AC200 1 33313 Part2 - en

Index
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Dimensions, Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 Road Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.4 Wheels / Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.5 Climatic Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Overview of the Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Chassis and Construction Number . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Preparation for Emergency Control, Superstructure . . . . . . . . . . . . 15
4 Driver’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Operator’s 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 Switch on the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.1 “Driver information system” (43) display . . . . . . . . . . . . . . . . . . . . . . 23
4.3.2 I−CAN Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3.3 Indicator lights in the driver information system . . . . . . . . . . . . . . . 51
4.4 Ignition−starter switch (15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.5 Steering wheel setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6 Combination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.6.1 Left−hand Side of the Steering Column . . . . . . . . . . . . . . . . . . . . . . 57
4.6.2 Right−hand Side of the Steering Column . . . . . . . . . . . . . . . . . . . . . 59
4.7 Driver’s Door / Passenger Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.7.1 Opening and Closing the Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.7.2 Window Controls (Z 200 141, Z 200 142) . . . . . . . . . . . . . . . . . . . . . 63
4.8 Entry / Exit for Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . 67
4.9 Driver’s Seat / Passenger’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.9.1 Folding the Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.9.2 Headrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.9.3 Safety belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.10 Hinged Bed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.10.1 Folding the Hinged Bed down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
200−1−2000−313_en 1
Index
5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.1 Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2 Starting aid with external batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3 Ignition−starter switch (see Sect. 4 “Driver’s cab”) . . . . . . . . . . . . . 9
5.4 Starting procedure (engine start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4.1 Start the engine in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4.2 Start the engine on 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 Driver’s 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 Shut−off Valve . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.9 Electronic Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.9.1 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.9.2 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.9.3 Tempomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Calculating Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.2 Calculating Axle Loads in kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.2.1 Arithmetical Basic Condition (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.2.2 Weight Table (component weights in kg) . . . . . . . . . . . . . . . . . . . . . 15
6.4.2.3 Example of an Axle Load Calculation (kg) . . . . . . . . . . . . . . . . . . . . 17
6.4.3 Calculating Axle Loads in lbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4.3.1 Arithmetical basic condition (lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4.3.2 Weight Table (component weights in lbs) . . . . . . . . . . . . . . . . . . . . . 21
6.4.3.3 Example of an Axle Load Calculation (lbs) . . . . . . . . . . . . . . . . . . . . 25
6.4.4 Possible Axle Loads / permitted Speeds . . . . . . . . . . . . . . . . . . . . . 29
6.4.4.1 Tyre, Manufactured by Michelin (XGC) . . . . . . . . . . . . . . . . . . . . . . . 29
6.4.4.2 Tyre, Manufactured by Michelin (X − Crane) . . . . . . . . . . . . . . . . . . 31
6.4.4.3 Tyres, Manufactured by Bridgestone . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.4.4 Tyres, Manufactured by Magna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.5 Driving with Uneven Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.4.6 Driving with Reduced Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4.7 Driving with Axle Loads over 12 t (26.4 kip) . . . . . . . . . . . . . . . . . . . 45
6.4.7.1 Driving with Axle Loads of up to 12.5 t (27.5 kip) . . . . . . . . . . . . . . 47
6.4.7.2 Driving with Axle Loads of up to 16.5 t (36.4 kip) . . . . . . . . . . . . . . 49
200−1−2000−313_en 2
Index
6.4.8 Shorter maintenance intervals for Axle Loads

above 12.5 t (27.5 kip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.5 Driving on Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5.1 Driving with Axle Loads of 12 t (26.4 kip) (EEC Directive) . . . . . . . 55
6.5.2 Driving in the United Kingdom (UK approval) . . . . . . . . . . . . . . . . . 55
6.5.3 Checks before Driving on the Road . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.6 Defined Driving Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.6.1 Driving with a Total Weight of 60 t (132.3 kip)
(Approval condition in accordance with EEC−directive) . . . . . . . . . 59
(with main boom, without outriggers) . . . . . . . . . . . . . . . . . . . . . . . . 61
6.6.3 Driving with a Total Weight of 39.2 t (86.5 kip)
(without main boom, with luffing cylinder) . . . . . . . . . . . . . . . . . . . . . 63
6.6.4 Driving with a Total Weight of > 60 t (132.3 kip)
(”Technical Drivability”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.7 Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.8 Driving over Hill Summits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.9 Checking the Operation Functions During the Journey . . . . . . . . . 73
6.9.1 Monitoring Elements in the Instrument Controls . . . . . . . . . . . . . . . 73
6.9.2 Indicator Lights on the Display (43)
“Driver Information System” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.9.3 On the display (75)
“Transmission information” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.10 Driving on the Construction Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.10.1 Driving in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.10.2 Driving the Crane with the Equipment Erected
“Driving in Erect Mode” (with main boom /
equipment erected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.10.3 Driving Tables (in SI − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.10.3.1 Driving the Crane with the Main Boom . . . . . . . . . . . . . . . . . . . . . . . 89
6.10.3.2 Driving with Main Boom Extension 9 m (in SI − Units) . . . . . . . . . . 91
6.10.3.3 Driving with Main Boom Extension 17 m (in SI − Units) . . . . . . . . . 95
6.10.4 Driving Tables (in US − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.10.4.1 Driving the Crane with the Main Boom (US) . . . . . . . . . . . . . . . . . . 107
6.10.4.2 Driving with Main Boom Extension 9 m (29.5 ft)
(in US − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
(in US − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.10.4.4 Driving with Main Boom Extension 25 m (82 ft)
(in US − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
(in US − Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.10.5 Driving the Crane with a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.11 Attachment Coupling / Supply Connections (optional) . . . . . . . . . . 125
6.11.1 Coupling and uncoupling a dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
200−1−2000−313_en 3
Index
6.12 Attaching and Removing the Spare Wheel

(Spare Wheel Holder, Hoist Arrangement, Option) . . . . . . . . . . . . . 133
6.13 Reversing Check System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.13.1 General System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.13.2 Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.13.3 Registering Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.13.4 Protruding Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.13.5 Critical Situations in the Registering Range . . . . . . . . . . . . . . . . . . . 143
6.13.6 First Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.13.6.1 Relation between Display and Tone Sequence with
Varying Distance to the Obstacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.13.6.2 Colours of the Light−emitting Diodes (LED’s) . . . . . . . . . . . . . . . . . 147
6.13.6.3 Example of a Display:
Obstacle at a distance of 1.20 m (3.9 ft) . . . . . . . . . . . . . . . . . . . . . . 149
Distance to the obstacle smaller than 0.40 m (1.3 ft) . . . . . . . . . . . 149
6.13.7 Activating and Using the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.13.8 Testing the Function / Diagnosis Function . . . . . . . . . . . . . . . . . . . . 153
6.13.9 Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.13.10 Maintenance and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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 / 3.3 ft) . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.13 Towing away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
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Index
8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1 Emergency Pressure Supply − Braking System . . . . . . . . . . . . . . . 3
8.2 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.2.1 Display of Wear to the Brake Linings (Disc Brake) . . . . . . . . . . . . . 7
8.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.4 Brake Pressure Limit
(Optional Equipment / National Regulations) . . . . . . . . . . . . . . . . . . 11
8.5 Test Points of the Braking Circuits
(Optional Equipment / National Regulations) . . . . . . . . . . . . . . . . . . 11
8.6 Retarder Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.6.1 Engine Brake (Exhaust Brake and Constant Throttle) . . . . . . . . . . 15
8.6.2 Hydraulic Retarder (System “ZF Intarder”) . . . . . . . . . . . . . . . . . . . . 17
8.6.3 Function “Sustained−Action Brake Cruise Control” . . . . . . . . . . . . . 19
8.7 Anti−Blocking−System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.7.1 ABS: Full Function / Off−road Mode . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.7.2 ABS Functions Check / Fault Display . . . . . . . . . . . . . . . . . . . . . . . . 25
8.7.3 Braking with ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.7.4 ABS with Dolly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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 electro−hydraulic 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” . . . . . . . . . . . . . . . . . . . 21
9.4.4 Synchronising the wheels when changing program . . . . . . . . . . . . 35
9.4.5 Raising/Lowering the “Lift Axle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.5 Steering Computer / Fault Diagnosis / Fault List . . . . . . . . . . . . . . . 41
9.5.1 Operating functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.5.2 Registration of a fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.5.3 Error memory / fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5.4 Fault categories / fault reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.5.5 Fault list (following) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.6 Manual emergency steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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
200−1−2000−313_en 5
Index
11 Hydraulic Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Distribution of the suspension circuits / assignment of
the pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.1.1 Normal case: 4−way system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.1.2 Special case: 3−way system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2 Setting for Driving in the Transport Position . . . . . . . . . . . . . . . . . . . 9
11.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2.2 “Automatic” setting road travel level . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2.3 “Manual” Setting of the Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11.3 Monitoring the Hydraulic Suspension . . . . . . . . . . . . . . . . . . . . . . . . 15
11.3.1 Monitoring the Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11.3.2 Level Control, Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.4 To lock the suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.4.1 Activating the Suspension Block
. . . Before Driving in an Erect Mode . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.5 Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.6 Raising Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.7 Hold axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.8 Lowering Brake Valves in the Basic Suspension Block . . . . . . . . . 25
11.9 Selection of the Operating Modes (Optional)
(”Axle Loads 12 t / 26.5 kip” or “Reduced Axle Loads”) . . . . . . . . . 27
12 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12.1 Notes on Outriggers: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12.2 Notes on Levelling with Counterweight . . . . . . . . . . . . . . . . . . . . . . . 7
12.3 Arrangement of Outrigger Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 9
12.4 Information System for the Outrigger Controls . . . . . . . . . . . . . . . . 13
12.4.1 Indicators on the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.4.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.4.3 Support Pressure Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12.4.4 Inclination Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.4.5 Outrigger Support Area Display (Optional) . . . . . . . . . . . . . . . . . . . . 31
12.5 Automatic Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.6 ”Hold Axles” / ”Raise Axles” Functions . . . . . . . . . . . . . . . . . . . . . . . 39
12.6.1 ”Hold Axles” Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12.6.1.1 Switching on ”Hold axles” after ”Moving on the Road” −
Suspension is Not Locked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12.6.1.2 Switching on ”Hold Axles” after
”Driving in the Configured State”− Suspension Locked . . . . . . . . . 41
12.6.1.3 Switching off ”Hold Axles” for ”Moving on the Road” −
Suspension Not Locked or Switching to
12.6.2 ”Raise Axles” Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.6.2.1 Switching on ”Raise Axles” after
”Moving on the Road” − Suspension is Not Locked. . . . . . . . . . . . . 47
”Driving in the Configured State” − Suspension Locked . . . . . . . . . 47
12.6.2.3 Switching off ”Raise Axles” for
”Driving on the Road” − Suspension Not Locked
or Switching to
12.7 Measures before Stabilising: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
200−1−2000−313_en 6
Index
12.7.1 Pinning Positions of the Outrigger Struts . . . . . . . . . . . . . . . . . . . . . 53

12.7.2 Transportation State of the Outrigger Struts . . . . . . . . . . . . . . . . . . 55
12.8 Stabilising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
12.8.1 Extending the Outriggers
(Outrigger Support Area 8.40 m x 8.20 m / 27.6 ft x 26.9 ft) . . . . . 57
12.8.2 Checking the Level at the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12.8.3 Retracting the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12.8.3.1 Retracting the Outriggers
. . . .for ”Driving in Transport Position” . . . . . . . . . . . . . . . . . . . . . . . 69
. . . . for ”Driving in the Configured State” . . . . . . . . . . . . . . . . . . . . . 73
12.9 Supporting Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.9.1 Outrigger Support Area 8.40 m x 8.20 m (27.6 ft x 26.9 ft)
(Standard Outrigger Support Area) . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.9.2 Outrigger Support Area 8.40 m x 6.85 m (27.6 ft x 22.5 ft) . . . . . . 75
12.9.3 Outrigger Support Area 8.40 m x 5.70 m (27.6 ft x 18.7 ft) . . . . . . 77
12.9.4 Outrigger Support Area 8.40 m x 2.80 m (27.6 ft x 9.2 ft) . . . . . . . 79
12.10 Fitting and Removing the Outrigger Struts
(Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12.10.1 Removing the Outrigger Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12.10.2 Installation of the Outrigger Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
12.11 Supporting the Outrigger Plates Due to Insufficient
Load−bearing Capacity of the Ground . . . . . . . . . . . . . . . . . . . . . . . 89
12.11.1 Permitted Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12.11.2 Determining the Required Support Area . . . . . . . . . . . . . . . . . . . . . . 93
12.12 Safe Distance to Slopes and Pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
13 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.1 Crane in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.2 Crane in Erect Condition and Supported on Outriggers . . . . . . . . . 3
14 Tow−starting and Towing the Crane . . . . . . . . . . . . . . . . . . . . . . . 3

14.1 Towing start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Towing away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
200−1−2000−313_en 7
Index
15 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.2 Cab heater arrangement (engine−dependent) . . . . . . . . . . . . . . . . . 3
15.3 Engine−independent heating with radiator preheater (optional) . . 5
15.3.1 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.3.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
15.3.3 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15.3.4 Heating operation without pre−set times . . . . . . . . . . . . . . . . . . . . . . 13
15.3.5 Heating operation with preselection . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15.3.6 Rectifying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
15.4 Air Conditioning Equipment, Standard, Optional Equipment . . . . . 23
15.5 Auxiliary AC system (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
15.6 Petrol gas heating (engine−independent), optional . . . . . . . . . . . . . 27
15.7 Instructions for winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . . 3

16.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.3 Setting the interval and operating times . . . . . . . . . . . . . . . . . . . . . . 7
16.3.1 Generalinformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.3.2 Setting the interval time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.3.3 Setting the operating time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.4 Additional lubrication impulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.5 Manual lubrication in the case of an emergency . . . . . . . . . . . . . . . 11
16.6 Filling the grease container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
200−1−2000−313_en 8
Safety instructions 1
1 Safety Instructions
All remaining risks that can occur during operation of the crane
chassis are listed in part 1, superstructure operating instructions,
section 1 ”safety instructions”.
Read this section thoroughly before beginning operation!
200−1−2010A_en 1/1
Crane Chassis 2
200−1−2020−001b_en 1/15
2
A6
A2
A5
A1
B
B
Z 200 632 Z 200 633
A7
A8
A3
A4
B B
Z 200 634 Z 200 635
2/15 200−1−2020−001b_en
Crane Chassis 2
2 Crane Chassis
(Z 200 632, Z 200 633, Z 200 634, Z 200 635)
The AC 200−1 is available in different versions depending on

customer wishes / regulations in force in the country where the
crane is to be operated.
Figure Z 200 632 shows the 5−axle standard version.
Figure Z 200 633 shows the AC 200−1 L with long wheel base
(between axles 3 and 4).
Figure Z 200 634 shows the 6−axle version (AC 200−1 P).
Figure Z 200 635 shows the 6−axle version with additional axle
(AC 200−1 PT).
2.1 Technical Data
2.1.1 Dimensions, Weights
Total length of the crane vehicle

∗ A1 = 14.46 m (47.4 ft)
∗ A2 = 14.47 m (47.5 ft)
∗ A3 = 14.47 m (47.5 ft)
∗ A4 = 15.97 m (52.4 ft)
Total height of the crane vehicle
∗ Height B = 4.00 m (13.1 ft)
Width of the crane vehicle
∗ Width = 3.00 m (9.8 ft)
Length of the crane chassis
∗ A5 = 13.0 m (42.7 ft)
∗ A6 = 13.0 m (42.7 ft)
∗ A7 = 13.0 m (42.7 ft)
∗ A8 = 14.5 m (47.6 ft)
Angle of gradient (without outrigger plate)
front rear
5−axle (AC200−1) 20° 11°
5−axle (AC200−1 L) 20° 13°
6−axle (AC200−1 P) 21° 17°
7−axle (AC200−1 PT) 21° 19°
200−1−2020−001b_en 3/15
2
4/15 200−1−2020−001b_en
Crane Chassis 2
Turn radius “5−axle standard version (AC200−1)”

∗ Interior: 5.71 m (18.7 ft)
∗ Chassis cabin, exterior: 11.05 m (36.3 ft)
∗ Boom head, exterior: 11.31 m (37.1 ft)
Turn radius “5−axle version with long wheel base
(AC 200−1 L)”
∗ Interior: 6.13 m (20.1 ft)
Turn radius “6−axle version (AC 200−1 P)”
∗ Interior: 6.60 m (21.7 ft)
Turn radius “6−axle version with additional axle
(AC 200−1 PT)”
∗ Interior: 6.90 m (22.6 ft)
Total weight
Road travel condition
5−axle (AC200−1 / AC200−1 L) 60 t (132.3 kip)
6−axle (AC200−1 P) 72 t (158.7 kip)
7−axle (AC200−1 PT) 84 t (185.2 kip)
Axle loads
∗ in road travel condition: each 12 t (26.4 kip)
200−1−2020−001b_en 5/15
2
6/15 200−1−2020−001b_en
Crane Chassis 2
2.1.2 Road Performance
Speed
∗ highest speed technically possible (due to design): 80 km/h
(50 mph)
∗ Permitted speed:
Depending on the axle load and tyres, various permitted
maximum speeds result (see section 6 “Driving” in “Possible
axle loads, permitted speeds”).
2.1.3 Drive
Engine
Type: OM 502 LA
8−cylinder diesel engine, water−cooled
Output: 390 kW (523 HP)
Torque: 2400 Nm (1770 lbf−ft)
Certification: EUROMOT 3a, TIER 3, CARB; 94/4/EC
(ATAX Directive) and EN1834−2
Transmission
ZF−AS TRONIC type 16 AS 2601 IT

automatic transmission
16 forward gears, 2 reverse gears
Distributor gear
with road travel and terrain driving, fitted emergency steering

pump
Axles
All axles have one tyre
200−1−2020−001b_en 7/15
2
8/15 200−1−2020−001b_en
Crane Chassis 2
2.1.3.1 Axles, Drive: 5−axle version
∗ Axle A1: not driven, steered

∗ Axle A2: driven, steered
∗ Axle A3: drive can be activated, not steered
∗ Axle A4: driven, independently steered

∗ Axle A4: not driven, independently steered

200−1−2020−001b_en 9/15
2
10/15 200−1−2020−001b_en
Crane Chassis 2
2.1.4 Wheels / Tyres
385/95 R 25 445/80 R 25 445/95 R 25 525/80 R 25

Tyres
(14.00 R 25) (17.5 R 25) (16.00 R 25) (20.50 R 25)
Rim 9.50−25/1.7 14−25/1.7 CR 11−25/1.7 17−25/1.7
Permitted speeds: see section 6 “Possible axle loads, permitted

speeds”
2.1.5 Climatic Operating Conditions
Instructions in part 1, section 1 of this document.
200−1−2020−001b_en 11/15
2
1 2 3 4
5 6 7 9
Z 171 290
12/15 200−1−2020−001b_en
Crane Chassis 2
2.2 Overview of the Crane Chassis

(Z 171 290 Principle drawing)
1 Driver’s cab
2 Front frame
3 Slew ring
4 Rear frame
5 Front back stop
6 Wheels / tyres, axles 1−5 (or 1−6 for 6−axle design)
7 Rear back stop
8 Spare wheel (optional)
9 Additional axle (optional)
2.3 Signs
See part 1, operating instructions of the superstructure, section 2

“Signs”
2.4 Chassis and Construction Number

The chassis number is on the chassis frame − in the front on the
right − hand side of the crane − in the area of the front outrigger
section.
The construction number is to be found (punched):

