2 Reduced Outrigger Span 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.12 Removal and installation of the outrigger struts with auxiliary
crane (optional) 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.12.1 Notes on removing and installing the outrigger struts 73 . . . . . . . . . . .
12.12.2 Removing the outrigger struts with the auxiliary crane 75 . . . . . . . . . .
12.12.3 Installation of the outrigger struts 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Parking 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1 Crane in the Transport Condition 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2 Crane in Erect Condition and Supported on Outriggers 3 . . . . . . . . .
14 Towstarting and Towing the Crane 3 . . . . . . . . . . . . . . . . . . . . . . .
14.1 Towing start 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.2 Towing 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.2.1 Important General Instructions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.2.2 Recovering from a Hazardous Area 3 . . . . . . . . . . . . . . . . . . . . . . . . .
14.2.3 Towing with Engine Damage 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.2.4 Towing with Damage to the Drive Gearbox 9 . . . . . . . . . . . . . . . . . . .
14.2.5 Towing with Damage to the Distributor Gear 11 . . . . . . . . . . . . . . . . . .
14.2.6 Neutral Position of the Distributor Gear for Towing with Damage
to Engine / Transmission 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.3 Towing Free From Rough Terrain 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Heating and Ventilation 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.1 Cab Heater Arrangement (Dependent of Engine) 3 . . . . . . . . . . . . . .
15.2 Hot Water Heater Arrangement with Preheating for coolant
(independent of engine), Optional Equipment 5 . . . . . . . . . . . . . . . . .
15.3 Petrol Gas Heating (independent of engine), Optional Equipment 17
15.4 Air conditioner, Optional Equipment 21 . . . . . . . . . . . . . . . . . . . . . . . . .
15.5 Instructions for Winter Operation 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 Central Lubricating System (Optional Equipment) 3 . . . . . . . . .
16.1 Components 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.2 Function 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3 Setting the Pause and Operating Time 7 . . . . . . . . . . . . . . . . . . . . . . .
16.3.1 General 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.2 Setting the Pause Time 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.3.3 Setting the Operating Time/Cycle 9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4 Additional Lubricating Pulses 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.5 Manual Lubrication in Case of an Emergency 11 . . . . . . . . . . . . . . . . .
16.6 Filling the Grease Container (Lube Tank) 11 . . . . . . . . . . . . . . . . . . . . .
16.7 Troubleshooting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions 1
1402010 1/1
1 Safety Instructions
All risidual risks which may occur with operation of the crane
chassis are given in Part 1, operating instructions for the super-
structure, Section 1, Safety Instructions.
Therefore, first read this Section carefully before starting opera-
tion.
Crane Chassis 2
1402020247 1/11
2 Crane Chassis
2.1 Technical Data
All specifications apply to tyres 16.00 R 25.
2.1.1 Dimensions, weights, axle loads for chassis / crane
vehicle
Total length of the crane vehicle: 14,18 m (46,5 ft)
Total height of the crane vehicle (transport condition): 4,00 m
(13,1 ft)
Length of the crane chassis: 12,35 m (40,5 ft)
Vehicle width: 3,00 m (9,7 ft)
Turning radius on the main boom head: 11,43 m (35,5 ft)
Transport weight crane vehicle (road travel): max. 60 t (132 kip)
Axle loads during road travel: 5 x 12 t (5 x 26,4 kip)
Number of axles: 5
2.1.2 Driving speed of crane vehicle 60 t (132 kip)
Technically possible maximum speed: 85 km/h (53 mph)
Permitted maximum speed for 12 t axle loads (26.4 kip: 80 km/h
(50 mph)
Climbing ability:
37 % in road gear
71 % in offroad gear
Starting on hills:
34 % in road gear
71 % in offroad gear
2
1402020247 2/11
Crane Chassis 2
1402020247 3/11
2.1.3 Drive
Engine
DAIMLERCHRYSLER 8cylinder diesel engine, type OM 502
LA, watercooled
Output: 380 kW bei 1800 U/min
Torque: 2400 Nm at 1200 U/min
Transmission
ZF ASTRONIC type 16 AS 2602
16 forward gears, 2 reverse gears
Distributor gear
with road and offroad gear
2.1.4 Climatic Operating Conditions
Exact information in this respect can be found in part 1, section
1 of these documents.
2.1.5 Tyres
14.00 R 25
at rim 9.525 / 1.7
Vehicle width: 3.00 m (9,8 ft)
Vehicle height: 3.95 m (13 ft)
Permitted travel distance for 12 t (26.4 kip) axle loads: 70 km
(43,5 mph)
16.00 R 25
at rim 11.0025 / 1.7
Vehicle height: 4,00 m (13,1 ft)
17.5 R 25
at rim 14.0025 / 1.7
Vehicle height: 3.95 m (13 ft)
Permitted travel distance for 12 t (26.4 kip) axle loads: 70 km
(43,5 mph)
20.5 R 25
at rim 17.0025 / 1.7
Vehicle height: 4,00 m (13,1 ft)
2.1.6 Optional Equipment
2
1402020247 4/11
Z 53 755
7
7
8
9
3
8
9
1 10
4 5 6 5
2
5
Crane Chassis 2
1402020247 5/11
2.2 Overview of the Crane Chassis
(Z 53 755)
(1) Frame
(2) Spare wheel
(3) Drivers cab
(4) Axle nondriven / steered
(5) Axle driven / steered
(6) Lift axle; can be raised for various steering programmes
cannot be steered (rigid), transmission can be activated
(7) Outrigger strut
(8) Outrigger cylinder
(9) Outrigger pad
(10) Counterweight support
2.3 Signs
See part 1, section 2 Structure of the Mobile Crane
2
1402020247 6/11
Z 26 866
1
3
2
Crane Chassis 2
1402020247 7/11
(Z 200 292)
2.4 Preparation for Emergency Control, Superstructure
On each side of the chassis (between axles 2 / 3), there are 3 hy-
draulic connections:
1 Connection T
chassis
(tank)
2 Connection L
chassis
(leakage)
3 Connection P
chassis
(pressure oil)
If the superstructure power units break down, a hydraulic trans-
former can be connected at these points, which enables limited
superstructure functions.
For exact details, see the operating instructions of the super-
structure, section 36.
The hydraulic connections 1 3 may only be used with a hy-
draulic transformer.
A direct connection to the superstructure hydraulic system
is not permitted as there is no capacity for this in the oil tank.
2
1402020247 8/11
Z 53 014
1
2
Z 53 016
A
B
97
Z 53 017
5
1
Crane Chassis 2
1402020247 9/11
(Z 53 014, Z 53 016, Z 53 017)
2.5 Additional fuel tank (additional tank 300 l / 80 US
gal) in the crane chassis (optional)
The vehicles tank capacity (500 l / 132 US gallons) can be in-
creased by 300 litres (80 US gallons) with an auxiliary fuel tank
(additional tank).
The additional tank is located in the frame area of the chassis, be-
neath the cover. It is filled independently of the normal fuel tank
(1) = main tank via its own filler neck (2) near axle 4 (righthand
side of vehicle). The same type of fuel (diesel) is added to the
additional tank as to the main tank.
Changeover
The contents of the additional tank can be moved to the main tank
(1) using an electric supply pump via a fixed installation line.
When moving fuel while the crane is being driven it must be en-
sured that the changeover is carried out in good time, to avoid the
crane stalling due to a lack of fuel.
The electric supply pump is switched on/off using the dual button
(97) in the dashboard of the chassis cab.
Press dual button (97B) = start changeover.
Press dual button (97A) = end changeover.
Press and hold dual button (97A) = switch over fuel gauge (51)
from main tank to additional tank.
The levels in both tanks are monitored during the changeover by
means of level switches.
A changeover of fuel is only possible if the levels in the giving and
taking tank permit it (additional tank filled above minimum; main
tank ready).
The changeover must always be started manually and can also
be ended manually at any time.
It is automatically ended when a certain minimum level is ex-
ceeded in the additional tank (protects the supply pump from run-
ning dry) or the maximum level is reached in the main tank (over-
load protection).
Exact instructions for filling/changing tanks can be found in part
4 (lubricating/ maintenance instructions), section 15.
2
1402020247 10/11
Z 53 014
1
2
Z 53 018
5
Crane Chassis 2
1402020247 11/11
(Z 53 014, Z 53 018)
2.6 Separate fuel tank (extra tank 300 l / 80 USgal) in
the chassis for superstructure operation (optional)
A separate fuel tank (extra tank 300 l / 80 US gal) can be fitted
for fuel supply of the superstructure engine. It is not linked to the
fuel system of the chassis.
The extra tank is located in the frame area of the chassis, be-
neath the cover. It is filled, independently of the normal fuel tank
(1) = main tank, via its own filler neck (2) near axle 4 (righthand
side of the vehicle).
Changeover
The content of the extra tank is automatically fed to the super-
structure tank via a fixed line/rotary joint, by means of an electric
supply pump.
The levels in both tanks are monitored during the changeover by
means of level switches.
The changeover begins when a certain lower level is reached in
the superstructure tank.
It is ended when the level in the extra tank falls below a certain
point (protects the supply pump against running dry) or when the
maximum level is reached in the superstructure tank (overflow
protection).
The capacity in the extra tank is displayed in the superstructure
cab on instrument (5).
Exact instructions for filling/changing tanks can be found in part
4 (lubricating/ maintenance instructions), section 15.
Drivers Cab 4
1402040215a 1/73
4
1402040215a 2/73
Z 200 316
18
19
14
12
1
20
3
13
26
23
24
25
7
6
5
10
8
11
9
2
4
29 27 28
21
22
17
16
15
Drivers Cab 4
1402040215a 3/73
4 Drivers Cab
4.1 Operators Platform
(Z 200 316)
No. Designation Function
1 Combination switch,
on the left of the
steering column
(S 6115)
Lower beam, upper beam, headlamp
flash, indicators, wipers, windscreen
washer, horn
2 EU Tachograph
(A 5320)
Tachograph
Display basic with time, speed, mile-
age.
(Observe the operating instructions of
the manufacturer.)
3 Combination switch,
on the right of the
steering column (S
4120)
Engine control (engine idle speed,
cruise control, limiter)
Retarder (engine brake, retarder, re-
tarder cruise control)
4 Autoradio (A 5511)
5 Pressure gauge Pressure display axles 1 and 2, right
6 Pressure gauge Pressure display * axle 3, right
7 Pressure gauge Pressure display axles 4, 5, right
8 Pressure gauge Pressure display axles 1 and 2, left
9 Pressure gauge Pressure display* axle 3, left
10 Pressure gauge Pressure display axles 4, 5, left
11 Dual button
(S 5192)
Window passenger side
(controls in passenger door trim)
12 Switch lever
(toggle) (A 2211)
Gear shifting high / back
Manual / automatic operating mode
13 Rotary switch
(A 2211)
F = Forwards / B = Backwards /
N = Neutral
(in position N = switch lever without
function)
14 Lever Parking Brake
15 Ignitionstarter
switch
(S 1271)
Ignition on / off
Engine start / engine stop
Standby start external
* Separate (different) pressure display, when axle 3 is in its raised
condition; otherwise, the same indicator value with axes 4 and 5.
4
1402040215a 4/73
Z 200 316
18
19
14
12
1
20
3
13
26
23
24
25
7
6
5
10
8
11
9
2
4
29 27 28
21
22
17
16
15
Drivers Cab 4
1402040215a 5/73
(Z 200 316)
No. Designation Function
16 Push button, pneu-
matic
Steering wheel control
Steering wheel unlocking / locking
17 Alarm buzzer
(H 1336)
onetime warning signal = malfunc-
tion
(Caution (36) lights up)
repeating warning signals = serious
malfunction (STOP (35) lights up)
18 Accelerator pedal Speed adjustment
19 Brake pedal Foot brake
20 Steering wheel
21 Drivers Seat
22 Safety belt
23 Rotary / rocker switch
(S 5435)
Outside mirror adjustment
Drivers side / passenger side
24 Dual button
(S 5192)
Window passenger side
(Controls in drivers door trim)
25 Dual button
(S 5191)
Window drivers side
(controls in drivers door trim)
26 Reading light
27 Switch for reading
light
(E 6614)
push forward = reading light off
push back = reading light on
28 Interior light
29 Switch for interior
light
(E 6614)
push forward = interior light off
push back = interior light on (lights up
when door is opened,
goes out when door is closed)
4
1402040215a 6/73
Z 48 996
5
1
5
2
5
4
5
3
5
5
5
6
5
7
5
8
3
1
4
0
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
4
3
5
0
.
1
5
0
4
2
4
1
.
1
4
1
k
m
/
h
m
p
h
Drivers Cab 4
1402040215a 7/73
4.2 Dashboard System
4.2.1 Instrument Panel
(Z 48 996)
No. Element Designation Function
31 Lamp ABS control, dolly
32 Lamp ABS control, vehicle, circuit 1
33 Lamp Upper beam switched on
34 Lamp Flashing light crane
35 Lamp STOP
36 Lamp Attention
37 Lamp Flashing light dolly
38 Lamp Hydr. retarder / exhaust brake
actuated
39 Lamp Parking brake applied.
40 Lamp Rear fog lamp actuated
41 Speedometer Speed display
Exterior scale: km/h
Interior scale: mph
41.1 LED Control tachograph
(when lit up, no speedometer
dial inserted)
42 LCD
(display for
ignition on)
7digit display of the
total distance travelled / part
distance
43 Display Driver information system
4
1402040215a 8/73
Z 48 996
5
1
5
2
5
4
5
3
5
5
5
6
5
7
5
8
3
1
4
0
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
4
3
5
0
.
1
5
0
4
2
4
1
.
1
4
1
k
m
/
h
m
p
h
Drivers Cab 4
1402040215a 9/73
(Z 48 996)
50 Revolution
counter
Engine speed display,
50.1 LED Monitoring the engine speed
(with lit up: Excessive engine
speed! (> 2350 min
1
)
51 Display Fuel supply
52 Reset button Reset partial mileage.
53 w/o function
54 w/o function
55 w/o function
56 w/o function
57 Press button Change brightness
58 Display Engine / coolant temperature
4
1402040215a 10/73
Z 51 321
61
60
62
63
64
65
66
67
Drivers Cab 4
1402040215a 11/73
4.2.2 Function Buttons on the Steering Wheel
(Z 51 321)
60 (A 4261) Arrow button back one level
61 (A 4261) Button 1 Menu selection 1
67 (A 4261) Button M to main menu / back to basic
display Indicator lights
4
1402040215a 12/73
Z 200 160
70 71
72 73 74
75
76 77
78 79
80 81
Drivers Cab 4
1402040215a 13/73
4.2.3 Switches on the Instrument Panel
(Z 200 160)
70 S 6114 2step switch Parking light / lower beam
71 S 6220 Switch Rear fog lamp
72 S 6400 Switch Rotaflare light
73 S 6310 Switch Hazard flashers
74 S 6240 Switch Lights in outrigger area
75* P 2319 Display Transmission information
Gear display / transmission
fault message
76 S 4411 Dual
switch
Set total level (raise / lower)
77 S 4424 Button automatic control road travel
level
78 S 4413 Dual
switch
Set level, front left (raise /
lower)
79 S 4412 Dual
switch
Set level, front right, (raise /
lower)
80 S 4415 Dual
switch
Adjust level, rear left, (raise /
lower)
81 S 4414 Dual
switch
Set level, rear right, (raise /
lower)
* Display layout on the (75) Transmission information display,
see Chap. 7.
4
1402040215a 14/73
Z 200 161
85
86 87 88 89
90
Drivers Cab 4
1402040215a 15/73
(Z 200 161)
85* S 4291 Double key Manual rearaxle steering
steering program:
Rear wheels swing to the left
/ right
86 S 4292 Button Close cornering steering
program:
Axle 4+5 electrically steered
87* S 4299 Button Steering program: Driving
away from the wall
88* S 4293 Button Steering program: Diagonal
steering: All wheels are
pointed in the same direc-
tion; steering wheel deter-
mines the steering angles
89 Visor not allocated
90 S 2217 Switch,
lockable
Manoeuvring operation
(cautious travel for distances
< 1 m;
with dragging clutch)
* Function only possible, if the (92) Steering program (construc-
tionsite operation) switch was previously actuated.
4
1402040215a 16/73
Z 54 358
92 93 94 95 96 97 98
99 100 101 102 103 104
Drivers Cab 4
1402040215a 17/73
(Z 54 358)
92 S 4290 Switch,
lockable
Release Steering program (for
constructionsite operation)
93 S 2216 Double key press upwards: Onroad gear
press downwards: Offroad gear
(Neutral externally possible)
94 S 2240 Switch,
lockable
Longitudinal differential lock
and lift axle activation
95 S 2220 Switch,
lockable
Transverse differential locks
96 S 364.1 Switch,
lockable
selector switch, hydraulic Sus-
pension (optional):
(Operating mode selection)
OFF = axle loads 12 t
ON = reduced axle loads
97 S 0420 Double key Pumping fuel
actuating top side: pump ON
actuating bottom side: pump
OFF
actuating top side and keeping
pressed:
changing display (51) from
showing main tank to showing
additional tank.
98 S 0913 Button Additional lubrication impulse
central lubricating system (op-
tional)
99 S 4425 Switch,
lockable
Suspension on threecircuit sys-
tem
100 S 4401 Switch,
lockable
Lock suspension
101 S 4428 Switch,
lockable
Hold axles
102 S 4427 Switch,
lockable
Raise lift axle *
103 S 2430 Switch,
lockable
Emergency operation of the su-
perstructure (optional)
104 S 4125 Button Switch ABS in towing vehicle
over to offroad mode
* Raise lift axle is done by driver in steering programs that can
be selected (for constructionsite operation).
Raise all axles is done on the switch panel of the outrigger con-
trols by actuating the Raise axles button, after previously actu-
ating the Raise axles button (101).
4
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Z 53 019
105 107 115
114
113
112
110 111
109
5A
24V
106
108
Drivers Cab 4
1402040215a 19/73
(Z 53 019)
105 S 5431 Switch Mirror heater
108 X 5412 Cigarette
lighter
109 A5111 Operating ele-
ment
Engineindependent cab
heater arrangement (optional)
110 S 5170 Switch Air conditioning equipment on
/ off
111 Control knob Air flow
Footwell / front window
112 X 5413 Socket 24 V, 5 A *
113 Control knob Control of enginedependent
cab heater arrangement / air
conditioning warm / cold
114 S 5141 Rotary switch Fan levels 01234
115 Control knob Air flap fresh air / ventilation
* Socket is fused with 5 ampere; do not overload!
Voltage is always on regardless of the ignitionstarter switch
position (danger of battery drain when device is offduty).
4
1402040215a 20/73
Z 200 144
61
60
62
63
64
65
66
67
75
51 52
54 53
55 56 57 58
31
40
32 33 34 35 36 37 38 39
43
50.1 50 42 41.1 41
Drivers Cab 4
1402040215a 21/73
4.3 Driver Information System
(Z 200 144)
The operators platform is equipped with a driver information sys-
tem. This provides the driver with important information on the ve-
hicle when it is in driving mode.
The driver information system consists of the instrument panel
with the items (31) (58) and the function buttons (60) (67) on
the steering wheel.
The Driver information system (43) display is in the middle of the
instrument panel.
To the left of the instrument panel, there is another display Trans-
mission information (75) which displays the transmission func-
tions(gear display / error messages).
Selftest
The electrical system performs a selftest when the ignition is
switched on. In this case, a control signal goes off once and all
indicator lights, (33) (40) and (50.1), are briefly illuminated.
The CH display appears on the Transmission information (75)
display.
Function buttons on the steering wheel
The function buttons (60) (67) are used to navigate around the
menu structure of the drivers information system.
Using the digit keys (61) (66), you can select between the
various menus 16. At the same time, the digits correspond to the
buttons of the segment numbering on the Driver information sys-
tem (43) display.
The Arrow key, (60) can be used to exit the current menu item
and return to the previous display.
Using the M key, (67)
you call up the main menu and
return to the basic display Indicator lights from the various
menu points.
4
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Z 200 145
10:07:2003
16:47
Drivers Cab 4
1402040215a 23/73
4.3.1 Driver Information System (43) Display
(Z 200 145)
Display fields
The display field is automatically divided into different segments.
A difference is made between permanent and changing displays.
The following is shown in the 3 permanent display fields (upper
bar):
Left field: not allocated
Middle field: not allocated
Right field: Date, time of day
Changing display fields, laterally marked with the numbers (1)
(6):
The indicator lights displayed in these fields are arranged from
left to right according to their priority. The indicator light having the
top priority is placed in the upper left corner. With this priority al-
location, a change from the current message to a new message
with greater priority can take place automatically, if necessary.
The brightness of the display can be changed with the but-
ton (57).
4
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Z 200 147
Z 51 331
31 40 32 33 34 35 36 37 38 39
Drivers Cab 4
1402040215a 25/73
Basic display / explanation of colours
(Z 200 147, Z 51 331)
After switching on the ignition, the basic message Indicator
lights always appears after the company logo and control sig-
nal. (Z 200 147)
In the basic display, the selected functions that are activated by
the corresponding switch settings are shown as symbols; e.g. dif-
ferential lock, offroad gear.
The display of the selected functions or subsequently occurring
malfunction / warning messages have different colours.
The colours are used as indicators for the influence of the mes-
sages on the operation/traffic safety of the vehicle and determine
the order of the displayed indicator lights (from upper left to lower
right) depending on their (colour) priority. The colours have the
following meanings:
DANGER!
Danger of injuries to persons and / or material damage dur-
ing an attempt by nonqualified personnel to eliminate er-
rors.
As soon as an error is displayed:
Stop operation
Identify the error immediately
Eliminate the error
Only qualified personnel (e.g. customer services) may rec-
tify faults.
CAUTION !
Errors must be eliminated only when the ignition is switched
off.
4
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Z 200 147
Z 51 331
31 40 32 33 34 35 36 37 38 39
Drivers Cab 4
1402040215a 27/73
(Z 200 147, Z 51 331)
The colours have the following meanings:
Colour additional
warning
light
Meaning
possible measures
red STOP (35) Severe malfunction
Stop the vehicle immediately! Contin-
ued operation is not permissible.
Caution
(36)
Malfunction
Locate the cause of the error and try
and rectify it at the earliest.
Pink STOP (35)
or Caution
(36)
Short circuit, cable breakage, plausi-
bility
Find the cause of the error and rectify
it.
yellow Caution
(36)
Warning message
The crane vehicle can still be oper-
ated, however, determine the cause.
white The function is selected, but not yet
active, e.g. one of the steering pro-
grams.
4
1402040215a 28/73
Z 51 321
61
60
62
63
64
65
66
67
Z 200 147
Z 200 148
0 25 50 75 100
FM
Drivers Cab 4
1402040215a 29/73
Main menu
(Z 51 321, Z 200 147, Z 200 148)
Pushing the M button (67) on the steering wheel (Z 51 321)
brings you from the Indicator lights (Z 200 147) basic display to
the main menu (Z 200 148).
Pushing the M button (67) again brings you back to the basic
display.
4
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Z 200 148
0 25 50 75 100
FM
Z 200 147
Z 200 149
Drivers Cab 4
1402040215a 31/73
Menu selection 1 2 3
Four menus (1, 2, 4, 5) can be selected in the main menu (Z 200
148). The menu items 3 and 6 are not assigned:
1 Indicator lights menu
identical with the basic display after Ignition on
Example of a possible display: (Z 200 147)
2 Multimedia menu (Z 200 149)
Reversing camera (optional)
3 not assigned
4
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Z 200 150 Z 200 151
Z 200 152 Z 200 153
Drivers Cab 4
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Menu selection 4
Output basis: Main menu (Z 200 148)
4 Control info menu (Z 200 150)
1 Suspension level (Z 200 151
2 Engine data* (Z 200 152)
4 Emergency pressure supply in the braking circuits 1 and
2 (Z 200 153)
* This display of the engine oil quantity (%) is only for purposes
of additional information. The oil level may only be monitored us-
ing the oil measuring stick.
Depending on the design it may be that these display functions
are not possible for technical reasons. The corresponding dis-
play will then always show 0%.
If this is the case, then B14 indicator light Engine oil level too low
will also not be displayed.
4
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Z 200 148
0 25 50 75 100
FM
Z 200 154
Z 200 155
00:00h 017
Drivers Cab 4
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Menu selection 5 6
Output basis: Main menu (Z 200 148)
5 Service / Diagnosis menu (Z 200 154)
Operating hours counter: Press submenu 5.1
Display (Z 200 155) left row: Partial operating hours
1 = Superstructure (without function)
2 = Chassis
3 = Sum superstructure / chassis (without function)
Display (Z 200 155) right row: Total operating hours
4 = Superstructure (without function)
5 = Chassis
6 = Sum superstructure / chassis (without function)
Software identification: Press submenu 5.4
Software display (only for customer service)
The partial operating hours can be deleted by holding down
(about 5 sec.) the steering wheel button (61 / 62 / 63).
The total operating hours cannot be changed.
6 not assigned
4
1402040215a 36/73
Z 200 157
A1
A2
3a
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
Drivers Cab 4
1402040215a 37/73
4.3.2 Indicator Lights in the Driver Information System
The symbols given below as Indicator lights on the Driver infor-
mation system (43) display can be displayed.
Signal indicator lights
the execution of manually activated functions (A row)
or the existence of malfunctions (B row)
4.3.2.1 Indicator lights for manually activated functions
(Z 200 157)
A1 Manoeuvring operation
A2 Manual rearaxle steering steering program active
A3 Steering program Close cornering active
A4 Steering program Driving away from the wall active
A5 Steering program Diagonal steering active
A6 Release Steering program (for constructionsite opera-
tion)
A7 Offroad distributor gear inserted
A8 Distributor gear in neutral
A9 Longitudinal differential lock actuated
A10 Transverse differential lock actuated
A11 Suspension in the threecircuit system
A12 Suspension locked
A13 Hold axles actuated
A14 Raise lift axle actuated
A15 Raise all axles actuated
4
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Z 200 157
A1
A2
3a
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
Drivers Cab 4
1402040215a 39/73
(Z 200 157)
A16 Emergency operation of the superstructure
A17 Axle that can be engaged in the function
(drive is connected with longitudinal differential lock)
A18 Speed lock effective
A19 Superstructure not locked with carrier
A20 Engine quick stop (optional) actuated
A21 Retarder cruise control switched on
4
1402040215a 40/73
Z 62 769
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32
B33
CHECK
BUS-
OFF
B34 CAN
B35
B36
Drivers Cab 4
1402040215a 41/73
4.3.2.2 Indicator lights resulting from malfunctions
(Z 62 769)
B1 Suspension beyond limits
B2 Error in the electric hydraulic rearaxle steering
B3 Emergency pressure supply in braking circuits 1 below 5.5 bar
B4 Emergency pressure supply in braking circuits 2 below 5.5 bar
B5 Clutch overload (temperature too high)
B6 Malfunction transmission
B7 Hydraulic oil filter chassis clogged
B8 Steering circuit 1 no throughflow
B9 Steering circuit 2 no throughflow
B10 Steering circuit 3 (emergency steering) no throughflow
B11 Engine coolant level too low
B12 Engine oil pressure too low
B13 Coolant temperature engine too high
B14 Engine oil level too low
B15 Malfunction engine
B16 Charging current too low
B17 Charging current in the superstructure too low (not as-
signed)
B18 Air filter clogged
B19 Fuel supply in the reserve
B20 (not assigned)
B21 (not assigned)
B22 Malfunction SPS
B23 Central lubricating system without grease (not assigned)
4
1402040215a 42/73
Z 62 769
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32
B33
CHECK
BUS-
OFF
B34 CAN
B35
B36
Drivers Cab 4
1402040215a 43/73
(Z 62 769)
B24 Malfunction on dolly (dolly = optional)
Stroke length exceeded, hydraulic cylinder
(if in addition to the indicator light (B24): Onetime
acoustic warning signal and indicator light Caution (36))
or
B24 Malfunction on dolly (dolly = optional)
Critical slanted position, hydraulic cylinder
(if in addition to indicator light (B24): Repeated acoustic
warning signal and indicator light STOP (35))
B25 scroll down to next mask (if no room on display)
B26 crane operation active (not assigned)
B27 (not assigned)
B28 Fault in exhaust brake/hydraulic retarder
B29 ABS malfunction, vehicle, all axles
(together with indicator light (32))
B30 ABS fault, trailer or additional axle or dolly (together with in-
dicator light (31))
B31 Check valve fault (electrohydraulic rearaxle steering)
B32 Malfunction oil supply (additional axle)
B33 Engine warning buzzer
B34 No CAN Bus connection (steering computer 1)
B35 Brake wear indicator (left disc brake)
B36 Brake wear indicator (right disc brake)
4
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Z 48 995
15
16
4
Drivers Cab 4
1402040215a 45/73
4.4 Ignitionstarter Switch (15)
(Z 48 995)
Position 1: Radio position
Most consumers are disconnected
from the battery.
Removable key.
Position 2: Parking position
Most consumers are disconnected
from the battery.
Removable key.
Position 3: Driving position
The ignition is switched on.
Position 4: Starting position
The engine starts.
NOTE:
In positions 1 and 2, the parking light, warning lights, tacho-
graph, socket, charging compensator of the battery in the super-
structure and outrigger lighting are not disconnected, for exam-
ple.
The radio can also be activated in position 1.
DANGER!
Danger of the vehicle being started by unauthorised per-
sons!
Even if you are only leaving the vehicle for a short time,
remove the key to prevent unauthorised persons start-
ing the vehicle.
When stowing/parking the vehicle, only remove the key
in position 2.
Only remove the key when the vehicle is stationary.
4
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Z 48 995
15
16
4
Drivers Cab 4
1402040215a 47/73
4.5 Steering Wheel Setting
(Z 48 995)
Both the height and tilt of the steering wheel can be adjusted. The
steering wheel is pneumatically released (or locked according to
the setting).
Steering wheel is set as follows:
1. Stop the vehicle and engage the parking brake.
2. Hold the steering wheel and press the push button (16).
3. Hold the push button (16) down and set the steering wheel.
4. After the steering wheel has been set, release the push but-
ton (16).
Only set when the vehicle is standing still and theparking
brake is set.
Always hold the steering wheel when making settings,
since otherwise the seat will rebound when pressing the
push button (16) and you could be caught between the
steering wheel and the seat.
4
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Z 306 016
5
4
2
6
3
1
1
2
3
4
5
6
Z 66 099
0
I
II 8
7
7
8
Drivers Cab 4
1402040215a 49/73
4.6 Combination switch
4.6.1 On the Left on the Steering Column
(Z 306 016, Z 66 099)
1 Lower beam
2 Upper beam
3 Headlamp flash
4 Indicators right
Up to pressure point = short indication
Beyond pressure point = continual indication
5 Indicators left
Up to pressure point = short indication
Beyond pressure point = continual indication
6 Horn
7 Wiper
0 deactivated
Intermittent wiping
Basic setting of the wiping pause: 5 seconds.
I Slow
II
Fast
8 Windscreen washing assembly
Press switch = switched on
NOTE:
Check the wiper blades regularly for dirt and damage.
4
1402040215a 50/73
Z 306 015
1
2
3
4
5
5
4
2
1
3
Drivers Cab 4
1402040215a 51/73
4.6.2 On the Right of the Steering Column
(Z 306 015)
Switch functions:
5. Engine control
= idle speed, cruise control, limiter
6. Sustainedaction brake
= engine brake, retarder, retarder cruise control
1 Engine control:
Increase idle speed,
accelerate vehicle,
store speed.
Sustainedaction brake:
Reduce braking effect (increase speed, store).
2 Engine control:
Reduce idle speed,
decelerate vehicle,
store speed.
Sustainedaction brake:
Increase braking effect, (reduce speed, save)
Level 1 = engine brake
Level 25 = engine brake and retarder
3 Switch on sustainedaction brake :
4 Engine control
Switch off idle speed increase,
Switch off cruise control,
Switch off limiter
5 Engine control
Switch on limiter
Using the limiter the driving speed can be limited at any level
above 30 km/h (19 mph).
4
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Z 104 329
7
6
6
4
5
Drivers Cab 4
1402040215a 53/73
4.7 Entry / Exit for Crane Operators Cab
(Z 104 329)
For entry and exit, completely lower the drivers seat (4) and fold
up the arm rest (5) (see section 4.9, page 61).
DANGER!
Risk of injury when climbing in and out!
Use the handles (6) and the step treads (7) on the drivers
side and the passengers side.
Do not jump out of the drivers cab.
DANGER!
There is a risk of injuries due to slipping.
Safety is diminished on the steps and at the entry areas due
to dirt and mud. This means you can slip on the steps.
Keep steps, entry areas and shoes clean of contamination
(for example:mud, clay, snow and ice).
DANGER!
Risk of accidents due to unauthorised use of the crane.
Children or unauthorised persons could cause danger to
themselves and others by releasing the retaining brake,
starting the engine and / or setting the vehicle in operation,
for example.
Even when leaving the vehicle for a short period of time, re-
move the key from the ignition and lock the door with the
vehicle key.
4
1402040215a 54/73
Z 104 326
1
Z 104 327
2
Z 104 328
3
Drivers Cab 4
1402040215a 55/73
4.8 Driver Door / Passenger Door
4.8.1 Opening and Closing the Cab Door
(Z 104 326, Z 104 327, Z 104 328)
DANGER!
Risk of injuries from becoming trapped!
There is a risk of pinching between the door and the door
frame when closing the vehicle door.
DANGER!
Risk of accidents and injury!
Only drive with correctly closed doors.
Locking / unlocking the door from the outside using the ve-
hicle key
The crane vehicle is not equipped with central locking. Only the
door is locked / unlocked which was locked / unlocked with the
vehicle key (1).
To lock the cab door:
Turn the vehicle key clockwise.
To unlock the cab door:
Turn the vehicle key anticlockwise.
Locking / unlocking the door from the inside using button
The cab door can be locked / unlocked from the inside using but-
ton (2).
To lock the cab door:
Press the button.
To unlock the cab door:
Pull out the close button
NOTE:
If the cab door has been locked from the inside using button (2),
it cannot be opened from the outside with a vehicle key or from
the inside with the opening lever. The cab door must be unlocked
again using the button.
To open the door from the inside using the opening lever
You can open the unlocked doors anytime from inside using the
opening levers (3).
4
1402040215a 56/73
Z 200 141
24
25
A
B
Z 200 142
11
A
B
Drivers Cab 4
1402040215a 57/73
4.8.2 Window Controls
(Z 200 141, Z 200 142)
The vehicle is equipped with automatic electric windows.
Risk of injuries from becoming trapped!
Take extra care when closing the windows. in case you
get caught, the system does not have an automatic auto
reversal / switch off for the closing motion; i.e. the win-
dow panel presses with all its strength upwards until the
Open window command is given.
The windows may only be closed when the operator has
a clear view of the windows and is sure that noone
could become trapped in the closing window.
Only the vehicle driver may activate the electrical win-
dow opener; other passengers are to be warned of the
danger by the vehicle driver.
Risk to life and limb, in particular with children!
To avoid someone becoming trapped as a result of incor-
rect use, the vehicle operator may only leave the cab
when he has removed the ignition key from the ignition
lock.
The vehicle driver must be aware of the situation; this is
his responsibility.
Allocation and arrangement of the controls:
The controls (dual button 11, 24, 25) are located in the door
mouldings on the driver / passenger side.
4
1402040215a 58/73
Z 200 141
24
25
A
B
Z 200 142
11
A
B
Drivers Cab 4
1402040215a 59/73
Drivers side: (Z 200 141)
Dual button (24) for window on passengers side.
Dual button (25) for window on drivers side.
Passenger side: (Z 200 142)
Dual button (11) for window on passengers side.
Controls for the automatic electric windows:
Turn the ignition key in the driving direction.
Push the dual button forwards (A), hold = close window.
Push the dual button backwards (B), hold = open window.
Tap dual button = open or close window partially.
4
1402040215a 60/73
Z 61 344
13
8
2 3 4 5 6 7
9
1
15
16
10 1112
17
14
Z 61 345
8
2 3 4 5 6 7 9 1
15
16
10 11 12
17
14
Drivers Cab 4
1402040215a 61/73
4.9 Drivers Seat / Passengers Seat
(Z 61 344, 61 345)
The airsprung seat (shockcushioning seat) with automatic
weight adjustment protects the driver / passenger against me-
chanical vibrations. The vibration behaviour can be adjusted to
the conditions (road surface, axle load, suspension). The seat is
equipped with a safety belt (threepoint belt). It can be set to any
position and can be locked at seat height.
Set the seat according to your own requirements.
Drivers seat (Z 61 344), passengers seat (Z 61 345)
1 Set the seat horizontally
Entire seat back and forth.
2 Seat cushion back and forth
3 Lower the seat (exiting aid)
Pull lever = lower completely
Push lever = lift again to saved height.
4 Set seat angle
Change the seat angle by shifting weight in the front part of
the seat.
5 Set the seat height (infinitely adjustable)
Pull lever = lift
Press lever = lower
6 Set backrest
Use your body weight to set the correct position.
7 Set seat damping (infinitely adjustable)
Pull lever = maximum damping
Push lever = minimum damping
8 Seat heating (switch on off)
only drivers seat
Electrical heating elements in the seat and back compo-
nents.
4
1402040215a 62/73
Z 61 344
13
8
2 3 4 5 6 7
9
1
15
16
10 1112
17
14
Z 61 345
8
2 3 4 5 6 7 9 1
15
16
10 11 12
17
14
Drivers Cab 4
1402040215a 63/73
(Z 61 344, Z 61 345)
9 Lock horizontal suspension
Lever to the left = locked
Lever to the right = suspended
10 Lumbar support, lower
Filling / emptying air cushion (switch + / )
11 Lumbar support, upper
12 Lumbar support, lateral
13 Set arm rests (only drivers seat)
Control knob for angle adjustment
14 Headrest (see section 4.9.2, page 69)
15 Latch plate of the safety belt (see section 4.9.3, page 69)
16 Belt buckle (see section 4.9.3, page 69)
17 Red button in the buckle (see section 4.9.3, page 69)
Drivers seat:
Only set when the vehicle is stationary and the parking
brake is engaged. Setting the seat while driving can dis-
tract the driver from the traffic situation. The seat fixing
device has to latch audibly into place.
When setting the seat, assume a relaxed, nonstrenu-
ous position and be sure that the safety belt is properly
put on.
Before getting out of the vehicle, lower the seat com-
pletely (press button 3 Exit assistance). Otherwise,
the seat will bounce up, blocking your legs between the
steering wheel and seat. Lift the armrest up and then turn
back / pull out the ignition key.
4
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Z 104 102
1
2
B
A
3
4
C
5
Drivers Cab 4
1402040215a 65/73
4.9.1 Folding the Passenger Seat
There are various electronic components under the passenger
seat. In order to reach the components, the entire seat must be
folded up.
Folding the passenger seat up:
(Z 104 102)
1. Completely lower the seat (1, Z 104 102 A).
2. Slide the seat completely to the front (2, Z 104 102 A).
3. Slide the headrest in entirely (3, Z 104 102 B).
4. Adjust the armrest as far back as pos-
sible (4, Z 104 102 B).
5. Unlock the passenger seat with your left hand and grip the
belt where it comes out at the top with your right hand. Fold
the seat to the front until it has reached its final position
(5, Z 104 102 C).
Risk of crushing between the swivelling cover (y) to
which the seat is fastened and the lock (z) on the cab
wall when folding the seat forward.
Risk of injury!
Check that the passenger seat is held safely in place.
If this is not the case, the folded seat must also be se-
cured against falling back.
4
1402040215a 66/73
Z 104 100
Drivers Cab 4
1402040215a 67/73
Opening the cover of the electronic compartment:
(Z 104 100)
1. Loosen the screws.
2. Open the cover (1) and secure against falling back (for ex-
ample, tie it up using a tie (2)).
Closing the cover on the electronic compartment:
1. Ensure that the material under the cover is in the correct
place and does not obstruct the closing procedure.
2. Close the cover and screw in place.
Folding the passenger seat back:
1. Ensure that the material under the seat is in the correct place
and does not obstruct the seat when locking in place.
2. Using both hands, grip the seat where the belt comes out at
the top and let it fall back carefully. The seat locks into place
due to its own weight.