− on the rear of the vehicle, on the right−hand side.
− on the front bumper brace next to the trailer coupling
The chassis and construction numbers are also engraved on the

serial plate.
The serial plate is located inside the driver’s cab (driver’s /
passenger door).
200−1−2020−001b_en 13/15
2
L
PUW
TUW
Z 200 636
14/15 200−1−2020−001b_en
Crane Chassis 2
2.5 Preparation for Emergency Control, Superstructure
(Z 200 636)
The following hydraulic connections are located on the left side

of the chassis between axle 2 and 3:
1 Connection LUW (leakage)
2 Connection TUW (tank)
3 Connection PUW (pressure oil)
If the superstructure power units break down, a hydraulic

transformer can be connected at these points, which enables
limited superstructure functions.
For exact details, see the operating instructions of the
superstructure, section 36.
The hydraulic connections 1 − 3 may only be used with a

hydraulic transformer.
A direct connection to the superstructure hydraulic system
is not permitted as there is no capacity for this in the oil tank.
200−1−2020−001b_en 15/15
Driver’s Cab 4
200−1−2040−313_en 1/83
4
5
6
7
26 29 27 28
4
2 8
3
9
10
16
1
17
15
11
12
18 13
19 14
21
20 22
23
24
25
Z 200 316
2/83 200−1−2040−313_en
Driver’s Cab 4
4 Driver’s Cab
4.1 Operator’s Platform

(Z 200 316)
No. Designation Function

1 Combination switch, Lower beam, upper beam, headlamp
on the left of the flash, indicators, wipers, windscreen
steering column washer, horn
(S 6115)
2 EU Tachograph Tachograph
(A 5320) Display basic with time, speed,
mileage.
(Observe the operating instructions of
the manufacturer)
3 Combination switch, Engine control (engine idle speed,
on the right of the cruise control, limiter)
steering column Retarder (engine brake, retarder,
(S 4120) retarder 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, (6), 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, (6), left
11 Dual button Window passenger side
(S 5192) (controls in passenger door trim)
12 Switch lever Gear shifting high / back
(toggle) (A 2211) Manual / automatic operating mode
13 Rotary switch F = Forwards / B = Backwards /
(A 2211) N = Neutral
(in position “N” = switch lever without
function)
* Separate (different) pressure display, when axle 3 is in its raised

condition; otherwise the same display values with axle 4 and 5
(5−axle basic unit) or axle 4, 5 and 6 (6−axle basic unit).
200−1−2040−313_en 3/83
4
5
6
7
26 29 27 28
4
2 8
3
9
10
16
1
17
15
11
12
18 13
19 14
21
20 22
23
24
25
Z 200 316
4/83 200−1−2040−313_en
Driver’s Cab 4
(Z 200 316)
No. Designation Function

14 Lever Parking Brake
15 Ignition−starter Ignition on / off
switch Engine start / engine stop
(S 1271) Standby start external
16 Push button, Steering wheel control
pneumatic Steering wheel unlocking / locking
17 Alarm buzzer One−time warning signal =
(H 1336) malfunction
(“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 Driver’s seat
22 Safety belt
23 Rotary / rocker Outside mirror adjustment
switch Driver’s side / passenger side
(S 5435)
24 Dual button Window passenger side
(S 5192) (Controls in driver’s door trim)
25 Dual button Window driver’s side
(S 5191) (controls in driver’s door trim)
26 Reading light
27 Switch for reading push forward = reading light off
light push back = reading light on
(E 6614)
28 Interior light
29 Switch for interior push forward = interior light off
light push back = interior light on (lights up
(E 6614) when door is opened,
goes out when door is closed)
200−1−2040−313_en 5/83
4
6/83
31 32 33 34 35 36 37 38 39 40
43
km/h
mph
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 48 996
200−1−2040−313_en
Driver’s Cab 4
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 7−digit display of the
(display for total distance travelled / part
ignition on) distance
43 Display “Driver information system”
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4
8/83
31 32 33 34 35 36 37 38 39 40
43
km/h
mph
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 48 996
200−1−2040−313_en
Driver’s Cab 4
(Z 48 996)

50 Revolution Engine speed display
counter
50.1 LED Monitoring the engine speed
(with lit up: Excessive engine
speed! (> 2350 min−1 / rpm))
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 Actuate key Change brightness
58 Display Engine / coolant temperature
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4
61 64
62 65
63 66
60 67
Z 51 321
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Driver’s Cab 4
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”
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4
70 71
76 77
78 79
72 73 74 80 81
75
Z 200 160
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Driver’s Cab 4
4.2.3 Switch on the instrument panel

(Z 200 160)

70 S 6114 2−step 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
malfunction message
76 S 4411 Dual Set total level (raise / lower)
switch
77 S 4424 Button Automatic activation road
travel level
78 S 4413 Dual Set level, front left (raise /
switch lower)
79 S 4412 Dual Set level, front right, (raise /
switch lower)
80 S 4415 Dual Adjust level, rear left, (raise /
switch lower)
81 S 4414 Dual Set level, rear right, (raise /
switch lower)
* Display layout on the (75) “Transmission information” display,

see Chap. 7.
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4
85
86 87 88 89
90
Z 200 161
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Driver’s Cab 4
(Z 200 161)

85* S 4291 Double key “Manual rear−axle steering”
steering program:
Rear wheels swing to the left
/ right
86 S 4292 Button “Close cornering” steering
program:
Axle 4, 5 (+6; for 6−axle
basic unit) electrically
steered
87* S 4299 Button Steering program: “Driving
away from the wall”
88* S 4293 Button Steering program: “Diagonal
steering”: All wheels are
pointing in the same direc-
tion; steering wheel deter-
mines the steering angles
89 Visor not allocated
90 S 2217 Switch, Manoeuvring operation
lockable (sensitive driving at
distances < 1 m (3.3 ft);
with dragging coupling)
* Function only possible, if the (92) “Steering program”

(construction−site operation) switch was previously actuated.
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4
92 93 94 95 96 97 98
99 100 101 102 103 104

Z 56 141
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Driver’s Cab 4
(Z 56 141)
92 S 4290 Switch, Release “Steering program” (for
lockable construction−site operation)
93 S 2216 Double key press up: On−road gear
press down: Off−road gear
(”Neutral” externally possible)
94 S 2240 Switch, Longitudinal differential lock
lockable and lift axle activation
95 S 2220 Switch, Transverse differential locks
lockable
96 Switch, Switchover suspension system
lockable (optional):
Not actuated: 12 t / 26.4 kip
axle load; Actuated: Reduced
axle load (see Sect. 11
’Hydraulic Suspension’)
97 S0420 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
(optional)
99 S 4425 Switch, Suspension on three−circuit
lockable system
100 S 4401 Switch, Lock suspension
lockable
101 S 4428 Switch, Hold axles
lockable
102 S 4427 Switch, Raise lift axle *
lockable
103 S 2430 Switch, Emergency operation of the
lockable superstructure (optional)
104 S 4125 Button Switch ABS in tractor unit to
off−road mode
* “Raise lift axle” is done by driver in steering programs that can
be selected (for construction−site operation).
“Raise all axles” is done on the switch panel of the outrigger
controls by actuating the “Raise axles” button, after previously
actuating the “Raise axles” button (101).
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4
105 106 107 115
114
113
24V
112
5A
108 109 110 111
Z 53 019
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Driver’s Cab 4
(Z 53 019)

105 S 5431 Switch Mirror heater
108 X 5412 Cigarette
lighter
109 A 5111 Operating Engine−independent cab
element heater arrangement (optional)
110 S 5170 Switch Air conditioning equipment on
/ off
111 Control knob Air flow
Footwell / front window
112 X 5413 Plug 24 V, 5 A *
113 Control knob Regulate engine−dependent
cab heater arrangement / A/C
equipment warm / cold
114 S 5141 Rotary switch Fan levels 0−1−2−3−4
115 Control knob Air flap fresh air / ventilation
* Socket is fused with 5 ampere; do not overload!

Voltage is always on − regardless of the ignition−starter switch
position (danger of battery drain when device is off−duty).
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31 32 33 34 35 36 37 38 39 40
43
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
75
61 64
62 65
63 66
60 67
Z 200 144
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Driver’s Cab 4
4.3 Driver information system
(Z 200 144)
The operator’s platform is equipped with a driver information

system. This provides the driver with important information on the
vehicle when it is in driving mode.
The driver information system consists of the instrument panel
with the pos. (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
“Transmission information” (75) which displays the transmission
functions(gear display / error messages).
Self−test
The electrical system performs a self−test when the ignition is
switched on; the most important signal connections are checked.
At the same time, a control signal sounds twice and all indicator
lights (31−40 and 50.1) flash.
The function control is ended after the control signals go out.
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 driver’s information system.
The menus 1−6 can be selected using the “Digit” buttons (61)
− (66). At the same time, the digits correspond to the buttons of
the segment numbering on the “Driver information system“ (43)
display.
The “Arrow” key (60) can be used to exit the current menu item
and return to the previous display.
With the “M” button (67)
− the main menu can be called up and
− it can be returned directly to the basic display “Indicator

lights” from any menu item.
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10:07:2003
16:47
Z 200 145
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Driver’s Cab 4
4.3.1 “Driver information system” (43) display
Display fields
(Z 200 145)
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
In the changing displays, the previously used display field can

be used for other display functions according to certain criteria.
The display is divided into segments 1−6 and is laterally marked
with these digits.
The brightness of the display can be changed with the button

(57).
All possible displays are assigned certain display priorities.

These control the urgency of each message. By setting these
priorities, you can automatically change from the current display
into a new display with higher priority, if needed.
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Z 61 331
31 32 33 34 35 36 37 38 39 40
Z 51 331
24/83 200−1−2040−313_en
Driver’s Cab 4
Basic display / explanation of colours

(Z 61 331, Z 51 331)
The basic display of “Indicator lights” always appears after the

ignitionis turned on. (Z 61 331)
The basic display provides information about

Active functions,
Selected but not yet active functions,
Fault messages
The functions and fault messages are indicated using symbols

with different colours in the display. The colours serve as
indicators for the effect of the messages on the operating safety
/ transport safety of the vehicle.
DANGER!
Risk of injury to persons or damage to objects when

personnel who are not qualified try to rectify faults!
As soon as an error is displayed:
− Stop operation
− Identify the error immediately
− Eliminate the error

Faults must be rectified by qualified specialist personnel
(customer services, for example).
Caution!
Errors must be eliminated only when the ignition is switched

off.
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Z 61 331
31 32 33 34 35 36 37 38 39 40
Z 51 331
26/83 200−1−2040−313_en
Driver’s Cab 4
(Z 61 331, Z 51 331)
The colours have the following meanings:

Colour Additional Meaning
warning possible measures
light
red “STOP” (35) Severe malfunction
Stop the vehicle immediately!
Continued operation is not
permissible.
“Caution” Malfunction
(36) Locate the cause of the error and try
and rectify it at the earliest.
pink “STOP” (35) Short circuit, cable breakage,
or “Caution” plausibility
(36) Find the cause of the error and rectify
it.
yellow “Caution” Warning message
(36) The crane vehicle can still be
operated, however, determine the
cause.
white − The function is selected, but not yet
active, e.g. one of the steering
programs.
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4
61 64
62 65
63 66
60 67
Z 51 321
Z 61 331
0 25 50 75 100
FM
Service
Z 200 667
28/83 200−1−2040−313_en
Driver’s Cab 4
Main menu
(Z 51 321, Z 61 331, Z 200 667)
Pushing the “M” button (67) on the steering wheel (Z 51 321)

brings you from the “Indicator lights” (Z 61 331) basic display to
the main menu (Z 200 667).
Pushing the “M” button (67) again brings you back to the basic
display.
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4
0 25 50 75 100
FM
Service
Z 200 667
Z 61 331
Z 61 314
30/83 200−1−2040−313_en
Driver’s Cab 4
Menu selection 1 − 2 − 3
(Z 200 667, Z 61 331, Z 61 314)
The following menu points are available in the main menu:

Actuate Menu
key
1 “Indicator light”
Identical with the basic display after ”Ignition on”
Example of a possible display: (Z 61 331)
2 “Multimedia“ (Z 61 314)
Reversing camera (optional)
Key 1 for camera 1
Key 2 for camera 2
Key 3 for camera 3
3 “Service”
Call−up only with PIN (only for the customer service
team)
4 “Check information”
Display of information on suspension, engine,
brakes
5 “Service / diagnosis”
Display of information on operating hours, system
settings, software and setting the brightness of the
display
6 not allocated
The individual menus are described on the following pages.
200−1−2040−313_en 31/83
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!
1
Z 61 342
32/83 200−1−2040−313_en
Driver’s Cab 4
Menu selection 1
1 ”Indicator lights” menu

(Z 61 342)
In the top two lines status messages (A) are displayed, fault
messages (B) appear in the bottom line. If three dots “...” are
shown in the display, there are further status or fault messages.
Actuate Function
key
1 not allocated
2 not allocated
3 Detailed fault message
(see 1_3 menu “Detailed fault messages”)
4 not allocated
5 other progress messages
6 other fault messages
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4
!
1
ABS Fahrzeug HP
Z 61 348
34/83 200−1−2040−313_en
Driver’s Cab 4
Menu selection 1_3
1_3 Menu “Detailed fault message”

(Z 61 348)
The fault messages with fault code and text are displayed in this
menu.
Actuate Function
key
1 not allocated
2 not allocated
3 Acknowledgement / buzzer signal off
Only possible if the crane is at a standstill.
4 Scroll upwards
5 not allocated
6 Scroll downwards
DANGER!
Risk of injury to persons or damage to objects when

personnel who are not qualified try to rectify faults!
As soon as an error is displayed:
− Stop operation
− Identify the error immediately
− Eliminate the error

Faults must be rectified by qualified specialist personnel
(customer services, for example).
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4
0 25 50 75 100
FM
Customer service
Customer service
01830
000000
OK?
Z 200 673
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Driver’s Cab 4
Menu selection 3
Starting with: Main menu (Z 61 348)
4 “Service” menu
(Z 200 673)
In this menu, the following menu window can be unlocked using

a PIN code.
Caution!
If you need to alter settings in this menu, please contact our

customer service department.
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4
0 25 50 75 100
FM
0mbar
0mbar
Z 200 668
38/83 200−1−2040−313_en
Driver’s Cab 4
Menu selection 4
4 Menu “Control information“

(Z 200 668)
Actuate Function
key
1 Suspension level
2 Engine data
Engine oil pressure
Pressure at the soot particle filter
Engine oil level *
Coolant temperature
Torque
3 not allocated
4 Emergency pressure supply in brake circuit 1
and 2:
5 not allocated
6 not allocated
* This display of the engine oil quantity (%) only serves as

additional information. The oil level may only be monitored using
the oil measuring stick.
Depending on the design, this display function is not possible for
technical reasons. The corresponding display then always
indicates 0%.
200−1−2040−313_en 39/83
4
40/83
0 25 50 75 100
FM
ZR32
AC200−1
Betriebstunden v03.00
0000001752.15 h DMUX
AC200−1
v03.00
Option Steering flow
Check ABS
Z 200 679
200−1−2040−313_en
Driver’s Cab 4
Menu selection 5
5 Menu “Service / diagnosis“

(Z 200 679)
Actuate Function
key
1 Operating hours meter
(scroll up / down with key 4 and key 6)
2 System settings
(see 5_2 menu “System settings”)
3 not allocated
4 Software identification
(display of software status and crane type) *
5 Brightness:
(see 5_4 menu “Brightness”)
6 not allocated
200−1−2040−313_en 41/83
4
42/83
0 25 50 75 100
FM
Option Steering flow
Check ABS
Sprache deutsch ABS Check [km/h]

Kamera 1 Auto EIN aktiv
Geschwindigkeit vorne 0.00
Kamera 2 Auto AUS 1 2 3
Rad vorne links 0.0000
Kamera 3 Auto Nicht verfügbar Rad vorne rechts 0.0000
Rad hinten links 0.0000 Endcheck
Rad hinten rechts 0.0000
Z 200 670
200−1−2040−313_en
Driver’s Cab 4
Menu selection 5_2
5_2 Menu “System settings“

(Z 200 670)
Actuate Function
key
1 Optional
(see 5_2_1 menu ”Optional”)
2 not allocated
3 not allocated
4 Throughfeed sensors 1 − 3
(see 5_2_4 menu ”Throughfeed sensors”)
5 Screen for checking the ABS sensors
6 not allocated
200−1−2040−313_en 43/83
4
Sprache deutsch
Kamera 1 Auto EIN
Kamera 2 Auto AUS
Kamera 3 Auto Nicht verfügbar
Z 200 671
Z 61 346
44/83 200−1−2040−313_en
Driver’s Cab 4
Menu selection 5_2_1
5_2_1 Menu “Optional“

(Z 200 671)
Actuate Function
key
1 not allocated
2 Change option
3 not allocated
4 Scroll upwards
5 Change option
6 Scroll downwards
R back to the menu “System settings”, the settings
are not saved
M to the menu ”Assume options”
Selection language
Display video automatically when applying

the reverse gear
activate
deactivate
nicht verfügbar not available
5_2_1_M Menu “Assume options”

(Z 61 346)
Actuate Function
key
3 back to the menu “System settings”, the settings
are not saved
6 back to the menu ”Indicator lights”, the settings
are saved
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4
1 2 3
Endcheck
Z 200 672
46/83 200−1−2040−313_en
Driver’s Cab 4
Menu selection 5_2_4 (only for customer services)
5_2_4 Menu “Throughfeed sensors“

(Z 200 672)
if the indicator light is displayed, there is

throughfeed at the sensor of steering
1 pump 1
throughfeed at the sensor of steering
2 pump 2
throughfeed at the sensor of the emergency
3 steering circuit
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Z 61 330
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Driver’s Cab 4
Menu selection 5_4
5_4 Menu “Brightness“

(Z 61 330)
Change the display brightness:

Actuate Function
key
1 Display darker
2 not allocated
3 not allocated
4 Display brighter
5 not allocated
6 not allocated
R back to the menu ”Service / diagnosis”. The
settings are not saved.
M back to the menu ”Indicator light”. The settings
are saved.
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Z 61 330
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Driver’s Cab 4
4.3.2 I−CAN Failure

(Z 61 330)
The communication between the driver information system and

the main computer is interrupted.
DANGER!
RISK OF ACCIDENTS due to lack of communication

between the driver information computer and the main
computer.
Information is no longer shown in the driver information
system. Continued operation is not possible.
Stop immediately and rectify the fault.
4.3.3 Indicator lights in the driver information system

Symbols can be displayed as “Indicator lights” on the display
“Driver information” (43).
Explanations to the individual indicator lights can be found in part
5 “Indicator lights in the driver information system” of these
operating instructions.
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16
15
Z 48 995
52/83 200−1−2040−313_en
Driver’s Cab 4
(Z 48 995)
4.4 Ignition−starter switch (15)
Position ”1”: All users are separated from the battery,

except: tachograph, radio. Engine stop
after external starting procedure.
Removable key.
Position ”2”: Ignition standby for external starting
procedure.
Removable key.
Position ”3”: Driving position
The ignition is switched on. Blower can be
switched on.
Position ”4”: Starting position
The engine starts.
DANGER!
Danger of the vehicle being started by unauthorised

persons!
− Even if you are leaving the vehicle for a short time
remove the key to prevent unauthorised persons
starting the vehicle.
− When stowing / parking the vehicle, only remove the key

in position ”2”.
− Only remove the key when the vehicle is stationary.
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16
15
Z 48 995
54/83 200−1−2040−313_en
Driver’s Cab 4
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:
− Stop the vehicle and engage the parking brake.
− Hold the steering wheel and press the push button (16).
− Hold the push button (16) down and set the steering wheel.
− After the steering wheel has been set, release the push
button (16).
DANGER!
Risk of injuries from becoming trapped.

When push button (16) is pressed, the steering wheel can
rebound abruptly. This can cause a risk of injury between
the steering wheel and the seat due to clamping.
− Only set when the vehicle is standing still and the
parking brake is set.
− Always hold the steering wheel during the setting

procedure.
200−1−2040−313_en 55/83
4
1
3
2
4
3 1
4 6
5
5
2
Z 306 016
INT
II
Z 306 017
56/83 200−1−2040−313_en
Driver’s Cab 4
4.6 Combination Switch
4.6.1 Left−hand Side of the Steering Column

(Z 306 016, Z 306 017)
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” Switched off
“INT” Intermittent wiping
Basic setting of the wiping pause: 5 seconds.
“I” Slow
“II” Fast
8 Windscreen washing assembly

Press switch = switched on
Check the wiper blades regularly for dirt and damage.
200−1−2040−313_en 57/83
4
3
1
4
4
5
5
3
2
Z 306 015
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Driver’s Cab 4
4.6.2 Right−hand Side of the Steering Column
(Z 306 015)
Switch functions:
− Engine control
= idle speed, cruise control, limiter
− Sustained−action brake
= engine brake, retarder, retarder cruise control
1 Engine control:
Increase idle speed,
Accelerate vehicle,
Store speed.
Sustained−action brake:
Reduce braking effect (increase speed, store).
2 Engine control:
Reduce idle speed,
Decelerate vehicle,
Store speed.
Sustained−action brake:
Increase braking effect, (reduce speed, save)
Level 1 = engine brake
Level 2−5 = engine brake and retarder
3 Switch on Sustained−action 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 40 km/h (25 mph).
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4
Z 104 326 Z 104 327
Z 104 328
60/83 200−1−2040−313_en
Driver’s Cab 4
4.7 Driver’s Door / Passenger Door
4.7.1 Opening and Closing the Cab Door

(Z 104 326, Z 104 327, Z 104 328)
DANGER!
When closing the vehicle door, there is a risk of pinching
between the door and the door frame.
DANGER!
Risk of accidents and injury!
Only drive with correctly closed doors.
Lock / unlock the door from the outside using the vehicle 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).
Locking the cab door:
Turn the vehicle key clockwise.
Unlocking the cab door:
Turn the vehicle key anticlockwise
Locking the door from the inside using the button

The cab door can be locked / unlocked from the inside using
button (2).
Locking the cab door:
Press the button
Unlocking 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.
Opening the door from the inside with the lever

You can open the unlocked doors using opening levers (3) at any
time.
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4
A
A
24 B
B
25
11
Z 200 141 Z 200 142
62/83 200−1−2040−313_en
Driver’s Cab 4
4.7.2 Window Controls (Z 200 141, Z 200 142)

The vehicle is equipped with automatic electric windows.
DANGER!

Take extra care when closing the windows. In case you get
caught, the system does not have automatic reversal /
switch off for the closing motion; i.e. the window panel
pushes upward with full force until the “Open window”
command is given.
− Close the window only if you have a clear view of the
window and are sure that no−one can be caught in it.
− Only the vehicle driver may activate the electrical

window opener; inform the other passengers of the
danger.
− Remove the ignition key from the driver’s cab before

exiting the vehicle.
Allocation and arrangement of the controls:
The controls, dual button (11), (24) and (25) are located in the
door mouldings on the driver / passenger side.
Driver’s side: (Z 200 141)
Dual button (24) for window on passenger’s side.

Dual button (25) for window on driver’s side.
Passenger side: (Z 200 142)
Dual button (11) for window on passenger’s side.
200−1−2040−313_en 63/83
4
A
A
24 B
B
25
11
Z 200 141 Z 200 142
64/83 200−1−2040−313_en
Driver’s Cab 4
Controls for the automatic electric windows:
(Z 200 141, Z 200 141)
Turn the ignition key in the driving direction.
Close window:
Push the dual button forwards (A), hold
Open the window

Push the dual button backwards (B), hold
Open or close window partially:

Tap dual button
200−1−2040−313_en 65/83
4
6
6
5
7
Z 104 329
66/83 200−1−2040−313_en
Driver’s Cab 4
4.8 Entry / Exit for Crane Operator’s Cab

(Z 104 329)
For entry and exit, completely lower the driver’s seat (4) and fold
up the arm rest (5) (see section 4.9, page 69).
DANGER!
Risk of injury during entry and exit!

− Use the handles (6) and the step treads (7) on the driver’s
side and the passenger’s side.
− Do not jump out of the driver’s cab.
DANGER!
Risk of injury 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 when using the crane in a prohibited

manner!
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,
remove the key from the ignition and lock the door with the
vehicle key.
200−1−2040−313_en 67/83
4
14
13
8
15
16
17
1 2 3 4 5 6 7 10 11 12 9 Z 61 344
14
8
15
16
17
12 11 10 7 6 5 4 3 2 1 9
Z 61 345
68/83 200−1−2040−313_en
Driver’s Cab 4
(Z 61 344, Z 61 345)
4.9 Driver’s Seat / Passenger’s Seat
The air−sprung seat (shock−cushioning seat) with automatic

weight adjustment protects the driver / passenger against
mechanical vibrations. The vibration behaviour can be adjusted
to the conditions (road surface, axle load, suspension). The seat
is equipped with a safety belt (three−point belt). It can be set to
any position and can be locked at seat height.
Set the seat according to your own requirements.
Driver’s seat (Z 61 344), passenger’s seat (Z 61 345)
1 Set the seat horizontally

Entire seat back and forth.
2 Seat cushion back and forth
3 Lower seat (exit assistance)

Pull lever = lower all the way
Press lever = return to set 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 driver’s seat
Electric heating elements in the seat and back
components.
9 Lock horizontal suspension

Lever to the left = locked
Lever to the right = suspended
200−1−2040−313_en 69/83
4
14
13
8
15
16
17
1 2 3 4 5 6 7 10 11 12 9 Z 61 344
14
8
15
16
17
12 11 10 7 6 5 4 3 2 1 9
Z 61 345
70/83 200−1−2040−313_en
Driver’s Cab 4
10 Lumbar support, lower

Filling / emptying air cushion (switch + / −)
11 Lumbar support, upper

12 Lumbar support, lateral

13 Setting armrests
Control knob for adjusting the angle of the armrests
14 Neckrest (see section 4.9.2, page 77)
15 Safety belt’s buckle tongue (see section 4.9.3, page 77)
16 Buckle (see section 4.9.3, page 77)
17 Red button in the buckle (see section 4.9.3, page 77)
DANGER!
RISK OF ACCIDENTS when adjusting the seat during

driving!
Setting the seat while driving can distract the driver from
the traffic situation.
Set the driver’s seat only when the vehicle is at a standstill
and the retaining brake is applied. The seat fixing device
has to latch audibly into place.
DANGER!
RISK OF ACCIDENTS when exiting!

The seat could rebound when exiting the cab and could
clamp your legs between the steering wheel and the seat.
Lower the seat fully before exiting (press key 3 exit aid).
Turn the arm rest upward and remove the ignition key.
DANGER!
RISK OF ACCIDENTS due to incorrect seat settings!

When setting the seat, make sure you assume a relaxed,
effortless posture and that the safety belt has been fitted
correctly.
200−1−2040−313_en 71/83
4
”A”
1 ”B”
2 3
”C”
Z 104 102
72/83 200−1−2040−313_en
Driver’s Cab 4
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)
− Completely lower the seat (1, Z 104 102 ”A”).
− Slide the seat completely to the front (2, Z 104 102 ”A”).
− Slide the neckrest in entirely (3, Z 104 102 ”B”).
− Adjust the armrest as far back as possible (4, Z 104 102 ”B”).
− 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”).
DANGER!
Risk of crushing when folding the seat forward!

Body parts could get stuck between the pivoted cover (y)
− to which the seat is fastened − and the lock (z) on the cab
wall.
DANGER!
Risk of injury when folding back the seat!

Body parts could get stuck.
Check that the passenger seat is held safely in place.
If this is not the case, secure the folded seat against falling
back.
200−1−2040−313_en 73/83
4
Z 104 100
74/83 200−1−2040−313_en
Driver’s Cab 4
Opening the cover of the electronic compartment:

(Z 104 100)
− Loosen the screws.
− Open the cover (1) and secure against falling back (for
example, tie it up using a tie (2)).
Closing the cover on the electronic compartment:
− Ensure that the material under the cover is in the correct

place and does not obstruct the closing procedure.
− Close the cover and screw in place.
Folding the passenger seat back:
− Ensure that the material under the seat is in the correct place
and does not obstruct the seat when locking in place.
− 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.
DANGER!
Risk of injury when folding the seat forward!

If the passenger seat is not locked in place correctly, the
seat could fold to the front during braking.
Check that the passenger seat has locked into place safely.
− Adjust the seat to the desired position.
200−1−2040−313_en 75/83
4
14
13
8
15
16
17
1 2 3 4 5 6 7 10 11 12 9 Z 61 344
14
8
15
16
17
12 11 10 7 6 5 4 3 2 1 9
Z 61 345
76/83 200−1−2040−313_en
Driver’s Cab 4
4.9.2 Headrest
The headrest (14) can be adjusted for height and angle

independent of the backrest.
DANGER!
Risk of injury due to incorrectly set headrest!

Adjust the head rest such that the rear of the head is
supported at around eye level.
4.9.3 Safety belt
The safety belt system incl. the seat belt anchorage points is an
essential part of the driver’s seat. No subsequent modifications
are allowed. If modifications are made, the operating licence will
expire.
The use of safety belts is a regulation in many countries.
DANGER!
Increased risk of injury when the safety belt is not worn!

For your own safety, always fasten your safety belt and
ensure that the passenger has fastened it as well.
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 into the belt buckle (16) and let it lock in
place audibly.
The belt must always be taut. Check for tightness regularly.
If need be, tension the lap belt by pulling the shoulder belt
upwards.
Releasing the safety belt:

Press red button (17) in the belt buckle.
Bring the latch plate back to the initial position.
200−1−2040−313_en 77/83
4
78/83 200−1−2040−313_en
Driver’s Cab 4
Automatic safety belt winder − operation

The automatic safety belt winder for the safety belt locks the belt
pull−out during vehicle deceleration in all directions and when
pulling down on the belt quickly.
Functional test
The locking function of the automatic can be checked by pulling
the belt quickly.
DANGER!
Deadly peril due to improper use of the safety belts!

− For your own safety, always fasten your safety belt and
ensure that the passenger has fastened it as well.
− However, use one safety belt for only one person.
− Three−point seat belts are not for people shorter than

150 cm (4.9 ft). Anyone shorter than 150 cm requires
special equipment for protection in the case of an
accident (because safety belts cannot be fastened
correctly).
− Avoid seat positions that interfere with the correct

action 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 were damaged during and accident

must be replaced. Get the belt anchor checked in a
specialist workshop.
− Replace damaged safety belts.
− Belts may not run across sharp edges.
− No changes may be made to the safety belts.
200−1−2040−313_en 79/83
4
2
1
a
1 3
Z 104 320 Z 104 321
c
3
5
b 1 4
3
1
Z 104 322 Z 104 323
80/83 200−1−2040−313_en
Driver’s Cab 4
4.10 Hinged Bed (Optional)
(Z 104 320, Z 104 321, Z 104 322, Z 104 323)
If the crane is equipped with a hinged bed (1) in the driver’s cab,
observe the following points:
DANGER!
Risk of injury due to releasing the hinged bed!

During driving, the hinged bed (1) must be folded up and
secured with a rubber strap (2).
DANGER!
Risk of crushing when folding the hinged bed down!

The hinged bed (1) may only be folded down from the
passenger side, as there is not enough space on the
driver’s side.
The weight of the hinged bed is approx. 21 kg (46 lbs).
200−1−2040−313_en 81/83
4
2
1
a
1 3
Z 104 320 Z 104 321
c
3
5
b 1 4
3
1
Z 104 322 Z 104 323
82/83 200−1−2040−313_en
Driver’s Cab 4
4.10.1 Folding the Hinged Bed down

(Z 104 320, Z 104 321, Z 104 322, Z 104 323)
DANGER!
Risk of crushing when folding the hinged bed down!

When folding the hinged bed down there is a risk of
crushing between the dashboard and bed frame.
− Hold the hinged bed (1) and release the rubber strap (2).
Caution!
Fold the hinged bed down carefully so that the dashboard is

not damaged.
− Carefully fold the hinged bed down (direction of arrow “a”)

until it is resting on the dashboard.
− Raise the hinged bed slightly and hang from the ceiling of the
operator’s cab using the middle chain (3).
− Unfold the hinged part on the passenger side in the direction
of the “b” arrow and using chain (4), hang from ceiling of the
crane operator’s cab.
− Unfold the hinged part on the passenger side on the driver’s
side in the direction of the “c” arrow and using chain (5), hang
from ceiling of the crane operator’s cab.
Note:
Carry out the same procedure in reverse sequence when folding

the hinged bed.
200−1−2040−313_en 83/83
Engine 5
5 Engine
Damage−prevention measures
The following safety measures must be observed to prevent

injury to persons and damage to the engine, components or
cables.
− Only start the engine when the batteries are properly
connected. Do not disconnect the batteries when the engine
is running.
− Only start the engine when the speed sensor is connected.
− Never use a boost charger to start the engine. Jump starting
only with separate batteries.
− For rapid charging of the batteries, the battery terminals must
be disconnected. Follow the operating instructions for the
boost charger.
− The batteries must be disconnected when electric welding
work is carried out, and the ”+” and ”−” cables are connected
to one another.
− The lines of the control units may only be disconnected and
connected when the electrical system is switched off.
− Switching the poles of the supply voltage for the control units
(e.g. by connecting the poles of the batteries incorrectly) can
lead to the destruction of the control units.
− Tighten the plug connections on the injection system to the
prescribed torque.
− For temperatures of higher than + 80° C (176 °F) (foundry
furnace) the control units must be removed.
− Use only suitable test cables for taking measurements on
plug connections (Mercedes−Benz connector set).
− Telephones and radio equipment which are not connected to
an external antenna can cause malfunctions to the vehicle
electronics and endanger the operating safety of the engine.
Before commissioning, make sure that you have read the

operating instructions of the engine manufacturer. They are
in part 5 of these papers.
The following points are primarily limited to information
which specifically affects the crane.
200−1−2050−120a_en 1/35
5
max
min
Z 51 911 Z 51 329
12
13
Z 51 929 Z 51 346
2/35 200−1−2050−120a_en
Engine 5
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 −255C (−135F).
− 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); must not be actuated.
See also section 6.1 ”Checks Before Driving”.
200−1−2050−120a_en 3/35
5
2B
1B
2A
1A
4
3
Z 200 336
4/35 200−1−2050−120a_en
Engine 5
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 foreign starting aid cables are
used to jump the batteries.
Depending on the crane version, two cable couplings (with one

plug and one socket each) are optionally located on the
right−hand side of the chassis.
On the 5−axle basic unit, the cable couplings are located in the
right−hand storage box underneath the outrigger controls
(Z 200 336).
On the 6−axle basic unit (not shown here), the cable couplings
are located behind a panel above the outrigger controls.
On the superstructure, similar connections are optionally located
on the front of the engine cowling. At the same time, “Minus”
(ground) is always installed on the plugs (1A / 1B) and “Plus” is
always installed on the sockets (2A / 2B).
Here, both supplied starting aid special cables (3, 4) (cable cross
section 95 mm2/ 0.15 in2) can be connected; the different shapes
of the connecting pieces ensures that the poles cannot be
confused.
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
batteries.
− Do not smoke in the vicinity of the batteries;
Avoid sparks or unshielded flames.
− A discharged battery can freeze at −105C (145F).
It must be thawed before using the starting aid.
200−1−2050−120a_en 5/35
5
2B
1B
2A
1A
4
3
Z 200 336
6/35 200−1−2050−120a_en
Engine 5
− 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 commu-
nication 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).
Action steps for the starting aid with cable couplings / 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 minus pole (cable 3) and then the plus pole
(cable 4).
Electrical components could be damaged if the connecting

sequence is reversed.
3. Start the current−supply engine; let the engine run at high

speed.
4. Current−consumption engine:
Turn the key in the ignition−starter switch to starting position.
Start the engine and let it run at idle speed.
5. Remove the cable, first from the “plus” (cable 4) and then
from the “minus” (cable 3).
200−1−2050−120a_en 7/35
5
75
15
Z 51 304 Z 51 325
31 32 33 34 35 36 37 38 39 40
43
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 51 334
8/35 200−1−2050−120a_en
Engine 5
(Z 51 304, Z 51 325, Z 51 334)
5.3 Ignition−starter switch (see Sect. 4 “Driver’s cab”)
5.4 Starting procedure (engine start)
Never start the engine without the batteries connected

properly.
The engine can either be started in the driver’s cab or on the

outrigger controls (external start).
5.4.1 Start the engine in the driver’s cab
1. Insert the key in the latch contact (15) and turn (to the right)
into the driving position (position “3”).
The electrical system performs a self−test when the ignition is

switched on; the most important signal connections are checked.
At the same time, a control signal sounds twice and all indicator
lights (31−40 and 50.1) flash.
The function control is ended after the control signals go out.
Some indicator lights that have been activated may light up; e.g.
item 39 “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 more information, see Sect. 4 in “Driver information system”.
2. Engine start
When the control signal has stopped: 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 does not start up after the third attempt: Look
for the cause of the fault with the help of the operating
instructions.
200−1−2050−120a_en 9/35
5
15
Z 51 304
Z 47 962
3°
1,5°
0°
0°
1,5°
3°
Z 60 982
10/35 200−1−2050−120a_en
Engine 5
5.4.2 Start the engine on 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, ”ramp up” data bus).
3. Press and hold the “caution” key (10 / 20) and also press key
“engine start“ (7B / 17B).
4. After the engine has started release both buttons.
When the outriggers are operated, an engine speed of 1200 rpm

is automatically set.
When the engine is started on the outrigger controls the

warning displays are not in the operator’s line of view. It is
therefore important to listen for acoustic warning signals
(buzzer).
200−1−2050−120a_en 11/35
5
B11 B15
B12 B16
B13 B18
B14
Z 51 328
31 32 33 34 35 36 37 38 39 40
43
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 51 324
12/35 200−1−2050−120a_en
Engine 5
5.5 After Starting the Engine
(Z 51 328, Z 51 324)
Never disconnect the battery terminals when the engine is

running.
Keep your eye on the engine oil pressure!