Risk of injury!
Check that the passenger seat has locked into place
safely.
If the passenger seat is not locked in place correctly, the
seat could fold to the front during braking.
3. Adjust the seat to the desired position.
4
1402040215a 68/73
Z 61 344
13
8
2 3 4 5 6 7
9
1
15
16
10 1112
17
14
Z 61 345
8
2 3 4 5 6 7 9 1
15
16
10 11 12
17
14
Drivers Cab 4
1402040215a 69/73
(Z 61 344, Z61 345)
4.9.2 Headrest
The headrest (14) can be adjusted for height and angle indepen-
dent of the backrest.
Set the headrest so that the rear part of the head is sup-
ported at about the height of the eyes.
4.9.3 Safety Belt
The safety belt system incl. the seat belt anchorage points is an
essential part of the drivers seat. No modifications of this equip-
ment are permitted. If modifications are made, the operating li-
cence will expire.
The use of safety belts is a regulation in many countries.
In the interest of your own safety, always put on the safety belts.
Fastening the safety belt:
Pull the belt with the latch plate (15) over your shoulder and
lap. The belt may not be twisted.
Press the latch plate (15) into the belt buckle (16) and until it
catches audibly.
The belt must always be taut. Check for tightness regularly.
If need be, tension the lap belt by pulling the shoulder belt up-
wards.
Releasing the safety belt:
Press the red button (17) in the belt buckle (16).
Bring the latch plate (15) back to the initial position.
4
1402040215a 70/73
Drivers Cab 4
1402040215a 71/73
Automatic safety belt winder operation
The automatic safety belt winder for the safety belt locks the belt
pullout during vehicle deceleration in all directions and when
pulling down on the belt quickly.
Checking for correct operation
To check the locking function of the retractor, pull the belt out with
a quick jerk.
Fasten your safety belt before driving
All safety belts are only to be used for one person.
Threepoint seat belts are not for people shorter than
150 cm (4.9 ft). These people require special equipment
for protection in the case of an accident (because safety
belt were no correctly fastened).
Avoid seat positions that interfere with the correct
course of the safety belt. Set the backrest to almost 90 .
Your back should touch the backrest. The belt must run
across the middle of your shoulder. Safety belts that
have been placed under heavy strain during an accident
must be replaced. Have belt anchors checked by a spe-
cialist workshop.
Replace damaged safety belts.
Belts may not run across sharp edges.
No changes may be made to the safety belts.
4
1402040215a 72/73
Z 104 320
1
2
a
Z 104 321
1
3
Z 104 322
3
1 b
C
Z 104 323
1
3
4
5
Drivers Cab 4
1402040215a 73/73
4.10 Hinged Bed (Optional)
(Z 104 320, Z 104 321, Z 104 322, Z 104 323)
If your crane is equipped with a hinged bed (1) in the crane opera-
tors cab, observe the following points:
During driving, the hinged bed (1) must be folded up and
secured with a rubber strap (2).
The hinged bed (1) may only be folded down from the pas-
senger side, as there is not enough space on the drivers
side.
The weight of the hinged bed is approx. 21 kg (approx. 46 lbs).
4.10.1 Procedure for Folding the Bed down
1. Hold the hinged bed (1) and release the rubber strap (2).
Risk of crushing!
When folding the hinged bed down there is a risk of
crushing between the dashboard and bed frame.
2. Carefully fold the hinged bed (1) down (direction of arrow a)
until it is resting on the dashboard.
Fold the hinged bed down carefully so that the dashboard is
not damaged (Z 104 320).
3. Raise the hinged bed (1) slightly and hang from the ceiling
of the operators cab using the middle chain (3) (Z 104 321).
4. Unfold the hinged component on the passenger side in the
direction of arrow b and attach with chain (4) (Z 104 322,
Z 104 323).
5. Now unfold the second component on the passenger side in
the direction of arrow c and attach it with chain (5) as well
(Z 104 322, Z 104 323).
To fold the hinged bed up, follow these instructions, but in the re-
versed sequence.
Engine 5
1402050201.ildoc 1/35
5 Engine (OM 502 LA)
Damageprevention measures
The following safety measures must be observed, in order
to avoid injury to persons and damage to the engine, com-
ponents or cables.
Only start the engine when the batteries are properly
connected. Never disconnect the batteries when the engine
is running.
Only start the engine with the speed sensor fitted.
Do not use a highspeed charger to start the engine.
Jump starting only permitted with separate batteries.
For highspeed charging of the batteries, the battery clamps
must be removed. Follow the operating instructions for the
highspeed charger.
In case of electric welding work, the batteries must be
disconnected and the two cables + and connected firmly
together.
The connections of the control devices may only be fitted and
removed when the electrical system is switched off.
Reversal of the polarity for the supply voltage of the control
devices (e.g. reversal of the battery poles) can lead to the
control devices being destroyed.
Tighten the plug connections on the injection system to the
prescribed torque.
Remove the control units if temperatures exceed 80C /
176F (foundry furnace).
Use only suitable test cables for taking measurements on
plug connections (MercedesBenz connector set).
Telephones and radios that are not connected to an outside
antenna can lead to malfunctions on the vehicle electronics
and can thus endanger the operational reliability of the
engine.
Before commissioning, make sure that you have read the
operating instructions of the engine manufacturer. These
can be found in section 5 of these documents.
The following information is limited to the factors that
directly affect the crane.
5
1402050201.ildoc 2/35
Z 51 911 Z 51 329
Z 51 929
1
Z 51 346
13
12
Engine 5
1402050201.ildoc 3/35
5.1 Before Starting the Engine
1. Follow the instructions in the operating manual of the engine
manufacturer (appendix in part 5 of this service literature).
2. Checking Before Starting Up:
Fuel supply (display 51)
Hydraulic oil level (example Z 51 911)
To avoid damage to the travelling hydraulic pumps, the engine
may no longer be started with normal hydraulic oil filling (ATF
Type A Suffix A) at temperatures under 25 C (13 F).
Engine oil level (Z 51 329)
Coolant level (Z 51 929):
The cooling system is filled correctly if the coolant level
reaches the marked line in the filler neck.
Parking brake (14) closed
Rotary switch (13) to N (Z 51 346)
Quick stop device (optional); may not be actuated.
Refer also to section 6.1 Checks Before Driving the Crane
5
1402050201.ildoc 4/35
Z 200 336
4
3
1B
2B
1A
2A
Engine 5
1402050201.ildoc 5/35
5.2 Starting Aid with External Batteries
(Z 200 336)
If the batteries are weak, the chassis engine can be started with
the aid of batteries from the superstructure engine and vice
versa.
In contrast to the specifications given in the separate engine
operating instructions (Part 5), no thirdparty starting aid cables
are used to jump the batteries.
Two cable couplings (consisting of 1 plug and socket each) are
attached to the chassis, on the right side (in the storage box
beneath the outrigger controls). The same connections can be
found in the engine area on the superstructure. At the same time,
Minus (ground) is always installed on the plugs (1A/1B) and
Plus is always installed on the sockets (2A/2B).
Both loose starting aid cables (3, 4) (cable cross section 95 mm
2
/ 0.15 in
2
) included in delivery can be connected at these points;
in which due to the different forms of the connection parts it
is not possible to transpose the polarity.
Other crane vehicles that are equipped with these connections
from our product program can also be used as a starting aid.
We do not recommend other forms of starting aid.
Risk of injury/explosion!
When using the starting aid, do not bend over the batter-
ies.
Do not smoke in the vicinity of the batteries;
Avoid causing sparks and open flames.
A discharged battery can freeze at 10C (14F). It must
be thawed before using the starting aid.
5
1402050201.ildoc 6/35
Z 200 336
4
3
1B
2B
1A
2A
Engine 5
1402050201.ildoc 7/35
To not use a starting aid with defective batteries.
Be sure that the voltage (24 V) is the same for the flat and
the booster battery.
Only use a starting aid with original starting aid cable.
In no case should you use a boost charger. (Damage to
electronic parts)
Before using the starting aid, separate mobile
communication systems from the electrical system.
Be sure that plugs / sockets do not come into contact
with the metal parts of the device (risk of short circuit).
Handling steps for starting aid with special cable:
1. Switch off ignition in the superstructure and chassis.
2. Connect the starting aid special cable to the cable couplings.
(connect and tighten with a short turn to the right.)
First connect the plus pole (cable 4) and then the minus pole
(cable 3).
3. Start the engine rendering assistance; let it rev up.
4. Engine receiving assistance:
Turn key to the start position in the ignitionstarter switch.
Start the engine and let it run at idle speed.
5. Remove the cable, first from Minus (cable 3) and then from
Plus (cable 4).
5
1402050201.ildoc 8/35
Z 51 304
15
4
Z 51 325
75
Z 51 334
51 52 54 53 55 56 57 58
31
40
32 33 34 35 36 37 38 39
43
50.1 50 42 41.1 41
Engine 5
1402050201.ildoc 9/35
(Z 51 304, Z 51 325, Z 51 334)
5.3 Ignitionstarter switch (see section 4 Drivers cab)
5.4 Starting Procedure (Engine Start)
Never start the engine without the batteries connected
properly.
The engine can either be started in the drivers cab or on the
outrigger controls (external start).
After the motor has been started, the steering performs a
selftest (see operating instructions of the crane chassis
section 9 Steering selftest).
Risk of crushing!
The wheels can move back and forth independently dur-
ing the steering selftest. Noone may be in the wheel
area.
5.4.1 Starting the Engine in the Drivers Cab
1. Insert the key into the latch contact (15) and turn (to the right)
to the driving position (position 3).
The electrical system performs a selftest when the ignition is
switched on; the most important signal connections to the
instrument panel are checked. At the same time, a control signal
sounds twice and all indicator lights (3140 and 50.1) flash.
The function control is ended after the control signals go out.
Activated indicator lights may light up on the instrument panel;
e.g. item39 Parking brake.
The CH display appears on the (transmission information)
display (75).
The basic display Indicator lights appears on the driver
information display (43). The selected functions or existing
malfunctions are shown.
For further notes, see section 4 Driver information system.
5
1402050201.ildoc 10/35
Z 51 304
15
4
Z 47 962
Z 60 982
Engine 5
1402050201.ildoc 11/35
2. Start the engine
After the indicator signal goes out: Turn the key on as far as
possible (position 4) and start the engine, without operating
the accelerator pedal.
If required, interrupt the starting procedure after no more than
20 seconds and repeat after approx. 1 minute.
Before attempting to start the engine again, turn the key back to
the first stop.
Release the key after the engine has started.
3. If the engine fails to start after the third attempt: Search for
the cause of the fault with the help of the operating
instructions of the engine manufacturer.
5.4.2 Starting the Engine at the Outrigger Controls
(External Engine Start)
(Z 51 304, Z 47 962, Z 60 982)
1. Insert the key in the latch contact (15) (position 2).
2. Press the Caution key (10/20) for approx. 5 secs. (ignition
on, Boot data bus).
3. Press and hold the Caution key (10/20) and also press the
engine start key (7B/17B).
4. After the engine has started release both buttons.
When the outriggers are activated, an engine speed of 1200
min
1
(rpm) is automatically set.
When the engine is started on the outrigger controls the
warning displays are not in the operators line of view. It is
therefore important to listen for acoustic warning signals
(buzzer).
5
1402050201.ildoc 12/35
Z 62 762
B11
B12
B13
B14
B15
B16
B18
B7
Z 51 324
51 52 54 53 55 56 57 58
31
40
32 33 34 35 36 37 38 39
43
50.1 50 42 41.1 41
Engine 5
1402050201.ildoc 13/35
5.5 After Starting the Engine
(Z 51 328, Z 62 762)
Never disconnect the battery terminals when the engine is
running.
Keep your eye on the engine oil pressure!
If the oil pressure is too low, the B12 indicator light will
appear on the driver information display. At the same time,
the STOP indicator light (35) will light up on the instrument
panel, and an acoustic warning signal (buzzer) will be
emitted.
When the Oil pressure warning (B12) is shown, the
operating safety of the engine is in danger.
Stop the vehicle immediately and switch off the engine.
Determine the cause of the fault!
Do not leave the engine running at a standstill to warm it up.
Only operate the engine at full speed/full load once the
prescribed operating temperature has been reached.
If indicator light (B18) lights up, service the air filter.
If the indicator light (B7) lights up, service the hydraulic oil
filter (see lubricating and maintenance instructions of
chassis).
This only applies when the hydraulic oil is at operating
temperature.
At lower temperatures, it is possible that this lamp does not go out
for a short period, even though no fault is present.
Switch the engine off immediately in the case of:
falling or heavily fluctuating oil pressure
falling output/rpm in spite of constant operating
conditions
heavily smoking exhaust
excessively high coolant and oil temperature
sudden abnormal engine noises.
5
1402050201.ildoc 14/35
Z 51 304
15
4
Z 47 962
Z 60 982
Engine 5
1402050201.ildoc 15/35
5.6 Before Switching Off the Engine
Leave the engine running at idle speed for approx. 12 minutes
before switching off:
when the coolant temperature is high (above 95 C /
203 F);
after driving at full engine power (e.g. after driving on a slope),
to allow the exhaust turbocharger to cool down.
5.7 Switching Off (Engine Stop) in Normal Circumstances
(Z 51 304, Z 47 962, Z 60 982)
The engine can be switched off both in the drivers cab and on the
outrigger controls.
When the ignition is off the transmission automatically switches
to neutral.
When leaving the crane, remove the ignition key and close
off the cab.
5.7.1 Switching off the Engine in the Drivers Cab
In the drivers cab the engine is switched off with the ignition
switch (15).
The following condition ensures when the engine is started:
If the engine is started in the drivers cab:Turn the
ignitionstarter switch (15) from driving position (position 3)
to position 2.
When the engine is started on the outrigger control:Turn
the ignitionstarter switch (15) from position 2 to position
1.
5.7.2 Switching Off the Engine on the Outrigger Control
The engine is switched off on the outrigger control by pressing
button (7A/17A).
At the same time, this results in the following interaction with the
ignitionstarter switch (15) in the drivers cab:
The ignition remains switched on when the ignition switch
(15) is in position 3.
The ignition is switched off when ignition switch (15) is in
position 1.
5
1402050201.ildoc 16/35
Z 47 991 Z 51 326
A20
Z 47 992
2
1
Engine 5
1402050201.ildoc 17/35
5.8 Switching Off the Engine in an Emergency
5.8.1 Switching Off Procedure Quick Stop (Optional
Equipment)
(Z 47 991, Z 51 326)
On the chassis, the engines of the superstructure and chassis
can be switched off together at two central points. A mushroom
pushbutton is located on the left and righthand side of the
crane near the outrigger controls for this purpose. (Example Z 47
991)
Press the knob to activate the quick stop device. Once it has been
activated, the mushroom pushbutton must be released again
before an attempt is made to restart the crane (turn and unlock).
The quick stop device only functions when the handbrake is
applied and the gear is in neutral.
After the quick stop device has been activated the indicating light
(A20) lights up until the Locked position is released again.
5.8.2 Quick Stop with Air Shutoff Valve
(Z 47 992, example)
Using a trap between the air filter and engine the air flow is cut
off when the device is actuated.
Independently of manual activation, the quick stop device is
automatically activated when a certain speed is exceeded
(approximately 2700 U/min / rpm). At the same time the fuel
supply is interrupted. The engine is switched off.
Before the engine is restarted the trap (1) must be manually
released. Return lever (2) to the starting position.
Risk of damage!
When the trap is closed the engine cannot be started.
Repeated starting attempts lead to engine damage.
Before the restart, all aircarrying hoses incl. the charge
air hoses between the engine and aftercooler must be
checked to ensure that they are fitted correctly and are
completely free of blockages.
5
1402050201.ildoc 18/35
Z 306 015
1
2
3
4
5
5
4
2
1
3
Engine 5
1402050201.ildoc 19/35
5.9 Electronic Engine Management
The chassis engine is equipped with an electronic control
system. This monitors both the engine and itself (selfdiagnosis).
The control and monitoring equipment is in the cab on the
chassis.
5.9.1 Engine Control
(Z 306 015)
1 Increase idle speed,
accelerate vehicle,
store speed.
2 Reduce idle speed,
decelerate vehicle,
store speed.
3 (Sustainedaction brake)
4 Switch off idle speed increase,
switch off cruise control,
switch off limiter
5 Switch on limiter:
Idle speed/intermediate speed/max. working speed
If required, the idle speed when the vehicle is stationary can be
increased from approx. 550 U/min (rpm) to max. 750 U/min (rpm).
Moreover, the engine speed (with applied handbrake) between
idle and a parameterised maximum engine speed fixed at
1200 min
1
(rpm) can be set to any value; e.g. when the
superstructure functions are actuated in an emergency.
When the outriggers are activated, an engine speed of 1200
min
1
(rpm) is automatically set.
When the intermediate revs are selected the engine speed can
only be changed to the max. working speed (1200 min
1
) by
pressing the accelerator pedal (18).
If the ignition switch (15) is placed in the Off position, the
set intermediate speed is deleted.
It must be reset.
5
1402050201.ildoc 20/35
Z 306 015
1
2
3
4
5
5
4
2
1
3
Engine 5
1402050201.ildoc 21/35
5.9.2 Idle Speed
(Z 306 015)
1 Hold down:
Increase idle speed.
1 Tap:
Increase idle speed by approx. 20 min
1
(rpm).
2 Hold down:
Reduce idle speed.
2 Tap:
Reduce idle speed by approx. 20 min
1
(rpm).
After releasing the lever the engine runs at the increased speed.
4 Tap:
Idle speed increase switched off.
The idle speed increase is automatically switched off after
starting off.
5
1402050201.ildoc 22/35
Z 306 015
1
2
3
4
5
5
4
2
1
3
Engine 5
1402050201.ildoc 23/35
5.9.3 Cruise Control
Using the cruise control, the vehicle drives at a stored speed
(without actuating the accelerator pedal).
Any speed above 30 km/h (19 mph) can be stored.
RISK OF ACCIDENTS!
Do not switch on the cruise control on a slippery surface.
Risk of skidding!
Only use the cruise control when the traffic conditions enable a
constant speed. It may not be possible to hold the speed on
inclines.
Do not exceed the highest speed in the individual gears (observe
the revolution counter).
When the cruise control is switched on take your foot off the
accelerator pedal.
Switch on the cruise control:
The cruise control is switched on using the actuating lever on the
right of the steering column.
Accelerate the vehicle with accelerator pedal (above 30 km/h
/ 19 mph)
Lever in position
1 Hold down:
Accelerate. Release lever, the speed that has been
reached is stored.
1 Tap:
Save current speed or increase saved speed by 0.5 km/h.
2 Hold down:
Decelerate. Release lever, the speed that has been
reached is stored.
5
1402050201.ildoc 24/35
Z 306 015
1
2
3
4
5
5
4
2
1
3
Engine 5
1402050201.ildoc 25/35
(Z 306 015)
2 Tap:
Save current speed or reduce saved speed by 0.5 km/h.
Resume stored desired speed.
After releasing the lever the engine runs at the speed that has
been reached.
Switch off the cruise control:
Tap the lever in position 4.
The cruise control is automatically switched off:
when the brake is activated.
for speeds under 30 km/h (19 mph).
If the vehicle is accelerated with the accelerator pedal when the
cruise control is switched on, the stored speed is resumed once
the accelerator pedal is released.
5
1402050201.ildoc 26/35
Z 306 015
1
2
3
4
5
5
4
2
1
3
Engine 5
1402050201.ildoc 27/35
5.9.4 Limiter (for Limiting the Maximum Speed)
(Z 306 015)
Using the limiter the driving speed can be limited at any level
above 30 km/h (19 mph).
Switch on limiter:
accelerate the vehicle to the desired speed.
Press button (5). The speed limiter is activated.
Switch off limiter:
Tap the lever in position 4.
The set maximum speed is automatically deleted if the cruise
control is switched on.
To exceed the set maximum speed:
If you want to exceed the set maximum speed (e.g. when
overtaking):
press down the accelerator pedal past the acceleration point up
to the stop (kickdown).
To reduce the set maximum speed:
If you want to reduce the set maximum speed:
release the accelerator pedal (if required, brake the vehicle).
Once the desired speed has been reached, press button (5).
5
1402050201.ildoc 28/35
Z 51 328
B11
B12
B13
B14
B15
B16
B18
Z 51 324
51 52 54 53 55 56 57 58
31
40
32 33 34 35 36 37 38 39
43
50.1 50 42 41.1 41
Engine 5
1402050201.ildoc 29/35
(Z 51 328, Z 51 324)
5.9.5 Monitoring the Engine
5.9.5.1 Fault Display
All faults in the engine system and the engine electronic system
are collected. If a fault occurs, this is shown by the indicator light
(B15).
Regardless of this general detection/display, certain faults are
shown directly by their own indicator lights (with the
corresponding symbol).
At the same time, the indicator light (35) STOP or Caution (36)
will light up on the instrument panel; in some cases, an acoustic
warning signal (buzzer) will also sound.
When there is a malfunction/warning display and at the same
time the red warning light STOP (35) lights up, the
operational safety of the engine is in danger. Stop the vehicle
immediately and remedy the fault.
Speed monitor
(50.1) LED, red
When lit up: The engine speed is exceeding 2350
U/min (rpm) (excessive engine speed).
Be sure that the engine does not exceed the permissible
speed range.
At an engine speed of 2300 U/min (rpm), the exhaust brake is
deactivated to protect the engine mechanic against damage.
Engine faults (engine system/electronic system)
(B15) Indicating light, red
When the fault indicator lights up read off the fault
code.
All faults are stored in the system and can be read off as fault
codes. Faults which are only displayed temporarily are also
stored.
5
1402050201.ildoc 30/35
Z 51 328
B11
B12
B13
B14
B15
B16
B18
Engine 5
1402050201.ildoc 31/35
Coolant level
The warning Coolant level (B11) is displayed if the
coolant level in the compensation tank has sunk by
approx. 2 l (0.5 gal) under the norm. At the same time,
the alarm buzzer will also sound.
Switch off the engine immediately and determine the
cause of the fault.
Oil pressure
The Oil pressure warning is displayed when while
the engine is running the oil pressure is too low in the
engine (= depending on the speed).
At the same time if the level continues to fall the
alarm buzzer sounds.
cause of the fault.
Coolant temperature
The warning Coolant temperature (B13) is displayed if
a coolant temperature of 104 C (219 F) is reached
during driving. Even the alarm buzzer sounds at 110 C
(230 F) and the engine performance reduces automatically.
The engine can still be used. however, the cause must be de-
termined.
Oil level
The Oil level warning (B14) is displayed when the oil
level in the engine has sunk considerably under the
minimum amount. At the same time, the alarm buzzer
will also sound.
cause of the fault.
This display serves only as additional information.
Monitoring of the oil level is not to be performed except with
the dipstick.
Depending on the version, it may turn out that this display
function is not possible because of technical reasons.
5
1402050201.ildoc 32/35
Z 51 328
B11
B12
B13
B14
B15
B16
B18
Z 51 335
Engine 5
1402050201.ildoc 33/35
(Z 51 328, Z 51 335)
Charging current
If the charging current warning is displayed when the
engine is running, switch off the engine and check the
belt drive.
Never run the engine without the belt drive. The coolant
pump is not working.
5.9.6 Reading Off the Fault Memory
When warning light (B15) lights up, the system has recognised
a fault.
The fault codes can be read off with the Minidiag 2
(MercedesBenz) diagnosis device. This is usually done by our
customer service or in a DAIMLERCHRYSLER AG workshop.
Action steps for error diagnosis:
Switch off the engine.
Connect the diagnosis device to the diagnosis socket
(14pole; in the control box X 300 in the drivers cab).
(Z 47 966)
Switch on the ignition.
Do not start the engine.
When the engine is running fault codes cannot be deleted. If no
fault codes are displayed, check the fuse and grounding of the
diagnosis socket.
Call up the menu for reading the fault codes from the control
unit.
Call up the fault codes.
A description of all fault codes can be found in the separate
operating instructions of the engine manufacturer (see part 5 in
this service literature).
5
1402050201.ildoc 34/35
Engine 5
1402050201.ildoc 35/35
5.9.7 Evaluation of the Displayed Faults
The error code has five digits; the first digit indicates the fault
group (0, 1 or 2). Depending on which fault group is displayed,
you should proceed as follows:
Fault group 0
The fault code is stored, but only displayed when the diagnosis
instrument is connected.
The fault can, if required, be rectified during the next service.
The engine can still be used.
Fault group 1
The fault must be rectified as soon as possible.
Risk of accidents! You must reckon with altered running
characteristics of the engine.
Fault group 2
The fault must be rectified immediately.
Risk of accidents! The running characteristics of the en-
gine are different (emergency running programme).
Driving the Crane 6
140_2060_237a_en 1/143
6 Driving the Crane
6.1 Instructions for all Types of Driving
All the control and monitoring elements required for driving the
crane are located in the drivers cab of the crane chassis.
The pedals freedom of movement must not be restricted. Be
sure that there is enough room for the pedals when using
foot mats and carpets. Do not store any objects in the dri-
vers foot area. Store or secure all loose objects (e.g. tins,
bottles, tools, bags, etc.) in such a way that they cannot enter
the foot area while driving. Such objects could get under the
brake pedal, block it and thereby make it impossible to brake
the crane vehicle.
6.2 Checks Before Driving the Crane
Check the capacities for all fuels and lubricants see lubricating
and maintenance instructions for the crane chassis (part 4).
The following checks must be made every time before the crane
is driven, even when only driving short stretches.
Driving condition of the mobile crane:
Check axle loads; observe instructions (see under axle
loads / speeds / tyres and defined driving conditions)
Check transport position of struts and outrigger plates (see
section 12)
Check the engine oil level, add extra oil if required.
Check the hydraulic oil level.
If there is fault: Determine cause only fill up afterwards.
Wait until the hydraulic oil has warmed up before running the en-
gine at speeds of over n=1600 min
1
.
Check the oil level in the transmission, add extra oil if requi-
red.
Check the coolant level.
If there is fault: Determine cause only fill up afterwards.
6
140_2060_237a_en 2/143
Z 51 300
B8
B9
B10
Driving the Crane 6
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Check the steering.
The indicator lights (B8, B9 and B10) must not light up as
a rule. (Z 51 300)
Depending on the system, in case of the fault No throughfeed
at the emergency steering pump (indicator light B10), there is a
display only once driving speeds > approx. 8 km/h (5 mph) have
been reached.
Driving the crane with defective steering constitutes a major
safety hazard. Faults must be rectified before the crane is
driven.
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Z 200 153
Z 51 301
B3
B4
1
2
Z 51 331
31 40 32 33 34 35 36 37 38 39
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Checking the brake system.
(Z 200 153, Z 51 301, Z 51 331)
Emergency pressure supply in brake circuit 1 and 2:
Driver information display, submenu 4.4:
Pressure supply is displayed.
Upper row = braking circuit 1
Lower row = braking circuit 2
Driver information display, basic display:
Red indicator light, if pressure supply is below 5.5 bar
(80 psi).
Indicator light (B3) = braking circuit 1
Indicator light (B4) = braking circuit 2
Retaining brake: indicator light (39) if retaining brake is ap-
plied.
If the emergency pressure supply is below 7 bar (102 psi), the air
tanks of the braking system must be topped up at medium revs
until a pressure of 8 bar (116 psi) is reached.
Air pressure of at least 6.2 bar (90 psi) is needed to switch gears.
It is not possible to shift gears below this mark.
Immediately after starting to drive, test the brakes on a dry,
antiskid road surface (service and parking brake). At the
same time be sure that the crane vehicle brakes evenly, does
not deviate to the side and that a faultless brake delay is
achieved.
There must be no oil or water in the brake linings. If water has
permeated into the brake lining, lightly brake with the ser-
vice brake until the brakes are again fully functional.
Check steering wheel/driver seat setting
Exact instructions on the steering wheel / drivers seat settings
are in section 4 Drivers cab.
Vehicle lighting; check flashing lights and brake lights
6
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Z 200 216
51
B1
B19
Z 200 151
Z 51 332
100
A12 A13
A14
101 102
A11
99
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(Z 200 216, Z 200 151, Z 51 332)
Check the suspension system.
If a suspension circuit is outside the road travel level, the indi-
cator light (B1) on the drivers information display lights up.
The exact level of individual suspension circuits can be ob-
served in submenu 4.1.
All suspension cylinders must be in the road travel position
(green range);
When driving on the road the suspension must be in the 4way
system and it must not be locked. (Switch 99, 100 in the off posi-
tion, no displays A11, A12).
Check the fuel level, fill up if required.
The fuel supply is displayed on the instrument panel with in-
strument (51). If the fuel level is in the reserve range, indicator
light (B19) lights up.
Do not fill up with fuel while the engine is running!
Other important specifications are outlined in the individual sec-
tions.
Check the function of the vehicle lighting, warning and brake
lights and make sure that they are clean. Replace any defective
bulbs.
Check the tyre condition and air pressure. The air pressure has
a large influence on:
The handling of the vehicle
The running characteristics of the tyres
Tyre damage is inevitable if tyre pressure is too low.
It is therefore essential to apply the correct air pressure.
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Z 36 570
Z 35 568 Z 36 571
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6.3 Transport Safety Locks
During transportation, the safety locks provided must be applied.
Following driving and before the superstructure is placed in ope-
ration, the safety locks must be removed again.
When driving with the hook block reeved, it must be fastened
to the front coupling ring of the crane chassis. (Z 36 570)
When driving without a hook block, the hoist rope is secured
with the rope socket on the front coupling ring of the crane
chassis. (Z 36 571)
Apply mechanical superstructure locking device.
(see section 4 of the operating instructions for the superstruc-
ture)
The platform on the superstructure cab must be pushed into-
transport position (switch actuation; see section 4 of the ope-
rating instructions for the superstructure)
If the reeved hook block is set down on the crane chassis
when the crane is driven, it must be inserted in the holding de-
vices provided (optional equipment) and must be secured ac-
cordingly. (Example Z 35 568)
The rope must be guided over the corresponding rope confi-
gurations on the chassis cab and chassis frame.
Outrigger struts pinned / locked in the transport position.
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6.4 Axle Loads / Speeds / Tyres
The permitted driving speed is dependent on the axle load and
the tyres. There is a direct correlation between the axle load, tyre
size and permitted speed.
With the axle loads we differentiate between the technically
possible loads and those permitted by road traffic regula-
tions.
All chassis parts / components are designed and approved ex
works for even axle loads of 12 t (26.4 kip) per axle.
Axle loads above and below 12 t (26.4 kip) represent a deviation
from the documented EEC approved condition.
Uneven or excessively high axle loads negatively affects the
handling of the crane in any case. Lower axle loads also have a
negative effect.
Deviation from the approved condition always means worse
handling characteristics. The larger the deviations, the
worse the crane handles.
The limitations that must be observed as a result are corres-
pondingly larger.
Observe the relevant instructions in the following subsec-
tions.
Before driving in public traffic the driver must be fully con-
versant with the altered driving/steering/braking behaviour
(e.g. longer braking distances) of the crane especially
where the driving condition of the crane deviates from the
standard configuration.
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6.4.1 Possible Axle Loads / Permitted Speeds
Pay attention to the relation between the axle loads, the driving
speed and the tyres fitted as shown in the following table.
The determining factor is the axle that is placed under the highest
load.
RISK OF ACCIDENTS due to overloading of tyres!
The maximum permitted speed for the actual axle load
must be observed at all times.
Failure to observe these instructions can result in the ty-
res being overloaded and bursting.
6.4.1.1 Tyres, Manufactured by Michelin (XGC)
Michelin Tyres
Tyre size 445/80 R 25 525/80 R 25 Tyre size
(17.50 R 25) (20.50 R 25)
Ply 170E 179E
Tyre pressure 7.0 bar 7.0 bar Tyre pressure
(102 psi) (102 psi)
Tread XGC
Maximum speed Axle loads Axle loads
km/h mph t kip t kip
80 50 9.8 21.6 12.7 28.0
70 44 12.0 26.4 14.5 32.0
60 37 13.1 28.8 15.0 33.0
50 31 14.2 31.3 16.6 36.6
40 25 14.9 32.8 17.5 38.6
30 18 15.6 34.4 19.8 43.6
20 12 15.9 35.0 21.1 46.5
10 6 20.1 44.3 26.9 59.3
5 3 22.8 50.3 30.4 67.0
2 1 26.2 57.8 35.0 77.1
6
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6.4.1.2 Tyres, Manufactured by Michelin (X Crane)
Michelin Tyres
On Road Off Road
Tyre size 385/95 R 25 445/95 R 25 385/95 R 25 445/95 R 25 Tyre size
(14.00 R 25) (16.00 R 25) (14.00 R 25) (16.00 R 25)
Ply 170F 174F 170F 174F
Tyre pressure 9.0 bar Tyre pressure
(131 psi)
Tread X Crane
Maximum speed Axle loads Axle loads Axle loads Axle loads
km/h mph t kip t kip t kip t kip
80 50 12.0 26.4 13.4 29.5
70 44 12.6 27.8 14.1 31.1
60 37 13.2 29.1 14.7 32.4
50 31 13.5 29.7 15.0 33.1
40 25 13.8 30.4 15.4 33.9
30 18 15.0 33.1 16.8 37.0 15.6 34.4 19.0 41.9
20 12 18.0 39.7 20.1 44.3 18.0 39.7 20.5 45.2
10 6 21.6 47.6 24.1 53.1 22.5 49.6 26.8 59.1
5 3 25.2 55.5 28.1 61.9 25.4 56.0 32.6 71.9
2 1 28.1 61.9 31.4 69.2 29.3 64.6 36.0 79.4
6
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6.4.1.3 Tyres, Manufactured by Bridgestone
Bridgestone Tyres
(17.50 R 25) (20.50 R 25)
Ply 170E 179E
(102 psi) (102 psi)
Tread VGT VHS
80 50 9.8 21.6 12.7 28.0
70 44 12.0 26.4 14.5 31.9
60 37 13.4 29.5 15.0 33.1
50 31 14.2 31.3 16.6 36.6
40 25 14.9 32.8 17.5 38.6
30 18 15.6 34.4 19.8 43.6
20 12 15.9 35.0 21.1 46.5
10 6 20.1 44.3 26.9 59.3
5 3 23.9 52.7 32.0 70.5
2 1
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Bridgestone Tyres
On Road Off Road
Tyre size 385/95 R 25 445/95 R 25 385/95 R 25 445/95 R 25 Tyre size
(14.00 R 25) (16.00 R 25) (14.00 R 25) (16.00 R 25)
Ply 170F 174F 170F 174F
Tyre pressure 9.0 bar 9.0 bar 9.0 bar 9.0 bar Tyre pressure
(131 psi) (131 psi) (131 psi) (131 psi)
Tread VHS
Maximum speed Axle loads Axle loads Axle loads Axle loads
km/h mph t kip t kip t kip t kip
80 50 12.0 26.4 13.4 29.5
70 44 12.6 27.8 14.0 30.9
60 37 13.2 29.1 14.7 32.4
50 31 13.4 29.5 15.0 33.1
40 25 13.8 30.4 15.4 33.9
30 18 15.0 33.1 16.7 36.8 15.0 33.1 16.7 36.8
20 12 18.0 39.7 20.1 44.3 18.0 39.7 20.1 44.3
10 6 21.6 47.6 24.1 53.1 22.0 48.5 26.8 59.1
5 3 25.2 55.5 28.1 61.9 25.4 56.0 31.0 68.3
2 1 32.0 70.6 36.0 79.4
6
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6.4.1.4 Tyres, Manufactured by Magna
Magna Tyres
On Road Off Road
(16.00 R 25) (16.00 R 25)
Ply 174F 174F
(131 psi) (131 psi)
Tread MA03
80 50 13.4 29.5
70 44 14.1 31.1
60 37 14.7 32.4
50 31 15.0 33.1
40 25 15.4 33.9
30 18 16.8 37.0 18.6 41.0
20 12 20.1 44.3 20.6 45.4
10 6 24.1 53.1 27.0 60.0
5 3 28.1 61.9 32.6 71.9
2 1 31.4 69.2 36.0 79.4
6
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6.4.2 Driving with Uneven Axle Loads
Uneven axle loads have a negative effect on the handling of the
crane.
The braking system is designed for even axle loads of 12 t
(26.4 kip) in accordance with EC guidelines and German
road traffic regulations.
Different axle loads at the front and rear represent a devia-
tion from the approved crane configuration. The vehicle
handling will deteriorate to a greater or lesser degree, de-
pending on the amount of deviation!
The larger the differences, the more serious the deteriora-
tion. Drive with appropriate caution and reduce the driving
speed; if necessary, walking speed must be maintained.
React to poor road conditions by further reducing the driving
speed.
Axle load ratios, heaviest axle : lightest axle > 2 : 1 are not
allowed as they cannot be properly handled from a driving
perspective.
Any driving conditions that deviate from these must be listed
under declared driving conditions or require express per-
mission from case to case.
In the case of uneven axle loads, the steering can be locally
overloaded. This can result in damage to the steering.
Caution when braking!
Apply force evenly when braking. Sudden and abrupt ap-
plication of the brake pedal can cause the wheels to lock;
the vehicle could career out of control.
Caution when steering!
When driving through curves, the vehicle tends towards
the straightahead steering position.
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6.4.3 Driving with Reduced Axle Loads
Reduced axle loads have a negative affect on the handling of the
vehicle.
Braking:
Risk of accidents!
The braking system is designed and approved for axle
loads of 12 t (26.4 kip). At lower axle loads, the crane is
overbraked.
Vehicles without ABS:
Abrupt use of the brake pedal could cause all the wheels
to lock suddenly. The lower the axle loads, the greater
the risk of the axles locking.
Use the brakes therefore with care, as appropriate to the
situation!
Vehicles with ABS:
The braking effect becomes less satisfactory.
Steering:
Risk of accidents!
The steering behaviour is changed.
The steering system is lighter and reacts more quickly
when axle loads are reduced. It becomes less smooth.
Risk of damage!
There is a risk of damage to the steering components; e.g.
as a result of external resistance at the wheels.
Suspension system:
Risk of accidents!
The standardequipped suspension system is designed
for axle loads of 12 t (26.4 kip). The suspension becomes
harder with lower axle loads. When axle loads are less
than 7 t (15.4 kip), the crane behaves as though the sus-
pension were blocked. The crane may begin to skid.
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There is a way to adjust the suspension system permanently to
the reduced axle loads. The preload pressure of the accumula-
tors must be adapted for this purpose. If this option is available
for your equipment, then you will find corresponding information
on the hydraulic circuit diagram or in the respective Lubrication
and Maintenance Instructions in the Hydraulics system section.
If no information concerning this is available, then corresponding
values are obtainable upon request.
Risk of accidents!
If the crane is to be moved again with axle loads of 12 t
(26.4 kip), then the preliminary tension of the suspension
accumulator must be modified again accordingly.
If the crane is driven alternately with 2 axle load statuses, then
the crane can be optionally equipped for switch actuation to
change the suspension back and forth between the 12 t
(26.4 kip) axis load configuration and the axis load configuration
with reduced axle loads.
A corresponding switch is then located in the drivers cab.
Additional information on this topic can be found then in sec-
tion 11 Hydraulic suspension.
Behaviour of the driver with reduced axle loads:
Risk of accidents! Risk of skidding!
If the preload pressure of the accumulators of the sus-
pension system is not reduced, then the maximum dri-
ving speed must be reduced. The lower the axle load, the
slower the driving speed must be. For axle loads of less
than 8 t (17.7 kip), the permitted maximum speed is still
no more than 30 km/h (18 mph). The maximum speed
must be reduced even further with additional axle load
reduction and/or poor road conditions.
Risk of accidents! Risk of skidding!
For vehicles without ABS:
If the charging pressure of the accumulators of the sus-
pension system is reduced (manually or with switcho-
ver), then the maximum driving speed must be reduced
to 50 km/h (31 mph).
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6.4.4 Driving with axle loads exceeding 12 t (26.4 kip)
Driving with axle loads of more than 12 t (26.4 kip) is always
an exceptional condition and is only permitted for short
stretches.
Drive extremely carefully and reduce your maximum driving
speed.
The correlation between the technically possible axle loads
and the maximum driving speed should be observed.
All travelling gear parts / components were designed in the fac-
tory for axle loads of 12 t (26.4 kip) and approved (approved con-
dition see Driving with an overall weight of 60 t (132.3 kip).
Axle loads of 12.5 t (27.6 kip) mean that the approved crane con-
dition has already been exceeded.
Axle loads exceeding 12 t (26.4 kip) mean:
Higher loads.
Overloading of tyres (for certain sizes).
Extended braking distances / risk of fading.
Increased loads
Axle loads of more than 12 t (26.4 kip) lead to increased loads on
the steering, axle suspension, axles, wheel hubs, bearings, sus-
pension system, suspension cylinders, brakes, wheels and tyres.
This means a considerable reduction in the life expectancy and
service life for the affected components.
Wear on brake linings is particularly increased. There is a risk of
overheating (fading).
Loading / overloading of tyres
Sudden loads (e.g. driving against kerbs), bead damage or cut-
ting damage must be avoided under these more exacting opera-
ting conditions.
Damage to a tyre can result from the combination of overloading
and / or increased speed. Damage does not necessarily have to
follow a handling error. These add up over time and can result in
more serious damage following a relatively minor incident.
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RISK OF ACCIDENTS when tyres are damaged!
Damage to tyres must be rectified by professionals.
You must observe the highest possible maximum speed
for the actual axle load (see section 6, Possible axle
loads / permitted speeds. Failure to observe these in-
structions can result in the tyres being overloaded and
bursting.
Extended braking distances / risk of fading
The braking system for this vehicle is designed in accordance
with EC directives and German road traffic regulations for an axle
load of 12 t (26.4 kip).
Extreme risk of accidents due to extended braking di-
stances!
At axle loads above 12 t (26.4 kip) the braking decelera-
tion as required in accordance with EC partial operating
approval, can no longer be guaranteed / maintained.
The braking distances are, as a result, considerably or
even extensively extended and there is a risk of overhea-
ting (fading).
6.4.4.1 Driving with axle loads up to 12.5 t (27.6 kip)
You must observe the highest possible maximum speed
for the actual axle load (see section 6, Possible axle
loads / permitted speeds. Failure to observe these in-
structions can result in the tyres being overloaded and
bursting.
Possible driving speeds are only permitted within existing tyre li-
mit values; i.e. the possible maximum speed may not be driven
when the tyres are not permitted for this speed (at certain axle
loads).
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6.4.4.2 Driving with axle loads up to 16.5 t (36.4 kip)
This technically possible driving condition does not meet the re-
gulations of the German road traffic licensing regulations and the
EEC directives.
Therefore driving in this region is only permitted on private roads
and grounds. These must have a sufficient loadbearing capa-
city and must be sufficiently level (e.g. no potholes).
If the crane is driven with axle loads above 12.5 t (27.6 kip), the
following points must be observed:
Only short driving stretches are permitted at any time.
Before driving take the axle loads from the listed driving con-
dition or recalculate based on the current configuration using
the weight table.
The determining factor is always the axle that is under the hig-
hest load.
With the lift axle raised, the crane may not be driven, as rai-
sing the lift axle leads to a further prohibited increase in the
axle load.
The crane must not be steered on the spot or when on very
uneven ground.
During driving the displayed pressures of the suspension cir-
cuits must be observed. They should be proportionate and
must not exceed 260 bar (3771 psi).
Calculate the maximum permitted speed based on the cur-
rent axle load and observe this maximum while the crane is
driven.
Before driving in public traffic, the driver must be fully conver-
sant with the changed driving / braking behaviour of the crane
(e.g. longer braking distances).
Reduce the maintenance intervals; carry out inspections
more often.
Risk of damage as a result of premature wear!
RISK OF ACCIDENTS as a result of worn components!
Special instructions / warnings related to this are summari-
sed in the subsection Shorter maintenance intervals for
axle loads over 12.5 t (27.6 kip).
The information given here must be observed at all times.
The crane manufacturer shall not be held liable for damage resul-
ting from premature wear when driving with axle loads above
12.5 t (27,6 kip).
Crane operators / crane drivers carry sole responsibility when the
crane vehicle is driven with axle loads > 12.5 t (27.6 kip).
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6.4.5 Shorter maintenance intervals for axle loads above
12.5 t (27.6 kip)
Even when observing the specified, axleloaddependent dri-
ving speeds, driving with axle loads > 12.5 t (27.6 kip) is only per-
mitted temporarily.
Driving with axle loads of more than 12.5 t (27.6 kip) is always
an exceptional condition and is only permitted for short
stretches. even if higher values are permitted by individual
national regulations.
The crane manufacturer shall not be held liable for damage resul-
ting from premature wear when driving with axle loads above
12.5 t (27,6 kip).
Risk of damage as a result of premature wear!
If the crane is driven with axle loads above 12.5 t (27.6 kip),
steering, axle suspension, axles, wheel hubs, bearings, sus-
pension system, suspension cylinders, brakes, wheels and
tyres must be checked regularly at least once every 3
months however for damage and wear.
This applies especially to the setting of the steering geome-
try and the brake linings!
RISK OF ACCIDENTS as a result of worn components!
When defects are discovered they must be dealt with imme-
diately in order to prevent safety risks, further wear orirrepa-
rable damage to the component.
The steering geometry and other components relevant to the
safety of the crane may only be checked and, if necessary,
repaired by our customer service technicians or a corres-
ponding specialist workshop.
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Z 160 015
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6.5 Driving on Public Roads
(Z 160 015)
This crane vehicle has extraordinary dimensions and
weights.
Make sure that the vehicle is driven with caution and fore-
sight (avoiding regular acceleration and braking).
The maximum permitted speed for this vehicle in Germany is
80 km/h (50 mph).
When driving on public roads the crane vehicle must be in a spe-
cific transport condition.
The transport condition of the mobile crane depends on the road
traffic regulations applicable in the country in which the crane is
to be operated.
In countries with EEC approval regulations, axle loads of
max. 12 t (26.4 kip) are permitted when driving on public
highways.
In countries with different national regulations the permitted
axle loads may actually be lower than 12 t (26.4 kip).
The crane operator / driver must ensure that the axle loads
are within the permitted limits and that they are evenly distri-
buted and that any additional restrictions are observed.
If the axle loads are exceeded or other regulations are not
followed, they carry sole responsibility.
As a rule, the specifications in the section Axle loads /
speeds / tyres and the corresponding subsections must be
observed exactly.
In the interests of safety, the technically possible maxi-
mum axle loads should not be exceeded at the corres-
ponding speed indicated in the lefthand column.
Adapt the driving speed to the actual axle loads and the
route conditions.
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6.5.1 Driving with axle loads of 12 t (26.4 kip)
In accordance with the EEC directive and the German road
traffic licensing regulations, axle loads are permitted of up
to 12 t (26.4 kip). This is equivalent to an overall weight of 60 t
(132.3 kip).
The vehicle is fully approved for this condition.
This transport condition is listed in the section Defined transport
conditions under Driving with overall weight 60 t (132.3 kip).
6.5.2 Driving in the United Kingdom (UK Approval)
In the United Kingdom (UK) special approval regulations apply.
In the United Kingdom (UK) as a result of a special national
regulation other (higher) axle loads can occur.
Instructions on applying the national regulation Special Type
General Order can be found in the additional section 61 Driving
in the UK.
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Z 53 777
1
Z 53 778
2
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6.5.3 Checks Always Done before Driving on the Road
Before driving on the road, always make sure the following condi-
tions are met:
All transport locks must be fitted (see under Transport
locks).
The main boom must be in Road travel condition (telescopic
sections pinned, locking / pinning unit locked in transport po-
sition (see part 1, section 12)).
The suspension is not to be locked; it must be set to the
4waysystem and be at the road travel level (see sec-
tion 11).
The steering must be in Road travel condition (see sec-
tion 9).
A disc must be inserted in the tachograph.
Emergency devices e.g. first aid box, warning triangle, fire ex-
tinguisher must be complete and easy to reach.
The housing cover of the outrigger controls on the side of the
chassis must be closed.
(Z 53 777)
The ladders, which are loose (1) must be attached to the hol-
ders on the chassis and secured with the rubber fixtures.
(Z 53 778)
The ladder, which is loose (2) must be attached to the holders
under the drivers cab and secured with the rubber fixtures.
No loose parts are permitted on the equipment.
This crane vehicle has extraordinary dimensions.
Pay attention in particular to the overhead clearance and
check the route in this respect.
Caution with the quick release coupling!
The equipment may be equipped with a quick release
coupling (between the superstructure and chassis).
In this case the height dimension is 4135 mm (13.6 ft).
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Z 200 235
X
Z 53 774
Y
2EXPLICIT
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(Z 200 235, Z 53 774)
Notes on the vehicle height for onroad driving:
A vehicle height of 4000 mm (13.12 ft) must be complied with.
The device can be equipped with additional rope carriers
(X) and / or a rope bracket (Y) at the boom head (on the
boom cases).
If such parts are attached, the vehicle height is 4120 mm
(13.51 ft). This is no condition for driving onroad!
Risk of damage!
In order not to exceed the maximum permitted height for
onroad driving of 4000 mm (13.12 ft), these components
must be removed.
If a quick coupling is attached, this results in an additio-
nal 135 mm (5.3 in) to the overall height.
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Z 53 791
1a
6
R
L
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6.6 Defined Driving Conditions
6.6.1 Driving with total weight 60 t (132.3 kip)
Version 1:
(Z 53 791)
Crane with:
Main boom
Locking and pinning unit in the transport position
Main boom extension 17 m (55.8 ft) at the side of the main
boom
Hook block 250 kg (551 lbs), hook suspension gear on bum-
per
Hoist 1
Counterweight base plate 1a (3.71 t / 8180 lbs) (set down /
secured onto chassis)
Counterweight plate 6R, 6L (2.59 t / 5699 lbs) (pinned to the
superstructure on the left / right)
Wooden box at rear (empty)
Tyres 16.00 R 25
Crane without:
Hoist 2
Spare wheel
Axle loads:
Axles 1 to 5: 12 t (26.4 kip) each
6
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Z 53 792
1a
1b
Driving the Crane 6
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Version 2:
(Z 53 792)
Crane with:
Main boom
Locking / pinning unit in transport position (at the rear in the
main boom)
Hook block 250 kg (551 lbs), hook suspension gear on bum-
per
Hoist 1
Hoist 2
Counter weight base plate 1a (3.71 t / 8180 lbs) + counter-
weight plate 1b (1.93 t / 4255 lbs) (attached to the chassis /
secured)
Wooden box at rear (empty)
Tyres 16.00 R 25
Spare wheel
Crane without:
Main boom extension
Counterweights on the superstructure
Axle loads:
Axles 1 to 5: every 12 t (26.4 kip)
6
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Z 53 793
Driving the Crane 6
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6.6.2 Driving with total weight 35.4 t (78 kip)
(Z 53 793)
Exceptional driving condition for reducing the axle loads to
meet respective national regulations.
Crane with:
Supports complete
Superstructure position 180 (turned to the rear)
Luffing cylinder
Tyres 16.00 R 25
Crane without:
Main boom
Main boom extension
Hoist 2
Counterweights
Spare wheel
Hook block
Axle load distribution:
Axle 1: 6.7 t (14.8 kip) Axle 4: 7.2 t (15.9 kip)
Axle 3: 7.5 t (16.5 kip)
The braking system for this vehicle is designed in accor-
dance with EC directives and German road traffic regula-
tions for an axle load of 12 t (26.4 kip).
When the main boom is removed, the axle loads arecorres-
pondingly lower; the crane is overbraked.
Use the brakes carefully, applying braking power in stages.
Abrupt use of the brake pedal could cause all the wheels to
lock suddenly.
Drive carefully and reduce the theoretically possible maxi-
mum speed accordingly. It must not exceed max. 50 km/h
(31 mph); the speed mustbe reduced further in case of bad
road conditions.
6
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Z 53 793
Driving the Crane 6
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To be observed when driving on the road:
Lash the luffing cylinder to the support.
Mark protruding luffing cylinder in accordance with road traffic
regulations.
The protruding luffing cylinder could present a danger
for the road users behind.
Only drive on public roads in this condition in accor-
dance with the applicable motor vehicle safety stan-
dards.
To remove and fit the main boom, see part 1 (operating instruc-
tions of the superstructure).
6
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Z 53 790
1a
6
R
L
5
1b
2
Driving the Crane 6
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6.6.3 Driving with total weight 73.8 t (162.7 kip)
(Z 53 790)
Technical drivability is only permitted on construction si-
tes and on private roads.
Relevant instructions and warnings in section Axle loads /
speeds / tyres must be followed.
Crane with:
Main boom
Locking / pinning unit in transport position (at the rear in the
main boom)
Main boom extension 17 m (55.8 ft) folded / locked on the
side of the main boom (see part 1, section 18).
Hook block 3sheave, model 63 (700 kg / 1543 lbs) at bum-
per
Hoist 1, hoist 2
Counter weight 13.57 t (29905 lbs) on the chassis:
Weight plate 1a (3.71 t / 8180 lbs) + weight plate 1b (1.93 t
/ 4255 lbs) + weight plate 2 (7.92 t / 17455 lbs).
Counter weight 5.19 t (11530 lbs) on the superstructure:
Weight plate 6R, 6L (2 x 1.3 t / 2 x 2866 lbs) + weight plate 5
(2.6 t / 5745 lbs).
Wooden box, empty
Tyres 16.00 R 25
Axle load distribution:
Axle 3: 15.0 t (33.1 kip)
The maximum permitted speed must be observed for the
current axle load (see section 6 under Possible axle
loads / permitted speeds). The determining factor is al-
ways the axle that is under the highest load. Failure to
observe these instructions can result in the tyres being
overloaded and bursting.
Extreme risk of accidents due to extended braking di-
stances!
Axle loads exceeding 12 t (26.4 kip) result in a signifi-
cantly longer braking distance and the risk of fading.
6
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Z 200 217
B13
58 50
Driving the Crane 6
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6.7 Driving Downhill
Reduce the speed and select a lower gear.
Observe the revolution counter (50, Z 200 217) to prevent the
engine speed moving into the danger zone.
Use nonwearing sustainedaction brakes (exhaust brake,
hydraulic retarder).
Only use the service brake briefly as an auxiliary brake.
The gear range in which the crane can be maintained at a
constant speed must be selected before the crane is
driven downhill.
When transmission is in automatic operation:
When the engineindependent sustainedaction brake is swit-
ched on, the transmission automatically adjust the gears to reach
an optimal braking effect (engine speed faster than 1100 min
1
).
The effect of the exhaust brake and the hydraulic retarder is de-
pendent on the engine speed.
The higher the rpm, the greater the braking effect.
When the hydraulic retarder is used, heat is created in the
transmission.
The transmission oil temperature is monitored indirectly (via
the coolant temperature of the engine) with the help of the
preheating indicator (B13) in the driver information display.
If the oil temperature rises to prohibited values (over 1505 C /
3025 F), which in turn leads to the coolant temperature being too
high, the retarder performance must be reduced until the coolant
temperature is consistently lower than 955 C (2035 F).
If the retarder output is not regulated by the driver, the system au-
tomatically reduces the braking effect until the permissible tem-
perature has been reached (again).
The service brake may only be used to brake the crane
until the speed is read at which the transmission shifts
down to the next gear.
The service brake must not be used for sustained pe-
riods under any circumstances. Risk of fading!
6
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Z 200 218
94
A9
Driving the Crane 6
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6.8 Driving over Hill Summits
(Z 200 218)
When driving over hill summits, it must be ensured that all axles
remain in contact with the ground.
The crane operator bears sole responsibility for any damage to
the crane chassis caused by exceeding the maximum suspen-
sion travel or block position of the suspension and exceeding
the maximum axle loads when an axle lifts off the ground.
When driving over hill summits, it is prohibited:
to lock the suspension
to exceed an axle load of 14 t (30.8 kip)
as components MAY BREAK otherwise!
If an axle should however lift off the ground, proceed as follows:
1. Stop the crane in a straight position and engage the longitudi-
nal differential lock by actuating Actuate switch (94) while do-
ing so; The indicator light (A9) lights up.
2. Driving over a hill summit at walking speed (max. 5 km/h
(3 mph)).
Whilst driving over the summit:
Avoid turning the steering.
Observe the suspension pressure continually.
If the pressure in one of the three suspension circuits ri-
ses to 260 bar (3773 psi), then AXLES MAY BREAK!
If a pressure of 300 bar (4354 psi) is reached, then the hill
top must not be driven over.
Reverse carefully.
3. After driving over the hill summit, stop the crane immediately
and switch off the longitudinal differential lock again. Actuate
switch (94) while doing so; indicator light (A9) goes out.
6
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Driving the Crane 6
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6.9 Checking the Operation Functions During the Jour-
ney
All indicator light/display instruments are located in the drivers
cab (see section 4).
While driving, the driver must constantly observe the display in-
struments and monitoring elements.
6.9.1 Monitoring Elements in the Instrument Controls
Item Monitoring element Display Comments (measure)
5
Pressure gauge
Suspension circuit, front right
Pressure falls abruptly in one suspension circuit during
travel: A hazardous fault has occurred.
6/7
Pressure gauge
Suspension circuit, rear right
8
Pressure gauge
Suspension circuit, front left
Stop the crane, rectify the fault.
9/10
Pressure gauge
Suspension circuit, rear left
35 STOP lamp
Display of a hazardous fault
35 STOP lamp
STOPobserve order
38 Lamp retarder
Hydr. retarder / exhaust brake actuated
38 Lamp retarder
Pay attention to coolant temperature
40 Rear fog lamp
Rear fog lamp switched on
40 Rear fog lamp
Only use rear fog lamp as intended
50 Revolution counter
Engine speed display
50 Revolution counter
Observe in driving mode
Engine speed monitoring
50.1 LED Excessive engine speed
Lights up when engine speed excessive; at the same
time, a warning buzzer sounds. Avoid excessive engine
speed, otherwise you will cause damage to the engine!
58 Display coolant temperature
Coolant temperature too high:
Indicator light (B13) on the display (43) is at 104 C
(219 F). An additional buzzer sounds at 110 C
(230 F).
Switch off the engine immediately and rectify the fault
6
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Z 200 158
B1
B2
B27
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B3
B28
B29
B30
B31
B32
B33
B34
CHECK
Driving the Crane 6
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6.9.2 Indicator Lights on the Display (43)
Driver Information System
(Z 200 158)
Item Indicator light Display Comments (measure)
B2
Electronic hydraulic rearaxle
steering
Electronic hydraulic rearaxle steering fault
B2
steering Stop vehicle, read out fault code, rectify fault.
B3
B4
Braking circuit 1
Braking circuit 2
Supply pressure has dropped below 5.5 bar (80 psi),
the correct functioning of the brakes is no longer ensu-
red.
B4 Braking circuit 2
Top up the supply tank with the engine running and the
vehicle at a standstill (before driving the crane).
B5 Clutch overload
Clutch temperature too high
B5 Clutch overload
Change operation condition (no dragging clutch)
Fault in drive gearbox
Stop vehicle, read out fault code, rectify fault.
B8 Steering circuit 1 Steering circuit 1 no throughflow
B9 Steering circuit 2 Steering circuit 2 no throughflow
B10 Steering circuit 3 (emergency
steering pump)
Steering circuit 3 (emergency steering pump) no flow B10 Steering circuit 3 (emergency
steering pump)
see section 9 Steering
If a fault is displayed while driving, then stop the crane
vehicle immediately; rectify fault.
B11 Engine coolant level
Coolant level too low
B11 Engine coolant level
Switch off engine and rectify fault
B12 Engine oil pressure
Engine oil pressure too low
B12 Engine oil pressure
B13 Engine coolant temperature
Coolant temperature in the engine is too high (above
104 C / 219 F). An additional buzzer sounds at 110 C
(230 F).
B14 Engine oil level
Engine oil level too low
B14 Engine oil level
B15 Engine malfunction
Fault display engine
B15 Engine malfunction
Read out fault codes; rectify fault.
B16 Charging current
Charging current too low
B16 Charging current
Switch off engine, rectify fault.
B18 Air filter
Air filter clogged
B18 Air filter
Service the air filter
B19 Fuel supply
Fuel supply in reserve range
B19 Fuel supply
Fill up with fuel
6
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Z 200 158
B1
B2
B27
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B3
B28
B29
B30
B31
B32
B33
B34
CHECK
Driving the Crane 6
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Follower axle steering circuit 1 no flow
B20 Follower axle steering circuit 1
If a fault is indicated during driving, stop the vehicle im-
mediately; rectify fault.
B21
Follower axle steering circuit 3
Follower axle steering circuit 3 (emergency steering
pump) no flow
B21
Follower axle steering circuit 3
(emergency steering pump)
If a fault is indicated during driving, stop the vehicle im-
mediately; rectify fault.
B22 SPS = data bus
Fault in the data bus system,
B22 SPS = data bus
Stop the vehicle, rectify the fault.
B24 Malfunction at dolly
Lift exceeded at hydraulic cylinder (if in addition to the
indicator light (B24): single acoustic warning signal and
indicator light Caution (36))
Critical inclination of the hydraulic cylinder (if in addition
to the indicator light (B24): Repeated acoustic warning
signal and indicator light STOP (35))
B25 Display
Display overload
B25 Display
Page down to next mask
B28
Engine brake / hydraulic retar-
der
Fault in exhaust brake / hydraulic retarder
B28
Engine brake / hydraulic retar-
der Reduce speed, if necessary stop, rectify fault
B29
ABS, vehicle, axles 1, 2, 3, 4
and 5
ABS malfunction
B29
ABS, vehicle, axles 1, 2, 3, 4
and 5 While driving: Adapt driving style, rectify fault
B30
ABS, trailer / follower axle / ad-
ditional axle
ABS malfunction
B30
ABS, trailer / follower axle / ad-
ditional axle While driving: Adapt driving style, rectify fault
B31
Malfunction check valves
B31
steering
If a fault is displayed during the journey, stop the vehi-
cle immediately, rectify fault
B32
Oil supply steering circuits ad-
ditional axle
Level in hydraulic oil reservoir too low
B32
Oil supply steering circuits ad-
ditional axle Stop vehicle immediately, rectify fault
B33 Warning buzzer engine
Engine fault
B33 Warning buzzer engine
Stop vehicle immediately, rectify fault
B34 CAN bus steering computer
no CAN bus connection to the steering computer
B34 CAN bus steering computer
Stop vehicle immediately, rectify fault
6
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Driving the Crane 6
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6.9.3 Displays on the Transmission Information
Displays (75)
Item Message Display Comments (measure)
CH = SelfCheck
Selfcheck of the system
CH = SelfCheck
Appears when Ignition on
AL = Airless
Air pressure in the transmission system is too low (be-
low 6.2 bar (90 psi)); Clutch does not open when stop-
ped Motor is stalled.
Transmission can stay in neutral = no through drive, no
engine braking
N = Neutral
R = Reverse
Transmission status, in gear
R = Reverse
116 = Gears
Further info, see section 7
FP = Accelerator pedal
Malfunction of accelerator pedal
FP = Accelerator pedal
Put accelerator pedal in idle position; if the display does
not go out, it is not possible to drive further
CL = Clutch
Clutch is overloaded
75
CL = Clutch
Change operation condition spare the clutch; select a
lower gear
CW = Clutch Wear
Clutch is worn out
CW = Clutch Wear
Go to a specialist workshop
EE = Electronic Error
Communication error in the electronic gear system
EE = Electronic Error
Rectify fault.
HT = Gear temperature
Transmission temperature too high
HT = Gear temperature
Change operation condition
Spanner symbol
System malfunction, indicator light (B6) together with
Caution (36)
Spanner symbol
Limited driving mode, go to specialist workshop
Spanner symbol
Serious system malfunction, indicator light (B6) toge-
ther with STOP (35)
Spanner symbol
+ STOP
Automatic driving mode deactivated, manual driving
mode possible, not permitted to continue driving, go to
specialist workshop
6
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Driving the Crane 6
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6.10 Driving on the Construction Site
6.10.1 Driving in the Transport Condition
Notes on ground conditions:
The ground conditions must be suitable for the individual axle
loads as well as the overall weight.
The route must be even and the ground must be able to support
the load.
When driving with the steering program Construction site
operation, deviating regulations apply (see section 9).
The differential locks may only be switched on for a brief period
of time, in order to bypass obstacles when driving straight
ahead.
Driving speeds of more than 5 km/h (3 mph) overload tyres and
driving unit.
Following the obstacle the differential locks must be switched off
again immediately.
The crane must be stationary when switching the differential
locks on and off.
The hydraulic suspension of the crane chassis must not be lok-
ked and must be set to level (see section 11).
When driving over hill summits or ramps, the same rules ap-
ply as for driving over hill summits on the road.
The instructions in that section must be followed.
For driving on surfaces that are not quite even, to improve the ve-
hicle handling the crane can be set to the 3circuit system (Notes
on this can be found in Sect. 11).
6
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Driving the Crane 6
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6.11 Driving in the Configured Condition
Driving in Erect Mode (with Erected Main Boom /
Equipment)
The crane can be equipped with another axle (trailing axle) in ad-
dition to the normal 5axlechassis (basic unit).
It is connected (on the rear of the vehicle) to the basic unit using
a hydraulic pinning system. This increases the number of axles
from 5 to 6.
The crane can be driven in erect mode in both versions.
There are different driving tables for both versions.
In order to avoid confusion, they are listed in separate sections.
The driving tables for the basic unit (5axlechassis) are
in this section (6, Driving).
If you driving with a fitted trailing axle (6axlechassis), the
driving tables are in a separate additional section (62).
The following Instructions on driving in erect mode are valid for
every chassis version.
6.11.1 Instructions on Driving in Erect Mode
Driving in Erect Mode always means: driving without
load on the hook!
Driving with load is prohibited!
The entire stability of the system during Driving in erect
mode is determined by the tyre.
Due to the high pressure, the tyre is greatly deformed.
The spring movements of the flanks lead to the erected
crane swinging. This means increased risk if tilting!
You must therefore drive with utmost care.
Driving in erect mode with steering program construction
site mode (switch (92) actuated) is PROHIBITED!
Driving in the configured condition is only permitted in the
4circuit system (for instructions, see Sect. 11).
6
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Z 39 851
2
1
Z 53 025
2
1
3
Z 52 106
90
Driving the Crane 6
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Notes on ground conditions:
The ground conditions must be suitable for the individual axle
loads as well as the overall weight.
The ground must be even and free of dips and rises, it must also
have sufficient loadbearing capacity.
Driving in erect mode with steering program construction
site mode (switch (92) actuated) is PROHIBITED!
Driving in the configured condition is only permitted in the
4circuit system (for instructions, see Sect. 11).
When driving in the erect mode:
The gradient must not exceed the following values:
2 % in the forward direction
1 % laterally (without additional equipment)
0.5 % laterally (with additional equipment)
Extend the outrigger struts and hold the outrigger feet just
above the ground.
There is a danger of overturning if the outrigger struts are not
extended!
Make sure that the outrigger struts are correctly pinned and
locked!
The suspension system of the crane chassis must be locked
(see section 11).
Driving speed is not to exceed walking pace.
Distributor gear: Offroad gear level.
Drive gearbox: 1st gear, Manual operating mode.
Clutch: Starting mode; (only for the last cm possibly Ma-
noeuvring mode with switch 90). (Z 52 106)
Risk of accidents!
If the CL warning appears on the transmission display,
immediately stop and let the system cool down.
If you do not stop, the sudden closing of the clutch (see
ch. 7. Clutch protection) will cause a jerky movement
of the rigged crane.
The crane could fall over.
Main boom to the rear apply mechanical superstructure lok-
king device. Locking bolt (1) must be inserted in locking strip
(2). Make sure that this is the case (Z 39 851).
For machines with dolly equipment (optional) the locking pin (1)
can only insert in locking strip (2) when the release lock (plug) (3)
has previously been removed. (Z 53 025)
6
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Z 200 233
5 7
9
6
8 10
Driving the Crane 6
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The hook block must be secured on the chassis e.g. on the
manoeuvring / trailer coupling, or also on the outriggers (tele-
scoped out) to prevent swinging movements (or it must be rai-
sed).
Apply the slew gear brake.
For devices with dolly equipment (option), the slewing gear brake
should not be locked open (see Driving with the dolly).
Caution with side winds, above all if they are acting in the
same direction as a transverse gradient.
Constantly monitor the suspension pressure on pressure
gauges (5) to (10) in the drivers cab. (Z 200 233)
If the pressure in one of the suspension circuits rises to
300 bar (4354 psi), stop the crane immediately and extend
the supporting cylinders, until the wheels are been relieved.
Level the crane by resetting the hydraulic suspension and/or
correcting the boom position.
If the crane is driven further it may OVERTURN or the AXLES
MAY BREAK!
6
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Driving the Crane 6
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The following tables concerning superstructure position, boom
angles and lengths and axle loads correspond to the following
configuration:
Basic unit with:
Counterweight (incl. hoist 2) in accordance with correspon-
ding table sheet.
Calculated hook block in accordance with the corresponding
table sheet.
Corresponding equipment (e.g. main boom extension).
Driving the crane with other rigging configurations other
than those specified in the following table sheets (driving ta-
bles) is PROHIBITED!
The driving tables are available using metric or British / Ame-
rican dimension units in the section. When using the tables,
make sure to use the correct units of measurement.
When changing the calculated hook block, slight adjustment of
the main boom (or of the equipment) can achieve a more balan-
ced axle load again.
The suspension pressure when lowering the crane from the ou-
triggers onto the wheels can be monitored via the pressure gau-
ges. When this is done, 260 bar (3773 psi) must not be excee-
ded.
Axle load Suspension pressure
12 t (26.4 kip) 105 bar (1524 psi)
15 t (33 kip) 140 bar (2032 psi)
20 t (44.1 kip) 190 bar (2903 psi)
25 t (55.1 kip) 240 bar (3483 psi)
27 t (59.5 kip) 260 bar (3773 psi)
In general balanced loads, as specified in the following table, are
to be aimed for.
6
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Z 200 075
B
A
RA
Driving the Crane 6
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6.11.2 Driving Tables with Metric Dimension Units
6.11.2.1 Driving with Main Boom
Counterweight 0 t 39 t
(metric dimensions)
(Z 200 075)
Axle load table: correlation of the axle loads with boom position
and configuration.
Counter-
weight
(t)
Super-
structure
to (*)
A
(m)
B
( )
RA
(m)
Axle load in (t)
Axle weight
(t)
structure
to (*)
(m)
( )
(m)
1 + 2 3, 4, 5
0 80 0.5 10.8 10.8
6.3 75 1.6 12.1 12.0
8.3 73 2.0 12.5 12.4
10.8 71 2.4 13.0 12.9
13.5 68 3.0 13.5 13.5
18.8
rear 12.5
64 3.7 14.6 14.5
21.4
rear 12.5
61 4.3 15.0 15.1
23.2 60 4.5 15.5 15.4
25.8 57 5.0 15.9 16.0
28.4 54 5.5 16.4 16.5
31 52 5.8 17.1 17.0
39 43 7.2 18.6 18.6
* Superstructure to: rear Main boom to the rear
The following hook block is included in the calculation:
3sheave, type 63 (700 kg)
6
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Z 200 079
B
A
C
D
RA
05
205
405
Driving the Crane 6
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6.11.2.2 Driving with the Main Boom Extension 9.1 m
Counterweight 6.3 t 39 t
(metric dimensions)
(Z 200 079)
and configuration.
Counter-
weight
(t)
Super-
structure
to (*)
A
(m)
B
( )
C
(m)
D
( )
RA
(m)
Axle load (t)
Axle weight
(t)
structure
to (*)
(m)
( )
(m)
( )
(m)
1 + 2 3, 4, 5
77 0 3.2 12.1 12.3
6.3 79 20 5.5 12.3 12.2 6.3
80 40 7.6 12.2 12.3
76 0 3.6 12.6 12.7
8.3 78 20 5.8 12.7 12.6 8.3
79 40 7.9 12.7 12.6
74 0 4.3 13.1 13.2
10.8 76 20 6.5 13.2 13.1 10.8
77 40 8.5 13.2 13.2
72 0 5.0 13.6 13.8
13.5 74 20 7.2 13.7 13.7 13.5
rear 12.5
75
9.1
40 9.1 13.7 13.7
rear 12.5
69
9.1
0 6.1 14.8 14.7
18.8 70 20 8.5 14.7 14.8 18.8
71 40 10.3 14.7 14.8
67 0 6.8 15.3 15.3
21.4 68 20 9.1 15.2 15.3 21.4
69 40 10.8 15.2 15.3
65 0 7.4 15.5 15.7
23.2 67 20 9.4 15.7 15.6 23.2
68 40 11.1 15.7 15.6
64 0 7.8 16.2 16.1
25.8 65 20 10.1 16.2 16.2 25.8
66 40 11.6 16.2 16.2
6
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Driving the Crane 6
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(Z 200 079)
Continuation of the table:
62 0 8.4 16.8 16.6
28.4 63 20 10.7 16.7 16.7 28.4
64 40 12.1 16.7 16.7
59 0 9.4 17.1 17.3
31 rear 12.5 61 9.1 20 11.2 17.3 17.2 31 rear 12.5
62
9.1
40 12.6 17.3 17.2
53 0 11.2 18.8 18.8
39 54 20 13.1 18.7 18.8 39
55 40 14.2 18.7 18.8
6
140_2060_237a_en 82/143
Z 55 658
A
B
C
D
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 83/143
6.11.2.3 Driving with the Main Boom Extension 17 m
(metric dimensions)
(Z 55 658)
and configuration.
Counter-
weight
(t)
Super-
structure
to (*)
A
(m)
B
( )
C
(m)
D
( )
RA
(m)
Axle load (t)
Axle weight
(t)
structure
to (*)
(m)
( )
(m)
( )
(m)
1 + 2 3, 4, 5
79 0 3.5 12.4 12.3
6.3 81 20 8.1 12.2 12.4 6.3
82 40 12.4 11.9 12.6
78 0 4.0 12.9 12.7
8.3 80 20 8.6 12.7 12.8 8.3
82 40 12.4 12.6 12.8
76 0 5.0 13.3 13.2
10.8 79 20 9.1 13.3 13.2 10.8
81 40 12.8 13.3 13.2
74 0 6.0 13.7 13.8
13.5 77 20 10.0 13.8 13.8 13.5
rear 12.5
79
17
40 13.6 13.8 13.8
rear 12.5
71
17
0 7.4 14.8 14.8
18.8 74 20 11.4 14.9 14.8 18.8
76 40 14.8 14.9 14.8
69 0 8.4 15.3 15.4
21.4 72 20 12.2 15.4 15.4 21.4
74 40 15.6 15.3 15.4
68 0 8.9 15.7 15.8
23.2 71 20 12.7 15.8 15.7 23.2
73 40 16.0 15.7 15.7
67 0 9.3 16.4 16.2
25.8 69 20 13.5 16.2 16.3 25.8
71 40 16.7 16.2 16.3
6
140_2060_237a_en 84/143
Driving the Crane 6
140_2060_237a_en 85/143
(Z 55 658)
65 0 10.3 16.8 16.7
28.4 67 20 14.4 16.7 16.8 28.4
69 40 17.4 16.7 16.8
63 0 11.2 17.3 17.3
31 rear 12.5 66 17 20 14.8 17.4 17.3 31 rear 12.5
68
17
40 17.7 17.4 17.3
58 0 13.4 18.9 18.8
39 60 20 17.2 18.8 18.9 39
62 40 19.7 18.9 18.9
6
140_2060_237a_en 86/143
Z 55 659
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 87/143
(metric dimensions)
(Z 55 659)
and configuration.
Counter-
weight
(t)
Super-
structure
to (*)
A
(m)
B
( )
C
(m)
D
( )
RA
(m)
Axle load (t)
Axle weight
(t)
structure
to (*)
(m)
( )
(m)
( )
(m)
1 + 2 3, 4, 5
81 0 3.7 12.6 12.4
6.3 82 20 8.7 12.2 12.7 6.3
82 40 13.5 11.7 13.0
80 0 4.4 13.0 12.8
8.3 82 20 8.7 12.9 12.9 8.3
82 40 13.5 12.4 13.2
78 0 5.6 13.3 13.5
10.8 81 20 9.4 13.5 13.3 10.8
82 40 13.5 13.3 13.5
77 0 6.3 13.9 14.0
13.5 79 20 10.6 13.9 14.0 13.5
rear 12.5
81
25
40 14.1 13.9 14.0
rear 12.5
74
25
0 8.2 14.9 15.1
18.8 77 20 11.8 15.1 14.9 18.8
78 40 15.7 14.9 15.1
73 0 8.8 15.5 15.5
21.4 75 20 13.0 15.4 15.6 21.4
77 40 16.2 15.5 15.5
72 0 9.4 15.8 15.9
23.2 74 20 13.6 15.8 15.9 23.2
76 40 16.7 15.8 15.9
71 0 10.0 16.4 16.4
25.8 73 20 14.1 16.4 16.4 25.8
75 40 17.3 16.5 16.4
6
140_2060_237a_en 88/143
Driving the Crane 6
140_2060_237a_en 89/143
(Z 55 659)
69 0 11.3 16.8 17.0
28.4 72 20 14.7 17.0 16.9 28.4
73 40 18.3 16.8 17.0
68 0 11.9 17.5 17.5
31 rear 12.5 70 25 20 15.9 17.4 17.5 31 rear 12.5
72
25
40 18.8 17.5 17.5
64 0 14.2 19.1 19.0
39 66 20 18.1 19.0 19.0 39
68 40 20.7 19.1 19.0
6
140_2060_237a_en 90/143
Z 55 660
B
D
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 91/143
(metric dimensions)
(Z 55 660)
and configuration.
Counter-
weight
(t)
Super-
structure
to (*)
A
(m)
B
( )
C
(m)
D
( )
RA
(m)
Axle load (t)
Axle weight
(t)
structure
to (*)
(m)
( )
(m)
( )
(m)
1 + 2 3, 4, 5
82 0 4.2 12.6 12.6
6.3 82 20 9.9 11.9 13.1 6.3
82 40 14.6 11.4 13.4
81 0 5.0 12.9 13.1
8.3 82 20 9.9 12.6 13.3 8.3
82 40 14.6 12.0 13.7
80 0 5.8 13.4 13.6
10.8 82 20 9.9 13.5 13.6 10.8
82 40 14.6 12.9 13.9
79 0 6.5 14.0 14.1
13.5 81 20 10.6 14.1 14.1 13.5
rear 12.5
82
33
40 14.6 13.9 14.2
rear 12.5
77
33
0 8.1 15.1 15.1
18.8 79 20 12.1 15.2 15.1 18.8
80 40 16.0 15.0 15.2
76 0 8.9 15.7 15.6
21.4 78 20 12.8 15.7 15.6 21.4
79 40 16.7 15.6 15.7
75 0 9.6 16.0 16.0
23.2 77 20 13.6 16.0 16.0 23.2
78 40 17.4 15.8 16.1
74 0 10.4 16.5 16.5
25.8 76 20 14.3 16.6 16.5 25.8
77 40 18.0 16.4 16.6
6
140_2060_237a_en 92/143
Driving the Crane 6
140_2060_237a_en 93/143
(Z 55 660)
73 0 11.1 17.1 17.0
28.4 75 20 15.0 17.1 17.0 28.4
76 40 18.7 17.0 17.1
72 0 11.9 17.7 17.5
31 rear 12.5 74 33 20 15.8 17.7 17.5 31 rear 12.5
75
33
40 19.3 17.6 17.6
68 0 14.9 19.1 19.2
39 70 20 18.6 19.1 19.2 39
72 40 21.3 19.3 19.1
6
140_2060_237a_en 94/143
Z 200 075
B
A
RA
Driving the Crane 6
140_2060_237a_en 95/143
6.11.3 Driving Tables with English / American Dimensions
6.11.3.1 Driving with Main Boom
Counterweight 0 86 kip
(US units of measurement)
(Z 200 075)
and configuration.