If the engine oil pressure is too low, the indicator light B12
appears on the driver information display. At the same time,
the indicator light (35) “STOP” lights up on the instrument
panel and an acoustic warning signal (buzzer) sounds.
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 pre-
scribed operating temperature has been reached.
If indicator light (B18) lights up, service the air filter.
Switch the engine off immediately in the case of:

− falling or heavily fluctuating oil pressure
− falling output / revs in spite of constant operating
conditions
− heavily smoking exhaust
− excessively high coolant and oil temperature
− sudden abnormal engine noises.
200−1−2050−120a_en 13/35
5
15
Z 51 304
Z 47 962
3°
1,5°
0°
0°
1,5°
3°
Z 60 982
14/35 200−1−2050−120a_en
Engine 5
5.6 Before Switching Off the Engine
Leave the engine running at idle speed for approx. 1−2 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 driver’s 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 Driver’s Cab
In the driver’s 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 driver’s cab:
Turn the ignition−starter switch (15) from driving position
(position “3”) to position “2”.
− If the engine is started at the outrigger controls:
Turn the ignition−starter 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
ignition−starter switch (15) in the driver’s 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”.
200−1−2050−120a_en 15/35
5
A20
Z 47 991 Z 51 326
Z 47 992
16/35 200−1−2050−120a_en
Engine 5
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 right−hand 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 rapid cutout 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 Shut−off 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, when a certain speed is
exceeded approx. 2700 min−1 (rpm) the quick stop device is
automatically activated. 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 shutoff flap is closed the engine cannot be started.
Repeated starting attempts result in engine damage.
Before restarting, all air−carrying hoses − incl. the charge air
hoses between the engine and charge air cooler − must be
checked to ensure that they are fitted correctly and are
completely free of blockages.
200−1−2050−120a_en 17/35
5
1
1
2
5 4 3
3 5
2
Z 46 643
18/35 200−1−2050−120a_en
Engine 5
5.9 Electronic Engine Management
The chassis engine is equipped with an electronic control

system. This monitors both the engine and itself (self−diagnosis).
The control and monitoring equipment is in the cab on the
chassis.
5.9.1 Engine Control
(Z 46 643)
1 Increase idle speed,

Accelerate vehicle,
Store speed.
2 Reduce idle speed,

Slow down vehicle,
Store speed.
3 (Sustained−action 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 min−1 (rpm) to max. 750 min−1 (rpm).
The engine speed (with parking brake on) can also be adjusted
to any value − from neutral gear to a fixed parameter maximum
working speed of 1200 min−1 (rpm); e.g. for emergency operation
of the superstructure functions.
When the outriggers are operated, 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 (120 min −1) (rpm) −
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 re−set.
200−1−2050−120a_en 19/35
5
1
1
2
4 4
Z 47 993
20/35 200−1−2050−120a_en
Engine 5
5.9.2 Idle Speed

(Z 47 993)
1 Hold = Increase idle speed.
Tap = Increase idle speed by approx.
20 min−1 (rpm).
2 Hold = Reduce idle speed.
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.
200−1−2050−120a_en 21/35
5
1
1
2
4 4
Z 47 993
22/35 200−1−2050−120a_en
Engine 5
5.9.3 Tempomat
(Z 47 993)
Using the cruise control, the vehicle drives at a stored speed

(without actuating the accelerator pedal).
Any speed above 40 km/h (25 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 40 km/h
(25 mph))
− Lever in position
1 Hold = Accelerate. Release lever, the speed
that has been reached is stored.
Tap = Store current speed or increase stored
speed by increments of 0,5 km/h
(0.3 mph)
2 Hold = Slow down. Release lever, the speed
that has been reached is stored.
Tap = Store current speed or reduce stored
speed by increments of 0,5 km/h
(0.3 mph).
Resume stored desired speed.
After releasing the lever the engine runs at the speed that has
been reached.
200−1−2050−120a_en 23/35
5
1
1
2
4 4
Z 47 993
24/35 200−1−2050−120a_en
Engine 5
(Z 47 993)
Switch off the cruise control:

Tap the lever in position 4.
The cruise control is automatically switched off:
− when the brake is activated.
(The set speed remains stored.)
− for speeds under 40 km/h (25 mph).
− when the cruise control is switched on.
By briefly tapping on the lever (position 2) the vehicle drives again

at the stored speed.
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.
200−1−2050−120a_en 25/35
5
1
1
2
5 4 3
3 5
2
Z 46 643
26/35 200−1−2050−120a_en
Engine 5
5.9.4 Limiter (for Limiting the Maximum Speed)
(Z 46 643)
Using the limiter the driving speed can be limited at any level
above 40 km/h (25 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 highest speed that can be set is automatically deleted, when

the ignition−starter switch (15) is turned back to position “2” or
when the cruise control is switched on.
To exceed the set maximum speed:
If the set maximum speed is to be exceeded (e.g. when

overtaking):
Press the accelerator pedal briefly as far as possible, past the full
throttle position (kick−down). After the vehicle has accelerated
release the accelerator pedal and press again. The set speed
limit is reactivated.
Increase the set maximum speed:
If the set maximum speed is to be increased:

Press button (5), hold and accelerate the vehicle. Once the
desired speed has been reached, release the button.
To reduce the set maximum speed:
If the set maximum speed is to be reduced:

Release the accelerator pedal (if necessary, brake the vehicle).
Once the desired speed has been reached, press button (5).
200−1−2050−120a_en 27/35
5
B11 B15
B12 B16
B13 B18
B14
Z 51 328
31 32 33 34 35 36 37 38 39 40
43
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 51 324
28/35 200−1−2050−120a_en
Engine 5
(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
directly shown 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) can also be heard.
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) Light−emitting diode, red

If it lights up: The engine speed is exceeding
2350 min−1 (rpm) (excessive engine speed).
Be sure that the engine does not exceed the permissible

speed range.
At an engine speed of 2300 min −1 (rpm), the exhaust brake is

deactivated to protect the engine mechanics 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.
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5
B11 B15
B12 B16
B13 B18
B14
Z 51 328
30/35 200−1−2050−120a_en
Engine 5
(Z 51 328)
− Coolant level

The “Coolant level” (B11) warning is displayed when the
coolant level in the expansion tank has sunk to about
2 l (0.5 gal) under the normal level. 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 “Coolant temperature” warning (B13) is displayed
when a coolant temperature of 104 °C (219 °F) is
reached in driving mode. At the same time the alarm
buzzer sounds at 110 °C (230 °F) and the engine
output is automatically reduced.
The engine can still be operated; however, determine
the cause.
− 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. The oil

level may only be monitored using the oil measuring stick.
Depending on the design, this display function is not
possible for technical reasons.
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5
B11 B15
B12 B16
B13 B18
B14
Z 51 328 Z 51 335
32/35 200−1−2050−120a_en
Engine 5
(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.
Do not let the engine run 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”
(Mercedes−Benz) diagnosis device. This is usually done by our
customer service team or in a garage of the engine manufacturer.
Action steps for error diagnosis:

− Switch off the engine.
− Connect the diagnosis device to the diagnosis socket
(14−pin; in the control box “X 300” in the driver’s cab).
(Z 51 335)
− 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).
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5
34/35 200−1−2050−120a_en
Engine 5
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

engine are different (emergency running programme).
200−1−2050−120a_en 35/35
Driving the Crane 6
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 driver’s cab of the crane chassis.
The pedals’ freedom of movement may not be restricted. Be

sure that there is enough room for the pedals when using
foot mats and carpet. Do not store any objects in the driver’s
foot area. Store or secure all loose objects (e.g. tins, bottles,
tools, bags, etc.) in such a way that they can’t 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 the axle loads; observe the instructions (see under
“axle loads / speeds / tyres” and “defined driving conditions”)
− Check the transport position of supports and outrigger plates
(see section 12)
− Check the engine oil level, add extra oil if required.
− Check the hydraulic oil level.
In case of fault: find out cause − only then top up.
Wait until the hydraulic oil has warmed up before running the
engine at speeds of over n = 1600 min −1 (rpm).
− Check the oil level in the transmission, add extra oil if

required.
− Check the coolant level.
In case of fault: find out cause − only then top up.
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6
B8
B9
B10
Z 51 300
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Driving the Crane 6
− 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 through−feed

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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6
Z 200 153
1 B3
2 B4
Z 51 301
31 32 33 34 35 36 37 38 39 40
Z 51 331
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Driving the Crane 6
− Check the brake system.

(Z 200 153, Z 51 301, Z 51 331)
− Emergency pressure supply in brake circuit 1 and 2:
− Driver’s information display, submenu 4.4:
Pressure is displayed.
Upper row = braking circuit 1
Lower row = braking circuit 2
− Driver’s information display, basic display:
Red indicator light, when the pressure is under 5.5 bar
(80 psi).
Indicator light (B3) = braking circuit 1
Indicator light (B4) = braking circuit 2
− Parking brake control light (39), if handbrake applied.
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) bar is reached.
Air pressure of min. 6.2 bar (90 psi) is needed to switch gears. It
is not possible to switch gears below this mark.
Immediately after starting to drive, test the brakes on a dry,

anti−skid 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
service brake until the brakes are again fully functional.
− Check steering wheel / driver seat setting
An exact description of the steering wheel / driver seat setting can

be found in Sect. 4 “Driver’s cab”.
− Vehicle lighting; check blinkers and brake lights
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6
B1
51
B19
Z 200 216 Z 200 151
99 100 101 102
A11 A12 A13 A14
Z 51 332
6/153 200−1−2060−297a_en
Driving the Crane 6
(Z 200 216, Z 200 151, Z 51 332)
− Check the suspension system.

If a suspension circuit is outside the road travel level, the
indicator light (B1) on the driver’s information display lights
up. The exact level of individual suspension circuits can be
observed 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 4−way
system and it must not be locked. (Switch 99. 100 in the “off”
position, no displays A11, A12).
− Check the fuel level, add fuel if required.

The fuel supply is displayed on the instrument panel with
instrument (51). If the fuel supply is in the reserve area, the
indicator light (B19) lights up.
Do not fill up with fuel while the engine is running!
Other important specifications are outlined in the individual

sections.
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 (see section 6.4.4). The
air pressure has a large influence on:
− The handling of the vehicle
− The running characteristics of the tyres
Tyre damage is inevitable if the tyre pressure is too low.
It is therefore essential to apply the correct air pressure.
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6
Z 36 570
Z 35 568 Z 36 571
8/153 200−1−2060−297a_en
Driving the Crane 6
6.3 Transport Safety Locks
During transportation, the safety locks provided must be applied.
Following driving and before the superstructure is placed in

operation, 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 Sect. 4 of the operating instructions for the super-
structure)
− The platform on the superstructure cab must be pushed into
its transport position (switch actuation; (see Sect. 4 of the
operating 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
devices provided (optional equipment) and must be secured
accordingly. ( Example Z 35 568)
The rope must be guided over the corresponding rope
configurations on the chassis cab and chassis frame.
− Outrigger struts pinned / locked in the transport position.
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Driving the Crane 6
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
regulations.
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
correspondingly larger.
Observe the relevant instructions in the following
sub−chapters.
Before driving in public traffic the driver must be fully

conversant 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
12/153 200−1−2060−297a_en
Driving the Crane 6
6.4.1 Calculating Axle Loads
Any addition or removal of components affects the vehicle /

displaces the axle loads.
Additional components can, depending on the centre of gravity
on the crane, cause an increase or decrease of weight on the
affected axles.
In section 6.4.2 information is given on how to calculate axle

loads in kg.
In section 6.4.3 information is given on calculating axle loads in
lbs.
6.4.2 Calculating Axle Loads in kg
6.4.2.1 Arithmetical Basic Condition (kg)
The basic condition serves as the basis for all axle load
calculations. The crane then weighs 54710 kg (120614 lbs) and
is equipped with the following:
Crane with:
− Superstructure, main boom
− Locking / pinning unit in transport position (at the front in the
main boom)
− Hoist 1
− Tyres 445/95 R 25 (16.00 R 25)
− Central lubricating system, air conditioning equipment,
auxiliary heating, wodden box
Crane without:
− Outriggers, front
− Outriggers, rear
− Counterweights
− Main boom extension
− Spare wheel
− Hook block
− Hoist 2
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6
14/153 200−1−2060−297a_en
Driving the Crane 6
6.4.2.2 Weight Table (component weights in kg)

Starting from the basic condition listed on the previous page −
using the weights listed − the current axle loads can be calculated
for the different combinations.
Where there is a “minus” sign, there is actually a reduction in the
axle load by the specified amount.
Description of the Dead Change in axle load in kg on axle
components weight
(kg) 1 2 3 4 5
Arithmetical basic condition 54710 11130 11078 10920 10815 10767
Outriggers front, complete 2102 1063 1022 6 6 6
Outriggers rear, complete 2318 −888 −854 1313 1366 1381
Trailer coupling D 120 31 −13 −13 19 19 19
Toolbox rear 127 −57 −55 77 80 81
Spare wheel 445/95 R 25 331 −162 −155 210 218 220
(16.00 R 25) / holder (rear)
Hook block holder, empty 87 58 56 −9 −9 −9
Additional tank / extra tank 300 l 294 93 89 36 38 38
Hoist 2 1637 −757 −727 1009 1050 1062
Hook block (1−sheave) in holder 615 410 394 −61 −64 −64
Hook suspension gear on bumper 350 330 318 −96 −100 −101
Hook block (1−sheave) on bumper 615 581 558 −169 −176 −178
Main boom extension 9 m (folded into 1080 652 627 −64 −67 −68
the transport position)
Main boom extension 17 m (folded 1760 954 917 −36 −37 −38
into the transport position)
Counterweight element A (5.7 t) set 5723 2310 2220 386 401 406
down on counterweight platform, front
Counterweight element B (7.3 t) set 7320 2954 2840 494 513 519
down on counterweight support at
front
Counterweight section F (3.2 t) fitted 3221 −1292 −1242 1861 1936 1958
on the superstructure frame
Minimum weight main boom removed, −20184 −4865 −4676 −3442 −3581 −3621
superstructure turned to the rear
Minimum weight superstructure −31539 −5951 −5720 −6425 −6684 −6758
removed (incl. main boom)
Minimum weight tyres 445/80 R 25 −305 −61 −61 −61 −61 −61
(17.50 R 25) to 445/95 R 25
(16.00 R 25)
(14.00 R 25) to 445/95 R 25
(16.00 R 25)
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Driving the Crane 6
6.4.2.3 Example of an Axle Load Calculation (kg)
The following calculation example shows how the current axle

load can be calculated with the help of the weight table.
The weights of the following components are added to the basic
condition:
− Outriggers, front and rear
− Hook block holder, at the chassis (empty)
− 3−sheave hook block type 80 (850 kg) on the bumper
− Main boom extension 17 m (folded into the transport position)
Description of the Dead Change in axle load in kg on axle

components weight
(kg) 1 2 3 4 5
Main boom extension 17 m (folded 1760 954 917 −36 −37 −38
into the transport position)
Total 61740 13061 12934 11969 11906 11870
Correspondingly the current weight of the crane, rounded up, is
61.8 t. The individual axle loads are then (rounded off):
∗ Axle 1: 13.1 t ∗ Axle 4: 12 t

∗ Axle 2: 13 t ∗ Axle 5: 11.9 t
∗ Axle 3: 12 t
RISK OF ACCIDENTS due to overloading of tyres!

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
always the axle that is placed 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

distances!
Axle loads exceeding 12 t (26.4 kip) result in a
significantly longer braking distance and the risk of
fading.
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6
18/153 200−1−2060−297a_en
Driving the Crane 6
For driving on public roads, the permitted axle loads and the
corresponding speed limits must be observed.
Risk of accidents!
For axle loads less than 12 t (26.4 kip), section 6.4.6 (page
41) ”Driving with reduced axle loads” must be observed.
6.4.3 Calculating Axle Loads in lbs
6.4.3.1 Arithmetical basic condition (lbs)
The basic condition serves as the basis for all axle load
calculations. The crane then weighs 54710 kg (120614 lbs) and
is equipped with the following:
Crane with:
− Superstructure, main boom
− Locking / pinning unit in transport position (at the front in the
main boom)
− Hoist 1
− Tyres 445/95 R 25 (16.00 R 25)
− Central lubricating system, air conditioning equipment,
auxiliary heating, wodden box
Crane without:
− Outriggers, front
− Outriggers, rear
− Counterweights
− Spare wheel
− Hook block
− Hoist 2
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6
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Driving the Crane 6
6.4.3.2 Weight Table (component weights in lbs)
Starting from the basic condition listed on the previous page −

using the weights listed − the current axle loads can be calculated
for the different combinations.
Where there is a “minus” sign, there is actually a reduction in the
axle load by the specified amount.
Description of the Dead Change in axle load lbs on axle

components weight
(lbs) 1 2 3 4 5
Trailer coupling D 120 68 −29 −29 42 42 42
Toolbox rear 280 −126 −121 170 176 179
Spare wheel 445/95 R 25 730 −357 −342 463 481 485
(16.00 R 25) / holder (rear)
Hook block holder, empty 192 128 123 −20 −20 −20
Additional tank / extra tank 300 l l 648 205 196 79 84 84
(79.3 gal)
Hoist 2 3609 −1669 −1603 2224 2315 2341
Hook block (1−sheave) in holder 1356 904 869 −134 −141 −141
Hook suspension gear on bumper 772 728 701 −212 −220 −223
Main boom extension 9 m (29.5 ft) 2381 1437 1382 −141 −148 −150
(folded into transport position)
Counterweight element A (5.7 t) 12617 5092 4894 851 885 895
(12.6 kip) set down on counterweight
platform, front
Counterweight element B (7.3 t) 16138 6513 6260 1088 1132 1145
(16.1 kip) set down on counterweight
platform, front
Counterweight section F (3.2 t) 7099 −2848 −2738 4103 4268 4314
(7.1 kip) attached to the
superstructure
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6
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Driving the Crane 6

components weight
(lbs) 1 2 3 4 5
Minimum weight main boom −44498 −10725 −10309 −7588 −7895 −7983
removed, superstructure turned to
the rear
Minimum weight superstructure −69531 −13120 −12610 −14165 −14736 −14899
removed (incl. main boom)
(17.50 R 25) to 445/95 R 25
(16.00 R 25)
(14.00 R 25) to 445/95 R 25
(16.00 R 25)
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Driving the Crane 6
6.4.3.3 Example of an Axle Load Calculation (lbs)
The following calculation example shows how the current axle

load can be calculated with the help of the weight table.
The weights of the following components are added to the basic
condition:
− Outriggers, front and rear
− Hook block holder, at the chassis (empty)
− 3−sheave hook block type 80 (850 kg; 1874 lbs) on the
bumper
− Main boom extension 17 m (55.8 ft) (folded into transport
position)
components weight
(lbs) 1 2 3 4 5
Total 136112 28794 28514 26387 26248 26182
Correspondingly the current weight of the crane, rounded up, is
61.8 t (136.2 kip). The individual axle loads are then (rounded
off):
∗ Axle 1: 13.1 t (28.8 kip) ∗ Axle 4: 12 t (26.4 kip)

∗ Axle 2: 13 t (28.6 kip) ∗ Axle 5: 11.9 t (26.2 kip)
∗ Axle 3: 12 t (26.4 kip)

current axle load (see section 6 under ”Possible axle loads
/ permitted speeds”). The determining factor is always the
axle that is placed under the highest load. Failure to
observe these instructions can result in the tyres being
overloaded and bursting.

distances!
Axle loads exceeding 12 t (26.4 kip) result in a significantly
longer braking distance and the risk of fading.
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Driving the Crane 6
For driving on public roads, the permitted axle loads and the
corresponding speed limits must be observed.
Risk of accidents!
For axle loads less than 12 t (26.4 kip), section 6.4.6 (page
41) ”Driving with reduced axle loads” must be observed.
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Driving the Crane 6
6.4.4 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.