Counter-
weight
(lbs)
Super-
structure
to (*)
A
(ft)
B
( )
RA
(ft)
Axle load in
(kip) Axle weight
(lbs)
structure
to (*)
(ft)
( )
(ft)
1 + 2 3, 4, 5
0 80 1.6 23.8 23.8
13.9 75 5.2 26.7 26.5
18.3 73 6.6 27.6 27.3
23.8 71 7.9 28.7 28.4
29.8 68 9.8 29.8 29.8
41.4
rear 41.0
64 12.1 32.2 32.0
47.2
rear 41.0
61 14.1 33.1 33.3
51.1 60 14.8 34.2 34.0
56.9 57 16.4 35.1 35.3
62.6 54 18.0 36.2 36.4
68.3 52 19.0 37.7 37.5
86.0 43 23.6 41.0 41.0
3sheave, type 63 (700 kg / 1.54 kip)
6
140_2060_237a_en 96/143
Z 200 079
B
A
C
D
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 97/143
6.11.3.2 Driving with the Main Boom Extension 29.9 ft
Counterweight 13.9 kip 86 kip
(Z 200 079)
and configuration.
Counter-
weight
(kip)
Super-
structure
to (*)
A
(ft)
B
( )
C
(ft)
D
( )
RA
(ft)
Axle load in
(kip) Axle weight
(kip)
structure
to (*)
(ft)
( )
(ft)
( )
(ft)
1 + 2 3, 4, 5
77 0 10.5 26.7 27.1
13.9 79 20 18.0 27.1 26.9 13.9
80 40 25.9 26.9 27.1
76 0 11.8 27.8 28.0
18.3 78 20 19.0 28.0 27.8 18.3
79 40 25.9 28.0 27.8
74 0 14.1 28.9 29.1
23.8 76 20 21.3 29.1 28.9 23.8
77 40 27.9 29.1 29.1
72 0 16.4 30.0 30.4
29.8 74 20 23.6 30.2 30.2 29.8
rear 41.0
75
29.9
40 29.9 30.2 30.2
rear 41.0
69
29.9
0 20.0 32.6 32.4
41.4 70 20 27.9 32.4 32.6 41.4
71 40 33.8 32.4 32.6
67 0 22.3 33.7 33.7
47.2 68 20 29.9 33.5 33.7 47.2
69 40 35.4 33.5 33.7
65 0 24.3 34.2 34.6
51.1 67 20 30.8 34.6 34.4 51.1
68 40 36.4 34.6 34.4
64 0 25.6 35.7 35.5
56.9 65 20 33.1 35.7 35.7 56.9
66 40 38.1 35.7 35.7
6
140_2060_237a_en 98/143
Driving the Crane 6
140_2060_237a_en 99/143
(Z 200 079)
62 0 27.6 37.0 36.6
62.6 63 20 35.1 36.8 36.8 62.6
64 40 39.7 36.8 36.8
59 0 30.8 37.7 38.1
68.3 rear 41.0 61 29.9 20 36.7 38.1 37.9 68.3 rear 41.0
62
29.9
40 41.3 38.1 37.9
53 0 36.7 41.4 41.4
86.0 54 20 43.0 41.2 41.4 86.0
55 40 46.6 41.2 41.4
6
140_2060_237a_en 100/143
Z 55 658
A
B
C
D
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 101/143
(Z 55 658)
and configuration.
Counter-
weight
(kip)
Super-
structure
to (*)
A
(ft)
B
( )
C
(ft)
D
( )
RA
(ft)
Axle load in
(kip) Axle weight
(kip)
structure
to (*)
(ft)
( )
(ft)
( )
(ft)
1 + 2 3, 4, 5
79 0 11.5 27.3 27.1
13.9 81 20 26.6 26.9 27.3 13.9
82 40 40.7 26.2 27.8
78 0 13.1 28.4 28.0
18.3 80 20 28.2 28.0 28.2 18.3
82 40 40.7 27.8 28.2
76 0 16.4 29.3 29.1
23.8 79 20 29.9 29.3 29.1 23.8
81 40 42.0 29.3 29.1
74 0 19.7 30.2 30.4
29.8 77 20 32.8 30.4 30.4 29.8
rear 41.0
79
55.8
40 44.6 30.4 30.4
rear 41.0
71
55.8
0 24.3 32.6 32.6
41.4 74 20 37.4 32.8 32.6 41.4
76 40 48.6 32.8 32.6
69 0 27.6 33.7 34.0
47.2 72 20 40.0 34.0 34.0 47.2
74 40 51.2 33.7 34.0
68 0 29.2 34.6 34.8
51.1 71 20 41.7 34.8 34.6 51.1
73 40 52.5 34.6 34.6
67 0 30.5 36.2 35.7
56.9 69 20 44.3 35.7 35.9 56.9
71 40 54.8 35.7 35.9
6
140_2060_237a_en 102/143
Driving the Crane 6
140_2060_237a_en 103/143
(Z 55 658)
65 0 33.8 37.0 36.8
62.6 67 20 47.2 36.8 37.0 62.6
69 40 57.1 36.8 37.0
63 0 36.7 38.1 38.1
68.3 rear 41.0 66 55.8 20 48.6 38.4 38.1 68.3 rear 41.0
68
55.8
40 58.1 38.4 38.1
58 0 44.0 41.7 41.4
86.0 60 20 56.4 41.4 41.7 86.0
62 40 64.6 41.7 41.7
6
140_2060_237a_en 104/143
Z 55 659
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 105/143
(Z 55 659)
and configuration.
Counter-
weight
(kip)
Super-
structure
to (*)
A
(ft)
B
( )
C
(ft)
D
( )
RA
(ft)
Axle load in
(kip) Axle weight
(kip)
structure
to (*)
(ft)
( )
(ft)
( )
(ft)
1 + 2 3, 4, 5
81 0 12.1 27.8 27.3
13.9 82 20 28.5 26.9 28.0 13.9
82 40 44.3 25.8 28.7
80 0 14.4 28.7 28.2
18.3 82 20 28.5 28.4 28.4 18.3
82 40 44.3 27.3 29.1
78 0 18.4 29.3 29.8
23.8 81 20 30.8 29.8 29.3 23.8
82 40 44.3 29.3 29.8
77 0 20.7 30.6 30.9
29.8 79 20 34.8 30.6 30.9 29.8
rear 41.0
81
82.0
40 46.3 30.6 30.9
rear 41.0
74
82.0
0 26.9 32.8 33.3
41.4 77 20 38.7 33.3 32.8 41.4
78 40 51.5 32.8 33.3
73 0 28.9 34.2 34.2
47.2 75 20 42.7 34.0 34.4 47.2
77 40 53.1 34.2 34.2
72 0 30.8 34.8 35.1
51.1 74 20 44.6 34.8 35.1 51.1
76 40 54.8 34.8 35.1
71 0 32.8 36.2 36.2
56.9 73 20 46.3 36.2 36.2 56.9
75 40 56.8 36.4 36.2
6
140_2060_237a_en 106/143
Driving the Crane 6
140_2060_237a_en 107/143
(Z 55 659)
69 0 37.1 37.0 37.5
62.6 72 20 48.2 37.5 37.3 62.6
73 40 60.0 37.0 37.5
68 0 39.0 38.6 38.6
68.3 rear 12.5 70 25 20 52.2 38.4 38.6 68.3 rear 12.5
72
25
40 61.7 38.6 38.6
64 0 46.6 42.1 41.9
86.0 66 20 59.4 41.9 41.9 86.0
68 40 67.9 42.1 41.9
6
140_2060_237a_en 108/143
Z 55 660
B
D
RA
05
205
405
Driving the Crane 6
140_2060_237a_en 109/143
(Z 55 660)
and configuration.
Counter-
weight
(kip)
Super-
structure
to (*)
A
(ft)
B
( )
C
(ft)
D
( )
RA
(ft)
Axle load in
(kip) Axle weight
(kip)
structure
to (*)
(ft)
( )
(ft)
( )
(ft)
1 + 2 3, 4, 5
82 0 13.8 27.8 27.8
13.9 82 20 32.5 26.2 28.9 13.9
82 40 47.9 25.1 29.5
81 0 16.4 28.4 28.9
18.3 82 20 32.5 27.8 29.3 18.3
82 40 47.9 26.5 30.2
80 0 19.0 29.5 30.0
23.8 82 20 32.5 29.8 30.0 23.8
82 40 47.9 28.4 30.6
79 0 21.3 30.9 31.1
29.8 81 20 34.8 31.1 31.1 29.8
rear 41.0
82
108.3
40 47.9 30.6 31.3
rear 41.0
77
108.3
0 26.6 33.3 33.3
41.4 79 20 39.7 33.5 33.3 41.4
80 40 52.5 33.1 33.5
76 0 29.2 34.6 34.4
47.2 78 20 42.0 34.6 34.4 47.2
79 40 54.8 34.4 34.6
75 0 31.5 35.3 35.3
51.1 77 20 44.6 35.3 35.3 51.1
78 40 57.1 34.8 35.5
74 0 34.1 36.4 36.4
56.9 76 20 46.9 36.6 36.4 56.9
77 40 59.1 36.2 36.6
6
140_2060_237a_en 110/143
Driving the Crane 6
140_2060_237a_en 111/143
(Z 55 660)
73 0 36.4 37.7 37.5
62.6 75 20 49.2 37.7 37.5 62.6
76 40 61.4 37.5 37.7
72 0 39.0 39.0 38.6
68.3 rear 41.0 74 108.3 20 51.8 39.0 38.6 68.3 rear 41.0
75
108.3
40 63.3 38.8 38.8
68 0 48.9 42.1 42.3
86.0 70 20 61.0 42.1 42.3 86.0
72 40 69.9 42.5 42.1
6
140_2060_237a_en 112/143
Driving the Crane 6
140_2060_237a_en 113/143
6.11.4 Driving the Crane with a Load
Driving the crane while it is carrying a load is strictly pro-
hibited!
6
140_2060_237a_en 114/143
Z 200 226
Z 53 775
Driving the Crane 6
140_2060_237a_en 115/143
6.12 Driving with dolly
(Z 200 226, Z 53 775)
6.12.1 Important instructions for Dolly operation
Dolly operation means: During transport travel, the boom is se-
cured to the rear (superstructure position 180) on a trailer (dolly).
There are very different Dolly designs and different types of sup-
port devices.
An example of a possible construction is illustrated (not binding).
Dolly version with hydraulic system
Dolly version without hydraulic system
No direct correspondence is to be expected between it and mo-
del which is actually at hand.
Risk of tipping, risk of skidding!
The handling of the vehicle can be seriously impaired depen-
ding on the type of dolly used.
The reduced axle loads represent an additional negative ef-
fect. The instructions in the section Driving with reduced
axle loads must be observed.
Drive with special care when a trailer is attached. Parti-
cular care is required in curves (swerving outwards, drif-
ting sideways, shifting centre of gravity).
Note the hydraulic pressures in the suspension circuits
while driving. If, on a level road, the hydraulic pressures
of the rear axles are greatly increased, then the luffing
cylinder must be completely retracted once again. Other-
wise there is a risk of the dolly failing to maintain suffi-
cient contact with the ground.
6
140_2060_237a_en 116/143
Z 53 776
A
Z 53 771
15
13
14
16
11
12
Driving the Crane 6
140_2060_237a_en 117/143
6.12.2 Dolly equipment for the towing vehicle (optional)
6.12.2.1 Dolly version without hydraulic system
See instructions under Dolly coupling / supply connections (op-
tional).
6.12.2.2 Dolly version with hydraulic system
(Z 53 771, Z 53 776)
If the dolly has a hydraulic cylinder (A), then the following additio-
nal equipment is at the rear of the vehicle:
11 Pressure gauge for displaying the pressure in the hydraulic
system of the dolly
12 Shutoff valve between the hydraulic system of the dolly and
pressure gauge
13 Hydraulic connection
14 Shutoff valve between the hydraulic systems of the towing
vehicle and the dolly
15 Electric connection (twist union 12pin) for supplying the
trailer
16 Electric connection (twist union 12pin) for filling the hy-
draulic system (trailer))
Actuation by remote control
6
140_2060_237a_en 118/143
Z 53 026
H1
Driving the Crane 6
140_2060_237a_en 119/143
6.12.3 Measures for Dolly operation
6.12.3.1 The following measures must be carried out before
driving with the dolly:
Float position of the superstructure
The superstructure must be in what is called the Float position
during Dolly operation in order to ensure that the dolly system
can follow vehicle movements (curves/dips and rises) whilst tra-
velling.
The Float position must be set before the beginning of the jour-
ney and consists of the following individual measures:
Set luffing gear.
Open the slew gear brake and lock in this position.
Release superstructure locking device and secure bolt.
Be sure to follow the sequence of the handling steps descri-
bed below.
Set luffing gear:
(Z 53 026)
Handling steps for Setting the Luffing Gear:
1. Put the crane on outriggers (outrigger span 8.23 m x 7.5 m
(27 ft x 24.6 ft))
2. Position the dolly behind the crane and secure with wheel
chocks.
Risk of accidents!
Secure dolly with wheel chocks against rolling away.
3. Start superstructure engine.
4. Place main boom (lengthways) on the dolly, fasten and se-
cure.
5. Join connections between the dolly and the towing vehicle.
6. Remove the wheel chocks from under the wheels of the dolly.
6
140_2060_237a_en 120/143
Z 53 026
H1
Driving the Crane 6
140_2060_237a_en 121/143
7. Retract luffing cylinder completely (until it hits stop).
Note:
The rear support cylinders may need to be extended out furt-
her in order to allow the luffing cylinder to be retracted until
it hits stop.
8. Close ball valve H1; this blocks the oil supply at the bottom
end to the luffing cylinder(luffing cylinder must be fully retrac-
ted).
9. Retracting Outriggers
10. Level apparatus
6
140_2060_237a_en 122/143
Z 53 779
75A
75B
B
A
63
32
A
39
Z 53 780
A
B
B
65
63
32
Driving the Crane 6
140_2060_237a_en 123/143
Open slew gear brake and lock it open:
(Z 53 779, Z 53 780)
Risk of tipping!
When the slew gear brake is open, the superstructure
can rotate involuntarily (influenced by wind / tilted posi-
tion of the crane). The crane can overturn when this hap-
pens.
For that reason, do not open the slew gear brake / lock it
open until after the boom has been secured to the dolly.
Whether the slew gear brake is closed or open can be determined
by the position of the shift rod (32).
The condition Slew gear brake closed (in operation) is
shown as position B.
Shift rod (32) extracted = slew gear brake in Crane mode;
that means Dolly operation is prohibited.
The condition Slew gear brake opened / locked open (not in
operation) is shown as position A.
Shift rod (32) inserted = slew gear brake in Dolly mode; that
means Operation of the crane is prohibited.
Handling steps to Slew gear brake open / locked open:
11. Open slewing gear brake hydraulically by pressing switch
(75A); Indicator light in the switch lights up.
12. Remove the padlock (63).
13. Mechanically lock the opened slew gear brake.
To do so, push the shift rod (32) in as far as possible (posi-
tion A) (switching distance 26 mm (1.0 in)).
14. Lock in position A with a padlock (63).
15. Cut off the air pressure by pressing the switch (75B); indica-
tor light in the switch goes out.
In this condition the slew gear brake is locked open and thus
out of function.
16. Switch off the superstructure engine.
17. Retract outrigger.
18. Set the device level.
19. Adjust the dolly behind the crane in accordance with the dolly
manufacturer s specifications (e.g. level, etc.).
6
140_2060_237a_en 124/143
Z 53 028
74
Z 53 025
2
3
1
Driving the Crane 6
140_2060_237a_en 125/143
Release superstructure locking device and secure bolt
(Z 53 025, Z 53 028)
Risk of tipping!
The superstructure locking device is not to be released
until the boom is fastened to the dolly.
If the superstructure locking device is released before
the boom is fastened to the dolly, then the superstruc-
ture, e.g in cases where it is tilted or subject to wind in-
fluences, could start to swivel on its own. The crane
could overturn in such situations.
Handling steps for Releasing superstructure locking device / Se-
curing bolt.
1. Release the superstructure locking device.
(When the superstructure engine is running, press switch
(74); to cause the locking bolt (1) to move out of the locking
strip (2). The indicator light in the switch lights up.)
2. Secure the locking pin (1) in the raised condition using fore
lock (3) mechanically, to prevent it being extended uninten-
tionally.
Risk of accidents!
Before the crane is driven with the dolly, the locking bolt
(1) of the superstructure locking device must be secured
mechanically in its raised condition by means of the fore
lock (3).
6
140_2060_237a_en 126/143
Driving the Crane 6
140_2060_237a_en 127/143
6.12.3.2 The following measures must be carried out when dri-
ving with the dolly attached
The available equipment, e.g. the indicator lights / warning
buzzer, must be used to monitor Dolly operation.
The available devices, e.g. the suspension pressure gau-
ges, should be monitored while driving or when at a
standstill. Should it happen that the axle loads of the ba-
sic unit and thereby the suspension pressures have in-
creased while driving on level ground, then the levelling
of the dolly must be readjusted. The contact pressure on
the dolly wheels, among other things, is reduced in this
condition, so that the dolly wheels could tend to lock
while braking. This would result in a reduction of braking
power.
Hill summits may only be passed at reduced speed: Due
to the restricted telescoping distance of the luffing cylin-
der, the dolly wheels could be relieved or lift off the road
surface
The dolly should be watched in the rear vision mirror
while driving, especially when driving round a bend.
6
140_2060_237a_en 128/143
Z 53 029
H1
Z 53 781
75A
75B
A
B
B
65
63
32
Driving the Crane 6
140_2060_237a_en 129/143
6.12.3.3 The following measures must be carried out after dri-
ving with the dolly attached
(Z 53 029, Z 53 781)
Danger of overturning while raising the boom!
The boom is not to be raised from the dolly until the slew
gear brake has once again been closed. Do not raise the
boom before you are convinced that the slew gear brake
really is closed!
Unlocking and Closing the Slew Gear Brake after Dolly Ope-
ration
Handling steps for unlocking and closing the slew gear brake af-
ter dolly operation:
1. Park the crane vehicle in alignment with the dolly.
Makes later assembly easier.
2. Secure dolly with wheel chocks.
Risk of accidents!
Secure dolly with wheel chocks against rolling away.
3. Put the crane on outriggers and level out (outrigger span
8.2 m x 5.4 m; 26.9 ft x 17.7 ft)
4. Open ball valve H1; in doing so release the oil supply to the
luffing cylinder on the ground side. The luffing gear is in ope-
ration.
5. Start superstructure engine.
6. Open the slew gear brake hydraulically (not yet operating) by
pressing switch (75A); Indicator light in the switch lights up.
7. Remove the padlock (63).
6
140_2060_237a_en 130/143
Z 53 029
H1
Z 53 781
75A
75B
A
B
B
65
63
32
Driving the Crane 6
140_2060_237a_en 131/143
8. To do so, pull the shift rod out (32) as far as possible (position
B) (switch distance 26 mm (1.0 in)).
9. Lock in position B with a padlock (63).
10. Cut off the air pressure by pressing the switch (75B); Indica-
tor light in the switch goes out. the brake is closed.
In this condition the slew gear brake is once again set to
Crane operation; that means Dolly operation is prohibi-
ted.
11. Release connection of the boom to the dolly.
12. Raise main boom slightly until there is space between the
boom and the dolly.
13. Telescope the main boom completely in.
6
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Z 53 031
2
1
3
Driving the Crane 6
140_2060_237a_en 133/143
Reversing superstructure locking device locking position
(Z 53 031)
Handling steps for reversing locking position:
14. Remove fore locks (3) from locking bolts (1)
The superstructure locking device is set to operation of the
crane again. The locking pin remains in the raised condition, but
is no longer mechanically locked.
15. Bring main boom into working position
16. Release the connections between the dolly and the towing
vehicle.
17. Release the connection between the dolly and the carrier
frame (if the crane vehicle is to be moved without the dolly).
6
140_2060_237a_en 134/143
Z 51 342
B24
Driving the Crane 6
140_2060_237a_en 135/143
6.12.4 Dolly not contained in crane manufacturers scope of
supply
(Z 51 342)
If the dolly is not contained in our scope of supply, assembly,
operation and maintenance of this component remain the
sole responsibility of the crane operator. The crane operator
is responsible for careful assembly, operation and mainte-
nance in accordance with national regulations.
The manufacturers instructions must be followed.
The dolly must be attached to the crane in such a way that
no dangers arise. For instance, the axles of the dolly must be
evenly burdened, in order to achieve an optimum braking ef-
fect.
Dolly operating conditions which are dangerous to travelling
operations must be monitored during the journey.
The crane operator must ensure, in consultation with the
dolly manufacturer, that important information is displayed
to the vehicle driver in an appropriate fashion.
A monitor lamp (B24) and a warning buzzer (17) are to be fac-
toryinstalled in the drivers cab for this purpose.
6.12.5 Dolly contained in the manufacturers scope of sup-
ply
If the dolly is part of the manufacturers scope of supply, detailed
instructions can be found in section 17 of these operating instruc-
tions.
Pay attention in this case to the instructions outlined and
the regulations for operating a dolly system.
6
140_2060_237a_en 136/143
Z 53 769
1 2 4 3 5
Driving the Crane 6
140_2060_237a_en 137/143
6.13 Dolly Coupling / Supply Connections (Optional)
(Z 53 769)
If the crane is prepared for the attachment of a trailer / dolly, then
the following equipment is at the rear of the vehicle:
1 Electric connection for dolly lighting equipment, rear
2 Compressed air connection (yellow) for braking
3 Compressed air connection (red) for supply output
4 ABS socket (7pole)
If a dolly coupling is part of our scope of delivery:
5 Dolly coupling
Pay particular attention to the road safety of the dolly coupling (5).
Instructions on maintenance and care can be found in part 4 of
this literature.
Check the dolly coupling daily for longitudinal play.
Longitudinal play is not permitted. Risk of dolly ripping free!
6.13.1 Coupling and uncoupling a dolly
The coupling and uncoupling, operation and maintenance of
a dolly is exclusively the sole responsibility of the crane ope-
rator. The crane operator is responsible for careful perfor-
mance of the coupling and uncoupling sequence, operation
and maintenance in accordance with national regulations.
The manufacturers instructions must be followed.
The dolly must be attached to the crane in such a way that
no dangers arise. For instance, the axles of the dolly must be
evenly burdened, in order to achieve an optimum braking ef-
fect.
6
140_2060_237a_en 138/143
Z 53 769
1 2 4 3 5
Driving the Crane 6
140_2060_237a_en 139/143
Risk of crushing!
The area between towing vehicle and dolly is not visible
during the steps in which the towing vehicle is moved.
It may be advisable to assign someone the job of monito-
ring that area.
Initial situation:
Dolly is switched off with parking brake actuated and wheel
chocks in place.
Risk of accidents!
Automatic braking by disconnecting the brake line is not
sufficient.
Sequence for coupling:
1. For dollies with rotating shafts:
Release front axle brake (if present).
Risk of accidents!
When the front axle brake is released, the fork may slam
back and forth if the wheels are not standing on a
smooth, level surface.
2. Move the towing vehicle up to approximately 1 m (3 ft) from
the coupling ring, then use the height adjustment device to
set the coupling ring at the coupling height.
3. Open the coupling on the towing vehicle.
4. Step out of the danger zone between towing vehicle and
dolly!
Risk of accidents!
Never step between the vehicles during the coupling se-
quence!
5. Carry out the coupling by moving the towing vehicle back-
ward, never by using the forbidden method of having the
dolly run up to it!
Risk of accidents!
Because of the extreme danger of accidents, it is forbid-
den to allow the dolly to move forward to couple the vehi-
cles no exceptions.
6
140_2060_237a_en 140/143
Z 53 769
1 2 4 3 5
Driving the Crane 6
140_2060_237a_en 141/143
6. Connect the connecting lines:
6.1 Connect the compressed air connection (yellow; 2) for
the brake line.
6.2 Connect compressed air connection (red; 3) for the
supply output.
6.3 Connect the electric connections for trailer lighting (1)
and ABS socket (4).
Risk of accidents!
The connections must be made in the sequence speci-
fied.
The brakes may release if this sequence is not adhered
to.
7. Remove the wheel chocks, release the dolly parking brake,
monitor departure.
Sequence for uncoupling
Uncoupling is accomplished in the same sequence as coupling,
but in reverse, whereby the vehicles should be positioned in a
straight line if at all possible.
Risk of accidents!
Before uncoupling, first actuate the parking brakes of
the towing vehicle and the dolly!
Before uncoupling, first put wheel chocks in place.
Sequence for disconnecting the connecting lines:
Disconnect compressed air connection (red; 3) for the supply
output.
Disconnect the compressed air connection (yellow; 2) for the
brake line.
Disconnect the electric connections for trailer lighting (1) and
ABS socket (4).
Risk of accidents!
The connections must be removed in the sequence spe-
cified.
The brakes may release if this sequence is not adhered
to.
6
140_2060_237a_en 142/143
Z 53 767
5
2
4
1
Z 53 768
2
1
5
Z 53 770
3
4
Driving the Crane 6
140_2060_237a_en 143/143
6.14 Attaching and Removing the Spare Wheel (Spare
Wheel Holder, Hoist Arrangement, Optional)
(Z 53 767, Z 53 768, Z 53 770)
In order to have a spare wheel while travelling, there is a spare
wheel holder (1, optional) to the rear of the vehicle.
In order to attach and/or remove the spare wheel from the spare
wheel holder, either ones own crane apparatus, the optionally
available lifting device or other equipment (3) (e.g. an auxiliary
crane or similar) must be used.
To remove the spare wheel using the optionally available lifting
device, proceed as follows:
Attach the holder (2) for the lifting device (3) to the carrier
frame.
Attach the lifting device (3) to the holder (2).
Uncoil lifting device (3).
Attach spare wheel with auxiliary rope (4) to the lifting de-
vice (3).
Tighten the rope with the lifting device and remove the bolts
(5) on the spare wheel.
Lower the spare wheel and set it on the ground.
Risk of crushing!
The spare wheel must be secured against tipping over
while being moved over the ground.
The spare wheel is fitted in the reverse order.
The spare wheel must be screwed firmly on to the holder.
Attachment/removal of the spare wheel is to be carried out in cor-
responding fashion with ones own crane apparatus and/or an
auxiliary crane.
The lifting device must be removed, together with the holder,
before rotating the superstructure or before moving the
crane on site.
Transmission 7
1402070b 1/55
7
1402070b 2/55
Z 200 092
1 2 4 5 3 7
6
Z 51 344
18
19
12
13
43
75
B5
B6
35
36
35 36
Transmission 7
1402070b 3/55
7 Drive gearbox / distributor gear
(Z 200 092, Z 51 344)
The drive gearbox (2) an automatic transmission ZFAS
TRONIC Type 16 AS 2601 (16 forward gears, 2 reverse gears)
is flanged together with the drive motor (1) via a dry clutch. A
twostage distributor gear (3) is rearmounted to this
combination.
7.1 Drive gearbox:
7.1.1 Description of the System
The ZFAS TRONIC consists of a fourspeed part, a splitter unit
(GV) and a rearmounted range unit (GP) in planetary design.
The basic gearbox is dogclutched; splitter and planetary units
are synchronised.
Thanks to the automatic coupling (no clutch pedal), the driver no
longer needs to activate the clutch.
The actual gear switching is done by the electronic transmission
system.
The transmission actuator and the clutch actuator are the most
important components for completely automating the
transmission.
The transmission actuator consists of the electronic gear system,
shift valves, shift cylinders and sensors.
The clutch actuator is an electropneumatic actuator with path
sensors; it takes over the entire transmission actuation.
A hydraulic retarder (system ZF Intarder), a nonwearing,
functioning, hydrodynamic auxiliary brake is integrated in the
transmission.
All essential system information, e.g. neutral, gear step, clutch
overload, fault and diagnosis information are display to the driver
in the Transmission information display (75).
Moreover, other special indicator lights are shown in the Driver
information system display (43) for:
Clutch overload (B5) and
transmission malfunction (B6) together with caution (36) or
serious transmission malfunction (B6) together with STOP
(35)
7
1402070b 4/55
Z 51 345
2 2.1
2.2
2.3
2.4
2.5
Z 51 346
18
19
12
13
43
75
Transmission 7
1402070b 5/55
7.1.2 System Design
(Z 51 345, Z 51 346)
The transmission system consists of the transmission (2) and
components, that are required for the automation of the system.
The transmission actuator (2.1) and clutch actuator (2.2)
components are integrated into the transmission.
The driving switch (2.3), display (2.4) and emodule (2.5)
periphery components are installed in the drivers cab.
Vehicle components such as display (75), accelerator pedal (18)
and brake pedal (19), engine electronic system, electronic
braking system with wheel speed sensors also belong to the
system.
Legend:
2 Transmission
2.1 Transmission actuator with electronic transmission control
system
2.2 Clutch actuator
2.3 Driving switch
2.4 Transmission information display (75)
2.5 Emodule
Vehicle components:
18 Accelerator pedal
19 Brake pedal
43 Driver information system display
7
1402070b 6/55
Z 51 346
13
12
Transmission 7
1402070b 7/55
7.1.3 Shifting Gears
7.1.3.1 Driving switch
(Z 51 346)
The driving switch consists of the switch lever (12) and the rotary
switch (13). It is the operating element for
Selecting the driving range
Selecting the gear
Activating / deactivating the automatic mode
Calling up the error display
Air pressure of min. 6.2 bar is needed to switch gears. It is not
possible to shift gears below this mark. Unsuccessful gear shifts
are saved as errors by the electronic system.
RISK OF ACCIDENTS!
If you shift when the air pressure is too low, thetransmis-
sion can remain in neutral, with the result that no
through drive and no engine braking effect are available.
Rotary switch
The rotary switch has three positions:
D Drive
N Neutral (no gear is engaged in the transmission)
R Reverse
If the rotary switch is in the N position, then the switch lever
wont work.
7
1402070b 8/55
Z 51 346
13
12
Transmission 7
1402070b 9/55
Switch lever (12)
The switch lever is used to switch gears and change the
transmission mode (manual / automatic).
The switch lever springs back into its initial position after every
actuation.
By tapping the switch lever several time, you can shift up / down
over several gear steps.
+ Shift up by one gear
+ + Shift up by two gears
Shift down by one gear
Shift down by two gears
Change transmission mode:
Manual / automatic and vice versa: press switch lever quickly to
the left.
Automatic transmission mode
Rotary switch (13) in position D: The shifting system
automatically selects the 3rd gear as programmed starting gear.
Rotary switch (13) in position R: The switching system
automatically selects the rapid reverse motion as a fixed
programmed driving gear.
The shifting system automatically shifts up and down while
driving.
You can change the transmission mode from automatic to
manual at any time.
Manual transmission mode
Rotary switch (13) in position D or R: If the gear shift lever is
tilted to the left, the switching system switches to the operating
mode Manual.
The driver can also select another driving gear as the
Overrevving the engine must be avoided by the driver by shifting
gears at the right time.
If you use the accelerator pedal in too high a gear, you might stall
the engine.
You must avoid slow driving which puts stress on the clutch by
possibly driving slowly or by driving in a lower gear than is fixed
and programmed.
7
1402070b 10/55
Z 51 348
1 8 14
2 9 15
3 10 16
4 11 17
5 12
6 13
7
Transmission 7
1402070b 11/55
7.1.4 (75) Transmission information display (Z 51 348)
All operating indicators (performed or preselected functions),
warning information and malfunctions / errors are shown on the
Transmission information display (75) with numbers and
symbols.
Malfunctions, see error code table at the end of the section.
7.1.4.1 Operating indicators
1 Selfcheck of the system
(during ignition, on)
2 Transmission in neutral
3 Engaged gear
4 Manual driving mode
engaged gear, possibility to shift back (two gears)
5 Slow reverse gear engaged
6 Fast reverse gear engaged
7 Automatic driving mode
is shown in the display by four bar with two arrows
(the eighth gear is engaged in the transmission)
7.1.4.2 Warning information
8 Insufficient air pressure (airless)
9 Take foot from the accelerator pedal
10 Clutch is overloaded. Select a lower gear (clutch)
11 Clutch is worn out (clutch wear)
12 Communication error to the display (electronic error)
13 Transmission temperature too high
7.1.4.3 System error
14 System malfunction. Continued operation is possible,
though limited.
15 Serious system malfunction. Continued operation is not
permitted.
16 Example: Error no. 74
17 Example: Error no. 168
Four bars are shown in addition to the number: Error no. +
100 (only for doubledigit display)
7
1402070b 12/55
Z 51 344
18
19
12
13
43
75
B5
B6
35
36
35 36
Transmission 7
1402070b 13/55
7.1.5 (43) Driver information system display
(Z 51 344)
Regardless of what is shown on the Transmission information
display (75), various malfunctions are also shown on the Driver
information system display (43) with the use of indicator lights.
Indicator light (B5) = clutch overload
The clutch temperature is too high. Change travelling
operation (do not drive with dragging clutch).
Indicator light (B6) + caution (36) = malfunction in the drive
gearbox
Stop vehicle, read off fault code, rectify fault. Continued
operation is possible, though limited.
Indicator light (B6) + STOP (35) = serious malfunction in the
drive gearbox
Stop vehicle, read off fault code, rectify fault.
Continued operation is not permitted.
7
1402070b 14/55
Z 52 100 Z 52 101
Transmission 7
1402070b 15/55
7.1.6 Driving and Shifting Gears
You are not allowed to leave the vehicle if is the engine is
running or a gear is engaged.
7.1.6.1 Starting the Engine
(Z 52 100)
8. Apply the parking brake.
9. Rotary switch to N (transmission in neutral)
10. Switch on the ignition. (Ignitionstarter switch, position 2)
At Ignition on, a selftest of the shifting system is done.
After the control signal: CH display.
11. Starting the Engine
N display; Transmission is in neutral.
It is not possible to switch gears when the engine is at standstill.
7.1.6.2 Driving, Driving Forwards
(Z 52 101)
Starting position:
Apply parking brake, engine running, transmission in neutral.
1. Turn rotary switch from N to D.
Automatic drive mode is activated.
The display (75) shows the driving gear engaged.
The shifting system automatically selects the 3rd gear as
programmed starting gear.
2. Push the accelerator pedal (18) and at the same time,
release the parking brake.
The vehicle can roll away without pushing the accelera-
tor pedal (18).
3. The vehicle starts to drive (clutch engages automatically).
7
1402070b 16/55
Z 51 349
13
12
Transmission 7
1402070b 17/55
Correcting the programmed driving gear
(Z 51 349)
At road inclines or declines, you can drive with a lower or higher
gear.
The programmed driving gear (gear 3) can be corrected as
follows:
Press the switch lever (12) in the direction or + ; the
engaged driving gear is shown on the display (75).
7.1.7 Change transmission mode: Manual / automatic
The transmission mode can be changed at any time, even while
driving.
Changing the transmission mode from manual to automatic:
Push the switch lever (12) to the left.
Changing the transmission mode from automatic to manual:
Push the switch lever (12) to the left or
in the direction + or .
7
1402070b 18/55
Z 51 346
13
12
Z 52 102
Transmission 7
1402070b 19/55
7.1.8 Changing Gears
A gear can be switched automatically while driving by the
automatic driving programme, or manually by the driver.
You can shift from any gear into neutral using the rotary switch
(13). This gear switch has priority. (Z 47 966)
The position of the accelerator pedal (18) must not be changed
while switching gears, because the engine is automatically
controlled.
A gear switch command is not executed when the max.
permissible engine speed was exceeded by the gearshift
mechanism.
RISK OF ACCIDENTS!
Shifting to neutral is also possible while driving. If you
shift to neutral, the drive train is interrupted
The engine braking effect no longer exists.
At the latest by an engine speed of 2350 rpm, the crane is to be
braked until the speed is reached at which the automatic
transmission shifts down to the next gear (possible gear range
change).
7.1.8.1 Shifting gears in the automatic transmission mode
All upshifting and downshifting is done automatically.
Shifting gears depends on various factors such as axle load,
acceleration pedal position, speed, engine speed or shift profile.
Upshifting:
When accelerating, as soon as the required speed is reached to
shift up a gear, the transmission automatically shifts into the next
higher gear.
Downshifting:
When decelerating, as soon as the required speed is reached to
shift down a gear, the transmission automatically shifts into the
next lower gear.
The gear display is shown as digits in the display (75) while
driving. (Z 52 102)
7
1402070b 20/55
Z 52 103
13
12
Transmission 7
1402070b 21/55
7.1.8.2 Shifting gears in the manual transmission mode
(Z 52 103)
Press the switch lever in the direction + or ; the engaged
gear is shown on the display (75).
When you shift gears manually, the shifting system leaves the
automatic transmission mode.
If you press the switch lever (12) to the left, the automatic
transmission mode is activated again.
Skipping gears
Skipping a gear:
Press the switch lever (12) twice quickly into the desired direction.
Skipping two gears:
Press the switch lever (12) three times quickly into the desired
direction.
7
1402070b 22/55
Z 200 317 Z 51 349
13
12
Transmission 7
1402070b 23/55
7.1.9 Reverse driving / changing the driving direction
(Z 200 317, Z 51 349)
You can only shift gear in another driving direction is the
wheels are at a standstill. Engine at idle speed!
If the vehicle is rolling, it will not shift into the reverse gear;
the transmission shifts into neutral.
Engage reverse gear:
1. Stop vehicle; wait for standstill; Apply the parking brake.
2. Turn the rotary switch (13) over N to R .
RH appears in the display (75)
(clutch remains disconnected)
The switching system automatically selects the rapid reverse
motion as a fixed programmed driving gear.
3. Push the accelerator pedal (18) and at the same time,
release the parking brake.
(clutch engages automatically)
4. The vehicle drive in reverse.
As soon as the rotary switch (13) is set in the R position, the
reverse gear warning signal sounds.
Correcting the programmed driving gear
(Z 51 349)
At road inclines or declines, you can drive with a lower or higher
gear.
The programmed driving gear (rapid reverse motion (display
RH)) can be corrected as follows:
Press gear shift lever (12) in direction . The transmission
switches to the slow reverse motion (display RL).
Changing the driving direction
Turn the rotary switch (13) from R over N to D or reversed
from D over N to R .
Remain in position N so that the gearshift is completed.
7
1402070b 24/55
Transmission 7
1402070b 25/55
7.1.10 Stopping
The vehicle can be braked in any gear to the point of standstill.
If the accelerator pedal is not actuated, the vehicle will decelerate
with the service brake to the point of standstill. Apply the parking
brake.
The clutch opens automatically before the vehicle comes to a
standstill, so that stalling the engine is avoided.
When engine is not in action, it is recommended to put the
transmission in neutral, because after the device has been in
standstill for a long time, the emergency pressure supply (6.2 bar)
level required for shifting gears could have sunk to a point where
it is no longer possible to shift into neutral.
RISK OF ACCIDENTS!
If the vehicle is standing with a running engine and an
engaged gear, it is enough to actuate the accelerator
pedal (18) in order to bring the vehicle into motion.
Before leaving the vehicle with the engine running, the
transmission must be in neutral and the parking brake
must be applied.
Applying the parking brake while driving on a smooth
surface can bring the engine to a standstill.
The hydraulic steering support is no longer available in
its previous form. A considerable amount of power is
needed for the steering wheel and the steering reacts
more slowly.
7
1402070b 26/55
Z 52 105
N
D
R
Z 51 304
15
4
Transmission 7
1402070b 27/55
7.1.11 Shutting off the engine and vehicle
(Z 52 105, Z 51 304)
1. Stop vehicle; wait for standstill; Apply the parking brake.
2. Turn rotary switch (13) to N (neutral).
3. Shut off the engine(ignitionstarter switch (15), position 1)
4. Place wheel chocks underneath (e.g. on inclines)
After Ignition off, the system automatically shifts into
neutral. If no brake is actuated, the vehicle can roll away.
Ignition off, special case
If the ignition is switched off while driving, it is not possible to shift
into neutral. The engaged gear remains engaged, the clutch
remains engaged.
When the driving speed goes below a certain limit, the clutch and
the transmission shifts into neutral.
7
1402070b 28/55
Z 52 106
90
Z 52 107
Z 52 108
18
19
12
13
43
75
B5
35 36
Transmission 7
1402070b 29/55
7.1.12 Manoeuvring (Distance < 1m)
(52 106, Z 52 107, Z 52 108)
When moving slowly and carefully (e.g. hooking up / detaching
a dolly), a manoeuvring operation is provided in the first driving
gear and in the first reverse gear. The transmission remains in
this gear; it does not upshift.
The manoeuvring operation is not effective in other gear. If it is
selected in another gear, the shift will not be executed
(transmission remains in the first gear).
In the manoeuvring operation, the clutch is switched from
Driving mode to Manoeuvring mode with the switch (90). The
clutch control is different to that for the normal Driving mode
(now: dragging clutch).
In this way, the vehicle can be positioned slowly and carefully
forward or backwards using the accelerator pedal (18).
During manoeuvring, the distributor gear should always be
shifted into Offroad gear because of the more favourable
transmission ratio. This prevents damage to the clutch.
The manoeuvring operation is associated with heat
development and increased clutch wear and can lead to
overloading the clutch.
The CL display (43) and the Clutch overload (B5) is
shown in the display (75) if the clutch is overloaded
(regardless of accelerator pedal position and driving speed).
The driver has to change the travelling operation now
(vehicle / stop) to prevent damage to the clutch.
In Manoeuvring mode, the vehicle can only be moved slightly.
The driving time is about three minutes; only a short distance (<
1 m) can be covered until the CL and B5 warning displays light
up as a result of heat development.
The system needs another 15 minutes or so with stationary
vehicle and running engine to cool off the clutch.
7
1402070b 30/55
Z 52 115
Transmission 7
1402070b 31/55
7.1.13 Towing
The towing procedure is described in detail in section 14.
Observe the procedures defined there exactly.
7.1.14 Towing start
It is not possible to start the engine by towing it along.
Jump start with external batteries, see section 5.
7.1.15 Rolling down a downhill slope
Prerequisite for this procedure: Running engine
RISK OF ACCIDENTS!
When the vehicle is rolling without an engaged gear
rotary switch (13) is on N there is no engine braking
effect.
Do not let the vehicle roll in the opposite direction of the
engaged gear.
If the vehicle rolls forward when the transmission is in neutral
after releasing the brakes and you shift from N to D , then
the system selects the gear that fits to the speed. The drive train
is closed (positively tied). (Z 52 115; Example with third gear)
7.1.16 Exhaust brake
The engine braking effect is interrupted when switching
gears. The vehicle can speed up during downhill driving.
Manual Driving Operation
The exhaust brake is deactivated by the system when shifting.
After shifting, the exhaust brake is automatically activated again.
Automatic Driving Operation
When actuating the exhaust brake, the system shifts back to the
gear where the highest brake performance was available.
7
1402070b 32/55
Z 52 107
Z 52 108
18
19
12
13
43
75
B5
35 36
Transmission 7
1402070b 33/55
7.1.17 Clutch protection
(Z 52 107, Z 52 108)
Despite the automated clutch, the driver has great influence on
the service life of the clutch lining. To cut down on wear and tear,
it is recommended to always select the lowest possible gear
when driving.
See Driving and Shifting in this section under Correction of the
To prevent damage to the mechanical parts of the clutch control,
shift the transmission to neutral for longer stops (more than 12
minutes, e.g. traffic jam, train crossing). In doing so, the clutch is
engaged and the clutch controller is released.
If the clutch is in danger of overloading, e.g. due to several short,
consecutive startup procedures or crawling with dragging
clutch, the CL display will appear on the display (75) and the
indicator light (B5) on the display (43).
Put the vehicle into an operating mode where the clutch is not
overloaded; for example:
when accelerating (to apply the clutch)
when stopping
when driving at a low gear
when driving at speeds below the walking speed: switch
distributor gear to terrain driving.
If the driver ignores the warning signal, the clutch en-
gages when the accelerator pedal (18) is pushed.
In this way, further strain on the clutch is avoided.
This can lead to the stalling of the engine, in which
case the vehicle may roll back if on an incline.
By releasing the accelerator pedal (18), the clutch opens
again.
Further information can be found under Manoeuvring in this
section.
7
1402070b 34/55
Z 48 996
5
1
5
2
5
4
5
3
5
5
5
6
5
7
5
8
3
1
4
0
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
4
3
5
0
.
1
5
0
4
2
4
1
.
1
4
1
k
m
/
h
m
p
h
Transmission 7
1402070b 35/55
7.1.18 Overspeed protection
To protect the entire drive train from too high a speed, the system
allows only gearshifts that are within a certain range.
Shifting and protective measures are in conjunction with the
permissible engine speed, that can be controlled at the revolution
counter (50) in the instrument panel.
If the engine speed exceeds 2350 rpm (excessive engine speed),
the LED (50.1) lights up and the warning buzzer sounds as long
as the engine speed is excessive.
Be sure that the engine does not exceed the permissible
speed range. especially when driving downhill.
At an engine speed of 2300 rpm, the exhaust brake is
deactivated to protect the engine mechanic against damage.
7.1.18.1 Manual transmission mode
If the vehicle accelerates when going downhill, the automatic
transmission will not shift into a higher gear.
The engine can be damaged, if the vehicle accelerates when
going downhill and the engine comes in to the overspeed
range.
The accordingly low gear range in which the crane
can be maintained at a constant speed must be selected
before the crane is driven downhill.
When driving downhill, pay special attention to the in-
structions in section 6 regarding gear selection and brak-
ing.
7.1.18.2 Automatic transmission mode
Caution when driving downhill!
At the latest by an engine speed of 2300 rpm, the vehicle is
to be braked until the speed is reached at which the
automatic transmission shifts down to the next gear.
RISK OF ACCIDENTS!
The vehicle can accelerate when travelling downhill.
To protect the engine during excessive engine speed, the
system upshifts.
7
1402070b 36/55
Z 52 105
Transmission 7
1402070b 37/55
7.1.19 Roller dynamometer
(Z 52 105)
After driving onto a roller dynamometer (brake dynamometer),
shift the transmission into neutral.
When rolling, the system recognises the function Driving
vehicle. If a gear is engaged, the clutch engages.
RISK OF ACCIDENTS!
The vehicle can drive off the roller even without the ac-
celerator pedal being pressed (18).
When rolling, it is not possible to shift into reverse gear.
7.2 Hydraulic Retarder (System ZF Intarder)
A hydraulic retarder (system ZF Intarder) isintegrated in the
transmission.
Further details about this can be found in Sect. 8 Brakes.
7
1402070b 38/55
Z 52 109 Z 52 110
Z 51 344
18
19
12
13
43
75
B5
B6
35
36
35 36
Transmission 7
1402070b 39/55
7.3 System malfunctions / error diagnosis
7.3.1 Fault messages
The drive gearbox has a selfdiagnosis system.
If the system recognises faults / errors, this will be shown to the
driver on the (75) Transmission information display.
The faults are divided into fault classes 1 to 3 and entered into the
fault memory of the transmission after the ignition has been
switched off. Up to ten different errors can be stored. If the fault
memory is full, a nonactive error will be overwritten.
Error class 1
Errors that even after occurring several time do not lead to a
reduced availability of the system.
Display: None
Unlimited driving mode possible.
Error class 2
If two or more class 2 errors occur, the system reacts in the same
way as with class 3 errors.
Display: Spanner symbol (Z 52 109)
If the Spanner symbol appears on the display, there is system
malfunction. It may be that the driving mode is only possible in
limited form, e.g. only in manual.
Fault category 3
Display: Spanner symbol plus STOP
(Z 52 110)
If the Spanner symbol plus STOP appears in the display, there
is a serious system malfunction. Continued operation is not
permitted. It is necessary to bring the vehicle to the workshop.
Regardless of what is shown on the Transmission information
display (75), various malfunctions are also shown on the Driver
information system display (43) with the use of indicator lights.
(Z 51 344)
See also section 6 Driver information display (75) and in this
section Transmission information display (43).
7
1402070b 40/55
Transmission 7
1402070b 41/55
Reset
It is possible to delete the fault message and the resulting error
reaction when the vehicle is at standstill using Ignition OFF; wait
until the display goes out.
If the display does not go out after Ignition OFF, switch on the
ignition again. If the fault message is still showing, it is time to
consult out customer service department.
In addition to this optical warning, the warning buzzer sounds in
the cab according to the error class.
7
1402070b 42/55
Z 52 105 Z 52 111
13
12
Z 52 112 Z 52 113
Transmission 7
1402070b 43/55
(Z 52 105, Z 52 111, Z 52 112, Z 52 113)
7.3.2 Reading off the fault code
If there is an error, the error number can be called up on the
display (75). If there is a serious system error (Spanner symbol
plus STOP), stop the vehicle and switch off the engine.
Calling up the current error numbers:
1. Switch on the ignition.
2. Turn rotary switch (13) to N.
3. Push the switch lever (12) to the front and hold.
An error number appears on the display (43). This corresponds
to the current error; Example: Error no. 74.
Display of threedigit error numbers:
If, in addition to the display number, four bars are shown, this
means that: Error no. + 100; Example: Error no. 168.
Retrieving the errors stored in the fault memory:
While holding down the brake pedal (19) at the same time, all
(saved and active) errors are shown on the display (43) in
sequence.
7.3.3 Error list
7.3.3.1 Error list explanation
GV = transmission in GV position (splitter unit)
Even and odd gears
GP = transmission in GP position (range unit)
Slow gears (gears 1 to 8)
Fast gears (gears 9 to 16)
7
1402070b 44/55
Transmission 7
1402070b 45/55
7.3.3.2 Listing / explanation of possible error displays
Fault category 3 Effect
02, 03, 04, 05, 06, 07, 08, 09, 22, 34, 35,
36, 37, 38, 39, 40, 41, 54, 61, 62, 66, 67,
68, 69, 70, 71, 72, 73, 77, 78, 82, 83, 84,
85, 90, 101, 105, 117, 132, 136, 140,
144, 169, 170, 177, 179, 180, 181, 188,
189, 190, 191, 193
Driving: gear shifting is locked.
Standstill: Automatically shifted into neutral and the
gear shifting is locked.
Continued operation is not possible.
System not available.
Error class 2 Effect
10, 42
Driving: gear shifting locked, incl. neutral.
Driving gear: Only when lowest gear is engaged for GP
high speed. Ignition on: System not available.
17, 18, 19, 20, 21, 49, 50, 51, 52, 53, 97,
98, 99, 107, 120, 121, 122, 123, 124,
164, 165
The following effects may happen:
Driving: Reduced comfort when driving, manoeuvring,
shifting, increased shifting time.
Standstill: Middle driving gear. No manoeuvring opera-
tion.
81
Driving: Gear shifting is locked.
Standstill: it is possible to engage the driving gear. Driv-
ing possible.
110
Driving: gear shifting is locked, including the shifting at-
tempts into neutral.
Standstill: Driving gears possible.
118
Standstill: Engine stalls, if the clutch does not open.
119
Driving: clutch engages quickly. Gear shifting is locked.
Standstill: Automatic shifting into neutral system not
available.
Error class 1 Effect
11 Warning buzzer permanently active.
12, 44 Activation of the backup light not possible.
23 Permanent control warning light.
25, 89 Display EE. No system reaction.
26, 27, 28, 30, 31, 32, 33, 91, 92, 93, 94,
96, 113, 171, 173, 182, 183, 184, 192,
197, 199
The following effects may happen:
Driving: Reduced comfort when driving, manoeuvring,
shifting, increased shifting time
Standstill: Middle driving gear. No manoeuvring opera-
tion.
43, 75 Cannot control the warning buzzer.
55, 87 Cannot control the warning light.
76 Backup light permanently switched on.
7
1402070b 46/55
Transmission 7
1402070b 47/55
Fault category 3 Effect
86
Display cannot be switched off.
Driving switch does not switch off.
No restriction of the system availability.
95, 100, 104, 111, 112, 125, 127, 128,
167, 174, 195, 196, 198
Since an isolated error, no effect on the system or on
certain calculations e.g. wear on clutch not possible.
102, 163
Driving: gear shifting is locked, including the shifting at-
tempts into neutral.
108, 175
The following errors may occur:
Standstill: System not available, driving gear possible.
126
System function not affected. Possible loss of pressure
was not displayed. Higher learning time.
129, 130, 131
Driving: gear shifting is locked, shifting out of neutral
possible. Standstill: Driving gears possible.
133, 134, 135
Driving: Restricted gear selection.
Standstill: Restricted driving gear, no reverse gear.
137, 138, 139, 145, 146, 147
Driving: GP shifting locked. Only gears can be engaged
in the shifted GP area.
Reduced shifting comfort, increased shifting time.
141, 142, 143, 148, 149, 152
Driving: Automatic gear correction (last GV position) or
shift into neutral.
Standstill: Driving in last GV position or using driving
switch.
150
System not available. Renewed GV shifting attempt
possible.
151
Driving: Automatic gear correction or shift into neutral.
Standstill: Driving gear can only be selected using driv-
ing switch.
153, 155, 156
Driving and standstill: Automatic shift into neutral. Re-
newed shifting using driving switch.
154
Driving: clutch engages. Next shifting attempt using
driving switch.
Standstill: Driving max. lower gear, higher GP.
158, 159, 160 Automatic gear correction.
166
Driving: possible to shift while driving.
Standstill: System not available.
168
Driving: no system restrictions.
Standstill: After reset, driving is possible.
7
1402070b 48/55
Z 40 589
A
B
C
D
E
J
I
H
G
F
Z 200 318
A8
Z 52 114
93
A7
Transmission 7
1402070b 49/55
(Z 40 589, Z 200 318, Z 52 114)
7.4 Distributor gear
The distributor gear is rearmounted to the actual drive gearbox.
It forms a unit with the Lift axle.
An emergency steering pump, that secure the steering ability of
the crane in case the engine fails, is located on the intermediate
shaft. It is driven from the rolling crane.
There are two gear levels (street / offroad gear).
A = onroad gear, B = drive, C = emergency steering pump 1, D
= front drive, E = differential lock,
F = offroad gear, G = shift cylinder, H = lubricating oil pump, I =
emergency steering pump 2, (not fitted) J = rear drive
7.4.1 Operating the distributor gear
Engage the offroad gear early enough (on level surface and
before entering difficult terrain); and not after the crane vehicle
has become stuck.
Onroad gear, offroad gear and the differential lock can only be
activated when the vehicle is at a standstill (dogclutching).
On rare occasions, it is not possible to switch from onroad gear
to offroad gear in one go due to the gear teeth locking.
If the attempt to shift the distributor gear fails (locked teeth), this
will be indicated on the display (43) by an indicator light (A8). The
distributor gear will then be in neutral; i.e. the drive train is not
closed.
To change the position of the teeth in the distributor gear, carry
out the following procedure:
2. Starting position for rotary switch (13): position N .
3. Press the dual button (93) and hold it down.
4. Change rotary switch (13) from N to D and / or R .
Do not push the accelerator pedal (18) (do not give it any
gas).
5. Observe the display (43)
If the indicator light (A7) is shown, the gear has been
successfully shifted. The offroad gear is engaged.
6. Release the dual button (93).
7
1402070b 50/55
Z 52 105 Z 52 114
93
A7
Transmission 7
1402070b 51/55
In case the offroad gear despite carrying out the described
procedures cannot be engaged:
Without the parking brake being engaged, turn the steering
wheel as far as it will go in one direction and then and repeat
procedures 16.
If the accelerator pedal was pushed at point 4 (the clutch closed),
the rotary switch (13) must be turned back to the starting position,
position N , before another attempt is made to shift the gear.
This will open the clutch again. Another gear shift attempt can be
made. (Z 52 105)
On/offroad gear
(Z 52 114)
The switch (93) can be used to choose between two different
gear steps in the distributor gear:
The transmission ratio in the distributor gear changes when
shifting from onroad to offroad gear.
If the distributor gear is in offroad gear, only manual
transmission mode may be used in the drive gearbox in
order to avoid interruptions of tensile force.
When driving below the walking speed or during manoeuvring
operation you should always switch to the gear Terrain driving
due to the more favourable transmission ratio. This prevents
damage to the clutch.
The gear shifts of the distributor gear operate independently of
the driving mode / gear mode of the drive gearbox.
A supply pressure of min. 7.0 bar is required for all distributor gear
shifts.
Distributor gear in onroad gear position:
The onroad gear is always engaged under normal
circumstances. No indicator light is shown.
Distributor gear in offroad gear position:
Press dual button (93); the indicator light (A7) lights up.
The offroad gear is primarily intended for:
Driving on a work site
Driving when rigged
Driving with the lowest speed possible.
7
1402070b 52/55
Z 52 114
93
A7
Transmission 7
1402070b 53/55
Differential lock
The differential in the distributor gear can be locked if the drive
wheels slip in difficult ground conditions.
When locked, there is a rigid connection between forwards
output and rear output.
Further details about this can be found in section 10 of these
operating instructions.
Be sure to follow the instructions and regulations out-
lined there.
Neutral position
If towing is required (for certain specific types of damage), the
distributor gear can also be put into the neutral position using a
manually actuated pneumatic valve.
For exact notes, see section 14 Towstarting and Towing the
Crane
When towing is finished, on/offroad gear must be reinstated in
the distributor gear by pressing dual button (93). (Z 52 114)
Driving in reverse
Prolonged driving in reverse should be avoided. (The lubricating
oil pump does not operate!)
7
1402070b 54/55
Z 52 114
93
A7
Z 52 115
Z 52 104 Z 200 319
B5
Transmission 7
1402070b 55/55
7.5 Driving stuck cranefree
(Z 52 114, Z 52 115, Z 52 104, Z 200 319)
If the crane is stuck on difficult terrain, it can be driven free by
driving forwards and backwards.
Action steps for driving crane free:
1. Engage offroad gear (press dual button (93)).
2. Turn rotary switch (13) to D.
The driving gear is selected automatically, but can still be
changed using the switch lever (12).
3. Apply careful pressure to the accelerator pedal (18).
Move the vehicle as far forwards as possible.
4. Engage the service brake and stop the vehicle.
Engine at idle speed!
5. Wait for standstill.
6. Move rotary switch (13) from D to N and then to R ).
The driving gear RH is automatically selected, however it
can still be modified using switching lever (12).
7. Apply careful pressure to the accelerator pedal (18).
Move the vehicle as far backwards as possible.
8. Engage the service brake and stop the vehicle.
Engine at idle speed!
9. Wait for standstill.
Repeat this procedure if the crane is getting a bit further with each
change of direction.
If the wheels are spinning, stop the attempt; the crane will have
to be towed free.
Towing free: see Section 14.3 of these operating instructions.
You can only shift gear in another driving direction is the
wheels are at a standstill (engine at idle speed).
If the vehicle is rolling, it will not shift gears; the
transmission shifts into neutral.
Keep an eye on the clutch temperature.
If the clutch is in danger of overloading, the CL display will
appear on the display (75) and the indicator light (B5) on the
display (43).
Brakes 8
1402080215 1/27
8
1402080215 2/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 200 150 Z 200 153
Brakes 8
1402080215 3/27
8 Brakes
The braking system is designed in accordance with German
road traffic regulations and European EEC directives for
axle loads of up to 12 tons.
Make sure therefore that these axle loads are observed.
Never drive with a defective brake system.
8.1 Emergency pressure supply braking system
(Z 52 136, Z 200 150, Z 200 153)
Display of the pressure supply
The pressure supply can be called up on the display (43) Driver
information (to do so, see notes in section 4).
10. Call up the menu selection 4 Information on Checks
(Z 200 150) in the main menu.
11. Then select menu point 4 Pressure supply in braking circuits
1 and 2 (Z 200 153).
In the top row, the pressure in braking circuit 1 and in the bottom
row the pressure in braking circuit 2 is displayed (bar display).
If the emergency pressure supply is below 7 bar, the braking
system must be topped up at medium revs, until a pressure of 8
bar has been reached.
Fault / warning displays
The following warnings are indicated on display (43), if the
pressure supply falls below 5.5 bar:
Preheating indicator (B3) for braking circuit 1
Preheating indicator (B4) for braking circuit 2
At the same time the preheating indicators (B3 / B4) appear, the
STOP display (35) lights up and the warning buzzer sounds.
If the preheating indicators (B3 / B4) light up together
with the STOP display (35) and the warning buzzer
sounds, the pressure supply in the braking system is too
low.
Stop the vehicle immediately; there is a serious risk of
accidents.
8
1402080215 4/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Brakes 8
1402080215 5/27
8.2 Service Brake
(Z 52 136)
The service brake (dual circuit compressed air braking system)
acts on all wheels.
To brake, press down the pedal (19) of the brake valve gently.
Immediately after driving, test the brakes on a dry, antiskid
road surface (service and retaining brake). When doing so,
make sure the crane brakes evenly, does not veer to the side
and that brake delay is faultless.
There must be no oil or water in the brake linings. If water has
permeated into the brake lining, lightly brake with the
service brake until the brakes are again fully functional.
The service brake must not be used for sustained peri-
ods under any circumstances. Danger of overheating
(fading)!
The service brakes may only be used when driving
downhill in order to brake the crane until a speed has
been achieved where the crane switches back to the next
gear.
This is why you must select the gear before driving
downhill with which the speed of the crane can be main-
tained when driving downhill.
Never drive with a defective brake system!
After the brakes have been used more intensely, do not switch
off the vehicle immediately but drive on for a little while in order
to allow the brakes to cool off faster from the driving wind.
8
1402080215 6/27
Z 62 761
B35
B36
Brakes 8
1402080215 7/27
8.2.1 Wear indicator for brake linings (disc brake)
(Z 62 761)
The brake linings are monitored by wear indicators. Wear is
indicated by the indicator light (B35) for disc brakes, left, and the
indicator light (B36) for disc brakes, right.
At first, the wear indicator light up only during braking. With
increasing wear, they light up permanently.
RISK OF ACCIDENTS!
If the indicator light (B35) or the indicator light (B36)
lights up only during braking or permanently, the brake
linings are worn and the braking effect is significantly
reduced.
Continuing to drive can cause damage to components of
the braking system.
The brake linings must always be replaced axle by axle.
8
1402080215 8/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 200 150 Z 200 153
Brakes 8
1402080215 9/27
8.3 Parking brake
(Z 52 136, Z 200 152, Z 200 153)
To park the crane, the parking brake (hand brake) must be
applied!
It is opened with compressed air and closed with accumulated
spring force. It is active on axles 1, 3, 4 and 5.
If the service brake fails, the parking brake can be used as an
emergency brake.
If the emergency pressure supply in the spring accumulator
brake circuit is too low, the spring accumulator parking brake can
be released mechanically in the case of an emergency (see
section 14).
As the parking brake does not work on all wheels, its braking
effect is less than that of the service brake.
Apply the parking brake:
Move lever (14) from the neutral position to the fully braked
position at the rear (lever locks in place). The indicator light
Parking brake (39) lights up.
With partial braking, the lever must be held in the desired position
as it otherwise returns automatically to the released (neutral)
position.
RISK OF ACCIDENTS!
Make sure that the lever (14) locks correctly in the full brake
position, as it can otherwise return automatically to the
released position.
The lever (14) must not be able to be pushed backed into the
released position (without actuating the lock).
8
1402080215 10/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Brakes 8
1402080215 11/27
(Z 52 136)
Release the parking brake:
Lift and hold the lock of the parking brake valve. Swing the lever
(14) forwards up to the stop. The indicator light Parking brake
(39) must go out.
The parking brake holds the crane on a max. inclination of 28 %
but not on the maximum inclination on which the crane can be
driven.
If required, additionally secure the crane with chocks to prevent
it from rolling away on downhill slopes.
When using the parking brake as an emergency brake, do not
move the lever (14) suddenly, but slowly and evenly. The braking
effect can thus be applied infinitely variable. Do not allow the
lever to lock in place!
Only use the parking brake for parking or in the case of an
emergency.
Never drive with a defective brake system.
8.4 Brake Pressure Limit
(Optional equipment / national regulations)
For special transport conditions with reduced axle loads (for
special national regulations) the vehicle can be equipped with a
brake pressure limit.
Observe the permitted axle loads and drive carefully.
Observe the information sign in the drivers cab.
Instructions on exceptional cases can be found in section 6 of
these operating instructions.
8
1402080215 12/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 62 770
III
I
II
IV
V
A21
3
0
38
Brakes 8
1402080215 13/27
8.5 Retarder Brakes
(Z 52 136, Z 62 770)
The standard crane vehicle is fitted with two sustainedaction
brakes (exhaust brake, hydraulic retarder).
Both are actuated using the combination switch (3). When
switching on (lever at level I) the indicator light (38) lights up.
Risk of skidding!
Do not activate the exhaust brake / retarder on a slippery
road surface. The wheels can lock.
The sustainedaction brake is automatically switched off as long
as there is ABS control. However, the indicator light (38) does not
go out. Afterwards, the operating mode most recently activated
is switched on.
In switching step I, only the exhaust brake is activated; from
switching step II onward, the hydraulic retarder is activated as
well. Depending on the lever position, the brake effect is
increased steadily from the first to the last step.
Lever in position
0 = switched off
I = exhaust brake
II V = exhaust brake + retarder, 4 steps
Especially when driving down longer downhill stretches, use the
sustainedaction brakes. Also in normal driving conditions, the
nonwearing sustainedaction brakes should be used where
possible for braking.
The effect of the exhaust brake and the hydraulic retarder is
dependent on the engine speed.
The higher the rpm/speed, the greater the braking effect.
The accelerator must not be pressed when the
sustainedaction brakes are in operation!
The correct gear level must be selected before a down-
hill/uphill stretch is reached at which the speed can be
held at a constant level.
The effect of a sustainedaction brake is interrupted dur-
ing a gear change. The vehicle can accelerate during
downhill driving.
8
1402080215 14/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 62 770
III
I
II
IV
V
A21
3
0
38
Brakes 8
1402080215 15/27
Manual Driving Operation
The exhaust brake is deactivated by the system when changing
gears. After changing gears, the exhaust brake is automatically
activated again.
Automatic Driving Operation
When activating the exhaust brake the system automatically
switches back to the gear for which there is the maximum braking
performance.
8.5.1 Engine Brake (Exhaust Brake and Constant Throttle)
The engine brake consists of a combination of exhaust brake and
constant throttle.
The constant throttle valve is closed during normal operation.
When the exhaust brake is activated, it opens constantly and
increases the braking effect by reduced compression.
When the combination switch (3) is activated (lever in position
I), the exhaust brake is switched on; the indicator light (38) is
illuminated.
The exhaust brake is only effective at an engine speed of more
than 900 U/min. If the engine speed falls below 900 U/min, the
exhaust brake is automatically switched off (and switched back
on again when the speed increases).
The exhaust brake is deactivated even with an engine speed
over 2300 min
1
.
8
1402080215 16/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 62 770
III
I
II
IV
V
A21
3
0
38
Brakes 8
1402080215 17/27
8.5.2 Hydraulic Retarder (System ZF Intarder)
(Z 52 136, Z 62 770)
The retarder is an additional hydrodynamic brake which is
integrated in the transmission and functions without causing
wear.
The hydraulic retarder is switched on by activating the
combination switch (3) (lever in position IIV); the indicator light
(38) is illuminated. The brake effect is increased steadily from the
first to the last step.
Using the retarder has no effect on changing speed gear.
If the clutch is applied (for switching gears), the braking force of
the retarder remains unchanged.
Depending on the engine speed, the retarder is activated with a
short time delay.
When the hydraulic retarder is used, heat is created in the
transmission.
The transmission oil temperature is monitored indirectly (via
the coolant temperature of the engine) with the help of the
preheating indicator (B13) in the driver information display.
Before and during downhill driving, make sure that the
engine speed does not fall below 1600 U/min. Otherwise,
sufficient cooling is not ensured.
You might have to switch back a gear in order to increase
speed and therefore water pump and fan performance.
If the oil temperature rises to unauthorised values (over 1505 C)
which leads to a coolant temperature which is too high the
retarder performance must be reduced until the coolant
temperature has reached a steady state of less than 955 C.
If the retarder output is not regulated by the driver, the system
automatically reduces the braking effect until the permissible
temperature has been reached (again).
When the retarder braking effect has been reduced, the indicator
light (38) starts to flash.
The reduced braking effect must be taken into consideration
and driving must be adapted (gear selection, service brake).
Following longer downhill stretches with the retarder
switched on, the engine can only be switched off when the
temperature indicator has returned to the permitted range.
8
1402080215 18/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 62 771
38
A21
III
I
II
IV
V
0
4
6
7
3
Brakes 8
1402080215 19/27
(Z 52 136, Z 62 771)
8.5.3 Function SustainedAction Brake Cruise Control
Using the function Sustainedaction brake cruise control a set
(fixed) speed can be kept at a constant level during a downhill
stretch within the limits of the existing braking capacity (engine
brake torque, gear level).
The sustainedaction brake cruise control is activated using the
actuating lever (3) on the righthand side of the steering column.
The preheating indicator (A21) of the driver display (43) is
illuminated.
The sustainedaction brake cruise control can only be activated
if the sustainedaction brake is switched on (= lever position IV).
The desired driving speed according to the speedometer can
be selected and fixed (lever position 6 or 7) in any lever position.
The electronic system saves the driving speed set in this way.
The saved speed is maintained when the braking effect of the
sustainedaction brake is sufficient.
If the current driving speed is lower than the set speed, the
sustainedaction brake remains without function. If speed attains
the saved value again, the sustainedaction brake becomes
active again.
If speed is increased while the sustainedaction brake cruise
control is activated, the vehicle returns to the saved speed after
the driving pedal has been released.
If speed is to be reduced to lower than the currently set speed
using the sustainedaction brake, the sustainedaction brake
cruise control must be switched off first (tap gearshift position 4).
Then the driving speed can be reduced manually via the different
levels (lever positions IV) of the sustainedaction brake. To do
so, the speed must be set again from lever positions 6 / 7 as
described above.
A saved speed is automatically deleted if the ignition is switched
off.
8
1402080215 20/27
Z 52 136
18
19
12
13
43
35 36
14
B3
B4
3
39 38
35
36
32
31
38
39
32 31
Z 62 771
38
A21
III
I
II
IV
V
0
4
6
7
3
Brakes 8
1402080215 21/27
Activating the sustainedaction brake cruise control:
Lever (3) in position
0 = Switched off
IV = sustainedaction brake step IV (engine brake
and retarder)
6/7 = sustainedaction brake cruise control
After the lever has been released, the current
speed is saved.
After the lever has been released, the vehicle drives with the
saved brake effect (speed).
Switching off the sustainedaction cruise control:
Tap actuating lever (3) in position 4.
8
1402080215 22/27
Z 52 137
18
19
12
13
43
35
36
35 36
14
3
32
31
B27
104
32 31
B29
B30
38 39
38
Brakes 8
1402080215 23/27
(Z 52 137)
8.6 AntiBlockingSystem (ABS)
The vehicle is equipped with the blocking protection ABS.
The ABS circuit covers all axles (of the vehicle) and possibly a
dolly as well.
The function is monitored as follows:
Lamps B29 + 32 for the vehicle axles.
Lamps B30 + 31 for possible dolly axles / additional axle /
dummy axle.
The ABS stops the wheels from blocking when the vehicle starts
driving at walking speed independent of the surface of the road
(water, iciness).
During ABS control, the sustainedaction brake is automatically
switched off. However, the indicator light (38) does not go out.
Afterwards, the operating mode most recently activated is
switched on.
RISK OF ACCIDENTS!
ABS does not free you from driving in a way that is suit-
able for traffic and road conditions. Tracking and steer-
ing of the vehicle are improved.
For example, ABS is not able to prevent the conse-
quences of keeping too small a safety distance or of in-
creased curve speeds.
8
1402080215 24/27
Z 52 137
18
19
12
13
43
35
36
35 36
14
3
32
31
B27
104
32 31
B29
B30
38 39
38
Brakes 8
1402080215 25/27
8.6.1 ABS: Full function / offroad mode
ABS is always active, however, the driver can switch it to
Offroad mode using key (104).
ABS in Offroad mode is indicated by indicator light (32)
flashing.
The brake path can be reduced on open country or unpaved
roads (i.e. soft or extremely bumpy surfaces as well as sloping
roads) by switching ABS over to Offroad mode.
The control is speeddependent; at higher speeds the ABS
control also switches to full function when in Offroad mode.
ABS can be switched over when the vehicle is at a standstill (key
in the ignition lock in driving position) or during driving.
After the engine has been switched off and started again, full
function is automatically activated. When driving off the road,
switch ABS over again.
The offroad mode may not be used in public traffic.
8.6.2 ABS Functions Check / Fault Display
Every time the ignition is switched on, the signal connections to
the instrument panel are checked again.
The indicator lights (32 / 31) must light up for a short period of
time.
The preheating indicators (B29, B30) are only displayed if there
is damage.
Once the dual control signal goes silent (approx. 30 sec.) the
function check has been completed.
The indicator lights (31, 32) must light up for a short period
of time and must have gone out after the acoustic check
signal sounds.
Blocking protection is not ensured if the displays for
functions check do not light up or do not go out after the
check signal.
The preheating indicators (B29, B30) may not be illuminated.
If they are illuminated, blocking protection is not ensured at
the individual axles.
8
1402080215 26/27
Z 52 137
18
19
12
13
43
35
36
35 36
14
3
32
31
B27
104
32 31
B29
B30
38 39
38
Z 26 866
1 2 4 3 5
Brakes 8
1402080215 27/27
RISK OF ACCIDENTS!
If an ABS fault is displayed, (CAUTION (35) would light
up at the same time), the braking behaviour of the ve-
hicle can change.
Drive especially carefully.
Have the fault rectified immediately at a specialist ga-
rage.
8.6.3 Braking with ABS
In case of danger, fully activate the brake pedal. This ensures
that all wheels are controlled and an optimum deceleration of
the vehicle is achieved.
During ABS control, the sustainedaction brake is
automatically switched off. However, the indicator light (38)
does not go out.
If you drive with a dolly without ABS, it can overbrake if you
have to make an emergency stop. In this case, the driver
must observe the towed vehicle in the rearview mirror. The
towing vehicle with ABS remains steerable; This means that
the driver can keep his towed vehicle steady.
If the indicator lights (31) ABS control, dolly or (32) ABS
control, vehicle light up, ABS will not function (defective) for
the dolly or towing vehicle.
If only the indicator light (31) ABS control, dolly lights up, the
dolly can overbrake. In this case, the driver must observe the
towed vehicle in the rearview mirror. The towing vehicle
(with ABS) remains steerable; This means that the driver can
keep his towed vehicle steady.
If indicator light (32) ABS control, vehicle light up, ABS is in
Offroad mode.
8.6.4 ABS with Dolly Operation
(Z 53 769)
If the crane vehicle has been fitted with a dolly coupling (optional)
ex works, there is a special ABS socket (4) for the transfer of the
ABS function at the rear of the vehicle rear.
4 ABS socket 7pole)
When using a dolly, the relevant regulations must be observed
(e.g. if for example ABS is required due to the number of axles).
Steering 9
1402090 1/51
9 Steering
9.1 General System Description
The steering of the crane chassis consists of a hydraulic
twocircuit steering system and electrohydraulic rearaxle
steering (auxiliary steering system).
The direction of travel is mainly determined by the rigidly
connected front axles.
The rear axles, controlled by the program, are aligned and are
steered electrohydraulically, depending on the speed.
A computer monitors the control of the electrohydraulic
rearaxle steering. Possible fault codes can be read out there.
(For information pertaining to this, see Steering computer / fault
diagnosis / fault list)
Various steering programs are available for road travel and
construction site operation.
The oil supply of the hydraulic components consists of two
enginedependent driven steering pumps and a
drivingdependent driven emergency steering pump.
During driving the emergency steering pump which is driven by
the moving crane controls the delivery rate from the main pump
2 and deactivates it as soon as the delivery rate is sufficient to
supply steering circuit 2.
If a steering circuit fails or in case of engine failure during
driving, the crane vehicle can still be steered until it comes to a
standstill. It does require increased effort, however, to move the
steering wheel and the steering reacts slower.
9
1402090 2/51
Steering 9
1402090 3/51
9.2 Safety Instructions
9.2.1 Safety instructions for protecting the system
Adjustments to the steering system may only be carried out
by our customer service.
Inspections / maintenance work must be carried out by
specialist personnel.
When working on the vehicle (painting, welding) suitable
measures must be put in place to protect the electronic
components (protection against overloading and static
charging).
In particular when carrying out welding work the steering
computer must be removed from the vehicle.
Never remove live plug connections.
9
1402090 4/51
Steering 9
1402090 5/51
9.2.2 Safety instructions for the protection of life and limb
for maintenance / service work
Caution risk of crushing!
When working on the steering system (e.g. inspections,
maintenance / service work, manual emergency steering)
there is an increased risk of crushing in the area of the
axles, wheels and track rods.
Always ensure that you have sufficient space for safe
movement.
Unauthorised persons must stay well clear of the turning
area of axles, wheels and track rods.
For maintenance work in the turning area of axles,
wheels and track rods, it must be ensured that these are
prevented from turning (switch off engine or deactivate
steering system).
If servicing is required (e.g. balancing the angle trans-
ducers), particular caution is required.
It must be ensured that no movements can occur on
axles, wheels, or track rods. This can be achieved by
switching off the engine or removing the connector at the
corresponding nonreturn valves.
Caution following servicing work!
Errors in the steering system can lead to axle move-
ments. When starting the engine, keep a safe distance
from the axles; nobody should be in the turning area of
axles, wheels and track rods.
Caution with the manual emergency steering control!
Particular care is required in case of manual emergency
steering. When actuating the valves for manual emer-
gency steering, the track rods and the wheels on the af-
fected axle will turn.
9
1402090 6/51
Z 52 123
43
35
36
35 36
B8
B9
B10
B2
Steering 9
1402090 7/51
(Z 52 123)
9.3 Monitoring functions for all steering programs
The most important components of the steering system (function
of the steering / emergency steering pumps and
electrichydraulic rearaxle steering) are monitored
electronically.
Faults are displayed on the drivers information screen (43) by
means of the following indicator lights:
B2 Fault electrichydraulic rearaxle steering
B8 Steering circuit 1 no flow
B9 Steering circuit 2 no flow
B10 Steering circuit 3 (emergency steering) no flow
The indicator lights can be displayed as either pink, white, yellow
or red.
The meaning of the colours is described in detail in section 4
(Drivers cab) Basic display / Meaning of colours.
Each time the ignition is switched on the electronic system
checks the signal connections to the instrument board.
Once the dual control signal goes silent (approx. 30 sec.) the
function check has been completed.
A pinkcoloured massage means that the function cannot be
monitored, because of a fault concerning the relevant
connection; e.g. short circuit or interruption.
In the case of pinkcoloured messages, the display Caution
(36) automatically lights up as well.
When an indicator light lights up at the same time as the
warning light caution (36) there is a malfunction.
Determine the cause of the malfunction and remedy the
problem as quickly as possible.
If an indicator light lights up at the same time as the red
warning light STOP (35) there is a serious malfunction.
The operational reliability of the vehicle is endangered.
Switch off the vehicle immediately and rectify the fault.
9
1402090 8/51
Z 52 123
43
35
36
35 36
B8
B9
B10
B2
Steering 9
1402090 9/51
(Z 52 123)
After rectifying the fault the warning display can be reset by
switching off the ignition for approx. 10 seconds. This also serves
to check that the fault has actually been rectified.
Equally, if an indicator light lights up, the system can be reset to
try and remedy the fault. To this end, stop the vehicle, switch off
the engine (switch off the ignition approx. 10 seconds) and
restart.
9.3.1 Monitoring the steering / emergency steering pump
The steering / emergency steering pump is monitored by the
indicator lights (B8 / B9 / B10) to ensure that it is working correctly.
These have the following meaning:
B8: Steering circuit 1 (main pump 1) no flow
B9: Steering circuit 2 (main pump 2) no flow
B10: Steering circuit 3 (emergency steering pump) no flow
at the emergency steering pump (indicator light B10) , there is
a display only once driving speeds > approx. 8 km/h have been
reached.
The indicator lights (B8, B9 and B10) must not light up as
a rule.
If one of these indicator lights is illuminated in red (at the
same time STOP (36) is displayed), there is a danger-
ous fault in the steering hydraulics.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!
In the case of a pinkcoloured message, a function display is not
possible as there is a faulty connection. (See Notes under
Monitoring functions in this section).
Function check
Regular inspections must be carried out to ensure that all
steering units, control units and monitoring equipment are fully
functional. Check for irregularities, e.g. leaks or pinkcoloured
indicator lights / changing displays.