The maximum permitted speed and driving distance
mustbe observed for the current axle load.
Failure to observe these instructions can result in the
tyres being overloaded and bursting.
6.4.4.1 Tyre, Manufactured by Michelin (XGC)
Michelin Tyres
Tyre size 445/80 R 25 525/80 R 25
(17.50 R 25) (20.50 R 25)
Ply 170E 179E
Tyre pressure 7.0 bar 7.0 bar
(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
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6.4.4.2 Tyre, 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
(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
(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
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6.4.4.3 Tyres, Manufactured by Bridgestone
Bridgestone Tyres
On Road Off Road
Tyre size 385/95 R 25 445/95 R 25 385/95 R 25 445/95 R 25
(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
(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
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Bridgestone Tyres
Tyre size 445/80 R 25 525/80 R 25
(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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6.4.4.4 Tyres, Manufactured by Magna
Magna Tyres
On Road Off Road
Tyre size 445/95 R 25 445/95 R 25
(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
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6.4.5 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

deviation from the approved crane configuration. The
vehicle handling will deteriorate to a greater or lesser
degree, depending on the amount of deviation!
The larger the differences, the more serious the
deterioration. Drive with appropriate caution and reduce the
driving speed; possibly walking speed should be followed.
React to poor road conditions by further reducing the driving
speed.
Axle load ratios, heaviest axle : lightest axle > 2 : 1 are not
allowed, as these are too difficult too drive with.
Any driving conditions that deviate from these must be listed
under “declared driving conditions” or require express
permission 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 pressing of the
brake pedal would lead to various wheels locking; the
vehicle could swerve as a result.
Caution when steering!

When driving through curves, the vehicle tends towards
the straight−ahead steering position.
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6.4.6 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 standard−equipped 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
suspension 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 accumulators
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 driver’s cab.
Additional information on this topic can be found then in Section
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
suspension system is not reduced, then the maximum
driving 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 preload pressure of the accumulators of the
suspension system is reduced (manually or with
switchover), then the maximum driving speed must be
reduced to 50 km/h (31 mph).
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6.4.7 Driving with Axle Loads over 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 chassis parts / components are designed and approved ex

works for axle loads of 12 t (26.4 kip) (approved condition, see
under ”Driving with total weight of 72 t (158.7 kip)” or ”Driving with
total weight of 84 t (185.1 kip)”.
Axle loads of 12.5 t (27.5 kip) mean that the approved crane
condition has already been exceeded.
Axle loads over 12 t (26.4 kip) mean:

− Higher loads.
− Overloading of the 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,
suspension system, suspension cylinders, brakes, wheels and
tyres.
This means a considerable reduction in service life and life
expectancy for the parts in question.
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

cutting damage must be avoided under these more exacting
operating 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
eventually lead to more major damage following a relatively minor
incident.
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RISK OF ACCIDENTS in case of tyre damage!

Tyre damage must be rectified by professionals.

loads / permitted speeds”). Failure to observe these
instructions 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).

distances!
At axle loads above 12 t (26.4 kip) the braking deceleration
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 over-
heating (fading).
6.4.7.1 Driving with Axle Loads of up to 12.5 t (27.5 kip)

loads / permitted speeds”). Failure to observe these
instructions can result in the tyres being overloaded and
bursting.
Possible driving speeds are only permitted within the framework

of the existing tyre limit values; i.e. the possible highest speed
must not be fully exploited, if the tyre is not approved for this
speed (at certain axle loads).
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6.4.7.2 Driving with Axle Loads of up to 16.5 t (36.4 kip)
This technically possible driving condition does not meet the

regulations 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 load−bearing
capacity and must be sufficiently level (e.g. no potholes).
If the crane is driven with axle loads above 12.5 t (27.5 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
condition or recalculate based on the current configuration
using the weight table.
The determining factor is always the axle that is placed under
the highest load.
− With the “lift axle” raised, the crane may not be driven, as
raising a “lift axle” represents an additional 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
circuits must be observed. They should be equal and are not
to exceed 260 bar (3773 psi).
− Calculate the maximum permitted speed based on the
current axle load and observe this maximum while the crane
is driven.
− Before driving in public traffic, the driver must be fully
conversant with the changed driving / braking behaviour (e.g.
longer braking distances).
− Shorten the maintenance interval; 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 in this respect are contained
in sub−section “Shorter maintenance intervals for axle
loads above 12.5 t (27.5 kip)”.
The information given here must be observed at all times.
The crane manufacturer shall not be held liable for damage

resulting from premature wear when driving with axle loads
above 12.5 t (27.5 kip).
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Crane operators / crane drivers carry sole responsibility when the

crane vehicle is driven with axle loads > 12.5 t (27.5 kip).
6.4.8 Shorter maintenance intervals for Axle Loads above

12.5 t (27.5 kip)
Even when observing the specified, axle−load−dependent

driving speeds, driving with axle loads > 12.5 t (27.5 kip) is only
permitted temporarily.
Driving with axle loads of more than 12.5 t (27.5 kip) is always
an exceptional condition and is only permitted for short
stretches. even if, as a result of special national axle load
regulations, higher values are permitted.
The crane manufacturer shall not be held liable for damage

resulting from premature wear when driving with axle loads
above 12.5 t (27.5 kip).
Risk of damage as a result of premature wear!

If the crane is driven with axle loads above 12.5 t (27.5 kip),
steering, axle suspension, axles, wheel hubs, bearings,
suspension 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
geometry and the brake linings!
RISK OF ACCIDENTS as a result of worn components!

When defects are discovered they must be dealt with
immediately in order to prevent safety risks, further wear
orirreparable 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
corresponding specialist workshop.
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6.5 Driving on Public Roads

(Z 200 354)
This crane vehicle has extraordinary dimensions and

weights.
Make sure that the vehicle is driven with caution and
foresight (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 very

specific 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
distributed 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 sub−sections must
be observed exactly.
In the interests of safety, the technically possible maximum

axle loads should not be exceeded at the corresponding
speed indicated in the left−hand 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) (EEC

Directive)
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 part 5. in the additional chapter 61
”Driving in the UK”.
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1c
Z 46 986
”X”
Z 200 235
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Driving the Crane 6
6.5.3 Checks before Driving on the Road
Before driving on the road, always:

− All transport locks must be fitted (see under “Transport
locks“).
− The main boom must be in the “road travel condition”
(telescopic sections pinned, locking−pinning unit locked in
the transport position (see part 1. section 12)).
− The suspension must not be locked; it must be switched to
the 4−way system and be at the road travel level (see section
11).
− The steering must be in the “road travel” condition (see
section 9).
− A disc must be inserted in the tachograph.
− Emergency devices e.g. first aid box, warning triangle, fire
extinguisher must be easy to reach and complete.
− The housing cover of the outrigger controls on the side of the
chassis must be closed.
− The ladders, which are loose (1c) must be attached to the
holders on the chassis and secured with the rubber fixtures.
(Z 46 986)
− No loose parts are permitted on the equipment.
− the superstructure cab − is locked; the superstructure cab
platform − is retracted.
This crane vehicle has extraordinary dimensions.

Pay attention in particular to the overhead clearance and
check the route in this respect.
− The vehicle height of 4.0 m (13.1 ft) must not be exceeded.
With optional hoist 2:

To maintain the vehicle height of 4.0 m (13.1 ft) the upper rope
sheaves (”X”, Z 200 235, similar display) (for hoist rope of
hoist 2) must be moved from the collar of the boom sections.
Risk of load being torn off!
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6.6 Defined Driving Conditions
Defined driving conditions are assigned in accordance with

national regulations or other appropriate requirements.
Driving conditions beyond these can be determined on a case by
case basis using the weight table (component weights) (see
under “axle loads / speeds / tyres”).

(Approval condition in accordance with
EEC−directive)
(Z 200 354)
Crane with:
− Main boom in transport condition
− 1−sheave hook block type 600 kg (1323 lbs) (on the bumper)
− Wooden box at rear (empty)
Crane without:
− Counterweight elements
− Hoist 2
− Spare wheel
Axle loads:
− Axles 1 to 5: 12 t each (26.4 kip)
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(with main boom, without outriggers)
(Z 200 355)
Exceptional driving condition for reducing the axle loads to

meet respective national regulations.
Crane with:
− Main boom in transport condition
Crane without:
− Outriggers front and rear
− Wodden box rear
− Spare wheel
− Hook block
− Counterweights
Axle load distribution:
∗ Axle 1: 11.2 t (24.7 kip) ∗ Axle 4: 10.9 t (24.1 kip)
∗ Axle 3: 11 t (24.3 kip)
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).
By lower the total weight lower axle loads are achieved; 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
maximum speed accordingly.
Observe the section 6.4.6 (from page 41) ”Driving with
reduced axle loads”.
You can find information on the removal and installation of the

following components in:
− Main boom extension: operating instructions superstructure,

section 18
− Outriggers: operating instructions chassis, section 12
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6.6.3 Driving with a Total Weight of 39.2 t (86.5 kip)

(without main boom, with luffing cylinder)
(Z 200 356)
Exceptional driving condition for reducing the axle loads to

meet respective national regulations.
Crane with:
− Superstructure rotated towards the back
− Luffing cylinder
− Supports complete
Crane without:
− Main boom
− Spare wheel
− Hoist 2
− Hook block
− Counterweights
Axle load distribution:

∗ Axle 2: 6.6 t (14.6 kip) ∗ Axle 5: 8.6 t (19 kip)
∗ Axle 3: 8.8 t (19.4 kip)
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).
By removing the main boom lower axle loads are achieved;
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
maximum speed accordingly. It must not exceed max.
30 km/h (18 mph); correspondingly less in poor road
conditions.
Observe the section 6.4.6 (from page 41) ”Driving with
reduced axle loads”.
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(Z 200 356)
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
accordance with the applicable motor vehicle safety
standards.
To remove and attach the main boom, see part 1 (superstructure

operating manual).
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6.6.4 Driving with a Total Weight of > 60 t (132.3 kip)

(”Technical Drivability”)
”Technical drivability” is only permitted on construction

sites and on private roads.
Instructions and warnings in this respect in the section “axle

loads / speeds / tyres” must be observed.
Driving condition 1 2 3 4 5 6 7 8
Hook block
3−sheave
x x x x x x x x
on the rear of the
vehicle
MBE 17 m (55.8 ft) x x x x x
Hoist 2 x x x x
CWT section A (5.7 t;
12.6 kip) set down
x x x x x x
on the undercarriage
(front)
CWT section B (7.3 t;
16.1 kip) set down
x x x
on the undercarriage
(front)
CWT section BF
(3.2 t; 7.1 kip) on the x x x x x x
superstructure frame
Axle load A 1 + A 2 13.1 t 12.4 t 13.2 t 14.1 t 13.4 t 16.1 t 15.4 t 16.3 t
(per axle) (28.9 (27.4 (29.1 (31.1 (29.6 (35.5 (34.0 (36.0
kip) kip) kip) kip) kip) kip) kip) kip)
Axle load A 3 + A 5 12 t 13 t 14.3 t 14.3 t 15.3 t 14.8 t 15.9 t 15.9 t
(per axle) (26.5 (28.7 (31.6 (31.6 (33.8 (32.7 (35.1 (35.1
Total weight 61.8 t 63.4 t 69 t 70.1 t 72.4 t 76.3 t 77.9 t 79.7 t
(136.3 (140.0 (152.2 (154.6 (159.7 (168.2 (171.8 (175.8
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B13
58 50
Z 200 217
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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 non−wearing sustained−action 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 engine−independent sustained−action brake is
switched on, the transmission automatically adjusts the gears to
reach an optimal braking effect (engine speed faster than
1100 min−1 / rpm).
The effect of the exhaust brake and the hydraulic retarder is

dependent 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 leads to a coolant temperature which is too high
− the retarder performance must be reduced until the coolant
temperature has reached a steady state at less than 955 C
(2035 F).
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).
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
periods under any circumstances. Risk of fading!
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A9
Z 200 218
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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
suspension 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
− Driving with axle loads over 14 t (30.9 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

longitudinal differential lock by actuating To do so, actuate
switch (94); the indicator light (A9) lights up.
2. Drive over the summit at walking pace (max. 5 km/h (3 mph)).
Whilst driving over the summit:

− Avoid turning the steering
− Observe the suspension pressure continually.
If the pressure rises to 260 bar (3773 psi) in any one of the
three suspension circuits, the AXLES MAY BREAK!
Do not drive over the summit if a pressure of 300 bar
(4354 psi) has been reached.
Reverse carefully.
3. After driving over the hill summit, stop the crane immediately
and switch off the longitudinal differential lock again. To do so,
actuate switch (94); the indicator light (A9) goes out.
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5 6 7
8 9 10
Z 200 233
31 32 33 34 35 36 37 38 39 40
43
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 200 219
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Driving the Crane 6
6.9 Checking the Operation Functions During the

Journey
All indicator light / display instruments are located in the driver’s

cab (see Sect. 4).
While driving, the driver must constantly observe the display
instruments and monitoring elements.
6.9.1 Monitoring Elements in the Instrument Controls
(Z 200 233, Z 200 219)
Item Monitoring element Display Comments (Measure)

Pressure gauge Pressure falls abruptly in one suspension circuit while
5
Suspension circuit, front right driving: A hazardous fault has occurred.
Pressure gauge
6/7
Suspension circuit, rear right
Pressure gauge Stop the crane, rectify the fault.
8
Suspension circuit, front left
Pressure gauge
9/10
Suspension circuit, rear left
Display of a hazardous fault
35 STOP lamp
STOP−observe order
Hydraulic retarder / exhaust brake actuated
38 Lamp − retarder
Pay attention to coolant temperature
Rear fog lamp switched on
40 Rear fog lamp
Only use rear fog lamp as intended
Engine speed display
50 Revolution counter
Observe in driving mode
Engine speed monitoring
50.1 LED − Excessive engine speed Lights up at excessive engine speed; at the same time
a warning buzzer can be heard. Avoid excessive engine
speed, otherwise you will cause damage to the engine.
Coolant temperature too high:
Indicator light (33.1) in the display (61) at 104° C
58 Display − coolant temperature (2195 F), Additional buzzer at 110° C (2305 F).
Switch off the engine immediately and rectify the fault
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B1 B11 B21 CHECK B31
B2 B12 B22 B32
B3 B13 B23 B33
B4 B14 B24 B34
B5 B15 B25
B6 B16 B26
B7 B17 B27
B8 B18 B28
B9 B19 B29
B10 B20 B30
Z 200 158
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Driving the Crane 6
6.9.2 Indicator Lights on the Display (43)

“Driver Information System”
Item Indicator light Display Comments (Measure)

Electro−hydraulic rear−axle Fault on the electro−hydraulic rear−axle steering
B2
steering Stop vehicle, read off fault code, rectify fault.
Supply pressure has fallen below 5.5 bar (80 psi),
B3 Braking circuit 1 function of the brakes cannot be guaranteed.
B4 Braking circuit 2 Top up the supply tank with the engine running and the
vehicle at a standstill (before driving the crane).
Clutch temperature too high
B5 Clutch overload
Change operation condition(no dragging clutch)
Fault in drive gearbox
B6 Malfunction transmission
Stop vehicle, read off fault code, rectify fault.
B8 Steering circuit 1 Steering circuit 1 no through−flow
B9 Steering circuit 2 Steering circuit 2 no through−flow
B10 Steering circuit 3 (emergency Steering circuit 3 (emergency steering pump) no flow
steering pump) If a fault is displayed during travel, stop the crane
immediately; Rectify fault.
Coolant level too low
B11 Engine coolant level
Switch off engine and rectify fault.
Engine oil pressure too low
B12 Engine oil pressure
Coolant temperature in the engine too high (above
B13 Engine coolant temperature 104° C) (2195 F). Additional buzzer at 110° C (2305 F).
Engine oil level too low
B14 Engine oil level
Fault display engine
B15 Engine malfunction
read off fault code; Rectify fault.
Charging current too low
B16 Charging current
Switch off engine, rectify fault.
Air filter clogged
B18 Air filter
Service the air filter
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B1 B11 B21 CHECK B31
B2 B12 B22 B32
B3 B13 B23 B33
B4 B14 B24 B34
B5 B15 B25
B6 B16 B26
B7 B17 B27
B8 B18 B28
B9 B19 B29
B10 B20 B30
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Driving the Crane 6
B20 Emergency steering pump / Emergency steering pump / follower axle no

follower axle through−flow
If a fault is displayed during travel, stop the crane
immediately; Rectify fault.
Fault in the databus system,
B22 “SPS” = data bus
Stop vehicle, rectify fault (customer service)
Display overload
B25
page down to next mask
Fault in exhaust brake / hydraulic retarder
B28 Retarder Reduce speed, stop if required, remedy the fault
(service department)
ABS malfunction
B29 ABS basic unit During driving: adapt the driving style, remedy the fault
(service department)
Malfunction in check valve
Electro−hydraulic rear−axle
B31 If a malfunction is displayed in the course of driving,
steering
stop the crane vehicle immediately, rectify malfunction.
Oil supply steering circuits Level in hydraulic oil reservoir too low
B32
additional axle Stop the crane vehicle immediately, remedy the fault
Engine fault
B33 Warning buzzer engine
Stop the crane vehicle immediately, remedy the fault
No CAN bus connection guidance computer
B34 CAN bus steering computer
Stop the crane vehicle immediately, remedy the fault
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75
Z 200 220
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6.9.3 On the display (75)

“Transmission information”
Item Message Display Comments (Measure)

System self−check
“CH” = self−check
Appears when “Ignition on”
Air pressure in transmission system too low (below
6.2 bar (90 psi)); clutch doesn’t open on stopping −
engine is “stalled“.
“AL” = Airless Gear can stay in neutral position = no through drive, no
engine braking effect
Stop the vehicle, rectify the fault.
“N” = Neutral Transmission status, in gear
“R” = Reverse
“1−16” = gears Further info, see Section 7
Malfunction of accelerator pedal
“FP” = Accelerator pedal Place the accelerator pedal in idle position; if the
display does not go out, the crane cannot be driven
further
Clutch is overloaded
75 “CL” = Clutch Change operating mode − relieve clutch; select lower
gear
Clutch is worn out
“CW” = Clutch wear
Go to a specialist workshop
Communication fault of electronic gear system
“EE” = Electronic Error
Rectify fault.
Transmission temperature too high
“HT” = Gear temperature
Change operation condition
System malfunction, indicator light (B6) together with
“Spanner“ symbol “caution” (36)
Limited driving mode, go to specialist workshop
Serious system malfunction, indicator light (B6)
together with “STOP” (35)
“Spanner“ symbol
+ “STOP” Automatic driving mode deactivated, manual driving
mode possible, not permitted to continue driving, go to
specialist workshop
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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 independent rear−axle steering, different

rules apply (see Sect. 9.3).
The differential locks may only be switched on for a brief period

of time, in order to bypass obstacles when driving straight
ahead.
Road speeds above 5 km/h (3 mph) overload both the tyres and
the drive.
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

locked and must be set level (see Sect. 11).
When driving over hill summits or ramps, the same rules

apply 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
vehicle handling the crane can be set to the 3−circuit system
(Notes on this can be found in Sect. 11).
Risk of tipping!
When the suspension is switched to the three−circuit
suspension system the vehicle has a lower lateral stability.
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92 93
A6 A7
Z 200 221
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6.10.2 Driving the Crane with the Equipment Erected

“Driving in Erect Mode” (with main boom / equipment
erected)
“Driving in the configured condition” always means:
Driving without load on the hook!
Driving with load is prohibited!
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 load−bearing capacity.
”Driving when rigged” with steering program “Construc-
tion−site operation mode” (operate switch (92), Z 200 221) is
PROHIBITED!
Driving in the configured condition is only permitted in the
4−circuit system (for instructions, see Sect. 11).
When driving in rigged configuration:
− The gradient must not exceed the following values:
− 2 % in the forward direction
− 1 % laterally (without additional equipment)
− 0.5 % laterally (with additional equipment)
− To set the crane down on the wheels from the outriggers, only
the outrigger cylinders are retracted, when starting from the
supported configuration, until the outrigger pads are located
close above the ground. The outrigger struts remain in
outrigger width, just as they were when the crane was
previously supported.
Unless otherwise specified in the driving tables, the large
outrigger span has been used as the basis for calculating the
driving tables.
− Keep the outrigger pads close above the ground while driving
the crane.
Risk of tipping!
If the outrigger plate is not just above the ground with the
support strut slid out accordingly or if the ground (under
the outrigger plate) does not have sufficient load−bearing
capacity, there is a risk of tilting if the crane starts to
rock during driving.
When driving, ensure that the position of the supports
and of the outrigger pads is correct and that the ground
has sufficient load−bearing capacity for the entire
“travelling distance” of the outrigger plates.
− The suspension system of the crane chassis must be locked

(see Sect. 11).
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92 93
90
A6 A7 Z 200 221 Z 52 106
81
80
80 2
Z 200 349 Z 200 224
5 6 7
8 9 10
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Driving the Crane 6
− Driving speed is not to exceed walking pace.