9
1402090 10/51
Z 52 123
43
35
36
35 36
B8
B9
B10
B2
Steering 9
1402090 11/51
(Z 52 123)
9.3.2 Monitoring the electrohydraulic rear axle steering
The function of the electrichydraulic rearaxle steering is
monitored during driving by an alarm buzzer and the indicator
light (B2).
The preheating indicator (B2) signals a fault in the
electrohydraulic rearaxle steering of the basic unit.
The warning buzzer sounds additionally for each new fault and
in the event of faulty operation during a program change.
The indicator light (B2) must not light up.
If it lights up red (at the same time STOP (36) would
also be displayed), there is a dangerous malfunction in
the electrohydraulic rearaxle steering of the basic unit.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!
In the case of a pinkcoloured message, a function display is not
possible as there is a faulty connection. (see Notes under
Monitoring functions in this section).
Function check
Check all steering components regularly for mechanical damage,
corrosion and wear.
In particular pay attention to the angle transducers on the front
/ rear axles and their steering (fixed properly, no corrosion).
Corroded parts must be replaced.
9
1402090 12/51
Z 52 124
43
92
A6
Steering 9
1402090 13/51
(Z 52 124)
9.4 Steering programs
9.4.1 Selection of the Steering Programme Road Travel
or
Construction Site Operation
With the lockable switch Enable steering programs (92) the
system can be set to the steering program road travel (switch
not actuated) or construction site mode (switch actuated). For
construction site mode the indicator light (A6) lights up.
The system can be changed back to the road travel program
from all steering programs.
For normal road travel no special measures need to be carried
out (no actuation of switch!).
Briefly, for road travel, the program narrow curving travel can
be used.
For the purpose of road travel, all axles must be in the
synchronous position for the steering program road travel
(information on this available under synchronisation of wheels
when changing the program in this section).
For the special construction site mode there are various
steering programs
Manual rear axle steering,
Narrow curving travel,
Driving away from the wall and
Diagonal steering,
which using various switches / buttons need to be selected
case by case. The driving speed is limited.
It is only possible to switch from road travel to construction site
operation (switch 92) when the speed is below the max.
permissible speed of 5 km per hour.
Road travel remains active until a corresponding steering
programme is selected.
Each selected steering program is assigned to a certain display.
The display follows in the form of an indicator light on the screen
(43) Drivers information. A white indicator light shows a
preselected steering program; a yellow indicator light shows the
steering program that is currently active.
9
1402090 14/51
Z 52 125
43
75
A6
B2
92
Z 160 025
Steering 9
1402090 15/51
9.4.2 Steering program road travel
(Z 52125, Z 160 025)
Caution, the vehicle swerves out.
The steering program road travel must be selected for driving
on public highways.
In the program road travel the axles are steered as follows:
Front axles 1 and 2 (rigidly coupled) with the steering wheel.
Rear axles 4 and 5 using the electrichydraulic rearaxle
steering (depending on the driving speed).
(Axle 3 cannot be steered = rigid axle).
For driving speeds < 20 km/hour, the steered rear axles steer
around the steering centre of the front axles.
For driving speeds > 20 km/h the steering lock of the rear axles
is reduced as the speed increases.
The rear axles no longer steer for driving speeds > 45 km/h.
Caution !
For road travel switch (92) Enable steering programs may
not be actuated and the related indicator light (A6) must not
light up.
In addition the indicator light (B2) Error electrichydraulic
rearaxle steering must not light up.
When the indicator light (B2) lights up together with the
warning light caution (36) the system has recognised a
malfunction. Determine the cause of the malfunction and
remedy the problem as quickly as possible.
Caution RISK OF ACCIDENTS !
When one of the indicator lights (A6 or B2) lights up to-
gether with the STOP display (35) and the warning
buzzer sounds, the operational reliability of the steering
is no longer guaranteed.
accidents. Never drive with a defective steering system!
9
1402090 16/51
Z 160 026
85
86 87 88 89
3a
A6
92
Steering 9
1402090 17/51
9.4.2.1 Narrow cornering for road travel
(Z 160 026)
When turning/manoeuvring through a small radius, for example
as in the road travel mode the steering program tight
cornering can be selected when the crane is driven at speeds of
V < 20 km/h).
With the steering program Tight cornering, the 4th axle turns
more sharply than during normal onroad driving (as soon as a
steering angle of >85% is reached at axle 1) .
This achieves a smaller turning radius albeit with increased tyre
wear.
Switch on steering program Tight cornering:
Reduce driving speed to < 20 km/h.
Press button (86) (Narrow cornering is preselected).
The indicator light (A3) appears (first in white).
Continue to reduce driving speed to < 5 km/h.
The selected programme is activated;
The indicator light (A3) changes from the colour white to
yellow.
If the driving speed is not reduced to < 5 km/h within 20 seconds
of the program being selected, the previously active steering
program (road travel) is automatically selected.
Switch off the steering program narrow road travel:
Press button (86) again.
The indicator light (A3) changes from the colour yellow to
white.
Synchronise axles (information on this under
Synchronising the axles during programme change in this
section).
In a usually rolling machine, the steering angle of axle 4 is
automatically synchronised with other steering axles after
a short stretch.
As soon as the synchronised position has been achieved,
the indicator light (A3) goes out.
When a driving speed > 20 km/h is reached, Tight cornering is
also automatically switched back off again; The indicator light
(A3) goes out.
9
1402090 18/51
Z 200 276
A B C D
Z 52 128
43
35
B2
35
6 9
Steering 9
1402090 19/51
9.4.3 Steering program construction site mode
(Z 200 276, Z 52 128)
Depending on the selected programme, the steered rear axles
are steered by the monitoring programme, corresponding with
the front axles (axles 1 and 2) (computercontrolled separate
hydraulic circuit).
The nonsteered axle 3 (lift axle) can be raised by the driver
from case to case (information on this under raising / lowering
the lift axle). The pressure gauges assigned to the raised axle
(6) and (9) do not display pressure in this case.
Through the various steering programs the following steering
figures are possible:
Manual rearaxle steering (steering figure A)
Narrow cornering (steering figure B)
Driving away from the wall (steering figure C)
Diagonal steering (steering figure D)
Enabling of the steering program construction site mode is
only permitted:
on construction sites / nonpublic highways
if the crane is in the transportation state
(boom set down, axle loads max. 17 t)
The ground conditions must be suitable for driving, i.e. flat and
even ground, no dips or rises in the ground, no obstructions.
The ground must be able to support the individual axle loads (up
to 17 t) and the overall weight.
The indicator light (B2) fault electrichydraulic rearaxle
steering, with which the electrichydraulic rearaxle
steering is monitored, must not light up.
When it lights up together with the STOP display (35)
DRIVING IS PROHIBITED!
9
1402090 20/51
Z 52 134
10
8
6
9
5
7
Steering 9
1402090 21/51
(Z 52 134)
Observe the following when using the steering programme
constructionsite operation:
If the lift axle is raised, this inevitably results in increased
axle loads on the remaining axles on the ground.
After the lift axle is raised with the vehicle stationary a
pressure of 260 bar must not be exceeded on any of the
pressure gauges (5, 8) and (7, 10).
For reasons of stability, the suspension must be set to the
fourcircuit system.
The differential locks must not be actuated in the steering
figures manual rearaxle steering and diagonal
steering.
With the steering figures tight cornering and driving away
from the wall switching the differential locks on must be
avoided.
The crane may only be driven at walking speed (max. 5
km/h).
9
1402090 22/51
Z 52 124
43
92
A6
Steering 9
1402090 23/51
9.4.3.1 Shared characteristics of all steering programs for
the construction site mode
The basic release of the various steering programmes
Construction site operation is done by pressing the switch
(92) at speeds < 5 km/h.
At higher speeds the switch (92) can be activated, however,
there will be no release of the steering programmes
Construction site operation. In this case, the buzzer
sounds.
In steering programmes Construction site operation only
driving speeds up to 20 km/h can be achieved (speed lock).
The speed lock is only effective as long as the wheels are
not synchronised (again).
If the preselected steering programme is not active within
20 seconds, the system automatically switches back to the
previously active steering programme.
The programmes can only be selected at low speed (V <
5 km/h); they are only activated once the axles have been
synchronised.
Normally lift axle (axle 3) remains on the ground; however,
it can be raised by the driver, in order to reduce the tyre
wear. (Information on this under Raising/lowering the lift
axle in this section.)
It is only possible to raise / lower the lift axle when the
vehicle is at a standstill, the hand brake is applied, the
vehicle is in the neutral position with activated transmission
and pressed switch (92).
It is only possible to lower the lift axle, if steering / turning
angles are within the permitted range (not raised for lift
axle state); Otherwise reduce the steering actions, e.g. by
turning the steering wheel (wheels straight).
When the lift axle is raised, speed is limited to < 20 km/h.
If the lift axle remains on the ground, the steering angles,
by which the rear axles are automatically steered, of the
steering figures are restricted; i.e. not restricted for Manual
rearaxle steering.
If the axles are not synchronised to the selected steering
programme, for example when limiting the steering angles
to protect against high tyre wear, each indicator light does
not appear in yellow but in white.
9
1402090 24/51
Z 160 027
85
86 87 88 89
A6
A18
2a
92
Steering 9
1402090 25/51
(Z 160 027)
9.4.3.2 Manual rearaxle steering (steering figure A)
The front axles are steered with the steering wheel.
The lifting axle (not steered) remains on the ground; can be
raised by the driver.
The rear axles steer according to the position of the front axles
and manual activation using the dual button (85). Manual
steering of the rear axles enables steering movements to the left
or right, independent of the position of the front axles.
The front and rear axles are aligned geometrically correctly
(within their combination).
The vehicle speed is limited.
There is no limit to the steering angle against increased tyre wear
(steering error); not even if the lift axle remains on the ground.
Switch on the steering program Manual rearaxle steering
Press switch (92) Release steering programmes.
The indicator light (A6) lights up.
Speed lock (20 km/h) is effective and indicator light (A18)
lights up.
Press button (85) Manual rearaxle steering.
After the wheels are synchronised, the selected
programme remains active.
The indicator light (A2) changes from white to yellow.
The rear axles can now be steered using switch (85):
Turn switch to the left = moves wheel to the left
Turn switch to the right = moves wheel to the right
Switch off the steering program manual rearaxle steering
Lock switch (92) in position Off.
The indicator light (A6) goes out.
The indicator light (A2) changes from yellow to white.
Synchronise axles (see Synchronising the axles).
the indicator light (A2) goes out. The steering program
road travel is back in action.
9
1402090 26/51
Z 160 028
85
86 87 88 89
A6
A18
92
3a
Steering 9
1402090 27/51
(Z 160 028)
9.4.3.3 Tight cornering (steering figure B)
The lifting axis (not steered) remains on the ground; can be
rectified by the driver.
The rear axles are steered analogous to the front axles by means
of the electrichydraulic rearaxle steering. The axle 4 then turns
more strongly towards the end than for normal road travel.
Driving speed is limited.
If the Lift axle remains on the ground, the steering lock is limited
to prevent excessive tyre wear (steering error).
Switch on steering program tight cornering
lights up.
Press button (86) (Narrow cornering is preselected).
The colour of the preheating indicator (A3) changes from
white to yellow.
Switch off the steering program tight cornering
The indicator light (A3) changes from the colour yellow to
white.
9
1402090 28/51
Z 160 029
85
86 87 88 89
A6
A18
92
A4
Steering 9
1402090 29/51
(Z 160 029)
9.4.3.4 Driving away from the wall (Steering figure C)
The steering centre is to the rear of the vehicle; the rear does not
swing out.
The rear axles are steered analogously to the front axles by
means of the electrichydraulic rearaxle steering.
Do not lock the front axles further once the indicator light
(A4) switches from yellow to white.
The rear axles have then reached their final position as
specified by the program (no further movement).
Further steering leads to a deterioration in the steering
figure / system benefits and tyres could be separated from
the rims.
Switch on the steering program Drive away from the wall
lights up.
Press button (87) (Driving away from the wall is
preselected).
the indicator light (A4) changes from white to yellow.
Switch off the steering program Driving away from the wall
9
1402090 30/51
Z 160 030
85
86 87 88 89
A6
A18
A5
92
Steering 9
1402090 31/51
(Z 160 030)
9.4.3.5 Diagonal steering (steering figure D (crab travel))
The rear axles steer in the same way and at the same angle
(parallel) as the front axles. The steering lock is determined by
the steering wheel.
Do not turn front axles further, once the indicator light (A5)
changes from yellow to white.
The rear axles have then reached their final position as
specified by the program (no further movement).
Further steering leads to a deterioration in the steering
figure / system benefits and tyres could be separated from
the rims.
Switch on the steering program diagonal steering
lights up.
Press button (88) (Diagonal steering is preselected).
the indicator light (A5) changes from white to yellow.
Switch off the steering program diagonal steering
9
1402090 32/51
Steering 9
1402090 33/51
9.4.4 Synchronising the wheels when changing program
Synchronisation means that the wheels of all steered axles are
brought into one specified position in accordance with the
individual steering program.
The change to a different steering program is complete once all
axles have been synchronised.
The change between the individual steering programs can only
be carried out once all axles have been synchronised.
Synchronisation can be achieved by:
Driving off
Moving the vehicle at speeds over 2 km/h.
While the unit is rolling, the steering angle of the rear axles
is automatically synchronised with the other steering axles
after a short stretch
or
Operation of keys during standstill
Continuous operation of the relevant steering programme
key during standstill; the axles automatically move to the
desired position, as long as the key is pressed.
When changing back to the steering programme Road
travel, synchronisation to the road travel state can be
achieved by continuously pressing the switch Narrow
cornering (E 141). To do so, the wheels of the front axles
must be aligned in the straightahead position.
If the adjustment force of the steering cylinders is not
sufficient to reach the desired position, e.g. if there is an
obstacle on the ground, the vehicle must be driven to another
spot.
or
Steering movements when stationary
Larger steering movements to the front axle when stationary
by adjusting the steering wheel (right / left).
With this procedure, the socalled capture of the
electrichydraulic steered axles, these are individually
moved along with the front axles. As soon as the front axles
are moved, the rear axles begin to synchronise.
An axle that is not positioned in the specified geometry, is
automatically positioned to the value preset by the selected
program (synchronised) at the latest when the vehicle starts to
move.
When synchronising in a stationary position, the procedure can
be assisted by releasing the retaining brake.
9
1402090 34/51
Z 52 133
A14 102
A6 92
Z 52 134
10
8
6
9
5
7
Z 160 031
IV V VI
I II III
Steering 9
1402090 35/51
9.4.5 Raising/Lowering the Lift Axle
(Z 52 133, Z 52 134, Z 160 031)
It is only possible to raise / lower the lift axle when the vehicle
is at a standstill, the retaining brake is applied, the transmission
is switched to the neutral position and the switch (92) is pressed.
With the lift axle raised the speed is limited to < 20 km/h.
9.4.5.1 Raise the Lift Axle
12. Stop vehicle; apply parking brake; transmission in neutral!
13. Set the engine speed to approx. 1500 rpm .
14. Actuate switch (92) enable steering programs.
15. Actuate Raise lift axle (102) switch (unlock); by doing so the
lift axle (axle 3) is raised to the upper end position.
The pressure gauges 6 and 9 display no pressure.
16. Carry out a visual check to make sure that the raised wheels
of axle 3 are actually clear of the ground.
9.4.5.2 Lower the Lift axle
It is only possible to lower the lift axle, if steering / turning angles
are within the permitted range (not raised for lift axle condition);
Otherwise reduce the steering actions, e.g. by turning of steering
wheel (wheels straight).
1. Stop vehicle; apply parking brake; transmission in neutral!
2. Switch off the switch raise lift axle (102) (lock).
The raised Lift axle is lowered to the ground again.
3. If the Lift axle is on the ground, a pressure of 105 bar is built
up automatically again in the separated suspension circuits
(II / V) and they are connected again to the individual overall
suspension circuit (III or VI).
4. The overall level must be checked for road travel (relevel if
required).
9
1402090 36/51
Z 52 116
F1 F2 F3 F4
A
Steering 9
1402090 37/51
9.5 Steering Computer / Fault Diagnosis / Fault List
The steering computers are in the floor of the drivers cab under
the passenger seat. In order to get to the steering computers, the
entire seat along with its baseplate must be moved into the
most frontal position and then folded up towards the front
(against the front window).
Risk of injury!
The raised seat must be secured in place with suitable
means (e.g. wooden block, strut) to prevent it falling
backwards.
9.5.1 Operating functions
(Z 52 116)
The display (A) and the 4 function keys (F1 F4) are directly on
the main computer.
The buttons have the following basic functions:
ESCAPE button (F1):
Exit the current menu.
End without saving.
Back one entry position.
MINUS button (F2):
Back one selection point (e. g. previous fault).
Reduce value by 1.
PLUS button (F3):
One selection point further (e. g. next fault).
Increase value by 1.
ENTER button (F4):
Activate selected menu.
Confirm value.
Save value.
One entry position further.
9
1402090 38/51
Z 52 117
43
35
36
35 36
B2
Z 52 116
F1 F2 F3 F4
A
Steering 9
1402090 39/51
(Z 52 117, Z 52 116)
9.5.2 Registration of a fault
The electrichydraulic rearaxle steering has a selfdiagnosis
system.
When the system recognises a fault, this is displayed to the driver
on the display (43) drivers information by the indicator light (B2)
and additionally signalled by the warning buzzer.
Although they cannot be seen by the driver while driving, all
errors are displayed simultaneously at the relevant steering
computer (main steering computer: display A ; no display at
steering computer: at doubledigit segment display)
Active faults are always displayed with the indicator light (B2).
If the vehicle is moving when a fault occurs, the warning
buzzer also sounds.
The warning buzzer sounds whenever the crane moves off
in the faulty condition.
Faults that occur remain active until the ignition is switched
off, regardless of whether the fault still exists or not.
An active fault is automatically stored in the error memory.
9.5.2.1 Fault display on the display (43) drivers
information
Caution !
warning light caution (36) the system has recognised a
malfunction. Determine the cause of the fault and rectify as
soon as possible.
An attempt can be made to rectify the fault by resetting the
system. To this end, stop the vehicle, switch off the engine
(switch off the ignition approx. 10 seconds) and restart.
STOP display (35) and the alarm buzzer sounds, the
operational reliability of the steering is no longer guaran-
teed.
accidents. Never drive with a defective steering system!
See also section 6: Driver information display (43).
9
1402090 40/51
Z 52 118
Z 52 119
Steering 9
1402090 41/51
9.5.2.2 Fault display on screen (A) of the steering computer
Display in the faultfree condition
(Z 52 118)
In addition to the display no error in the second text line a >
sign moves from left to right. This moving display signals that the
steering computer is active and the software is being processed.
Display of active faults
(Z 52 119)
As soon as the system has recognised a fault, the display
changes to the fault code screen.
Faults are described according to location of fault, type of fault
and category of fault. All three individual codes are displayed.
Example place of error: 10
Example error type: 07
Example error class: 01
If several faults exist at the same time, the display automatically
switches to the next fault after 2.5 seconds.
If all faults have been rectified, the display changes back to the
faultfree state (no error, > symbol).
9
1402090 42/51
Z 52 120
F1 F2 F3 F4
A
3 sec.
Z 52 121 Z 52 122
Steering 9
1402090 43/51
9.5.3 error memory / fault codes
Up to 32 various faults with 3 fault codes each can be stored in
the error memory of each steering computer. If the error memory
is full, the first entered fault is overwritten.
The fault codes can be read off the display of the steering
computer. They are subdivided according to the location, type
and category.
9.5.3.1 Activate / read off error memory
(Z 52 120, Z 52 121)
To read off the error memory with the display (A), first the menu
point error memory must be selected in the menu for special
functions.
Select special functions menu:
The menu for special functions is activated by pressing the ESC
and ENTER keys (F1, F4) at the same time for at least 3 seconds.
The change is made when the screen switches to i/o data
display.
Move on to the menu item error memory:
The PLUSkey (F 3) switches from i/o data display to error
memory.
Activate error memory:
Use the ENTERkey (F4) to activate the error memory function.
The display changes to the first fault that is stored. (Z 52 121)
Reading Off the Error memory
Using the PLUS and MINUS keys (F2 / F3), all faults can be read
out one after the other. At the end of the error memory (fault 32)
the system automatically returns to the beginning (fault 1).
As soon as the code display 255, 255, 255 appears on the
screen, there are no additional faults in the memory.
The fault before the display 255 is the last entered fault. With
a completely deleted error memory, only code entries with 255
are maintained. (Z 52 122)
Exit error memory function:
Using the ESC key (F1), the error memory function can be exited
at any time.
9
1402090 44/51
Z 52 116
F1 F2 F3 F4
A
Z 53 001
LCD
Steering 9
1402090 45/51
(Z 52 116, Z 53 001)
Remotecontrolled operation:
Individual steering computers of the system do not have their own
display. The faults of all steering computers are read off centrally
at the display screen (A) of the main steering computer.
To do this, the menu point remote control must be selected in
the special functions menu.
1. Select the special functions menu (press buttons F1, F4 at
the same time for at least 3 seconds).
2. Using the ENTER button (F4) select the menu point remote
control.
Display text: remote control LCD
3. With the PLUS and MINUS button the numbers of the
steering computer can be selected.
The display changes to select the desired steering computer.
4. Note:
When the desired steering computer is selected, the display
switches constantly between choose SLC: ?? and the
contents of the display of the other steering computer. If the
selected computer fails to answer, No connection appears.
5. Using the ENTER button (F4) change to the selected
steering computer.
6. Activate / read error memory of the selected steering
computer:
Carry out Activate / read error memory procedure (as
described on the previous page).
7. Exit the selected steering computer:
By switching off the ignition.
9.5.3.2 Delete error memory
The error memory may only be deleted in consultation with our
customer service department.
9
1402090 46/51
Z 52 117
18
19
12
13
43
75
35
36
35 36
B2
Steering 9
1402090 47/51
9.5.4 Fault categories / fault reaction
(Z 52 117)
The faults are divided into the fault categories 0 to 3 and are
entered in the error memory of the steering computer.
The fault category determines the reaction of the steering to the
fault and the subsequent effect on steering operation.
Fault category 0
Display (43) shows: No
reaction of the steering: Warning; steering behaviour is not
affected.
Effect: Unlimited driving mode possible.
Error class 1
Display (43) shows: Indicator light (B2) + Caution (36) + single
warning signal.
Reaction of the steering: the axle / system is steered to the next
straight position.
Effect: Speed block is partially active.
Error class 2
Display (43) shows: Indicator light (B2) + Caution (36) + single
warning signal or indicator light (B2) + STOP (35) + repeated
warning signal.
Reaction of the steering: Automatic steering in straight position.
Effect: Speed limiter active.
Fault category 3
Display (43) shows: Indicator light B2 + STOP (35) + repeated
warning signals.
Reaction of the steering: Selfcentring / locking of the axles
(safe condition).
Effect: Speed limiter active.
If faults of categories 1, 2 and 3 are present in the error
memory, these codes must be provided to our customer
service department; they will then determine the causes of
the fault and issue suitable measures to be taken.
9.5.5 Fault list (following)
9
1402090 48/51
Z 52 123
Y1
Y
X1
X2
Z 200 283
A
Steering 9
1402090 49/51
(Z 52 123, Z 200 283)
9.6 Manual emergency steering
Caution, increased risk of crushing!
When the valves for the manual emergency steering con-
trol are actuated the track rods and the wheels move on
the affected axle. In the case of manual emergency steer-
ing, particular caution is therefore required.
Make sure that you have sufficient space to move in
freely.
If the steering computer fails, the electrical current is cut off to all
valves; i.e. the steered rear axles are only locked in their current
position.
To be able to adjust these axles without the computer being
active, the steering system is equipped with a manual emergency
steering control. This enables the nonreturn valves (Y) to be
moved from their locked position, thus releasing the axles.
Subsequently, each individual axle can be moved into a useable
position by manual actuation of the solenoid valves (X1 / X2), for
example to move the vehicle out of a hazardous area. The
requirement for this is that the steering hydraulics are available
(vehicle engine running).
Each axle has its own valve block with nonreturn valve (Y) and
solenoid valve (valve tappet X1 / X2) assigned to it. The valve
block is at point A of the undercarriage under the aluminium
cover.
For normal operation, the nonreturn valves must not be
actuated manually.
They may only be used in a case of emergency; e.g. in
order to remove the vehicle from a danger area. The
check valves must then immediately jump back to their
initial position.
If the check valves do not jump back to their initial posi-
tion, e.g. because they are stuck, then safe steering is no
longer ensured. The axles can change position in an un-
controlled fashion. Safety risk!
9
1402090 50/51
Z 52 123
Y1
Y
X1
X2
Steering 9
1402090 51/51
(Z 52 123)
Steps for positioning an axle
1. Stop vehicle; apply parking brake; secure against rolling
away; transmission in neutral; engine running.
2. Release axle:
Operate check valve (Y) by pressing the button (Y1) in the
blue anodised knurled nut; keep button pressed.
The axle is no longer locked as long as this button is pressed.
3. Move axle:
to the left: valve tappet, press left (X1).
to the right: valve tappet, press right (X2).
4. Lock axle:
If the axle is in the desired position (usually this will be the
straight ahead position):
Release the valve tappet (X1 / X2).
The axle no longer moves.
Let go of button (Y1); the valve anchor will jump back to its
initial position.
The axle is locked again.
RISK OF ACCIDENTS!
If the check valve is not set back to its initial position, the
relevant axle can shift in an uncontrolled manner during
driving.
Differential Locks 10
1402100 1/7
10 Differentials / Differential Locks
10.1 Differentials
To distribute the drive torque to the driven wheels and to adapt
the wheel speeds when driving through curves the following
differentials (drive assemblies) are fitted:
Longitudinal differential in the distributor gear
The distributor gear forms a unit with axle 3.
Longitudinal Differential in the Axles
The longitudinal differential is fitted in axle 4.
Activating axle 3:
Axle 3 is activated by activating the longitudinal lock in axle
4.
Transverse Differential
A transverse differential is fitted in each drive axle.
10.2 Differential Locks
The differentials in the distributor gear and axles which work
lengthways and the transverse differentials can be locked.
In the locked condition, there is a rigid connection between the
two outputs of the differentials.
The differential locks need to be switched on in the following
circumstances:
A wheel of a drive axle is standing on a loose surface and is
spinning:
The transverse differentials must be locked.
Both wheels of a drive axle are spinning:
The longitudinal differentials must be locked.
Only in extreme cases may both differential locks be switched on
together.
If the differential locks are switched on, you may only drive
at walking speed.
The differential locks may not be activated in the steering
figures Manual rearaxle steering and Diagonal
steering.
You must avoid activating the differential locks during
steering figures Narrow cornering and Driving away from
the wall.
10
1402100 2/7
1402100 3/7
10.3 Activating the Differential Locks
When the differentials are locked there is a risk of parts of the
drive being overloaded. Extreme caution is always required when
driving the crane with the differentials locked.
Only use the differential locks to drive on difficult territory
(sand, mud, loose ground).
Only switch on differential locks shortly before reaching an
obstacle and switch them off immediately after the obstacle.
Only switch on and off when the crane is at a standstill. There
is an extremely high risk of the crane being damaged if the
differential locks are switched on when the drive wheels are
turning.
When the longitudinal differential is locked, the steering can
be actuated with extreme caution.
When the transverse differential is locked, the crane may
only be driven in a straight line.
Only use differential locks when the crane is in the transport
condition. Under no circumstances may they be used when
the crane is erected!
Drive carefully! Do not start or stop abruptly! Do not apply
full throttle!
When the differentials are locked, never drive on longer
stretches or on solid surfaces with good traction.
10
1402100 4/7
Z 52 140
94 95
A9
A10
1402100 5/7
10.3.1 Activating the Longitudinal Locks
(Z 52 140)
Activate the longitudinal locks as follows:
1. Stop the crane; wait for it to come to a standstill!
2. Press switch (94).
The longitudinal locks in the distributor gear and in axle 4 are
switched on and axle 3 is selected.
3. The indicator light (A9) lights up.
Switch off the longitudinal locks as follows:
2. Press switch (94) again.
The longitudinal locks in the distributor gear and in axle 4 are
switched off and axle 3 is cut out.
3. The indicator light (A9) goes out.
If, when switching off the longitudinal locks, display (A9) does not
go out, the lock has not disengaged.
activate the lock again and carry out small changes in direction
with the crane vehicle. At the same time turn the steering a few
times to the left and right.
At a standstill, switch off the locks again.
10
1402100 6/7
Z 52 140
94 95
A9
A10
1402100 7/7
10.3.2 Activating the Transverse Locks
(Z 52 140)
First switch on the longitudinal locks.
The transverse differentials may only be applied when it is no
longer possible to proceed even though the differential locks are
applied.
Switch on the transverse locks:
2. Press switch (95).
The transverse locks of the drive axles are activated
together.
3. The display (A10) lights up.
Switch off the transverse locks as follows:
2. Press switch (95) again.
The transverse locks of all drive axles are switched off
together.
3. The display (A10) goes out.
If, when the transverse differentials are switched off, the display
(A10) does not go out, the lock has not disengaged.
Activate the transverse lock again and carry out small changes
in direction with the crane vehicle.
When at a standstill switch off the lock again.
Hydraulic Suspension 11
1402110113a 1/25
11
1402110113a 2/25
Z 52 145
43
A6
99
Z 200151
1402110113a 3/25
11 Hydraulic Suspension
(Z 52 145, Z 200 151)
All axles of the crane chassis have hydraulic suspension.
During normal use (e.g. when driving on the road) the hydraulic
suspension is divided into four separate circuits.
When driving on road surfaces which are very uneven (extreme
ramps, slopes, humps), the suspension can be switched over to
a threecircuit system to improve road handling.
You switch to the threecircuit system by pressing the lockable
switch (99).
When indicator light (A6) comes on, the suspension is in the
threecircuit system.
Driving with the threecircuit system means less lateral
stability. The max. road speed should therefore not exceed
15 km/hour.
When the cranes equipment is erected, it must be driven
with the fourcircuit system.
All operating and monitoring equipment is located in the cab of
the chassis.
You can call up the current settings of the suspension circuits on
display (43) under menu point 4.1 Suspension levels. (Example
middle position Z 200 151)
Proceed with caution when carrying out adjustment
work! Risk of crushing!
Make sure that noone is in the danger zone of the verti-
cally extending / retracting suspension cylinders.
11
1402110113a 4/25
Z 53 784
5 7
9
6
8 10
Z 53 785
1402110113a 5/25
11.1 Distribution of the suspension circuits / assignment
of the pressure gauge
(Z 53 784, Z 53 785)
11.1.1 In normal situations: Fourcircuit System
Suspension circuit I:
axle 1 to 2, front right
pressure gauge I (5)
Suspension circuit II: *
separate suspension circuit for Lift axle
axle 3, right
pressure gauge II (6)
Suspension circuit III:
axle 4 to 5, rear right
pressure gauge III (7) + II (6)
Suspension circuit IV:
axle 1 to 2, front left
pressure gauge IV (8)
Suspension circuit V: *
separate suspension circuit for Lift axle
axle 3, left
pressure gauge V (9)
Suspension circuit VI:
axle 4 to 5, rear left
pressure gauge VI (10) + V (9)
When the lift axle (axle 3) is raised, the suspension circuits
II / V assigned to this axle are automatically separated from
the other axles (separate pressure display on pressure
gauges II / V (6 / 9)) and after it has been lowered to the
ground switched to suspension circuits III / VI again.
11.1.2 Exception: Threecircuit System
Suspension circuit I + IV:
axle 1 to 2, front right and left
pressure gauge I (5) / IV (8)
Suspension circuit III:
axle 3 to 5, rear right
pressure gauge III (7) + II (6)
Suspension circuit VI:
axle 3 to 5, rear left
pressure gauge VI (10) + V (9)
11
1402110113a 6/25
Z 35 554 Z 52 148
78
81
79
76
80
77
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
1402110113a 7/25
11.2 Setting for Driving in the Transport Position
(Z 35 554, Z 52 148, Z 51 302)
11.2.1 General
When driving the mobile crane in the transport position
(construction site or road travel) the suspension must be at the
road travel level (all suspension cylinders in the road travel
position).
In this case, the gap of the fastening eyes on the suspension
cylinders (measurement X ) is 630 mm. Only this state ensures
that there is sufficient suspension travel for driving operation.
At the road travel level the suspension travel is + 110 / 110 mm
(110 mm to the top / 110 mm to the bottom).
The hydraulic suspension can only be set if:
Hold axles is activated (display (A13) lights up).
Raise axles is activated (display (A15) lights up).
Raise all axles is activated on the switch panel of the outrigger
controls (button 9/19).
First Hold axles (button 101) must be actuated in the cab.
When the Lift axle is raised (steering program Construction site
operation), the suspension circuits only react partially. The two
front ones can be set, the two rear ones cannot (with the
exception of axle 3).
The levels of the suspension circuits can either be set together
(dual button 76) or individually (dual buttons 78 / 79 / 80 / 81).
11.2.2 Automatic setting road travel level
Using the AUTO (77) button the road travel level is set
automatically.
The road travel level is the condition for normal driving operation.
All suspension cylinders are located in the road travel position.
The individual suspension travel movements equal 110 / +110
mm.
The requirement for smooth functioning is a level, even road
surface (no potholes, no lateral gradient).
11
1402110113a 8/25
Z 51 303
78
81
79
A
B
76
80
77
Z 200151
1402110113a 9/25
(Z 51 303, Z 200 151)
11.2.3 Manual Setting of the Level
Using manual setting of the level, the individual suspension
circuits can be set independently of each other. Each level in the
entire range of the suspension movement (between 0 and 220)
can be set.
Manual level setting is only possible when standing still (parking
brake applied, transmission in neutral).
Starting position:
set crane down on level and horizontal ground; apply parking
brake; transmission in neutral!
Set the engine speed to approx. 1500 rpm .
11.2.3.1 Function of the dual buttons (78, 79, 80, 81)
Press dual button on item A: The corresponding
suspension circuit is raised
Press dual button on item B: The corresponding
suspension circuit is lowered
11.2.3.2 Setting the Suspension Circuits (Fourcircuit System)
The suspension circuits can be reset using the Raise / lower
function of the dual buttons (78, 79, 80, 81).
To level the crane quickly and/or evenly, different (or all) circuits
must be filled or emptied at the same time.
It is not possible to set circuits in different directions (filling one
circuit while emptying another) at the same time.
Suspension circuit 1 (front right)
Press dual button (79A):
Raise level (extend suspension cylinder)
Press dual button (79B):
Lower level (retract suspension cylinder)
11
1402110113a 10/25
Z 51 303
78
81
79
A
B
76
80
77
Z 200151
1402110113a 11/25
(Z 51 303, Z 200 151)
Suspension circuit 2 (rear right)
Suspension circuit 3 (front left)
Suspension circuit 4 (rear left)
Information for setting the overall level:
The difference with this compared to the individual settings is that
all suspension circuits can be reset together using key (76). Any
possibly existing level differences remain.
Press / hold key (76A) = raise total level
Press / hold key (76B) = lower total level.
Check: On display (43) under menu point 4.1 Suspension
levels.
With the manual level setting, the suspension cylinders can
be extended / retracted up to the stop (in a block). In this
case make sure that the pressures shown at the middle
position are not exceeded. It is prohibited to drive
suspension cylinders that are set to in a block.
11.2.3.3 Setting the Suspension Circuits (Threecircuit
System)
The suspension circuits are normally set in the fourcircuit
system (road travel).
However, the setting can also be made in the threecircuit
system (offroad travel).
Make sure that the two front circuits react correspondingly; even
when only one of the assigned dual buttons (78, 79) are
activated.
11
1402110113a 12/25
Z 52 147
10
8
6
9
5
7
Z 53 786
B1
1402110113a 13/25
11.3 Monitoring the Hydraulic Suspension
11.3.1 Monitoring the Pressure
(Z 52 147, Z 53 786)
For constant control of the pressure in the hydraulic suspension,
there are corresponding pressure gauges (items 510) in the
drivers cab.
The desired value of the suspension pressure can only be
determined precisely after the suspension cylinders have been
levelled.
With a 12 t axle load, the suspension pressure should be
approximately 105 bar (average value) and can be different for
each suspension circuit.
If the suspension system is switched to road travel, the
suspension pressure can fall on one side and rise on the other
side of the vehicle when driving around corners.
If the suspension pressure falls abruptly in one of the
suspension circuits during road travel, or / and the level
changes noticeably (display B1 is illuminated), the
suspension has a dangerous malfunction.
In this case you must stop the mobile crane, find the cause
of the fault and rectify it.
11
1402110113a 14/25
Z 52 149
B
A 1 2 C
D
1402110113a 15/25
11.3.2 Level Control, Level Indicator
(Z 52 149)
Level control of the suspension circuits takes place on the display
(43) in the drivers cab. The current level of the individual
suspension circuits is indicated with symbols under menu point
4.1 Suspension level.
Symbol (A): suspension circuit I (front, right)
Symbol (B): suspension circuit III (rear, right)
Symbol (C): suspension circuit IV (front, left)
Symbol (D): suspension circuit VI (rear, left)
A level indicator has been assigned to each suspension circuit
which consists of fixed vertical bars (1) and a piston (2) which
moves up and down as the level goes up or down.
In the roadtravel level
the bar (1) is coloured green and the piston (2) is in the middle
of the bar corresponding to the road travel position of the
suspension cylinders.
In all intermediate positions
outside the road travel level the bar (1) is coloured yellow and the
piston (2) moves further upwards or downwards.
Carry out a level check on level, even ground with the wheels
facing straight ahead.
Deviating suspension circuits must be reset.
If constant deviations occur, the suspension must be
checked by our customer service.
11
1402110113a 16/25
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
1402110113a 17/25
11.4 to lock the suspension
The hydraulic suspension system must be blocked for driving in
an erect mode (see section 6).
When driving in the transport position (on the road and
construction site) the hydraulic suspension may not be
blocked.
If the suspension were blocked, it would cause great
damage to the chassis at speeds > 5 km/h!
11.4.1 Activating the Suspension Block
. . . Before Driving in an Erect Mode
(Z 51 302)
Driving in the erect condition always means driving wi-
thout load!
Driving with load is prohibited!
Before supporting the crane on outriggers:
Align the crane horizontally (level).
Activate switch Hold axles(101), display (A13) is illuminated.
All axles remain in the prescribed position.
The crane can be lowered onto the wheels after it has been
supported on outriggers for driving in the erect condition by
retracting the vertical outrigger cylinders.
The crane is aligned horizontally and the suspension cylinders
are in the road travel position.
Before driving in the erect mode:
The regulations for ground characteristics and road slope
(see section 6) must apply.
Extend the outrigger struts and hold the outrigger feet just
above the ground.
Before the crane is lowered onto the wheels for driving in
the erect/configured condition, all suspension cylinders must
be in the road travel position.
This is always guaranteed if the axles which are level are set to
Hold axles before extending the outriggers.
11
1402110113a 18/25
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Z 51 303
78
81
79
A
B
76
80
77
1402110113a 19/25
(Z 51 302, Z 51 303)
Place the crane in the condition Driving in the Erect Mode;
Steps for the Procedure:
Starting position:
The crane is supported on outriggers.
Switch (101) Hold axles is activated; display (A13) is
illuminated.
1. Retract outrigger cylinders slowly and evenly until the wheels
of all axles are pressed evenly on the ground.
Pressure check at the pressure gauge (5 to 10) in cab (see
section 12, Outriggers).
2. Switch off Hold axles with switch (101).
The display (A13) goes out.
3. Switch on Lock suspension with switch (100).
The display (A12) is illuminated.
4. Check the level of the crane (horizontal alignment) optically.
The suspension cylinders of all axles must be approximately
in the road travel position.
The clearance between the fastening eyes on the
suspension cylinder (dimension X) is then 630 mm.
If the crane is not level, extend the outrigger cylinders again
and support the crane lightly on the outriggers.
Fill up the corresponding suspension circuit by pressing
buttons (78A, 80A) for the lefthand side or (79A, 81A) for the
righthand side.
The suspension may only be filled up to a maximum sus-
pension pressure of 270 bar.
An attempt to fill the suspension up to higher pressures
can cause the suspension to sag.