Distributor gearbox: level “Off−road gear“ (button 93. display
A7).
Driving gearbox: 1st gear, operation mode “Manual”.
Clutch: “starting mode” (switch 90 not actuated; only actuate
in the last cm (1 cm = approx. 0.4 inch) possibly in
“manoeuvring mode” with switch 90). (Z 52 106)
Risk of accidents!
When the warning message ’CL’ appears in the
transmission display, stop immediately and let the
system cool down.
If you do not stop, the following abrupt closing of the
clutch (see sect. 7 ’Clutch protection’) causes the rigged
crane to make jerky movements. The crane could tip
over.
− Main boom to the rear − apply mechanical superstructure

locking device. Locking bolt (80) must be inserted in locking
strip (2). Make sure that this is the case (Z 200 349).
Risk of tipping!
When the crane is not stabilised (free on wheels), then
the boom must not be rotated out of the vehicle’s
longitudinal axis.
For machines with dolly preparation (optional) the locking bolt (1)
can only latch into the locking strip (2) when the extension guard
(screw) (81) has previously been removed. (Z 200 224)
− The hook block must be secured on the chassis e.g. on the

manoeuvring / trailer coupling, or also on the outriggers
(telescoped out) to prevent swinging movements (or it must
be raised).
− 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 driver’s cab. (Z 200 233)
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If the pressure in one of the suspension circuits climbs to

300 bar (4354 psi), stop the crane immediately and extend
the outrigger cylinders until the wheels are relieved of load.
Level the crane by resetting the hydraulic suspension and /
or correcting theboom position.
If the crane is driven further it may OVERTURN or the AXLES
MAY BREAK!
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 corre-
sponding table sheet.
− Calculated hook block in accordance with the corresponding
table sheet.
− Corresponding equipment (e.g. main boom extension).
Driving the crane with other configurations than the ones

specified in the following table sheets is PROHIBITED!
When changing the calculated hook block, slight adjustment of

the main boom (or of the equipment) can achieve a more
balanced axle load again.
The suspension pressure when lowering the crane from the

outriggers onto the wheels can be monitored via the pressure
gauges. At the same time, 260 bar (3773 psi) must not be
exceeded.
Axle load (t) Suspension pressure in bar

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.
Possible driving variants in the following sections:
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6.10.3 Driving Tables (in SI − Units)
6.10.3.1 Driving the Crane with the Main Boom

(Z 200 075)
Axle load table: Correlation of the axle loads with the boom
position and configuration.
Counter− Super- A B RA Axle load in (t)
weight structure (m) (°) (m) Axle
(t) to the (*)
1+2 3, 4, 5
5.7 80 0.6 13.6 13.4
8.9 77 1.2 14.1 14.1
13 74 1.8 15 14.9
14.8 72 2.2 15.3 15.3
16.3 71 2.4 15.5 15.6
18 69 2.8 15.9 16
22.1 66 3.4 16.7 16.7
rear 12.4
25.3 63 4 17.3 17.4
31.1 58 4.8 18.6 18.5
34.3 55 5.3 19.3 19.2
40.2 49 6.3 20.5 20.3
43.4 45 6.9 21.1 21
59.9 20 9.3 24.3 24.3
69 1 9.7 27.2 25.5
* Superstructure to the: rear − Main boom to the rear
The following hook block is included in the calculation:
− 3−sheave, type 80 (850 kg; 1874 lbs)
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6.10.3.2 Driving with Main Boom Extension 9 m (in SI − Units)

(Z 200 079)
Counter− Super- A B C D RA Axle load (t)

weight structure (m) (°) (m) (°) (m) Axle
(t) to the (*) 1+2 3, 4, 5
81 0 1.9 13.7 13.7
5.7 82 20 4.6 13.6 13.7
82 40 7.1 13.3 13.9
79 0 2.6 14.4 14.3
8.9 80 20 5.3 14.3 14.3
81 40 7.4 14.3 14.3
76 0 3.7 15.1 15.1
13 77 20 6.3 15.1 15.1
78 40 8.4 15 15.1
74 0 4.4 15.4 15.6
14.8 76 20 6.7 15.6 15.5
77 40 8.7 15.6 15.5
rear 12.4 9
74 0 4.4 15.8 15.7
16.3 75 20 7 15.7 15.7
76 40 9 15.7 15.7
72 0 5.1 16.1 16.2
18 73 20 7.7 16.1 16.2
74 40 9.6 16.1 16.2
69 0 6.2 16.8 17
22.1 71 20 8.3 17 16.8
72 40 10.2 17 16.8
67 0 6.9 17.6 17.6
25.3 68 20 9.3 17.5 17.6
69 40 11 17.5 17.6
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(Z 200 079)
Continuation axle load table:
Driving with Main Boom Extension 9 m in SI − Units

(t) to the (*) 1+2 3, 4, 5
62 0 8.5 18.6 18.8
31.1 64 20 10.5 18.8 18.7
65 40 12.1 18.9 18.7
60 0 9.2 19.4 19.4
34.3 61 20 11.4 19.4 19.4
62 40 12.8 19.4 19.4
55 0 10.7 20.6 20.6
40.2 56 20 12.7 20.5 20.6
57 40 14 20.6 20.6
rear 12.4 9
52 0 11.6 21.2 21.3
43.4 53 20 13.5 21.2 21.3
54 40 14.6 21.2 21.3
36 0 15.5 24.5 24.5
59.9 37 20 16.8 24.5 24.5
37 40 17.2 24.4 24.5
22 0 17.9 26.3 26.4
69 23 20 18.5 26.3 26.4
23 40 18.1 26.3 26.4
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(Z 200 080)
(t) to the (*)
1+2 3, 4, 5
82 0 2.5 13.8 13.8
5.7 82 20 8.1 13.1 14.3
82 40 12.8 12.4 14.7
80 0 3.5 14.5 14.4
8.9 82 20 8.1 14.3 14.5
82 40 12.8 13.7 14.9
78 0 4.5 15.3 15.1
13 80 20 9.1 15.2 15.2
82 40 12.8 15.2 15.2
76 0 5.5 15.6 15.7
14.8 79 20 9.5 15.8 15.5
81 40 13.2 15.7 15.6
rear 12.4 17
75 0 6 15.7 15.9
16.3 78 20 10 15.9 15.8
80 40 13.6 15.9 15.8
74 0 6.5 16.2 16.3
18 77 20 10.4 16.4 16.2
79 40 14 16.4 16.2
72 0 7.5 17.1 17
22.1 74 20 11.8 17 17
76 40 15.1 17 17
70 0 8.4 17.8 17.6
25.3 72 20 12.7 17.7 17.7
74 40 15.9 17.7 17.7
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(Z 200 080)
(t) to the (*)
1+2 3, 4, 5
66 0 10.3 19 18.8
31.1 68 20 14.4 18.9 18.9
70 40 17.3 18.9 18.8
63 0 11.6 19.4 19.6
34.3 66 20 15.2 19.6 19.5
68 40 18 19.6 19.4
59 0 13.4 20.7 20.7
40.2 62 20 16.7 20.8 20.6
63 40 19.6 20.6 20.8
rear 12.4 17
57 0 14.2 21.4 21.3
43.4 59 20 17.8 21.3 21.4
61 40 20.1 21.4 21.3
44 0 19.2 24.7 24.6
59.9 46 20 22 24.6 24.6
47 40 23.4 24.6 24.6
35 0 22 26.5 26.4
69 37 20 24.1 26.5 26.4
38 40 24.7 26.5 26.4
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(Z 200 081)
(t) to the (*)
1+2 3, 4, 5
82 0 3.6 13.6 14.2
5.7 82 20 9.2 12.8 14.7
82 40 13.9 12.2 15.1
81 0 4.3 14.5 14.6
8.9 82 20 9.2 14.1 14.9
82 40 13.9 13.4 15.3
79 0 5.6 15.2 15.4
13 81 20 9.9 15.2 15.4
82 40 13.9 14.9 15.6
78 0 6.2 15.7 15.8
14.8 80 20 10.5 15.7 15.8
82 40 13.9 15.8 15.7
rear 12.4 25
78 0 6.2 16.1 15.9
16.3 80 20 10.5 16.1 15.9
81 40 14.4 15.8 16.1
76 0 7.5 16.3 16.5
18 78 20 11.7 16.2 16.5
80 40 15 16.3 16.4
74 0 8.7 17.1 17.2
22.1 76 20 12.8 17 17.2
78 40 16 17.1 17.2
73 0 9.3 18 17.7
25.3 75 20 13.4 18 17.7
76 40 17.1 17.7 17.9
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(Z 200 081)
(t) to the (*)
1+2 3, 4, 5
69 0 11.8 18.9 19
31.1 71 20 15.7 18.9 19
73 40 18.6 19 19
67 0 13 19.5 19.7
34.3 69 20 16.8 19.5 19.7
71 40 19.6 19.6 19.6
64 0 14.7 20.9 20.8
40.2 66 20 18.4 20.9 20.8
67 40 21.4 20.7 20.9
rear 12.4 25
62 0 15.8 21.5 21.5
43.4 64 20 19.5 21.5 21.5
65 40 22.3 21.3 21.6
52 0 21.2 24.9 24.7
59.9 54 20 24.3 24.9 24.7
55 40 26.3 24.8 24.7
45 0 24.5 26.6 26.6
69 47 20 27.1 26.6 26.6
48 40 28.6 26.6 26.6
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(Z 200 082)
(t) to the (*)
1+2 3, 4, 5
82 0 4.8 13.2 14.7
5.7 82 20 10.4 12.4 15.2
82 40 15 11.8 15.6
82 0 4.8 14.4 14.9
8.9 82 20 10.4 13.7 15.4
82 40 15 13 15.8
81 0 5.5 15.5 15.5
13 82 20 10.4 15.2 15.7
82 40 15 14.5 16.1
80 0 6.3 15.9 15.9
14.8 82 20 10.4 16 15.8
82 40 15 15.4 16.3
rear 12.4 33
80 0 6.3 16.3 16
16.3 81 20 11.1 16 16.2
82 40 15 15.8 16.3
79 0 7.1 16.8 16.4
18 80 20 11.8 16.4 16.6
82 40 15 16.7 16.5
77 0 8.6 17.4 17.3
22.1 79 20 12.6 17.5 17.2
80 40 16.4 17.3 17.3
75 0 10.2 17.8 18.1
25.3 77 20 14 17.9 18
79 40 17 18.2 17.8
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(Z 200 082)
(t) to the (*)
1+2 3, 4, 5
73 0 11.7 19.3 19
31.1 74 20 16.2 19 19.2
76 40 19 19.3 19.1
71 0 13.2 19.8 19.8
34.3 73 20 16.9 19.9 19.7
74 40 20.3 19.7 19.9
68 0 15.4 20.9 21.1
40.2 70 20 19 21 21
71 40 22.2 20.9 21.1
rear 12.4 33
67 0 16.1 21.7 21.6
43.4 68 20 20.3 21.5 21.8
70 40 22.8 21.7 21.6
59 0 21.6 25.1 24.8
59.9 60 20 25.5 24.8 25
61 40 27.9 24.8 25
54 0 24.9 26.9 26.7
69 55 20 28.4 26.7 26.8
56 40 30.4 26.6 26.8
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6.10.4 Driving Tables (in US − Units)
6.10.4.1 Driving the Crane with the Main Boom (US)

(Z 200 075)
Counter− Super- A B RA Axle load in
weight structure (ft) (°) (ft) (kip) Axle
(kip) to the (*)
1+2 3, 4, 5
12.6 80 2 30 29.5
19.6 77 3.9 31.1 31.1
28.7 74 5.9 33.1 32.8
32.6 72 7.2 33.7 33.7
35.9 71 7.9 34.2 34.4
39.7 69 9.2 35.1 35.3
48.7 66 11.2 36.8 36.8
rear 40.7
55.8 63 13.1 38.1 38.4
68.6 58 15.7 41 40.8
75.8 55 17.4 42.5 42.3
88.6 49 20.7 45.2 44.8
95.7 45 22.6 46.5 46.3
132.1 20 30.5 53.6 53.6
152.1 1 31.8 60 56.2
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6.10.4.2 Driving with Main Boom Extension 9 m (29.5 ft) (in US

− Units)
(Z 200 079)
Axle load in
Counter− Super- A C RA (kip)
B D
weight structure Axle
(kip) to the (*) (ft) (°) (ft) (°) (ft)
1+2 3, 4, 5
81 0 6.2 30.2 30.2
12.6 82 20 15.1 30 30.2
82 40 23.3 29.3 30.6
79 0 8.5 31.7 31.5
19.6 80 20 17.4 31.5 31.5
81 40 24.3 31.5 31.5
76 0 12.1 33.3 33.3
28.7 77 20 20.7 33.3 33.3
78 40 27.6 33.1 33.3
74 0 14.4 34 34.4
32.6 76 20 22 34.4 34.2
77 40 28.5 34.4 34.2
rear 40.7 29.5
74 0 14.4 34.8 34.6
35.9 75 20 23 34.6 34.6
76 40 29.5 34.6 34.6
72 0 16.7 35.5 35.7
39.7 73 20 25.3 35.5 35.7
74 40 31.5 35.5 35.7
69 0 20.3 37 37.5
48.7 71 20 27.2 37.5 37
72 40 33.5 37.5 37
67 0 22.6 38.8 38.8
55.8 68 20 30.5 38.6 38.8
69 40 36.1 38.6 38.8
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Z 200 079
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Driving the Crane 6
(Z 200 079)
Driving with Main Boom Extension 9 m (29.5 ft) in US −
Units
Axle load in
B D
(kip) to the (*) (ft) (°) (ft) (°) (ft)
1+2 3, 4, 5
62 0 27.9 41 41.4
68.6 64 20 34.5 41.4 41.2
65 40 39.7 41.7 41.2
60 0 30.2 42.8 42.8
75.8 61 20 37.4 42.8 42.8
62 40 42 42.8 42.8
55 0 35.1 45.4 45.4
88.6 56 20 41.7 45.2 45.4
57 40 45.9 45.4 45.4
rear 40.7 29.5
52 0 38.1 46.7 47
95.7 53 20 44.3 46.7 47
54 40 47.9 46.7 47
36 0 50.9 54 54
132.1 37 20 55.1 54 54
37 40 56.4 53.8 54
22 0 58.7 58 58.2
152.1 23 20 60.7 58 58.2
23 40 59.4 58 58.2
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RA
Z 200 080
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Driving the Crane 6
6.10.4.3 Driving with Main Boom Extension 17 m (55.8 ft) (in

US − Units)
(Z 200 080)
Axle load in
B D
(ft) (°) (ft) (°) (ft)
(kip) to the (*)
1+2 3, 4, 5
82 0 8.2 30.4 30.4
12.6 82 20 26.6 28.9 31.5
82 40 42 27.3 32.4
80 0 11.5 32 31.7
19.6 82 20 26.6 31.5 32
82 40 42 30.2 32.8
78 0 14.8 33.7 33.3
28.7 80 20 29.9 33.5 33.5
82 40 42 33.5 33.5
76 0 18 34.4 34.6
32.6 79 20 31.2 34.8 34.2
81 40 43.3 34.6 34.4
rear 40.7 55.8
75 0 19.7 34.6 35.1
35.9 78 20 32.8 35.1 34.8
80 40 44.6 35.1 34.8
74 0 21.3 35.7 35.9
39.7 77 20 34.1 36.2 35.7
79 40 45.9 36.2 35.7
72 0 24.6 37.7 37.5
48.7 74 20 38.7 37.5 37.5
76 40 49.5 37.5 37.5
70 0 27.6 39.2 38.8
55.8 72 20 41.7 39 39
74 40 52.2 39 39
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Z 200 080
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Driving the Crane 6
(Z 200 080)
Driving with Main Boom Extension 17 m (55.8 ft) in US
− Units
Axle load in
B D
(ft) (°) (ft) (°) (ft)
(kip) to the (*)
1+2 3, 4, 5
66 0 33.8 41.9 41.4
68.6 68 20 47.2 41.7 41.7
70 40 56.8 41.7 41.4
63 0 38.1 42.8 43.2
75.8 66 20 49.9 43.2 43
68 40 59.1 43.2 42.8
59 0 44 45.6 45.6
88.6 62 20 54.8 45.9 45.4
63 40 64.3 45.4 45.9
rear 40.7 55.8
57 0 46.6 47.2 47
95.7 59 20 58.4 47 47.2
61 40 65.9 47.2 47
44 0 63 54.5 54.2
132.1 46 20 72.2 54.2 54.2
47 40 76.8 54.2 54.2
35 0 72.2 58.4 58.2
152.1 37 20 79.1 58.4 58.2
38 40 81 58.4 58.2
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RA
Z 200 081
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Driving the Crane 6
6.10.4.4 Driving with Main Boom Extension 25 m (82 ft) (in US

− Units)
(Z 200 081)
Axle load in
B D
(ft) (°) (ft) (°) (ft)
(kip) to the (*)
1+2 3, 4, 5
82 0 11.8 30 31.3
12.6 82 20 30.2 28.2 32.4
82 40 45.6 26.9 33.3
81 0 14.1 32 32.2
19.6 82 20 30.2 31.1 32.8
82 40 45.6 29.5 33.7
79 0 18.4 33.5 34
28.7 81 20 32.5 33.5 34
82 40 45.6 32.8 34.4
78 0 20.3 34.6 34.8
32.6 80 20 34.5 34.6 34.8
82 40 45.6 34.8 34.6
rear 40.7 82
78 0 20.3 35.5 35.1
35.9 80 20 34.5 35.5 35.1
81 40 47.2 34.8 35.5
76 0 24.6 35.9 36.4
39.7 78 20 38.4 35.7 36.4
80 40 49.2 35.9 36.2
74 0 28.5 37.7 37.9
48.7 76 20 42 37.5 37.9
78 40 52.5 37.7 37.9
73 0 30.5 39.7 39
55.8 75 20 44 39.7 39
76 40 56.1 39 39.5
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Z 200 081
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Driving the Crane 6
(Z 200 081)
Driving with Main Boom Extension 25 m (82 ft) in US −
Units
Axle load in
B D
(ft) (°) (ft) (°) (ft)
(kip) to the (*)
1+2 3, 4, 5
69 0 38.7 41.7 41.9
68.6 71 20 51.5 41.7 41.9
73 40 61 41.9 41.9
67 0 42.7 43 43.4
75.8 69 20 55.1 43 43.4
71 40 64.3 43.2 43.2
64 0 48.2 46.1 45.9
88.6 66 20 60.4 46.1 45.9
67 40 70.2 45.6 46.1
rear 40.7 82
62 0 51.8 47.4 47.4
95.7 64 20 64 47.4 47.4
65 40 73.2 47 47.6
52 0 69.6 54.9 54.5
132.1 54 20 79.7 54.9 54.5
55 40 86.3 54.7 54.5
45 0 80.4 58.6 58.6
152.1 47 20 88.9 58.6 58.6
48 40 93.8 58.6 58.6
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RA
Z 200 082
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6.10.4.5 Driving with Main Boom Extension 33 m (108.3 ft) (in

US − Units)
(Z 200 082)
Axle load in
B D
(ft) (°) (ft) (°) (ft)
(kip) to the (*)
1+2 3, 4, 5
82 0 15.7 29.1 32.4
12.6 82 20 34.1 27.3 33.5
82 40 49.2 26 34.4
82 0 15.7 31.7 32.8
19.6 82 20 34.1 30.2 34
82 40 49.2 28.7 34.8
81 0 18 34.2 34.2
28.7 82 20 34.1 33.5 34.6
82 40 49.2 32 35.5
80 0 20.7 35.1 35.1
32.6 82 20 34.1 35.3 34.8
82 40 49.2 34 35.9
rear 40.7 108.3
80 0 20.7 35.9 35.3
35.9 81 20 36.4 35.3 35.7
82 40 49.2 34.8 35.9
79 0 23.3 37 36.2
39.7 80 20 38.7 36.2 36.6
82 40 49.2 36.8 36.4
77 0 28.2 38.4 38.1
48.7 79 20 41.3 38.6 37.9
80 40 53.8 38.1 38.1
75 0 33.5 39.2 39.9
55.8 77 20 45.9 39.5 39.7
79 40 55.8 40.1 39.2
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Z 200 082
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(Z 200 082)
Driving with Main Boom Extension 33 m (108.3 ft) in US
− Units
Axle load in
B D
(ft) (°) (ft) (°) (ft)
(kip) to the (*)
1+2 3, 4, 5
73 0 38.4 42.5 41.9
68.6 74 20 53.2 41.9 42.3
76 40 62.3 42.5 42.1
71 0 43.3 43.7 43.7
75.8 73 20 55.4 43.9 43.4
74 40 66.6 43.4 43.9
68 0 50.5 46.1 46.5
88.6 70 20 62.3 46.3 46.3
71 40 72.8 46.1 46.5
rear 40.7 108.3
67 0 52.8 47.8 47.6
95.7 68 20 66.6 47.4 48.1
70 40 74.8 47.8 47.6
59 0 70.9 55.3 54.7
132.1 60 20 83.7 54.7 55.1
61 40 91.5 54.7 55.1
54 0 81.7 59.3 58.9
152.1 55 20 93.2 58.9 59.1
56 40 99.7 58.6 59.1
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1 2 5 3 4
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Driving the Crane 6
6.10.5 Driving the Crane with a Load
Driving the crane while it is carrying a load is strictly

prohibited!
6.11 Attachment Coupling / Supply Connections (optional)
(Z 53 769)
If the crane is equipped for a trailer (dolly) to be fitted, the

following equipment is available 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 (7−pin)
If a dolly coupling is part of our scope of delivery:
5 Dolly coupling
Particular attention should be paid to the road safety of the dolly

coupling (5).
Instructions on maintenance and care can be found in part 4 of
this publication.
Check the dolly coupling daily for longitudinal play.

Longitudinal play is not permitted. Risk of dolly ripping free!
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6.11.1 Coupling and uncoupling a dolly
The coupling and uncoupling, operation and maintenance of

a dolly is exclusively the sole responsibility of the crane
operator. The crane operator is responsible for careful
performance of the coupling and uncoupling sequence,
operation and maintenance in accordance with national
regulations.
The manufacturer’s 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
effect.
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
monitoring 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 dollys 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 standing on a smooth,
level surface.
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Z 53 769
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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
sequence!
5. Carry out the coupling by moving the towing vehicle

backward, 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
forbidden under any circumstances to allow the dolly to
move forward to couple the vehicles.
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
specified.
The brakes may release if this sequence is not adhered
to.
7. Remove the wheel chocks, release the dolly parking brake,

monitor departure.
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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
specified.
The brakes may release if this sequence is not adhered
to.
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2
2
4
5
1
5 1
Z 53 767 Z 53 768
Z 53 770
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Driving the Crane 6
6.12 Attaching and Removing the Spare Wheel (Spare

Wheel Holder, Hoist Arrangement, Option)
(Z 53 767, Z 53 768, Z 53 770)
An optional spare wheel holder (1) is to be found on the rear end

of the vehicle to make it possible to have a spare wheel available
while driving.
In order to attach and / or remove the spare wheel from the spare
wheel holder, either one’s own crane apparatus, the optionally
available lifting device or other equipment (3) (e.g. an auxiliary
crane or similar) must be used.
Spare wheel Transport dimensions Weight*
Diameter Width
1.4 m 0.6 m 380 kg
(4.6 ft) (2.0 ft) (838 lbs)
max.
* depending on the tyre type
The load−handling device must be selected in accordance

with this weight.
To remove the spare wheel using the optionally available lifting

device, proceed as follows:
− Affix the holder (2) for the lifting device (3) to the carrier frame.
− Attach the lifting device (3) to the holder (2).
− Unreel hoist arrangement (3).
− Attach the spare wheel using the auxiliary reeving rope (4) to
the hoist arrangement (3).
− Tighten the rope with the hoist arrangement and remove the
screws (5) on the spare wheel.
− Lower the spare wheel and set it on the ground.
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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

corresponding fashion with one’s 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.
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ÁÁ
ÁÁ
ÁÁ
ÁÁ
ÁÁ
Z 58 429
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6.13 Reversing Check System (Optional)

(Z 58 429 Principle diagram)
6.13.1 General System Description
Using ultrasound, the reversing check system monitors the
space behind the vehicle during reversing. It warns visually and
acoustically of obstacles registered by the system.
The max. range is approx. 3 m (9.8 ft) for visual display and
approx. 1.5 m (4.9 ft) for acoustic display.
The height range for registering obstacles (over the road surface)
is approx. 1 m (3.3 ft).
When reversing you must always take great care. Critical
obstacles might not be registered or not precisely registered
due to physical reflection characteristics.
The reversing check system serves to help you when

reversing; however, it does not release the driver from taking
special care when reversing.
The system can only fulfil its purpose for slow reverse
motion (shunting speed).
When reversing, the driver must behave in such a way

excludes any danger to others.
When reversing, we recommend that you always have a

reliable person as a banksman.
Make sure that the hydraulic suspension is at road travel

level. The level setting directly affects obstacle recognition.
Keep the sensors clean. Remove snow, ice or dirt; these

affect the function.
The system does not register any components hanging over

the crane, i.e. toolboxes, ladders, trailer couplings or spare
wheels. The driver must plan ahead and take these into
consideration himself.
The system cannot recognise and therefore does not display

obstacles exceeding the registering range (approx. 1 m =
3.3 ft). The driver must remember this and register obstacle
lying higher up himself.
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A6
A5 A1 A3
A2 A4
S1 S2 S3 S4
Z 58 428
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6.13.2 Function Description

(Z 58 428 Principle diagram)
The system consists of:

− Sensors (S1 − S4) on the rear bumper
− Dialogue unit (A) in the driver’s cab with
− Display for visual distance illustration consisting of:
Digit display (A5) and
four LED columns (A1 − A4) with 6 rows each
− Speakers (A6) for acoustic signals
− Electronic control device at the rear of the vehicle
When reversing, the sensors

transmit ultrasound signals continuously and receive ultrasound
signals reflected by obstacles.
The distance to the obstacle is calculated by the run time of the
ultrasound signals and signalised by the speaker using a pulse
tone sequence. The closer the obstacle, the faster the tone
sequence.
The sensors must be aligned precisely horizontal.

If they face the ground, uneven ground might be displayed as
obstacles. If they face too far upwards, lower lying obstacles are
not registered.
The display
signals the position of the obstacle using LEDs in four columns
/ six rows. Each sensor has its own column.
The digit display (A5) shows the distance to the obstacle in 1 cm

steps. It is indicated in metric form.
The sensors and the dialogue unit are connected to the

electronic control device.
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S1 S2 S3 S4
Z4 ~0,40 m (1,3 ft)
Z3 ~0,95 m (3,1 ft)
Z2 ~1,50 m (4,9 ft)
Z1 ~3 m (9,8 ft)
Z 58 424
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
~0,40 m
Z4 Z3
STOP
Z 58 431
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Driving the Crane 6
6.13.3 Registering Range

(Z 58 424)
The system’s registering range is divided into four zones:

∗ Zone Z1
Large objects, i.e. private cars. The distance is displayed
acoustically and using the digit display.
∗ Zone Z2
Small or badly reflected objects might not be registered.
Other objects are displayed visually and acoustically.
∗ Zone Z3
Almost all objects are displayed.
∗ Zone Z4
Almost all objects are displayed, but some could be in the
sensors’ blind spot.
6.13.4 Protruding Components
(Z 58 431)
Risk of accidents and damage
If parts have been fitted to the vehicle which protrude over
the close−up range of 0.4 m (1.3 ft), they could collide with
an obstacle before the sensors (S1 − S4) register it and issue
a STOP warning to the system.
Parts which do not protrude over the sensors more than
0.4 m (1.3 ft) are within the close−up range (Zone Z4) of up to
0.4 m (1.3 ft) in which a STOP warning will be issued and the
driver should stop.
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Z 58 425
A
B
C
Z 58 426
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Driving the Crane 6
6.13.5 Critical Situations in the Registering Range
Risk of accidents / damage!

The registering range is limited in height; the entire vehicle
height is not monitored. Only obstacles up to approx. 1 m
(3.3 ft) over the road surface are registered.
Please observe:
The following examples show that situations can occur in which
the system does not register certain objects and does not
indicate the correct distance due to their physical composition.
Example 1 (Z 58 425)
Objects which are not in the sensors’ registering range from the
start, cannot be registered.
If the object has a jagged surface, the shortest distance is not
automatically indicated. In the example contour “A” is not
indicated, only “B” and “C”.
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3
A
Z 58 427
B
Z 58 430
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Driving the Crane 6
If the obstacle is oblique, the shortest distance “A” is indicated.
The system indicates the distance “A”. When driving up to the
obstacle, once the acoustic display has gone over to the stop
range, distance ”A” will be in the blind spot if driving continues,
which means that distance ”B” is indicated instead.
As the examples show, situations can occur in which an

obstacle or the shortest distance to it is not displayed.
This is why you must always take great care when reversing.
If an object is in the area which is not monitored, the system

automatically displays the distance to the next object. This
means that the acoustic signal will jump from the fast
sequence to a slower one and that the digit display (A5) will
indicate a greater distance in the display.
In this case, always stop the vehicle immediately and check

the situation.
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S1 S2 S3 S4
Z4 ~0,40 m (1,3 ft)
Z3 ~0,95 m (3,1 ft)
Z2 ~1,50 m (4,9 ft)
Z1 ~3 m (9,8 ft)
Z 58 424
ÁÁ
ÁÁ
F7 A1 A2 A3 A4
F6
F5
F4
F3
F2
F1
Z 58 435
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Driving the Crane 6
6.13.6 First Operation

(Z 58 424. Z Z 58 435)
When reversing you must always take great care. You must be
especially careful the first time you use it. The driver must
acquaint himself with the distance indication by the acoustic
signal’s various tone sequences.
6.13.6.1 Relation between Display and Tone Sequence with

Varying Distance to the Obstacle
Zone Meaning Tone sequence
The system recognises obstacles from a distance of
Z1 approx. 3 m (9.8 ft) and indicates the distance on the −
display. The blue LED lights up.
The system signals obstacles using acoustic signals
Z2 (long tone sequence) from a distance of approx. 1.5 m Bi Bi Bi Bi
(4.9 ft). The green and / or yellow LEDs light up.
The system jumps to the middle tone sequence from a
Z3 distance of approx. 0.95 m (3.1 ft). The yellow and / or Bi Bi Bi Bi Bi Bi
red LEDs light up.
The system jumps to a continuous tone from a
distance of approx. 0.4 m (1.3 ft). The round red LED
lights up (STOP warning).
Z4 Biiiiii.....
When this zone has been reached, the vehicle must
be stopped. If this is not followed through it will cause
damage to the vehicle and to the obstacle.
Obstacles might not be recognised in zone 4 if they are not

in the sensors’ registering range (due to their construction).
6.13.6.2 Colours of the Light−emitting Diodes (LED’s)

The different distances are assigned certain colours (F1 − F6). At
the end of the 6−row square colour scale there is a round red
warning light (F7) which is for demanding a stop.
Distance Colour
> 1.20 m (3.9 ft) blue
1.20 m − 0.80 m (3.9 ft − 2.6 ft) green
0.80 m − 0.40 m (2.6 ft − 1.3 ft) yellow
< 0.40 m (1.3 ft) red
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A1 A2 A3 A4
Z 58 432
F7 A1 A2 A3 A4
F6
F5
F4
F3
F2
F1
Z 58 433
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Obstacle at a distance of 1.20 m (3.9 ft)
(Z 58 432)
− The obstacle has been registered by both middle sensors

and is shown in the display.
− Digit display “1.20” means: obstacle at a distance of
1.20 m (3.9 ft).
− LEDs in columns A2 and A3 illuminated (blue / green)
means: the obstacle is in the registering range of both
middle sensors S2 / S3 (distance zones Z1 / Z2).
∗ Acoustic signal: long tone sequence (Bi Bi Bi Bi).

Distance to the obstacle smaller than 0.40 m (1.3 ft)
(Z 58 433)
− The obstacle has been registered by both middle sensors

and is shown in the display.
− Digit display “0.00” means: distance to the obstacle is less
than 0.40 m (1.3 ft).
− LEDs in columns A2 and A3 illuminated (blue / green /
yellow / red) means: the obstacle is in the registering range
of both middle sensors S2 / S3 (distance zone Z4).
∗ Acoustic signal: continuous tone (B i i i i i i . . . . . ).
Stop demand
If the distance to the obstacle is less than 0.40 m (1.3 ft) (zone
4) the round red LED (F7) is illuminated in each row. The acoustic
signal switches to continuous tone.
RISK OF DAMAGE!
If the round red LED (F7) is illuminated − at the same time the
acoustic signal jumps to the continuous tone − the vehicle
must always be stopped and the situation must be checked.
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6
A6
A5 A1 A3
A2 A4
S1 S2 S3 S4
Z 58 428
13
Z 58 434
150/153 200−1−2060−297a_en
Driving the Crane 6
6.13.7 Activating and Using the System

(Z 58 428, Z 58 434)
The reversing check system is automatically activated once the

reverse gear has been applied if the ignition is switched on and
the engine is running.
As soon as an obstacle is in the registering range, a consistent,

repeated signal is sounded.
At the same time the display shows where the obstacle is: if the
right−hand side of the vehicle is approaching an obstacle (sensor
S4), the right−hand LED row (A4) is illuminated.
If the vehicle approaches an obstacle on the left−hand side
(sensor S1), the left−hand LED row (A1) is illuminated.
If the obstacle is within the range of one the middle sensors (S2.
S3), the corresponding one of both middle LED rows (A2. A3) is
illuminated.
When reversing, the tone sequence is changed, depending on

which zone the obstacle is in, indicating a certain distance. The
digit display (A5) of the display shows the calculated distance in
metres.
Stop the vehicle immediately and check the situation if the

following occurs:
When reversing the machine first indicates an obstacle and
the tone sequence gets faster in the usual manner (for
example, changes from the slow to the middle tone
sequence). Suddenly the tone jumps to the slow sequence
or no longer indicates an obstacle.
This means that the obstacle originally registered is no
longer in the sensors’ registering range (due to design), but
could still be in the way.
If the reverse gear is applied (rotary switch (13) to position “R”),

the standard acoustic reverse gear warning signal sounds (at an
interval). You must register this very consciously; it must not be
confused with the acoustic signal of the reversing check system.
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6
A6
A5 A1 A3
A2 A4
S1 S2 S3 S4
Z 58 428
13
Z 58 434
152/153 200−1−2060−297a_en
Driving the Crane 6
6.13.8 Testing the Function / Diagnosis Function

(Z 58 428 Principle diagram, Z 58 434)
Carry out the function test as follows:

− Apply the parking brake.
− Rotary switch to “N”.
− Activate ignition, if required start the engine; apply reverse
gear (rotary switch to ”R”).
− A short double tone sounds as a function check.
− The digit display (A5) in the display shows the distance to an
obstacle if it is within the registering range.
Diagnosis function
The system has a diagnosis function. If the sensors are faulty,

three short signals are sounded instead of the double tone if the
reverse gear is applied.
6.13.9 Fault Display
Defective sensor is displayed (three tones when applying
the reverse gear)
Proceed as follows if a defective sensor is displayed (see “Test

function”):
− Park the vehicle at a distance of approx. 1 m (3.3 ft) in front
of a large obstacle, i.e. a garage door.
− Apply parking brake, apply reverse gear (rotary switch to “R”).
∗ The slow tone sequence sounds (zone Z1) and the LEDs of
the intact sensor light up in green.
− Cover sensors one after the other (stand in front of them).
∗ The acoustic signal jumps to the fast tone sequence um.
The tone sequence does not change at the defective sensor.
Dialogue unit does not indicate any function
Check all connecting cables / plugs / contacts for correct fit

(display, sensors, control device).
6.13.10 Maintenance and Care
Occasionally clean the sensors with a damp cloth.

Do not use any abrasive or aggressive cleaning agents as
this can lead to damage of the sensors.
200−1−2060−297a_en 153/153
Drive gearbox / distributor gear 7
200−1−2070c_en 1/55
7
1 2 4 5 7 3 6
Z 200 092
35 36 B5
43
B6
35
75
36
12
18 13
19
Z 51 344
2/55 200−1−2070c_en
7 Drive gearbox / distributor gear
(Z 200 092, Z 51 344)
The drive gearbox (2) − an automatic transmission ZF−AS

TRONIC Type 16 AS 2601 (16 forward gears, 2 reverse gears)
− is flanged together with the drive motor (1) via a dry clutch. A
two−stage distributor gear (3) is rear−mounted to this
combination.
You see here the drive line of the 5−axle model. In the 6−axle
model, an additional non−driven axle has been fitted between the
third and fourth axles.
7.1 Drive gearbox:
7.1.1 Description of the System
The ZF−AS TRONIC consists of a four−speed part, a splitter unit

(GV) and a rear−mounted range unit (GP) in planetary design.
The basic gearbox is dog−clutched; 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 electro−pneumatic actuator with path
sensors; it takes over the entire transmission actuation.
A hydraulic retarder (system “ZF Intarder”), a non−wearing,

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)
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7
2.1 2
2.5
2.3
2.4
2.2
Z 51 345
43
75
12
18 13
19
Z 51 346
4/55 200−1−2070c_en
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 e−module (2.5)
periphery components are installed in the driver’s 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 E−module
Vehicle components:
18 Accelerator pedal
19 Brake pedal
43 “Driver information system“ display
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7
12
13
Z 51 346
6/55 200−1−2070c_en
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 (90 psi) is needed to shift 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,
thetransmission 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
won’t work.
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7
12
13
Z 51 346
8/55 200−1−2070c_en
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 third gear as a fixed programmed
driving 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.
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7
1 8 14
2 9 15
3 10 16
4 11 17
5 12
6 13
Z 51 348
10/55 200−1−2070c_en
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 Self−check 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 two digit display)
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7
35 36 B5
43
B6
35
75
36
12
18 13
19
Z 51 344
12/55 200−1−2070c_en
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.
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7
Z 52 100 Z 52 101
14/55 200−1−2070c_en
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)
1. Apply the parking brake.
2. Rotary switch to “N“ (transmission in neutral)
3. Switch on the ignition. (Ignition−starter switch, position “2”)
At “Ignition on”, a self−test of the shifting system is done.