5. Afterwards, retract the outrigger cylinders until the crane is
standing free on its wheels; check for horizontal alignment.
Outrigger plates just above the ground!
11
1402110113a 20/25
Z 35 554
1402110113a 21/25
(Z 35 554)
Repeat this procedure until the crane is horizontally aligned and
level with the outrigger cylinders retracted.
Observe the road travel position of the suspension cylinders.
The suspension cylinders must be in the road travel position.
The clearance between the fastening eyes on the suspension
cylinder (dimension X) is then 630 mm.
The suspension pressure should be monitored continually.
If the pressure in one of the suspension circuits rises up to
300 bar, stop the crane immediately and extend outrigger
cylinders until the load is taken off the wheels.
Make sure the crane is evened out by resetting the hydraulic
suspension and / or correcting the boom position.
If the crane is driven further there is a risk of the crane
TIPPING or of AXLE BREAKAGE !
11.5 Height Adjustment
The level of the suspension circuits can in the context of the
suspension travel be adjusted up or down. This can be helpful,
for example
if the height clearance is too low;
if more ground space is required;
if the mobile crane is stuck on terrain;
before retracting the outriggers.
When adjusting the height, always leave some clearance to the
final upper and lower position so that there is a degree of
suspension play remaining.
In this state the suspension is only effective in a limited capacity.
Drive with extreme caution and return the level to normal
(road travel level) once the obstacle has been passed.
11
1402110113a 22/25
1402110113a 23/25
11.6 Raising Axles
Raise all axles when supporting on the outriggers, see section
12.
Raise Lift axle in the steering program Construction site
operation, see section 9.
11.7 Hold axles
Holding axles when supporting on outriggers, see section 12.
Driving the crane in the Hold axles position leads to heavy
damage to the hydraulic suspension.
D R I V I N G P R O H I B I T E D !
After every special setting:
Activate suspension block
Height setting
Raise axles
The hydraulic suspension must be reset for Driving in the
Transport Position.
11.8 Lowering Brake Valves in the Basic Suspension
Block
The lowering brake valves are set ex works to ensure slow and
even lowering of the suspension.
The lowering brake valves may only be adjusted by our
customer service technicians.
11
1402110113a 24/25
Z 56 500
X
Y
92 93 94 95 96 97 98
99 100 101 102 103 104
1402110113a 25/25
11.9 Selecting the Operating Modes
(Axle loads 12 t / 26.5 kip or Reduced axle loads)
(Z 56 500)
Various driving configurations are possible in the operating mode
Reduced axle loads. Examples include:
driving without main boom
driving without superstructure
driving with different axle loads < 12 t / 26.5 kip
driving with trailer (dolly operation)
Risk of accidents!
The suspension must always be set to the operating mode
in which the crane vehicle is being operated. Settings are
only to be changed when vehicle is at a standstill.
Disregarding this rule can lead to an increased risk of
accidents.
When Reduced axle loads mode is selected, only the hydraulic
suspension is set to the changed axle loads. All other
components (e.g. brake system and steering) remain
unchanged.
A releasable switch (96) is used to select the operating mode.
If the switch is set to OFF (switch position X), the suspension
is set to 12 t / 26.5 kip axle load mode.
If the switch is set to ON (switch position Y), the suspension
is set to Reduced axle loads mode.
After a new operating mode has been selected, a level check
of the suspension circuit must be carried out. If necessary,
the level should be reset.
If the equipment is operated in dolly mode, it is essential to
follow the instructions contained in the section Information
on dolly operation in chapter 6.
The suspension can be locked in both operating modes (switch
100).
Outriggers 12
1402120193a
1/79
12 Outriggers
12.1 Notes on Outriggers:
Always observe the following information, in order to ensure safe
working:
Before stabilising:
Main boom in longitudinal direction;
Superstructure locked in transport position.
No other persons other than the crane operator are per-
mitted in the danger zone.
Only rotate the superstructure if the crane is stabilised
on outriggers.
Always stabilise the crane before picking up loads.
During the stabilising procedure the outrigger pads
need some space for shifting movements to the sides.
Always extend outrigger struts to the appropriate pin-
ning position (coloured or arrowed marking) and pin.
For safety reasons, the outrigger struts may only be ex-
tended at the side with the corresponding switch panel.
The crane driver can thereby only extend the outrigger
struts that are always in his line of view.
Always keep both switch panels locked.
Only the switch panel that is needed directly for opera-
ting may be opened.
In order to avoid improper use, it must be locked again,
directly after use.
After being put on outriggers (before beginning work
with the crane), the tyres must no longer touch the
ground.
Extend/retract the supporting cylinders only one at a
time and only at the side that can be seen from the switch
panel.
Be particularly careful when the outrigger pads are mo-
ved to the ground. Risk of crushing!
Make sure the ground for the outrigger pads is flat and
firm; permitted inclination max. 55 (9 %)!
No foreign material (for example: stones, metal objects,
etc.) are permitted under the outrigger plates!
12
1402120193a 2/79
Outriggers 12
1402120193a
3/79
The maximum surface pressure for the standard series
outrigger pads at the front ( 600 mm/23.6 in) is approxi-
mately 260 N/cm
2
(377 psi).
This is equivalent to a force of 736 kN (75 t (165 kip)).
The maximum surface pressure for the standard series
outrigger pads at the rear ( 700 mm/27.6 in) is approxi-
mately 242 N/cm
2
(350 psi).
This is equivalent to a force of 932 kN (95 t (209 kip)).
If the loadcarrying capacity of the ground is insuffi-
cient, then the ground pressure around the outrigger
pads must be reduced with the help of backup plates
(rigging mats) (see also Permitted ground pressure).
The maximum permitted support forces must be obser-
ved.
Levelling the crane with counterweight and fitted
apparatus only to be accomplished by EXTENDING
the vertical outrigger cylinders.
See section Notes on levelling with counterweight.
In order to protect the supporting cylinders from over-
loading, they must not be extended to the limit; there
should still be a residual stroke length of 2 to 3 cm (0.8
to 1.2 in) after levelling.
The remaining lift is also necessary, so that actual sup-
port pressure values can be displayed.
Extending and retracting the supports with a load
attached is not permitted. Risk of tilting!
In order to avoid damage to the outriggers as well as
accidents in the course of driving or operating the crane,
take special care to do the following:
Unlock the supports before they are extended or
retracted.
Pin/secure the supports for work with the crane.
Pin / secure the (retracted) supports in transport
position.
Secure the outrigger pads in transport position
There is a danger of accidents, if the prescribed outrigger
span, specified in the load capacity table, is not used.
No other outrigger span is permitted HIGH RISK OF
DAMAGE !
12
1402120193a 4/79
Z 47 962
Outriggers 12
1402120193a
5/79
12.2 Arrangement of Outrigger Controls
Outrigger controls are located on the chassis to the left and right
(in the direction of travel).
Switch panel left side
(Z 47 962)
Item Function
1 Rocker switch Outrigger cylinder, front right
1A: Retracting
1B: Extending
2 Rocker switch Outrigger cylinder, front left
2A: Retracting
2B: Extending
3 Rocker switch Outrigger cylinder, rear right
3A: Retracting
3B: Extending
4 Rocker switch Outrigger cylinder, rear left
4A: Retracting
4B: Extending
5 Rocker switch Outrigger strut, front left
5A: Retracting
5B: Extending
6 Rocker switch Outrigger strut, rear left
6A: Retracting
6B: Extending
7 Rocker switch Engine start/engine stop
7A: Engine stop
7B: Engine start
8 Rocker switch All outrigger cylinders together
8A: Retracting
8B: Extending
8B with key 10: Level automatically
9 Pushbutton Raise all axles
10 Pushbutton Caution (safety button)
1.) Ramp up data bus (press for approximately
5 sec.)
2.) before/with button (7B) for Engine start
3.) before/with button (8B) for Automatic level-
ling
21 Display
with crane symbol on the lefthand side
The symbols on the rocker switch determine the operation of the
outrigger cylinders.
12
1402120193a 6/79
0
?
0
?
1
.
5
?
3
?
3
?
1
.
5
?
Z 60 982
Outriggers 12
1402120193a
7/79
Switch panel right side
(Z 60 982)
Item Function
11 Rocker switch Outrigger cylinder, rear left
11A: Retracting
11B: Extending
12 Rocker switch Outrigger cylinder rear right
12A: Retracting
12B: Extending
13 Rocker switch Outrigger cylinder front left
13A: Retracting
13B: Extending
14 Rocker switch Supporting cylinder, front right
14A: Retracting
14B: Extending
15 Rocker switch Outrigger strut, rear right
15A: Retracting
15B: Extending
16 Rocker switch Outrigger strut, right front
16A: Retracting
16B: Extending
17 Rocker switch Engine start/engine stop
17A: Engine stop
17B: Engine start
18 Rocker switch Outrigger cylinders together
18A: Retracting
18B: Extending
18B with key 20: Level automatically
19 Pushbutton Raise all axles
20 Pushbutton Caution (safety button)
1.) Ramp up data bus (press for approximately
5 sec.)
2.) before/with button (17B) for Engine start
3.) before/with button (18B) for Automatic level-
ling
22 Spirit level
The symbols on the rocker switch determine the operation of the
outrigger cylinders.
12
1402120193a 8/79
Z 60 983
F1 F2 F3 F4 F5 F6
M N P Q O
8
8
8
8
L
K
21
Outriggers 12
1402120193a
9/79
12.3 Information System for the Outrigger Controls
(Z 60 983)
The display is at the outrigger controls (to the left of the chassis).
The system on the lefthand vehicle side is described and
illustrated as an example (crane symbol P to the left).
The system consists of the display (21) and the function keys F1
F6.
Legend:
(K) Function buttons F1 F6
F1 = Contrast
F2 = Brightness
F3 = Inversion
F4 = Not assigned
F5 = Angle
F6 = Support forces
(L) Symbols for the function buttons
(M) Support forces at the rear support
(N) Spirit level
(O) Electronic bubble
(P) Crane symbol
(Q) Support forces at the front support
12
1402120193a 10/79
Z 60 984
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
O
M1
M2
L
P
Q1
Q2
R
A
Z 60 985
0.1
0.1
P
L2
Y
X
O
L
B
N
Outriggers 12
1402120193a
11/79
12.3.1 Indicators on the Display
(Z 60 984, Z 60 985)
Diagram A (level indicator and supporting force)
Basic display with electronic level indicator / bubble and
indication of supporting force.
When the supporting cylinders are operated, the moving
direction is displayed in the form of an arrow, as well as the
supports, indicated as symbols.
Diagram B (inclination)
Legend:
L2 = Adjustment, menuassisted (leads to figure
F)
M1 = Supporting force left rear
M2 = Supporting force right rear
(N) Spirit level
(O) Electronic bubble
(P) Crane symbol
Q1 = Supporting force left front
Q2 = Supporting force right front
(R) Retraction/extension movement of the outrigger cylin-
ders
(X) Inclination perpendicular to the direction of travel
(Y) Inclination in the direction of travel
12
1402120193a 12/79
Z 60 986
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
C
L
M2
M1
P
Q1
Q2
L1
Z 60 987
. m
D
L
S2
S1
P
S3
S4
. m
. m
. m
Outriggers 12
1402120193a
13/79
(Z 60 986, Z 60 987)
Diagram C (supporting force)
Diagram D (support length), menuassisted, (optional)
Legend:
L1 = Support length, menuassisted (optional)
M1 = Supporting force left rear
M2 = Supporting force right rear
(P) Crane symbol
Q1 = Supporting force left front
Q2 = Supporting force right front
(S) Support length (extension length of the outrigger struts
in metres)
S1 = Outrigger strut left rear
S2 = Outrigger strut right rear
S3 = Outrigger strut left front
S4 = Outrigger strut right front
12
1402120193a 14/79
Z 47 972
E
Z 47 973
F
Z 47 974
E n t e r P I N C o d e
G
Outriggers 12
1402120193a
15/79
(Z 47 972, Z 47 973, Z 47 974)
Diagram E (contrast), menuassisted
Modify contrast:
Key F2 = darker
Key F5 = brighter
Key F1 (Quit) leads to View A (spirit level and supporting
force)
Diagram F (brightness), menuassisted
Modify brightness:
Key F2 = darker (in accordance with bar display)
Key F5 = brighter (in accordance with bar display)
Key F1 (Quit) leads to View A (spirit level and supporting
force)
Diagram G (coding; only for customer service)
12
1402120193a 16/79
Z 47 962
Z 60 984
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
O
M1
M2
L
P
Q1
Q2
R
A
Outriggers 12
1402120193a
17/79
12.3.2 Functions
(Z 47 962, Z 60 984)
Starting position:
Crane parked in transport position
Parking brake applied
Ignitionstarter switch in position 0 (external start
readiness)
Boot data bus
Press and hold Caution key (10 / 20) for approx. 5 sec.
External engine start:
Caution key (10 / 20) ahead / press Engine start key (7B / 17B)
and hold until engine is running.
External engine stop:
Caution key (10 / 20) ahead / press Engine stop key (7A / 17A)
and hold until engine has stopped.
Modify contrast:
Call up figure A (Z 60 984)
Key F1 = figure E (contrast) (Z 47 972)
Key F2 = darker
Key F5 = brighter
Key F1 = Quit, return to figure A (Z 60 984)
12
1402120193a 18/79
Z 47 962
Z 60 984
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
O
M1
M2
L
P
Q1
Q2
R
A
Outriggers 12
1402120193a
19/79
(Z 47 962, Z 60 984)
Modify brightness:
Key F2 = figure F (Brightness) (Z 47 973)
Key F2 = darker (in accordance with bar display)
Key F5 = brighter (in accordance with bar display)
Inversion
Key F3 = Inversion
Inclination display
Key F5 = figure B (Gradient) (Z 60 985)
Support pressure display
Key F6 = figure C (Supporting force) (Z 60 986)
12
1402120193a 20/79
Z 47 962
Z 60 984
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
O
M1
M2
L
P
Q1
Q2
R
A
Z 60 986
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
L
M2
M1
P
Q1
Q2
L1
C
Outriggers 12
1402120193a
21/79
12.3.3 Support Pressure Display
(Z 47 962, Z 60 984, Z 60 986)
The supporting force is determined via the pressure absorber at
the four supporting cylinders and indicated at the display of the
outrigger controls.
Monitor the supporting forces at every support procedure
with the help of the support pressure display.
Boot data bus:
Displaying supporting force:
Call up figure A
Key F6 = figure C (supporting force)
Key F1 = Quit, return to figure A
The following supporting force values must not be
exceeded:
75 tons (165 kip) at the front supporting cylinders.
95 tons (209 kip) at the rear supporting cylinders.
Important note on complying with limit values:
The limit values to be followed are not monitored
automatically.
The support pressure display shows tolerance values. The
display value can differ from the actual value by up to
approx. 10% (plus / minus). Keep this in mind, e.g. in relation
with limited loadcarrying capacity of the ground.
While the crane is in operation, the support pressure display is
supplied with power from the superstructure via an electrical
swivelling connection.
12
1402120193a 22/79
Z 47 962
Z 60 984
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
1 8 . 0 t
O
M1
M2
L
P
Q1
Q2
R
A
Z 60 985
0.1
0.1
P
L2
Y
X
O
L
B
N
Outriggers 12
1402120193a
23/79
12.3.4 Inclination Indicator
(Z 47 962, Z 60 984, Z 60 985)
The inclination of the crane is detected by an electronic
inclination transmitter and displayed at the switch panels of the
outrigger controls on the chassis.
The display consists of an electronic level indicator / bubble and
numerical values for the X and Y axes (one each).
Depending on the direction of a deviation, a negative value (with
a minus before the value) can also be displayed.
The level indicator is for general orientation; the numerical values
are definitely the decisive values.
Boot data bus
Display gradient
Call up figure A
Key F5 = figure B (gradient)
Key F1 = Quit, return to figure A
The inclination indicator must be observed during the
levelling procedure.
Deviations must not exceed 0.1 degrees (equivalent to
approx. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.
12
1402120193a 24/79
Z 47 962
Z 60 982
0?
0?
1.5?
3?
3?
1.5?
Z 60 985
0.1
0.1
P
L2
Y
X
O
L
B
N
Outriggers 12
1402120193a
25/79
12.4 Automatic Levelling
(Z 47 962, Z 60 982, Z 60 985)
The crane can also be levelled automatically (by extending the
supporting cylinders together). This is only possible when
Extending (not when Retracting) the supporting cylinders.
It is of no importance for the function, in which starting position
the supporting cylinders are.
Risk of crushing!
When levelling automatically, all supporting cylinders are
extended simultaneously; that means also those cylin-
ders that cannot be seen from the switch panel. It must
be ensured that no persons are present in the danger
zone.
Starting position:
Crane parked in transport position
Parking brake applied
Outrigger struts extended/pinned/locked
Display: diagram B (inclination)
Automatic levelling procedure (work steps):
1. Press Caution key (10 / 20) and Extend all supporting
cylinders key (8B / 18B) simultaneously.
Inverse display during Automatic operation.
The supporting cylinders are extended one after the other
until a defined supporting force has been reached. This
ensures that all supporting cylinders are on the ground
before the actual levelling procedure begins.
If supporting forces are identical, then all supporting cylinders are
extended together in this (possibly different) condition, as long as
both keys are held pressed (10 / 20) and (8B / 18B).
2. If there is sufficient clearance between wheels and the
ground (including bending after taking up a load later on), let
go of button (8B / 18B) and continue to keep Caution key
(10 / 20) pressed.
12
1402120193a 26/79
Z 47 962
Z 60 982
0?
0?
1.5?
3?
3?
1.5?
Z 60 985
0.1
0.1
P
L2
Y
X
O
L
B
N
Outriggers 12
1402120193a
27/79
(Z 47 962, Z 60 982, Z 60 985)
3. As soon as the crane is level (angle tolerance value 0.1
degrees), the procedure is automatically stopped. The
engines working speed switches automatically back to idle
speed.
After the procedure, the system might change the displayed
inclination value from 0.1 to 0.2. This however has no negative
effect on the required precision.
4. Let go of key (10 B / 18 B).
Make sure there is a remaining lift (2 to 3 cm/0.8 to 1.2 inch) in
the supporting cylinders; Compare supporting forces.
The system does not automatically take the remaining lift into
consideration.
If relevelling is necessary:
Press and hold caution key (10 / 20) and press Extend all
supporting cylinders key (8B / 18B) briefly.
Levelling is carried out as already described.
Combined retraction of all supporting cylinders:
Press caution key (10 / 20) and Retract all supporting cylinders
key (8A / 18A) simultaneously.
12
1402120193a 28/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Outriggers 12
1402120193a
29/79
12.5 Hold Axles / Raise Axles Functions
(Z 51 302)
When the crane is on outriggers, the wheels must not touch the
ground. The functions Hold axles or Raise axles are for this
purpose.
The decision as to which function should be selected to achieve
clearance, depends on the ground conditions at the site.
If ground conditions at the site are as described in section 11.4.1
(flat, firm ground), select Hold axles .
If the ground conditions at the site are not as described in section
11.4.1, then select Raise axles .
12.5.1 Hold Axles Function
Hold axles is selected before the crane is stabilised.
All axles are locked in their initial position (aligned horizontally
and suspension cylinders in road traffic position).
If the crane is lowered back on to the wheels for moving (by
retracting the supporting cylinders), then it need not be
relevelled. It is aligned horizontally and the suspension
cylinders are in road traffic position.
12.5.1.1 Switching on Hold Axles after
Moving on the Road Suspension Is Not Locked
1. Stop the crane, switch to neutral gear, apply the parking
brake.
2. Actuate (101) Hold axles switch.
The display (A13) lights up.
If Hold axles is switched on (display A13 lights up), the
crane may no longer be moved. RISK OF BREAKAGE!
3. Support the crane (see section Extend the support)
Extend the support until no wheel is in contact with the ground.
12
1402120193a 30/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Outriggers 12
1402120193a
31/79
(Z 51 302)
12.5.1.2 Switching on Hold Axles after
Driving in the Configured Condition Suspension
Locked
brake.
The crane is aligned horizontally,
suspension cylinder in onroad position.
2. Extend horizontal support.
3. Extend the outrigger cylinder, until the outrigger pads are
pressed to the ground. Set the contact pressure until the
suspension pressure is still approximately 100 bar (1450
psi).
Pressure control at the pressure gauges (5, 8), (6, 7) and (9,
10).
The distance of the mounting eyelets at the suspension cylinder
is 630 mm (24.8 in.) (see Section Extending the outrigger).
4. Switch off the suspension locking system by actuating switch
(100).
5. Actuate (101) Hold axles switch.
6. The supporting cylinders are extended further and the crane
is stabilised (see section Extend the support).
Keep to the sequence!
12
1402120193a 32/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Outriggers 12
1402120193a
33/79
(Z 51 302)
12.5.1.3 Switching off Hold Axles for Moving on the Road
Suspension not Locked or Switching to
Locked
1. Retract supporting cylinders, until the wheels of all axles
have light and even contact with the ground.
10).
Nominal value: approx. 100 bar (1450 psi)
(see Sect. Retracting the Outriggers)
2. Lock Hold axles switch (101) in Off position.
For Driving in the configured condition, switch on suspension
locking system with switch (100).
The display (A12) is illuminated.
For Driving in the configured condition the outrigger remains
just above the ground.
Driving when rigged is only permitted if ground conditions are
as described in section 11.4.1.
3. Continue to retract supporting cylinder / retract outrigger
entirely and lock.
4. For Driving the crane in transport position (onroad driving,
axle load max. 12 t / 26.4 kip), see section 6 of the operating
instructions for the chassis.
12
1402120193a 34/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Outriggers 12
1402120193a
35/79
(Z 51 302)
12.5.2 Raise Axles Function
Raise axles is carried out before the crane is stabilised.
Switch on Raise axles
Two steps are required for Raise axles.
Between the two steps, the crane must be stabilised.
1. Press the Hold axles switch (101) in the drivers cab. The
display (A13) lights up.
The axles remain in onroad position (on the ground).
If Hold axles is switched on (display A13 lights up), the
crane may no longer be moved. RISK OF BREAKAGE!
Now the crane must be stabilised (see Stabilisation procedure).
2. Press and hold down the key (9/19) at the outrigger controls.
All axles are raised as long as the button is pressed. The
Switch off Raise axles
When the switch (101) in the drivers cab is turned off, all wheels
are lowered back to the ground.
The indicators (A13 and A15) go out.
The crane must be relevelled before being moved (aligned
horizontally and suspension cylinders in onroad position).
When the suspension is locked (switch 100 on, display A12
illuminated) Raise axles or Hold axles is not possible.
12
1402120193a 36/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Outriggers 12
1402120193a
37/79
(Z 51 302)
12.5.2.1 Switching on Raise Axles after
Moving on the Road Suspension Not Locked.
If the crane is in Onroad driving position before being
stabilised, then raise the axles as described in the following:
brake.
3. Support the crane (see section Extend the support)
If wheels are still in contact with the ground:
4. Press and hold down the Raise axles button (9/19) at the
outrigger controls. The display (A15) lights up.
All axles are raised as long as the button is pressed.
12.5.2.2 Switching on Raise Axles after
Locked
If the crane is in Driving in the configured condition mode
(supports extended, outrigger pads on the ground) before
stabilising, then proceed as follows to raise the axles:
brake.
2. Extend the outrigger cylinder, until the outrigger pads are
pressed to the ground. Set the contact pressure until the
suspension pressure is still approximately 100 bar (1450
psi).
10).
3. Switch off the suspension locking system by actuating switch
(100). The display (A12) goes out.
5. Keep the crane stabilised.
6. If necessary: Press and hold Raise axles button (9/19) at
the outrigger controls until all wheels no longer touch the
ground. The display (A15) lights up.
12
1402120193a 38/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Z 51 303
78
81
79
A
B
76
80
77
Outriggers 12
1402120193a
39/79
(Z 51 302, Z 52 303)
12.5.2.3 Switching off Raise Axles for Driving on the Road
Suspension not Locked or Switching to Driving in
the Configured Condition Suspension Locked
The Raise axles procedure is switched off in the drivers cab via
the Hold axles button (101). All wheels are then lowered to the
ground.
1. Turn off the switch Hold axles (101) in the drivers cab. The
display (A13) goes out.
When the switch (101) in the drivers cab is turned off, all
wheels are lowered back on to the ground.
2. Actuate switch (76A). Fill all suspension circuits to
approximately 100 bar (1450 psi) (see Section 11).
Check pressure increase at the pressure gauges (5 to 10).
3. Retract supporting cylinders; Reset suspension.
Before the supporting cylinders are retracted, the wheels of
all axles must first be in contact with the ground. Then the
suspension must be readjusted (aligned horizontally and
suspension cylinder in central position; see section 11 of
these operating instructions).
If they are not readjusted, the suspension cylinders are
locked. Driving is not permitted in this condition. Damage
to undercarriage!
12
1402120193a 40/79
Z 51 304
15
4
Outriggers 12
1402120193a
41/79
12.6 Measures before Stabilising:
On sloping ground in the longitudinal direction of the
vehicle, the vehicle must be prevented from rolling away by
placing wheel chocks at the axle last released.
2. Switch to neutral gear.
3. Lock the slew gear brake in the superstructure cab.
The superstructure may only be rotated if the crane is
stabilised.
4. Start crane chassis engine.
The engine can also be started at the switch panels of the
outrigger controls. To do so, the ignitionstarter switch (15) must
be in position 2 (external ignition standby). (Z 51 304)
An engine speed of 1200 U/min (rpm) is set automatically when
the outriggers are operated.
12
1402120193a 42/79
Z 41 654
Outriggers 12
1402120193a
43/79
12.7 Supporting the Outrigger Plates
The loadbearing capacity of the ground must be sufficient to
absorb the maximum support forces which can occur.
Normally, the outrigger plates would not be sufficient by surface
area to set the crane up safely on backfilled or natural ground.
If necessary, increase the support area by stacking suitable
materials under the outrigger plates.
Suitable materials (for example, timbers with the same di-
mensions, special panel constructions made of wood or
metal) must be used for the support! The crane operator
must make these available.
(Z 41 654)
The struts must be in the centre of the support and must co-
ver all supporting timbers sufficiently.
Check as well whether hollow spaces such as canals, co-
vered ditches or cellars are in the planned location of the
crane and how they run. You must also take hidden dan-
gers such as melting ice or flooding into consideration.
These dangers are often the cause for cranes falling over.
In the following segment you will find details on Permitted ground
pressures of various types of ground and how to determine the
required support area.
12
1402120193a 44/79
Z 53 789
Outriggers 12
1402120193a
45/79
12.7.1 Permitted Ground Pressures
(Z 53 789)
If there are doubts about the load capacity of the base at the
site, then have the ground tested.
The following load capacity values are determined according to
standard DIN 1054 for various types of ground.
Type of ground p
(kg/ cm2)
p
[psi]
Type of ground p
(kg/ cm2)
p
[psi]
A Backfilled, not artificially compacted ground 01 015
B Grown, obviously untouched ground B
Mud, peat, marsh 0 0
Noncohesive, sufficiently firm grounds:
Fine to medium sand 1.5 21
Coarse sand to gravel 2.0 28.5
Cohesive grounds:
pulpy 0 0
soft 0.4 5.7
stiff 1.0 14.2
semifirm 2.0 28.5
hard 4.0 56.9
Rock with hardly any cleavage in healthy, unwea-
thered condition and in convenient stratification:
in closed succession of beds 15.0 213.4
in massed and columnar formation 30.0 426.7
Example of noncohesive ground with fine sand (p=1.5 kg/cm
2
)
(21 psi):
The values in curve 3 apply for p=1.5 kg/cm
2
(21 psi) . (see table
above in the diagram at the side).
This results, e.g. for a supporting force of Fs=36 t (79.4 kip) in a
required surface area As of 2.4 m
2(
25.8 ft
2
) for the outrigger pad.
The standard outrigger pad at the front has a diameter of 600 mm
(support surface area 0.28 m
2
/4 ft
2
); the standard outrigger pad
at the back has a diameter of 700 mm (0.38 m
2
/4 ft
2
).
The required surface area of the outrigger is to be established
with the help of suitable bases (e.g.: support mats, wooden
planks and similar objects).
Supporting forces can be looked up e.g. in the supporting force
tables.
12
1402120193a 46/79
Z 170 688
Outriggers 12
1402120193a
47/79
12.8 Safe Distance to Slopes and Pits
(Z 170 688)
Erect the crane with a sufficiently safe distance to slopes or pits.
The distance also depends on the type of ground.
The distance to the edge of a slope (X) must be at least 2 m.
A general rule is:
if the ground is loose or filled, then the safety distance (a)
must be twice the depth of the pit (b). The slope angle a must
be < 30.
if the ground is firm and not loose, then the safety distance
(a) must be equivalent to the depth of the pit (b). The slope
angle a must be < 45.
Thesafety distance is measured starting at the base of the pit (C).
12
1402120193a 48/79
Z 110 013
1
2
B
5.4 m
X
Z 110 014
C
7.5 m
B
X
1
2
Z 110 015
X
Outriggers 12
1402120193a
49/79
12.8.1 Pinning positions of the outrigger struts
(Z 110 013, Z 110 014, Z 110 015)
(1) = Outrigger strut
(2) = Chassis frame
(B) = Position of outrigger struts (1) outrigger span 5.4 m
(17.7 ft) (outrigger struts partially extended)
(C) = Position outrigger strut (1) outrigger support area 7.5
m (24.6 ft) (outrigger struts completely extended)
(X) = Locking point/locking bolt on chassis frame
The supporting box is unlocked by removing the locking pin X
from transport position.
When each locking position is reached, peg/secure it with locking
pin X.
For retracting again in transport position, the locking pin X must
be removed again and then reinserted in transport position.
Lock supporting box in position X, as soon as it has been
retracted to transport position!
12
1402120193a 50/79
Z 36 594
3 2 1
Z 36 595
3 2 1
Z 47 962 Z 60 982
0
?
0
?
1
.
5
?
3
?
3
?
1
.
5
?
Outriggers 12
1402120193a
51/79
12.9 Stabilising Procedure
12.9.1 Extend support (outrigger support area 8.23 m x
7.50 m/27 ft x 24.6 ft)
(Z 36 594, Z 36 595, Z 47 962, Z 47 963)
When the crane is on outriggers, the wheels must not touch the
ground (Hold axles / Raise axles functions).
Once you are sure that no obstacles or persons are in the
extension area for the supports and that all notes on dangers in
section 12.1 have been observed, then proceed as described in
the following.
1. Placing the outrigger plates in operating position
(Z 36 594, Z 36 595)
RISK OF ACCIDENTS!
The contact surface between the outrigger cylinders
piston rod and the outrigger plate must be clean. In particu-
lar, no foreign matter is permitted (for example: stones,
sand, etc.).
1.1 Clean the bottom of the outrigger cylinders piston rod
and the top of the outrigger plate (if contaminated).
1.2 remove the forelocks (3) and the socket pins (2),
1.3 pull the outrigger pad (1) into support position.
1.4 Attach plug bolts and forelock again.
2. Remove locking pin X on the outrigger struts.
Open required switch panel.
Only the switch panel that is needed directly for operating
may be opened.
In order to avoid improper use, it must be locked again,
directly after use !
12
1402120193a 52/79
Z 47 962
Z 60 982
0?
0?
1.5?
3?
3?
1.5?
Outriggers 12
1402120193a
53/79
3. Extending the outrigger struts
Left side: Press rocker switch 5B or 6B (Z 47 962)
Righthand
side :
Press rocker switch 15B or 16B (Z 60 982)
The outrigger struts can only be extended / retracted
(horizontally) at the switch panel of the corresponding side.
Extend the outrigger struts one at a time up to the coloured
marking.
Hold on to the rocker switch while extending.
Risk of crushing!
Before extending the outrigger struts, make sure that no-
body is present in the danger area where the outrigger
struts are extended horizontally !
12
1402120193a 54/79
Z 47 962
Z 60 982
0?
0?
1.5?
3?
3?
1.5?
Outriggers 12
1402120193a
55/79
(Z 47 962, Z 60 982)
4. Extending the outrigger cylinders
Switch panel left side: Press rocker switch 1B, 2B, 3B or
4B.
Switch panel right side: Press rocker switch 11B, 12B, 13B
or14B.
In order to protect the supporting cylinders from
overloading, they must not be extended to the limit; a
residual stroke length of 2 to 3 cm (0.8 to 1.2 in)should still
be left.
The remaining clearance is also necessary, so that actual
support pressure values can be displayed.
Risk of crushing!
There is a risk of crushing while the outrigger cylinders
are extended.
The outrigger cylinders may only be extended at the side
that is within the crane operators view at the switch pa-
nel.
Extend the outrigger cylinders of the relevant side until
they have made contact with the ground.
While operating the outriggers, no corrections may be
made to the positions of the outrigger pads.
RISK OF ACCIDENTS!
When attaching the outrigger plates in this operating step,
make sure that there is no foreign matter (for example: sto-
nes, metal objects, etc.) under the outrigger plates!
If the crane is tilted visibly, then carry out a rough correction by
further extending the appropriate outrigger cylinders. When
doing so, make sure that the outrigger cylinders can be further
extended for the following levelling procedure.
5. Attach counterweight (see load capacity table and operating
instructions for the superstructure, section 9).
6. Position superstructure in the direction of travel and thereby
position counterweight above the rear outrigger.
7. Move boom to steep position.
The slew gear brake must be released at points 5 and 6.
Now reinsert it.
12
1402120193a 56/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Z 47 962 Z 60 982
0
?
0
?
1
.
5
?
3
?
3
?
1
.
5
?
Outriggers 12
1402120193a
57/79
(Z 51 302, Z 47 962, Z 60 982)
8. Raise axles now
Raise axles consists of two steps:
8.1 Press the Hold axles switch (101) in the drivers cab.
The axles are still on the ground.
8.2 Press and hold down the key (9/19) at the outrigger
controls.
All axles are raised.
Raise axles until no wheel is in contact with the ground.
If Hold axles was actuated before stabilising, display (A13)
lights up, then the axles do not need to be raised. However, make
sure that none of the wheels is still touching the ground.
When putting the crane on outriggers, make sure that the
ground has sufficient load bearing capacity.
The individual supporting forces are indicated at the display
of the outrigger controls (to the left and right of the chassis)
or at the PDC installation of the superstructure.
Only the current supporting forces are displayed; not those
that will occur when a load is picked up.
9. Extend rear supporting cylinder, until the lateral axis is
balanced.
Switch panel left side: Press rocker switch 3B / 4B.
Switch panel right side: Press rocker switch 11B / 12B.
10. Extend the supporting cylinders at the front, in order to also
bring the longitudinal axis in the balance.
Switch panel left side: Press rocker switch 1B / 2B.
Switch panel right side: Press rocker switch 13B / 14B.
Then use inclination indicator on the crane chassis to level
it to 0.1 (equivalent to approx. 0.2 %).
In order to achieve a most even coordination of the
supporting forces, the supporting cylinders at the front
should finally be briefly pressed further together and then
the same applies to the supporting cylinders at the rear. In
doing so, make sure that all supporting cylinders are evenly
loaded.
12
1402120193a 58/79
Outriggers 12
1402120193a
59/79
11. Check the set level once more.
If the lateral axis has shifted, then the levelling procedure must
be repeated.
a.) Balance the rear lateral axis.
b.) Retract the front supporting cylinder slightly and
then balance the longitudinal axis by extending.
Retracting the supporting cylinders is only permitted if
the supporting forces specified in section 12.2 are not
exceeded.
In order to level the crane precisely, it will finally be
necessary to operate all supporting cylinders from the
switch panel on one side. In this case be particularly careful,
especially when the supporting cylinders are operated that
are not in the direct line of view.
Immediately afterwards, lock the switch panel !
12
1402120193a 60/79
Z 60 985
0.1
0.1
P
L2
Y
X
O
L
B
N
Outriggers 12
1402120193a
61/79
12.9.2 Checking the Level at the Chassis
(Z 60 985)
After each new configuration, the level of the crane must be
rechecked (see Inclination indicator).
Careful levelling is essential for safe working with the crane.
Deviations must not exceed 0.1 degrees (equivalent to
approx. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.
12
1402120193a 62/79
Z 51 302
100
A12 A13
A14
101 102
9/19
A15
Z 51 303
78
81
79
A
B
76
80
77
Outriggers 12
1402120193a
63/79
12.9.3 Retracting the Outriggers
Retracting the outrigger is carried out in reverse sequence to the
extending procedure.
Important notes on retracting the outrigger:
Retract the outriggers separately and completely.
Unbolt only the outrigger strut to be retracted.
As soon as a support is in the transport position, insert
the transport lock.
When retracting the outrigger struts, reeving and crus-
hing movements around the retracting parts and the car-
rier frame are possible.
It must be ensured that no persons are present in the
danger zone.
Extending and retracting the supports with a load
attached is not permitted. Risk of tipping!
12.9.3.1 Retracting the Supports
. . . for Driving in transport position
(Z 51 302, Z 51 303)
1. Lower main boom to transport position.
2. Remove counterweight (see operating instructions for the
superstructure, section 9).
Risk of crushing!
When lowering the suspension / retracting the suppor-
ting cylinders, crushing movements between tyres and
ground space are possible. Watch your feet !
It must be ensured that no persons are present in the
danger zone.
3. Lock Hold axles switch (101) in Off position. The wheels
are lowered to the ground. The display (A13) goes out.
The following step Pressing down the wheels applies only if
Raise axles (switch 9 / 19) was also actuated.
4. Pressing down the wheels
Actuate switch (78A/79A/80A/81A) or switch (76A), until the
wheels of all axles are pressed on the ground.
12
1402120193a 64/79
Z 110 015
X
Z 47 962 Z 60 982
0
?
0
?
1
.
5
?
3
?
3
?
1
.
5
?
Outriggers 12
1402120193a
65/79
(Z 47 962, Z 60 982, Z 110 015)
5. Retracting the supporting cylinders:
Switch panel left side: Press rocker switch 1A, 2A, 3A or
4A.
Switch panel right side: Press rocker switch 11A, 12A, 13A
or 14A.
Retract all supporting cylinders completely!
When retracting the supporting cylinders on slopes in the
longitudinal direction of the vehicle, the vehicle must be
secured with support blocks at the axle that is to touch the
ground first.
6. Retracting the outrigger struts:
Left side: Press rocker switch 5A or 6A
Righthand side : Press rocker switch 15A or 16A
Retract all outrigger struts completely, one by one!
Extending and retracting the supports with a load attached
is not permitted. RISK OF OVERTURNING !
Risk of crushing and reeving !
When retracting the outrigger struts, reeving and crus-
hing movements around the retracting parts and the car-
rier frame are possible.
Make sure that no persons are present in the danger
area!
Lock the supporting boxes in position X, as soon as they
have been retracted to transport position!
12
1402120193a 66/79
Z 36 594
3 2 1
Z 36 595
3 2 1
Z 51 303
78
81
79
A
B
76
80
77
Outriggers 12
1402120193a
67/79
(Z 36 594, Z 36 595, Z 51 303)
7. Move outrigger pads to transport position.
Remove flap plug (3) and socket pin (2), pull outrigger pad
(1) to transport position.
Attach plug bolts and forelock again.
8. If Raise axles was actuated:
By actuating switch (76) level all axles. See section 11
Settings for driving in transport position.
Or,
9. If Hold axles was actuated:
Lock Hold axles switch (101) in Off position. The display
(A13) goes out.
Driving in the Hold axles condition is prohibited. Damage
to undercarriage!
12.9.3.2 Retracting the Supports
. . . . for Driving in the configured condition
See section 11.4, Switching on suspension locking . . . . Before
Driving in the configured condition.
Before lowering the crane on to the wheels (for subsequent
Driving in the configured condition), always pay attention
to the permitted axle loads relating to rigging mode,
counterweights, superstructure position, main boom length
and angle (see section 6 Driving in the configured
condition).
When lowering the crane on to the wheels, check the
suspension pressure at pressure gauges (5) to (10) in the
drivers cab. It may not exceed 300 bar (4.351 psi).
12
1402120193a 68/79
Z 53 787
Outriggers 12
1402120193a
69/79
12.10 Levelling with the Counterweight
Before attaching the counterweight, the crane must be
on outriggers and levelled.
After attaching the counterweight, the crane must be re
levelled in the range of 3605 (in steps of 905) .
Starting position:
Crane on outriggers; outrigger span 8.23 m x 7.50 m (27 ft x
24.6 ft).
Superstructure position 180 degrees = main boom to the rear.
Procedure for levelling with counterweight:
1. Check the supporting forces at the support pressure display
on the crane chassis (see Support pressure display).
Make sure that the supporting forces are symmetrically
balanced (left / right).
2. By adjusting the inclination of the main boom or by extending
telescope 1, distribute the load moment of the counterweight
in such a way, that the outrigger pressure on all 4 supports
is roughly identical. (Z 53 787)
3. Check the levelling of the crane, if necessary repeat the
procedure (see Checking the levelling of the chassis).
RISK OF ACCIDENTS!
The levelling can be done by extending or retracting the
supporting cylinders, up to a maximum supporting force
of 50 t (110 kip).
If the supporting force of one of the 4 supports exceeds
50 t (110 kip), then the levelling procedure may only be
carried out by extending the supporting cylinders (no
longer by retraction).
However, this is only possible, if the supporting force of
the support to be extracted does not exceed 50 t (110
kip).
Therefore the supporting forces must first be shifted by
a light adjustment / rotation of the superstructure / main
boom / equipment.
4. Rotate superstructure by 180 .
5. Repeat steps 2 and 3.
12
1402120193a 70/79
Z 110 014
1
2
C
7.5 m
B
X
Z 110 013
1
2
B
5.4 m
X
Outriggers 12
1402120193a
71/79
12.11 Supporting Spans
12.11.1 Normal Outrigger Span
Outrigger span 8.23 m x 7.50 m (27 ft x 24.6 ft).
(Z 110 014)
For the outrigger support area 8.23 m x 7.50 m (27 ft x 24.6 ft),
the outrigger strut (1) is completely extended and pinned at point
X/C.
Working with the crane is permitted only with the load
capacity tables supplied with the crane. The cranes
construction number is noted on the load capacity tables.
If there are no specifications for the outrigger span in the
load capacity tables, then the outrigger struts must be
extended completely and pinned.
12.11.2 Reduced Outrigger Span
Outrigger span 8.23 m x 5.40 m (27 ft x 17.7 ft).
(Z 110 013)
For the outrigger support area 8.23 m x 5.40 m (27 ft x 17.7 ft),
the outrigger strut (1) is partially extended and pinned at point
X/B.
The extension length is marked in colour on the outrigger struts
(1).
If the outrigger span is reduced, then only certain
counterweights / main boom lengths / equipment are
permitted.
Details of these can be found in the corresponding load
capacity tables. Only the combinations specified there are
permitted.
12
1402120193a 72/79
Z 110 014
1
2
C
7.5 m
B X
Z 53 788
E P
Q
R
5
8
6
7
Outriggers 12
1402120193a
73/79
(Z 110 014, Z 53 788)
12.12 Removal and installation of the outrigger struts with
auxiliary crane
(optional)
12.12.1 Notes on removing and installing the outrigger struts
An auxiliary crane is required for removing and installing the
outrigger struts.
One entire outrigger strut weighs around 0.85 t (1874 lbs).
The lifting tackle must be selected and calculated in
accordance with this weight.
Danger risk of crushing!
There is a risk of being crushed at all work related to the
installation and removal of the supports!
Quick connection couplings
The quick connection couplingsat the hydraulic lines R, E and
P are marked with labels.
Connection R = Extending the horizontal cylinders.
Connection E = Retracting the horizontal cylinders and
the vertical cylinders:
Connection P = Extending the vertical cylinders
Observe designations/coloured markings provided; do not mix
up the lines.
Take care to ensure that the chassis engine has been turned off.
The hydraulics connections are then depressurise and easier to
mount.
In order to avoid damage to the threads, make sure that their
initial engagement is clean; particularly when pliers are used to
connect the quick connection coupling.
Make sure that the coupling pieces are completely screwed
in (up to the stop), otherwise it causes damage to the
hydraulic system.
If there are no labels on the quick assembly hose couplings,
mark them before disconnecting.
12
1402120193a 74/79
Z 110 014
1
2
C
7.5 m
B X
Z 53 788
E P
Q
R
5
8
6
7
Outriggers 12
1402120193a
75/79
(Z 110 014, Z 53 788)
12.12.2 Removing the outrigger struts with the auxiliary crane
Starting position:
suspension (in position for driving on normal roads) locked.
boom secured in folded position (retracted).
superstructure locking device inserted
Risk of tipping!
The superstructure locking device may only be detached
again when the crane is on outriggers (outrigger span
8.23 m x 7.50 m/27 ft x 24.6 ft).
If the superstructure locking device is detached before
the crane is on outriggers, the superstructure can swivel
on its own, for example, due to sloped positioning or the
effect of wind. In this situation the crane can tip over.
Procedure (action steps) for removing the outrigger struts
1. Supporting cylinder and outrigger strut (1) are in transport
position (completely retracted).
Remove locking pin at position C.
2. Extend outrigger strut (1) entirely, as far as possible.
3. Disconnect the quick release couplings for the hydraulic
lines R, E and P.
Release the outrigger pressure display connection (plug
Q).
When the quick release couplings are released/connected,
none of the switches at the switch panel may be actuated.
4. Remove flap plug (8) and attach pin (5) on the piston rod of
the horizontal cylinder (6).
5. Connect the extension hoses to the quick release couplings
for the hydraulic lines R and E.
Check the connecting components for cleanliness and also
check the seal rings (Orings); Check that the extension
tubes are not impeded.
6. Retract the horizontal cylinder. Release the extension hoses
to the quick release couplings for the hydraulic lines R and
E.
12
1402120193a 76/79
Z 110 014
1
2
C
7.5 m
B X
Z 53 788
E P
Q
R
5
8
6
7
Outriggers 12
1402120193a
77/79
(Z 110 014, Z 53 788)
7. Attach the outrigger struts (1) to the auxiliary crane with
suitable lifting gear.
8. Disconnect the extension hoses at the quick release
couplings for the hydraulic lines R and E.
Attach dust guard caps to all quick release couplings.
Load outrigger struts on an adequate transport vehicle and
secure.
12.12.3 Installation of the outrigger struts
Starting position:
suspension (in position for driving on normal roads) locked.
boom secured in folded position (retracted).
superstructure locking device inserted
Risk of tipping!
The superstructure locking device may only be detached
again when the crane is on outriggers (outrigger span
8.23 m x 7.50 m/27 ft x 24.6 ft).
If the superstructure locking device is detached before
the crane is on outriggers, the superstructure can swivel
on its own, for example, due to sloped positioning or the
effect of wind. In this situation the crane can tip over.
Procedure (action steps) for installing the outrigger struts
1. The outrigger struts are folded together (transport position)
on the transport vehicle.
2. Using the auxiliary crane, pick up the outrigger struts from
the transport vehicle and move them to their individual
supporting boxes in a horizontal, aligned insertion position.
Clean and grease the slide faces.
3. Before inserting the hooked outrigger strut: Push the
extension hoses through the supporting boxes in the
direction of the quick release couplings.
4. Insert the outrigger struts (1) horizontally (approx. 700
mm/27.5 inches).
12
1402120193a 78/79
Z 110 014
1
2
C
7.5 m
B X
Z 53 788
E P
Q
R
5
8
6
7
Outriggers 12
1402120193a
79/79
(Z 110 014, Z 53 788)
5. Connect the extension hoses to the quick release couplings
R and E.
Check the connecting components for cleanliness and also
check the seal rings (Orings); Check that the extension
tubes are not impeded.
6. Extend horizontal cylinder; Retract piston rod (6) in bearing.
In doing so, observe the extension hoses in the supporting
box and protect from damage.
7. Use socket pin (5) to connect piston rod (6) to frame bracket
(7) and secure with flap plug (8).
8. Disconnect the extension hoses from the quick release
couplings R and E.
9. Connect all hydraulics connections (R, E and P) to the
hoses at the frame side.
10. Join outrigger pressure display connection (plug Q).
11. Detach lifting tackle.
12. When all 4 outrigger struts are installed, stabilise the crane.
Parking 13
1402130 1/3
13 Parking
The crane vehicle must be made completely safe before it is left.
The following basic instructions should be observed.
13.1 Crane in the Transport Condition
1. Apply the parking brake (14) of the crane chassis.
The retaining brake cannot hold the mobile crane at every slope
or descent that it can drive!
If you must park on a slope or descent, the wheels must be
secured additionally using chocks.
2. Switch the transmission to the neutral position using rotary
switch (13).
3. Switch off the engine.
4. Switch off the heating if necessary (in case of
engineindependent heating).
5. The main boom must be in the road travel
condition(telescopic sections pinned, lockingpinning unit
locked in the transport position (see part 1, section 12)).
6. Place all control levers in the off or middle position (O
position).
7. Pull out the ignition key (superstructure and crane chassis).
If the crane is equipped with an engineindependent heater,
wait one or two minutes before switching off the ignition
switch.
(Afterrun time of the heater fan for cooling off the heating).
8. Lock the drivers cab and crane operators cab.
13
1402130 2/3
Parking 13
1402130 3/3
13.2 Crane in Erect Condition and Supported on
Outriggers
1. Set the crane load down on the ground and detach
(whenever the crane operator leaves the crane operators
cab).
2. Lock the slew gear brake (see Operating instructions for the
superstructure, part 1, section 8).
3. Retract and pin lock the telescopic sections.
4. Put all control levers in the off or middle position (O
position).
5. Switch off the engine.
6. Switch off the heating if it is on.
7. Pull out ignition key (superstructure and crane chassis).
If the aircraft warning light is to remain switched on while parking,
the ignition key in the crane operators cab of the superstructure
must not be pulled out, but must be switched to parking position.
In this case, make sure that the radio, fan and any additional
ventilators are switched off.
The batteries will run down if the aircraft warning lights are
switched to constant operation and the engine is switched off.
To avoid this, the crane operator must provide a secondary power
source (e.g. charging set).
If the crane is equipped with an engineindependent heater,
wait one or two minutes before switching off the battery
switch or ignition key (afterrun time of the heater fan for
cooling off the heater).
8. Lock the drivers cab and crane operators cab.
Observe the permitted wind speeds!
If necessary, the boom or equipment must also be lowered!
Towstarting and Towing the Crane 14
1402140 1/15
14
1402140 2/15
Z 200 092
1 2 4 5 3 7
6
1402140 3/15
14 Towstarting and Towing the Crane
(Z 200 092)
14.1 Towing start
The engine cannot be started by towstarting the crane.
If the batteries are dead the engine can be started with the help
of jumpstart cables and the batteries of another vehicle. (see
also section 4)
14.2 Towing
14.2.1 Important General Instructions
The trailer coupling on the front frame is designed for manoeu-
vring and towing the crane.
The towing vehicle must be sufficiently dimensioned (brakes, en-
gine output).
Use only a permitted towbar to tow the crane. Lock the coupling
bolts to safeguard against them falling out.
Avoid oblique pull under all circumstances.
Voice contact must exist between the towing machine and the
crane vehicle.
14.2.2 Recovering from a Hazardous Area
As a rule, certain joint shafts must be removed before the crane
is towed.
The only exception: Neutral position of the distributor gear for
towing with damage to the engine / transmission
Further details about this can be found in sect. 14. 2. 6.
Failure to observe this regulation will unavoidably result in
damage to the crane.
14
1402140 4/15
Z 200 092
1 2 4 5 3 7
6
Z 51 301
B3
B4
35
Z 200 320
1 L
3 R
M
1
6
x
1
.
5
1402140 5/15
14.2.3 Towing with Engine Damage
(Z 200 092, Z 51 301, Z 200 320)
First option:
Remove drive shaft (4) from between drive gearbox (2) and
distributor gear (3).
Ignition on.
Drive gearbox in neutral position.
Distributor gear in road travel position.
Second option:
Under certain conditions (max. 30 km at 30 km/h), you can avoid
removing the universal joints for towing. In this case, the distribu-
tor gear must be switched to neutral position instead (for more in-
formation see Neutral position of the distributor gear in this sec-
tion).
Ignition on.
For both options the following applies:
The braking system of the mobile crane must be supplied with
pressurised air using a hose from the towing vehicle. For this
purpose there is a combined external filling and tyre filling
connection with M 16 x 1.5 thread on the right side of the
crane base.
The connection for the filling hose must only be screwed on
to the combined connection in such a way, that the cylindrical
component is pressed in by approx. 1 mm (position L: exterior
filling). (Information: on filling up the tyres: screw filling tube
on so that the cylindrical component is pressed in approx. 3
mm (position R).
If the air pressure in the supply tanks falls below 5.5 bar (indi-
cator lights B3 / B4 and STOP display (35) are illuminated),
the crane must be stopped immediately.
If the pressure in the braking system falls to such an extent that
the spring accumulators brake cylinder close of their own ac-
cord, the spring tension can be released again mechanically.
To do this, unscrew the release bolts on the spring accumulators
brake cylinder using an SW 27 wrench until they move freely.
14
1402140 6/15
Z 200 092
1 2 4 5 3 7
6
Z 52 142
43
35
36
35 36
B8
B9
B10
B3
B4
1402140 7/15
The spring accumulator brake cylinders may only be re-
leased once the vehicle has been secured to prevent it
from rolling away.
(Z 200 092, Z 52 142)
Following towing with the spring accumulators brake cylinders
released, the braking action of the parking brake must be re-
stored before the crane is placed back in operation.
The compressed air must first be raised to a pressure of 8 bar with
the engine running. The displays (B3 / B4) go out at 5.5 bar.
Then with the parking brake released the release bolts on the
spring accumulator brake cylinders must be fully screwed into the
cylinders and tightened.
Once you have done this, check the free travel of the brake cylin-
der and adjust as necessary.
To ensure the road safety of the vehicle, this work may only
be carried out by trained and qualified personnel.
Important note on steering while engine is at a standstill:
When the engine is at a standstill, the main steering circuits
1 and 2 do not function. Only when the vehicle is in motion
does the emergency steering pump, which is connected to
the drive train (distributor gearbox), rotate and supply (de-
pending on speed) the steering circuit 3. This means:
The joint shafts 5 AND 6 may not be removed at the same
time. One of the shafts must always be fitted so that the
emergency steering pump will pump.
Much greater effort is required to move the steering
wheel.
The steering times for the vehicle being towed are in-
creased 3 to 4fold.
In tight bends the vehicle may need to be manoeuvred in
the area of the bend.
The steering circuits 1 and 2 do not function at the mo-
ment. This is indicated while towing by red indicator
lights (B8, B9) in combination with Caution (36).
While towing the indicator light (B10) must be observed.
14
1402140 8/15
Z 52 142
43
35
36
35 36
B8
B9
B10
B3
B4
Z 200 092
1 2 4 5 3 7
6
1402140 9/15
(Z 52 142)
The indicator light (B10) may not light up.
If these indicator lights are illuminated in red (STOP
(35) would be displayed at the same time), the crane
must be stopped immediately. It is no longer possible to
steer the crane.
at the emergency steering pump (indicator light B10) , there is
a display only once a driving speed > approx. 8 km/h has been
reached.
14.2.4 Towing with Damage to the Drive Gearbox
(Z 200 092)
First option:
The drive shaft (4) must be disconnected between the drive
gearbox (2) and the distributor gear (3).
Distributor gear in road travel position.
Second option:
Under certain conditions (max. 30 km at 30 km/h), you can avoid
removing the universal joints for towing. In this case, the distribu-
tor gear must be switched to the neutral position instead (for more
information see Neutral position of the distributor gear in this
section).
For both options the following applies:
Start the engine of the chassis and set the speed to 1200 rpm.
This speed must be maintained during the towing procedure.
If the chassis engine should stop running for some reason,
follow the towing regulations outlined for towing the crane
in the case of engine damage.
14
1402140 10/15
Z 200 092
1 2 4 5 3 7
6
Z 51 300
36
B8
B9
B10
1402140 11/15
14.2.5 Towing with Damage to the Distributor Gear
(Z 200 092, Z 51 300)
The drive shaft (4) must be disconnected between the drive
gearbox (2) and the distributor gear (3).
The drive shaft (5) must be removed between the distributor
gear (3) and front axles.
The drive shaft (6) must be removed between the distributor
gear (3) and rear axles.
Start the engine of the chassis and set the speed to 1200 rpm.
This speed must be maintained during the towing procedure.
If the warning lights (B8, B9) light up during towing, the
crane must be stopped immediately. It is no longer pos-
sible to steer the crane.
When towing with damage to the distributor gear the drive
motor must always run; otherwise the vehicle cannot be
steered.
In this case, the indicator light (B10) which controls the function
of the emergency steering pumps is also illuminated during tow-
ing (red together with Caution (36)) as there is no connection to
the emergency steering pump due to the missing drive shafts.
Depending on the system, the message is only shown at driving
speeds > approx. 8 km/h.
14
1402140 12/15
Z 52 143
A8
1
2
Z 52 144
93 A7
Z 200 321
1402140 13/15
14.2.6 Neutral Position of the Distributor Gear for Towing
with Damage to Engine / Transmission
(Z 52 143, Z 52 144, Z 200 321)
The neutral position of the distributor gear is meant to ease the
drivers job, so that the universal joints do not have to be removed
if there is damage to the engine / transmission.
It is only permitted to tow with the distributor gear in neutral posi-
tion if the journey is no longer than 30 km and speeds do not ex-
ceed 30 km/h.
Avoid longer towing journeys (the lubricating oil pump does not
work).
If the max. towing distance (30 km) and / or the max. towing
speed (30 km/h) is not adhered to, it will always lead to dam-
age.
The neutral position is switched on via a manually activated
pneumatic valve (1) (key function). In order to carry out a switch-
ing procedure, a pressure supply of 7 bar is required.
The button is on the righthand side of the machine in the outer
covering under the rubber sheeting (Z 200 321).
Steps for neutral position of the distributor gear
1. Stop vehicle; apply parking brake; secure against rolling
away; transmission in neutral.
2. Switch to neutral position in the distributor gear by pressing
the button (2). The indicator light (A8) is displayed in the
driver display (43).
3. After towing is completed (wait for the vehicle to come to
a standstill), road travel must be activated again in the distrib-
utor gear by pressing the dual button (93). The indicator light
(A8) goes out.
No resetting is required at the actual pneumatic valve.
Make sure that the dual button (93) is not pressed during tow-
ing (not even by accident).
14
1402140 14/15
1402140 15/15
14.3 Towing Free From Rough Terrain
Towing the crane free (pulling out) if the wheels have become
stuck in the ground is only allowed with extreme caution.
It is prohibited to pull it out using the trailer coupling at the front
frame, as it is only for towing on a firm surface.
The crane vehicle may only be towed backwards using the rear
trailer clutch or long steel ropes, fastened to the rear outrigger
beams. The crane should then be towed along the track that it
has already made.
Sudden, jerking movements and oblique pull are prohibited, as
these could result in damage to the chassis.
If it is not possible to pull the crane out in a straight line, a deflec-
tion point may need to be set up between the crane and the re-
covery vehicle. Make sure that there is sufficient air in the braking
system.
Heating and Ventilation 15
1402150103 1/25
15
1402150103 2/25
Z 53 019
105 107 115
114
113
112
110 111
109
5A
24V
106
108
1402150103 3/25
15 Heating and Ventilation
15.1 Cab Heater Arrangement (Dependent of Engine)
(Z 53 019)
This heating system is dependent on the temperature of the en-
gine coolant.
When the engine coolant is warm, the temperature in the cab can
be regulated via control knob (113).
A fan can also be switched on with rotary switch (114) in order to
accelerate the air circulation in the drivers cab or to bring more
warm air into the cab when the crane is standing still.
Using control knob(111) for air circulation windscreen or drivers
cab.
Using rotary button (115) an air flap can be set to fresh air or circu-
lating air.
15
1402150103 4/25
Z 35 590
P
20:30
C MO
3
6
7
8 9 10 11
1 2 3 4 5
1402150103 5/25
15.2 Hot Water Heater Arrangement with Preheating for
coolant (independent of engine), Optional Equipment
(Z 35 590)
The crane is equipped with the Eberspcher D 9 W hot water
heater arrangement.
With low ambient temperatures (up to 20 C) it makes starting
the engine easier. With temperatures lower than 20 C the cool-
ant must be preheated.
For operating the heater there is a timer (109) in the cabin.
1. Clock time
2. Preselection
3. Heating
4. Back
5. Forward
6. Memory display
7. Symbol for radio remote control
8. Weekday or preselected day
9. Actual clock time or preselected time
10. Temperature display
11. Operating display
If the coolant has been replaced or topped up considerably,
the vehicle engine must be brought up to an operating tem-
perature of approx. 80 C (activation point of the coolant ther-
mostat) before the independent heater is switched on so that
the coolant circuit and the circuit for the independent heater
can be bled automatically.
When the heater is switched on, the lower fan level is automati-
cally switched on when the water temperature reaches approx.
55 C measured on the independent heater.
15
1402150103 6/25
Z 35 590
P
20:30
C MO
3
6
7
8 9 10 11
1 2 3 4 5
1402150103 7/25
(Z 35 590)
The following operating conditions can be preselected:
cab preheating only, via preset time
Set the heater control (control knob 113) to the desired tempera-
ture and using the timer (9), program the time when the heater is
to begin operation.
This heating procedure is fast and saves electricity.
cab and engine preheating via preset time
Set the heater control (control knob 113) to the desired tempera-
ture and using the timer (9), program the time when the heater is
to begin operation.
engine preheating only, via preset time
Set the heater control (control knob 113) to the temperature posi-
tion 0, and using the timer (9), program the time when the heater
is to begin operation.
If the power supply is interrupted, the display on the heating
timer flashes.
The clock must then be completely reset.
To do this, proceed as follows:
1.) Setting the time and weekday for the first time
Press push button 1 briefly.
12:00 flashes on the display.
Set the clock time with push button 4 or 5.
The time is stored as soon as it stops flashing.
Then the weekday flashes. Set the current weekday with push
button 4 or 5. It is stored as soon as is stops flashing.
When the ignition is switched on, the clock time and weekday are
displayed continuously. When the ignition is switched off, the dis-
play goes out after 10 seconds.
15
1402150103 8/25
Z 35 590
P
20:30
C MO
3
6
7
8 9 10 11
1 2 3 4 5
1402150103 9/25
(Z 35 590)
2.) Changing the clock time and weekday
Press push button 1 and hold it down until the clock time flashes.
Proceed as described under point 1.).
If you only want to change the clock time, press the push button
1 twice after setting the clock time to skip weekday adjustment.
After changing the weekday, flashing on the weekday can be re-
duced by pressing the push button 1.
3.) Heating without preselection when ignition is OFF
Heating symbol (11) = Observe operating display
Switching on heater
Operating display (11) appears and the heating duration is dis-
played (120 Min).
The heating duration is factorypreset to 120 min., and can be
changed once only or permanently.
Changing the heating duration once only
After poweron:
To reduce heating duration (to min. 1 min.): Press push button 4.
To increase heating duration (to max. 120 min.): Press push but-
ton 5.
Changing the heating duration permanently
Do not switch on push button 3.
Press the push button 4 and hold it down (approx. 3 seconds)
until the display appears and flashes.
Release push button briefly.
Then set the heating duration using the push button 4 or 5 (on 10
to 120 min.).
The new heating duration is set when the display disappears.
Switching off heater
Operating display 11 disappears.
The blower automatically continues to operate to cool the heater
down.
15
1402150103 10/25
Z 35 590
P
20:30
C MO
3
6
7
8 9 10 11
1 2 3 4 5
1402150103 11/25
(Z 35 590)
4.) Heating without preselection when ignition is ON
Switch on the heater
The operating display (11) and time and weekday.
The heating stays in operation until the ignition is switched off.
If the ignition is switched off, a residual heating period of 15 min.
remains. This can be extended to max. 120 min. by pressing the
push button 5 or reduced by pressing the push button 4.
Switching off heater
Operating display (11) disappears.
The blower automatically continues to operate to cool the heater
down.
5.) Heating operation preselection
3 switchon times within the following 24 hours or one switchon
time in 7 days can be programmed.
Only one switchon time can be activated at a time.
5.1. Heating via preset time
Selecting and activating memory:
(starting from neutral status with display visible)
First memory press push button (2) once
Memory display: 1 (default setting 12 00)
Second memory press push button (2) twice
Third memory press push button (2) three times
Neutral status no memory activated.
Press push button 2 repeatedly until the memory display dis-
appears.
15
1402150103 12/25
Z 35 590
P
20:30
C MO
3
6
7
8 9 10 11
1 2 3 4 5
1402150103 13/25
(Z 35 590)
5.2. Start of heating within 24 hours
Set the program day:
The correct program day is automatically displayed no ad-
justment necessary.
Set the program time:
Press push button 2 repeatedly until the desired memory dis-
play (1, 2, 3) begins to flash.
Briefly press and then release push button 4 or 5. the program
time flashes.
Then set the program time for heating using push button 4 or
5.
Setting is only possible if the program time is flashing.
To select another memory: press push button 2.
5.3. Start of heating after 24 hours (max. 7 days)
Set the program time:
Press push button 2 repeatedly until the desired memory dis-
play (1, 2, 3) begins to flash.
Briefly press and release push button 4 or 5.
The program time flashes.
Then set the program time for heating using push button 4 or
5.
Set the program day:
The program day begins to flash approx. 5 seconds after the
program time has been set.
Then set the program day for heating using push button 4 or
5.
The program time and program day are stored when the time
display disappears or when the current time appears.
The memory display indicates the activated memory.
The flashing heatingon symbol (3) also indicates that a
memory has been activated.
6.) Checking activated memory:
The program time of the displayed memory is displayed for ap-
prox. 5 seconds. The display then disappears or the current time
is displayed (if the ignition is ON).
The program time display together with the program day can then
be called up by pressing push button 2 once for 5 seconds.
15
1402150103 14/25
Z 35 590
P
20:30
C MO
3
6
7
8 9 10 11
1 2 3 4 5
1402150103 15/25
(Z 35 590)
7.) Attention !
When the ignition is switched on, the clock time and weekday are
displayed continuously. When the ignition is switched off, the dis-
play goes out after approx. 15 seconds.
Radio remote control operation is possible with the appropriate
accessory.
If a fault occurs, with the heater switched on and a diagnosis line
connected, operating display (11) flashes and the fault code No.
is displayed (contact repair workshop).
8.) If faults occur, we recommend the following:
Switch off and on again (max. twice)
Check the main fuse
Check the air channels for blockages
Consult a workshop.
15
1402150103 16/25
8
Z 27 544
A
B
C
3
2
1
4
1402150103 17/25
15.3 Petrol Gas Heating (independent of engine), Optional
Equipment
(Z 27 544)
Heating
Switch on the heater as follows:
1. Remove the cap (if there is one) from the heater.
2. Open the steel cylinder valve and quick lock valve in the gas
pipe.
3. Set the desired temperature on control knob (4) of the oper-
ating panel.
4. Set switch (3) to heating (position A) and switch (2) to the
desired output (FULL, high flame or 1/2, low flame). With
low ambient temperatures leave the heater running on
FULL.
Ventilation
Switch on the fan as follows:
1. Set switch (3) to ventilation (position C).
2. Set switch (2) to the desired level (FULL or 1/2).
When switch (3) is in position B, the system is switched off.
15
1402150103 18/25
Z 27 544
A
B
C
3
2
1
4
1402150103 19/25
Notes on operating the heater
(Z 27 544)
If switch (3) is set on heating (position A) or ventilation (posi-
tion C), the green indicator lamp under control knob (4) must be
on. The fan is in operation.
If the indicator lamp is not on, the fuse in the electrical control unit
must be renewed (see lubrication and maintenance instructions
for the crane chassis, Part 4, Sect. 19).
If, after a while, the heater is switched off, the green light means
that the fan is continuing to run to cool down the heater. The igni-
tion switch must therefore not be switched off until the fan has
gone off.
When filling up the tank and in enclosed spaces (garage etc.) the
heater must not be switched on.
If the red indicator lamp (1) comes on and is not flickering, this
can, amongst other things, mean the gas is low, there is air in the
gas pipe, the blower is badly clogged or theres a defect in a
safety part.
The malfunction is cleared each time by switching the heater off
and on again.
If the red indicator lamp (1) is flickering, this indicates that the op-
erating voltage is too low for the heater.
Make sure that the heater is always free from dirt (slush, leaves
etc.) for gas emission and for the combustion air supply.
The heater cap must always be replaced when the heater is not
in operation.
For operation and maintenance of the heater also see the operat-
ing instructions from the manufacturer, Part 5.
Before carrying out any welding the corresponding breaker must
be switched off.
15
1402150103 20/25
Z 53 019
105 107 115
114
113
112
110 111
109
5A
24V
106
108
1402150103 21/25
15.4 Air conditioner, Optional Equipment
(Z 53 019)
The air conditioner operates with the refrigerating agent R 134a
and is therefore without florchloridecarbonhydrogen.
To operate the air conditioner, there are two control buttons either
in the cabin.
1. control button air conditioner (110) (on/off)
2. blower switch, 3settings (114)
The air conditioner only operates by running motor.
The air conditioner is switched off if the control button air condi-
tioning (110) is in position out.
To switch on the air conditioner, you have to turn the blower
switch (114) in clockwise direction to setting 1 at least. The cool-
ing temperature can be chosen with the control button tempera-
ture (113). By turning the button in clockwise direction, you can
reach a higher efficiency of the air conditioner. The room temper-
ature in the cabin decreases.
The higher you chosen the cooling temperature of the air condi-
tioner with the control button temperature, the higher you should
put the blower setting.
Should the efficiency the air conditioner noticeably decrease by
same speed and normal adjustment there is the possibility that
the evaporator is frozen. In that case, switch off the air conditioner
by running evaporator about 3 minutes. The ice on the evapora-
tor defreezes.
To obtain the most effective cooling in the cabin, you have to....
turn control button temperature in clockwise direction as far
as it will go
switch on the highest blower setting
turn off the heater
keep close the windscreens.
On cold and damp days the air conditioner can dehumidify the air
in the cabin. With the vehicles heater, the cooling is compen-
sated again. An agreeable climate of the cabin is obtained and
the steaming up of the windscreens is prevented.
The air conditioner should be switched on for a short time one
time every month a least. The operate is necessary so that all run-
ning parts will be lubricated.
Servicing the air conditioning system see part 3 (Lubrication and
Maintenance Manual of the Superstructure) .
15
1402150103 22/25
1402150103 23/25
15.5 Instructions for Winter Operation
Starting the Engine at Ambient Temperatures below 16 C
If the crane does not have an engine oil or engine coolant pre-
heating system, the engine can be equipped with a flame start
system for very low ambient temperatures.
Information is available from any DAIMLERCRYSLER service
station.
Fuel
Refer to the engine manufacturers operating instructions.
Engine oil for low temperatures
Coolant for low temperatures
Batteries
At ambient temperatures below 15 C the batteries must be
heated or removed when the vehicle is at a standstill for a pro-
longed period outdoors (e.g. overnight). Always ensure that bat-
teries are well charged in the winter.
Discharged batteries will freeze at 10 C.
Transmission
With ambient temperatures below 20 C start the engine and
allow the transmission to warm up.
With the crane at standstill and the parking brake applied, the en-
gine must be operated for at least 10 minutes until the trans-
mission oil is warmed up.
15
1402150103 24/25
Z 2542 Z 22 699
1402150103 25/25
Draining the Air Tanks
(Z 2542)
All tanks with a manual valve are to be drained regularly. By pull-
ing or pushing the pin on the drain valve sideways, the tilting valve
opens and the condensation water can escape.
Windscreen Washing Assembly
(Z 22 699)
The windscreen washing assembly should be checked at least
once a week to ensure that it is functioning correctly. The supply
tank should always be filled with water. At low temperatures, an
amount of antifreeze appropriate to the temperature should be
added to the water.
Central Lubricating System 16
1402160 1/15
16
1402160 2/15
Z 42 271
2
1
4
5
3
Z 29 548
6
7
8
9
10
1402160 3/15
16 Central Lubricating System (Optional Equipment)
(Z 29 548, Z 42 271)
16.1 Components
(1) Lubricating nipple for manual lubrication
(2) Grease container
(3) Safety valve
(4) Filler nipple
(5) Plug
After removing plug (5) the control board with the following items
can be seen:
(6) Lightemitting diode live battery voltage
(7) Rotary switch set the pause time
(8) Rotary switch set the operational time
(9) Lightemitting diode display of a lubricating procedure
(10) Button for additional lubricating pulse
16
1402160 4/15
Z 42 271
2
1
4
5
3
Z 29 548
6
7
8
9
10
1402160 5/15
16.2 Function
(Z 42 271, Z 29 548)
The central lubricating system automatically supplies the
connected lubricating points via local subdistributors with
grease.
It works according to preprogrammed cycles, i.e. there are pause
times and operating times. These begin to run as soon as the
ignition on the chassis is switched on.
Pause time: Period in which no lubrication is carried out
(exception possible if the additional lubricating
pulse is used)
Operating time: Period in which lubrication is carried out.
An exact description of the pause and operating times can be
found in section 16.3.
If there is a blockage in the system, lubricant is emitted from the
safety valve (3) of the pump.
An exact description of how to proceed in the event of faults can
be found in section 16.7.
To check that the system and controls are functioning correctly,
a test run can be carried out.
1. Switch on the ignition:
Lightemitting diode (6) must light up.
2. Press button (10) for additional lubrication for approx. 2
seconds (or button 98 in the dashboard).
The pause time is then abbreviated and the usual lubrication
procedure is carried out; lightemitting diode (9) and
indicator light in button (98) light up.
16
1402160 6/15
Z 29 548
6
7
8
9
10
1402160 7/15
16.3 Setting the Pause and Operating Time
(Z 29 548)
16.3.1 General
The pause and operating times are electronically regulated.
As soon as the ignition is switched on, the pause time begins.
Once the pause time is completed, the operating period begins,
the actual lubrication procedure.
If, for example, a pause time of 6 hours has been set, the time that
has already run when the ignition is switched off (e.g. 4 hours) is
stored. When the ignition is switched back on, a further two hours
pause time remain.
If the battery voltage is disconnected for more than four days
a complete pause cycle will run again (6 hours).
An operating cycle will run as long as the ignition is switched on.
If the operating cycle is interrupted by switching off the ignition
it continues where it left off once the ignition is switched back on.
The individual cycle periods are stored electronically.
Example: Operating time already run 3 min.
Remaining operating time 3 min.
The duration of the lubricating cycle is dependent on the amount
of lubricant required by the system. The pause / operating times
of the chassis are set ex works as follows:
Pause cycle: 6 hours
Position of rotary switch (7) = 6
Operating cycle:
6 min.
Position of rotary switch (8) = 3
That means that every 6 hours a lubricating procedure of 6
minutes is carried out.
16
1402160 8/15
Z 29 548
6
7
8
9
10
1402160 9/15
16.3.2 Setting the Pause Time
(Z 29 548)
The pause time is set on rotary switch (7) in 15 increments.
Switch
position
1 2 3 4 5 6 7 8 9 A B C D E F
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
The pause time set ex works is 6 hours.
For normal operating conditions this setting must be maintained.
16.3.3 Setting the Operating Time/Cycle
(Z 29 548)
The operating time can be set using 15 settings on rotary switch
(8).
Switch
position
1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 2 3 6 8 10 12 14 16 18 20 22 24 26 28 30
The operating time set ex works is 6 minutes.
For normal operating conditions this setting must be maintained.
16
1402160 10/15
Z 29 548
6
7
8
9
10
Z 42 271
2
1
4
5
3
Z 53 751
98
1402160 11/15
(Z 29 548, Z 42 271, Z 53 751)
16.4 Additional Lubricating Pulses
In addition to the automatic lubricating cycles, it is possible to end
the pause time early and to carry out additional lubricating cycles.
These can be carried out either by pressing (approx. 2 seconds)
the following buttons:
1. Button (98) in the dashboard;
the indicator light lights up in the button.
Or
2. Button (10) on the control board of the lube pump;
lightemitting diode (9) lights up on the control board.
The ignition must be switched on!
Once the additional lubrication has been carried out, the usual
pause time begins again from the start.
16.5 Manual Lubrication in Case of an Emergency
If the lube pump fails, the lubrication points can also be supplied
manually with grease.
The grease is then fed into the system using a grease gun via
lubricating nipple (1).
16.6 Filling the Grease Container (Lube Tank)
The grease container or lube tank (2) is filled up to the max.
marking using filler nipple (4). This is carried out using a standard
grease pump or a handlever press.
During filling, the pump must be set in motion (by first activating
the additional lubricating pulse).
The grease that has been added must be free of impurities
and and must not change in consistency with time.
Pay attention to the instructions on the prescribed lubricants in
the lubricating / maintenance instructions of the chassis (part 4).
16
1402160 12/15
1402160 13/15
16.7 Troubleshooting
Fault: The engine of the pump is not running
Cause Remedy
Power supply interrupted. Check power supply / fuses. Rectify fault / re-
place fuses if necessary.
Fault: Pump is not delivering
Cause Remedy
Container empty. Fill up the container with clean grease, allow
the pump to run (additional lubrication) until
the lubricant is emitted at all lubricating points.
Note: Depending on the ambient temperature
and/or lubricant the pump elements require up
to 10 minutes run time in order to reach their
full delivery capacity.
Air pockets in the lubricant. Carry out an additional lubricating pulse.
Loosen the outlet plug on the safety valve.
The lubricant must be emitted without bubbles.
Unsuitable lubricant used. Replace the lubricant, see lubricants table (lu-
bricating and maintenance instructions of the
chassis, part 4).
Suction hole of the pump element is clogged. Remove the pump element, check the suction
hole for impurities/blockages and clean.
Pump pistons worn. Replace the pump element.
Nonreturn valve in the pump element defec-
tive or clogged.
Replace the pump element.
Fault: Different lube quantities at the lubricating points
Cause Remedy
Corresponding valve body is fitted without
clamping ring.
Remove the valve body and check whether a
clamping ring is fitted. If not, fit a clamping
ring.
16
1402160 14/15
Z 29 549
1402160 15/15
Fault: Blockage in the connected progressive system (Z 29 549)
Cause Remedy
Bearing, leads or distributor
clogged.
The fault can be recognised by
the following characteristics:
a) Grease emitted at the safety
valve.
b) The check pins on the distrib-
utor pistons (if fitted) are not
moving.
Find and rectify the blockage as described in the following
example.
1. Leave the pump running (additional lubricating pulse).
2. Individually release all main lines (G) from the main dis-
tributor (B) to the sub distributors. If, for example, grease
is emitted under pressure from outlet (1) of the main dis-
tributor (B), the blockage must be looked for in the lubri-
cating circuit of the subdistributor (D).
3. Leave the pump running.
4. Individually release all lubricating lines (E) of the subdis-
tributor (D) one after the other. If, for example, grease is
emitted under pressure from outlet (3) of distributor (D),
the blockage must be looked for in the line of outlet (3) or
in the connected bearing.
5. Replace safety valve A.
Note: To check the individual outlets, leave each outlet
loose for a longer period of time, as only one piston
stroke is carried out for each rotation of the pump. Sev-
eral piston strokes are required, however, to carry out a
complete run through all distributors.
c) If a distributor is blocked, lu-
bricant is not emitted at any
outlet.
Pump out the blocked line / bearing using a hand pump.
Replace the distributor or clean as described below:
1. Remove all pipe connection screws.
2. Unscrew the piston sealing plugs.
3. Drive out the pistons, if possible, with a small soft mandrel
( smaller than 6 mm).
Caution: The pistons are fitted flush in the distributor bores.
After removing, mark the pistons to make sure they are
fitted again in the right position and direction. They must
not be mixed up when refitting.
4. Clean the distributor body in greasedissolv-
ing cleaner and blow off with compressed air.
5. Press through the cross channels ( 1.5 mm) on the
thread ends of the piston bores with a pin.
6. Clean the distributor again and blow out.
7. Assemble the distributor.
8 Replace the copper washers.
9. Before screwing in the pipe connectors, pump through the
distributor several times with oil using a manual pump. The
pressure in the distributor must not exceed 25 bar ( 362.8
psi) when doing this.
If this is the case, replace the distributor.

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