After the control signal: “CH” display.
4. 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 third gear as a fixed

2. Push the accelerator pedal (18) and at the same time,

release the parking brake.
The vehicle can roll away without pushing the

accelerator pedal (18).
3. The vehicle starts to drive (clutch engages automatically).
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7
12
13
Z 51 349
16/55 200−1−2070c_en
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 “ − ”.
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7
12
13
Z 51 346 Z 52 102
18/55 200−1−2070c_en
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 51346)
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 U/min (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)
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7
12
13
Z 52 103
20/55 200−1−2070c_en
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.
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7
12
13
Z 200 317 Z 51 349
22/55 200−1−2070c_en
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.
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24/55 200−1−2070c_en
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
(90 psi)) 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.
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7
N
D R 4
15
Z 52 105 Z 51 304
26/55 200−1−2070c_en
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(ignition−starter 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.
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7
90
Z 52 106 Z 52 107
35 36 B5
43
75
12
18 13
19
Z 52 108
28/55 200−1−2070c_en
7.1.12 Manoeuvring (Distance < 1m / 3.3 ft)
(Z 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 ”Off−road 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 / 3.3 ft) 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.
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7
Z 52 115
30/55 200−1−2070c_en
7.1.13 Towing away
The towing operation is described in detail in Sect. 14.

Observe the procedures defined there exactly.
7.1.14 Towing start
It is not possible to start the engine by towing it along.
Starting aid with external batteries, see Sect. 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 accelerate when travelling
downhill.
Manual driving mode
The exhaust brake is deactivated by the system when shifting.

After shifting successfully, the exhaust brake is automatically
switched on again.
Automatic driving mode
When actuating the exhaust brake, the system shifts back to the
gear where the highest brake performance was available.
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7
Z 52 107
35 36 B5
43
75
12
18 13
19
Z 52 108
32/55 200−1−2070c_en
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
programmed driving gear”.
To prevent damage to the mechanical parts of the clutch control,

shift the transmission to neutral for longer stops (more than 1−2
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 start−up 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

engages 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.
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7
34/55
31 32 33 34 35 36 37 38 39 40
43
km/h
mph
41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 48 996
200−1−2070c_en
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 U/min (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 U/min (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
specifications given in Sect. 6 referring to the gear
selection and braking.
7.1.18.2 Automatic transmission mode
Caution when driving downhill!

At the latest by an engine speed of 2300 U/min (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.
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Z 52 105
36/55 200−1−2070c_en
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
accelerator 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.
More information can be found in Sect. 8 “Braking”.
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7
Z 52 109 Z 52 110
35 36 B5
43
B6
35
75
36
12
18 13
19
Z 51 344
38/55 200−1−2070c_en
7.3 System malfunctions / error diagnosis
7.3.1 Fault messages
The drive gearbox has a self−diagnosis 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 non−active 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 there are two or more occurring errors from error class 2, the
system reacts as under error class 3.
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.
Error class 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)
Also see Sect. 6 under “Driver information system display (75)”

and in this section under “Transmission information display (43)”.
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7
40/55 200−1−2070c_en
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.
200−1−2070c_en 41/55
7
12
13
Z 52 105 Z 52 111
Z 52 112 Z 52 113
42/55 200−1−2070c_en
(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 three−digit 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)
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7
44/55 200−1−2070c_en
7.3.3.2 Listing / explanation of possible error displays
Error class 3 Effect

02, 03, 04, 05, 06, 07, 08, 09, 22, 34, 35, Driving: gear shifting is locked.
36, 37, 38, 39, 40, 41, 54, 61, 62, 66, 67, Standstill: Automatically shifted into neutral and the
68, 69, 70, 71, 72, 73, 77, 78, 82, 83, 84, gear shifting is locked.
85, 90, 101, 105, 117, 132, 136, 140, Continued operation is not possible.
144, 169, 170, 177, 179, 180, 181, 188, System not available.
189, 190, 191, 193
Driving: gear shifting locked, incl. neutral.
10, 42 Driving gear: Only when lowest gear is engaged for GP
high speed. Ignition on: System not available.
The following effects may happen:
17, 18, 19, 20, 21, 49, 50, 51, 52, 53, 97, Driving: Reduced comfort when driving, manoeuvring,
98, 99, 107, 120, 121, 122, 123, 124, shifting, increased shifting time.
164, 165 Standstill: Middle driving gear. No manoeuvring
operation.
Driving: Gear shifting is locked.
81 Standstill: it is possible to engage the driving gear.
Driving possible.
Driving: gear shifting is locked, including the shifting
110 attempts into neutral.
Standstill: Driving gears possible.
Driving: Gear shifting is locked.
118
Standstill: Engine stalls, if the clutch does not open.
Driving: clutch engages quickly. Gear shifting is locked.
119 Standstill: Automatic shifting into neutral system not
available.
11 Warning buzzer permanently active.
12, 44 Activation of the back−up light not possible.
23 Permanent control warning light.
25, 89 Display EE. No system reaction.
The following effects may happen:
26, 27, 28, 30, 31, 32, 33, 91, 92, 93, 94, Driving: Reduced comfort when driving, manoeuvring,
96, 113, 171, 173, 182, 183, 184, 192, shifting, increased shifting time
197, 199 Standstill: Middle driving gear. No manoeuvring
operation.
43, 75 Cannot control the warning buzzer.
55, 87 Cannot control the warning light.
76 Back−up light permanently switched on.
200−1−2070c_en 45/55
7
46/55 200−1−2070c_en

Display cannot be switched off.
86 Driving switch does not switch off.
No restriction of the system availability.
95, 100, 104, 111, 112, 125, 127, 128, Since an isolated error, no effect on the system or on
167, 174, 195, 196, 198 certain calculations e.g. wear on clutch not possible.
Driving: gear shifting is locked, including the shifting
102, 163 attempts into neutral.
The following errors may occur:
108, 175 Driving: Gear shifting is locked.
Standstill: System not available, driving gear possible.
System function not affected. Possible loss of pressure
126
was not displayed. Higher learning time.
Driving: gear shifting is locked, shifting out of neutral
129, 130, 131
possible. Standstill: Driving gears possible.
Driving: Restricted gear selection.
133, 134, 135
Standstill: Restricted driving gear, no reverse gear.
Driving: GP shifting locked. Only gears can be engaged
in the shifted GP area.
137, 138, 139, 145, 146, 147
Reduced shifting comfort, increased shifting time.
Driving: Automatic gear correction (last GV position) or
shift into neutral.
141, 142, 143, 148, 149, 152
Standstill: Driving in last GV position or using driving
switch.
System not available. Renewed GV shifting attempt
150
possible.
Driving: Automatic gear correction or shift into neutral.
151 Standstill: Driving gear can only be selected using
driving switch.
Driving and standstill: Automatic shift into neutral.
153, 155, 156
Renewed shifting using driving switch.
Driving: clutch engages. Next shifting attempt using
154 driving switch.
Standstill: Driving max. lower gear, higher GP.
158, 159, 160 Automatic gear correction.
Driving: possible to shift while driving.
166
Standstill: System not available.
Driving: no system restrictions.
168
Standstill: After reset, driving is possible.
200−1−2070c_en 47/55
7
A F
B H
C I
D J
E
Z 40 589
93
A8 A7
Z 200 318 Z 52 114
48/55 200−1−2070c_en
(Z 40 589, Z 200 318, Z 52 114)
7.4 Distributor gear
The distributor gear is rear−mounted 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 / off−road gear).
A = on−road gear, B = drive, C = emergency steering pump 1, D
= front drive, E = differential lock,
F = off−road 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 off−−road gear early enough (on level surface and
before entering difficult terrain); and not after the crane vehicle
has become stuck.
On−road gear, off−road gear and the differential lock can only be
activated when the vehicle is at a standstill (dog−clutching).
On rare occasions, it is not possible to switch from on−road gear

to off−road 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:
1. Apply the parking brake.

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 off−road gear is engaged.
6. Release the dual button (93).
200−1−2070c_en 49/55
7
93
A7
Z 52 105 Z 52 114
50/55 200−1−2070c_en
In case the off−road 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 1−6.
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/off−road 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 on−road to off−road gear.
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 (101.5 psi) is required for all
distributor gear shifts.
− Distributor gear in ”on−road gear” position:

The on−road gear is always engaged under normal
circumstances. No indicator light is shown.
− Distributor gear in ”off−road gear” position:
Press dual button (93); the indicator light (A7) lights up.
The off−road gear is primarily intended for:

− Driving on a work site
− “Driving when rigged”
− Driving with the lowest speed possible.
200−1−2070c_en 51/55
7
93
A7
Z 52 114
52/55 200−1−2070c_en
− 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.
Detailed operating information regarding this can be found in

Sect. 10 of these operating instructions.
Be sure to follow the instructions and regulations

outlined 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 more details, see Sect. 14 “Towing”.
When towing is finished, on/off−road 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!)
200−1−2070c_en 53/55
7
93
A7
Z 52 114 Z 52 115
B5
Z 52 104 Z 200 319
54/55 200−1−2070c_en
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 off−road 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 Sect. 14.3 of this operating manual.
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).
200−1−2070c_en 55/55
Brakes 8
200−1−2080−247_en 1/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
Z 200 150 Z 200 153
2/29 200−1−2080−247_en
Brakes 8
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 (26.4 kip).
Ensure 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).
1. Call up the menu selection 4 (Check information” (Z 200 150)

in the main menu.
2. 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 (101.5 psi), the
braking system must be topped up at medium revs, until a pres-
sure of 8 bar (116 psi) has been reached.
Fault / warning displays
The following warnings are displayed on display (43), if the pres-

sure supply falls below 5.5 bar (79.8 psi):
− 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) is shown 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 acci-
dents.
200−1−2080−247_en 3/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
4/29 200−1−2080−247_en
Brakes 8
8.2 Service Brake
(Z 52 136)
The service brake (dual circuit compressed air braking system)

acts on all wheels.
To brake, press down pedal (19) of the brake valve sensitively.
Immediately after driving, test the brakes on a dry, anti−skid

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 moisture

has seeped through to the brake linings, apply the service
brake lightly until braking is faultless.
The service brake must not be used for sustained periods

under any circumstances. Danger of overheating (fading)!
The service brakes may only be used when driving down-

hill in order to brake the crane until a speed has been achie-
ved where the crane switches back to the next gear.
This is why you must select the gear before driving down-
hill with which the speed of the crane can be maintained
when driving downhill.
Never drive with a defective brake system!
After the brakes have been used more intensively, 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.
200−1−2080−247_en 5/29
8
B35
B36
Z 62 761
6/29 200−1−2080−247_en
Brakes 8
8.2.1 Display of Wear to the Brake Linings (Disc Brake)

(Z 62 761)
The brake linings are monitored by wear displays. Any wear on

the left disc brake is indicated by indicator light (B35) and any
wear on the right disc brakes is indicated by indicator light (B36).
At first, the wear displays are only illuminated during braking.

They are constantly illuminated as wear increases.
RISK OF ACCIDENTS!
The brake linings are worn and the braking effect is
greatly reduced if indicator light (B35) or indicator light
(B35) is illuminated constantly or during braking.
Components of the braking system could become dama-
ged if driving is continued.
The brake linings must always be replaced axle by axle.
200−1−2080−247_en 7/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
Z 200 150 Z 200 153
8/29 200−1−2080−247_en
Brakes 8
8.3 Parking Brake
(Z 52 136, Z 200 150, Z 200 153)
To park the crane, the parking brake (hand brake) must be ap-
plied!
It is opened with compressed air and closed with accumulated
spring force.
In the 5−axle basic unit the retaining brake is effective for axles
1, 3, 4 and 5.
In the 6−axle basic unit the retaining brake is effective for axles
1, 3, 5 and 6.
If the service brake fails, the retaining 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 mechanically released in 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 posi-
tion 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) po-
sition.
RISK OF ACCIDENTS!
Make sure that the lever (14) locks correctly in the full brake
position, as it can otherwise return automatically to the re-
leased position.
The lever (14) must not be able to be pushed backed into the
released position (without actuating the lock).
200−1−2080−247_en 9/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
111
112
Z 200 421
10/29 200−1−2080−247_en
Brakes 8
(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. incline of 28 % but

not on the maximum incline on which the crane can be driven.
If required, additionally secure the crane with chocks to prevent

it from rolling 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 increasingly. Do not allow the lever to
lock in place!
Only use the parking brake for parking or in case of an emer-

gency.
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 spe-
cial 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 driver’s cab.
Instructions on exceptional cases can be found in section 6 of

these operating instructions.
8.5 Test Points of the Braking Circuits

(Optional Equipment / National Regulations)
(Z 200 421 principle illustrations)

Depending on customer requirements and national regulations,
the vehicle can be equipped with additional test points (111, 112)
for both braking circuits. The test points have been marked with
signs so they can assigned to a braking circuit.
The test connections (111, 112) are located in the storage com-
partment on the left side of the vehicle between the axles.
200−1−2080−247_en 11/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
3
0 38
I
II
III
IV
V
Z 53 048
12/29 200−1−2080−247_en
Brakes 8
8.6 Retarder Brakes
(Z 52 136, Z 53 048)
The crane vehicle is fitted with two sustained−action brakes (ex-

haust brake, hydraulic retarder) as standard.
Both are actuated using the combination switch (3). When swit-
ching on (lever in 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 cannot lock.
The sustained−action 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; froms-
witch stage II the hydraulic retarder is switched on as well. De-
pending on the lever position, the brake effect is increased stea-
dily 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
sustained−action brakes. Also in normal driving conditions, the
non−wearing sustained−action brakes should be used where
possible for braking.
The effect of the exhaust brake and the hydraulic retarder is de-
pendent on the engine speed.
The higher the rpm/speed, the greater the braking effect.
The accelerator must not be pressed when the sustained−

action brakes are in operation!
The correct gear level must be selected before a downhill/

uphill stretch is reached at which the speed can be held
constant.
The effect of a sustained−action brake is interrupted du-

ring a shifting procedure. The vehicle can speed up du-
ring downhill driving.
200−1−2080−247_en 13/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
3
0 38
I
II
III
IV
V
Z 53 048
14/29 200−1−2080−247_en
Brakes 8
Manual Driving Operation
The exhaust brake is deactivated by the system during gear

shifts. After shifting, 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.
8.6.1 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 in-
creases 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 illu-
minated.
The exhaust brake is only effective at an engine speed of more

than 900 min−1 (rpm) . If the engine speed falls below 900
min−1 (rpm), the exhaust brake is automatically switched off (and
switched back on again when the speed increases).
The exhaust brake is deactivated even when engine speeds are
over 2300 min−1 (rpm).
200−1−2080−247_en 15/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
3
0 38
I
II
III
IV
V
Z 53 048
16/29 200−1−2080−247_en
Brakes 8
8.6.2 Hydraulic Retarder (System “ZF Intarder”)

(Z 52 136, Z 53 048)
The retarder is an additional hydrodynamic brake which is inte-

grated in the transmission and functions without causing wear.
By actuating the combination switch (3) (lever in position II−V) the
hydraulic retarder is switched on; the indicator light (38) is illumi-
nated. The brake effect is increased steadily from the first to the
last step.
Using the retarder has no effect on transmission operation.
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 en-
gine speed does not fall below 1600 min−1 (rpm). Otherwise,
sufficient cooling is not ensured.
You might have to switch back a gear in order to increase
speed and water pump and fan performance.
If the oil temperature rises to unauthorised values (over 1505C /

3025F) − 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 at less than 955C
(2035F).
If the retarder performance is not regulated by the driver, the sy-
stem automatically reduces the braking effect until the permitted
temperature has been achieved (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 swit-

ched on, the engine can only be switched off when the tem-
perature indicator has returned to the permitted range.
200−1−2080−247_en 17/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
38
3 6
0
A21
I
II
III
IV
7
V
Z 53 049
18/29 200−1−2080−247_en
Brakes 8
(Z 52 136, Z 53 049)
8.6.3 Function “Sustained−Action Brake Cruise Control”
Using the function “Sustained−action brake cruise control” a set

(”fixed”) speed can be kept constant during a downhill stretch −
within the limits of the existing braking capacity (engine brake tor-
que, gear step).
The sustained−action brake cruise control is activated using the

actuating lever (3) on the right−hand side of the steering column.
The preheating indicator (A21) in the driver display (43) is illumi-
nated.
The sustained−action brake cruise control can only be activated

if the sustained−action brake is switched on (= lever position I−V).
The desired driving speed − in relation to the speedometer − can
be selected and ”fixed” (lever position 6 or 7) in any lever position.
The electronic system saves the driving speed ”fixed” in this way.
The saved speed is maintained when the braking effect of the su-
stained−action brake is sufficient.
If the current driving speed is lower than the “set” speed, the su-
stained−action brake remains without function. If speed attains
the saved value again, the sustained−action brake becomes ac-
tive again.
If speed is increased while the sustained−action 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 sustained−action brake, the ”sustained−action brake
cruise control” must be switched off first (tap gearshift position 4).
Then the driving speed can be reduced manually via the different
steps (lever positions I−V) of the sustained−action 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.
200−1−2080−247_en 19/29
8
31 32 35 36 38 39
B3
43
3 B4
39
38
36
35
12
18 13 32
19 14
31
Z 52 136
38
3 6
0
A21
I
II
III
IV
7
V
Z 53 049
20/29 200−1−2080−247_en
Brakes 8
Activating the sustained−action brake cruise control:
− Lever (3) in position
0 = deactivated
I−V = sustained−action brake step I−V (engine brake
and retarder)
6/7 = sustained−action 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 sa-
ved brake effect (speed).
Switching off the sustained−action cruise control:
Tap actuating lever (3) in position “4”.
200−1−2080−247_en 21/29
8
31 32 35 36 38 39
B27
B29
43
3 104
B30
38
36
35
12
18 13 32
19 14
31
Z 52 137
22/29 200−1−2080−247_en
Brakes 8
(Z 52 137)
8.7 Anti−Blocking−System (ABS)

The vehicle is equipped with the blocking protection “ABS”.
5−axle basic unit

The ABS circuit consists of 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.
6−axle basic unit

The system consists of two separate circuits (not to be confused
with braking circuits).
ABS circuit 1
consists of axles 1, 2, 3, 5 ,6 (of the vehicle) and possibly a dolly
as well.
The function is monitored as follows:
− Lamps B29 + 32 for the vehicle axles (without axle 4).
− Lamps B30 + 31 for possible dolly axles / additional axle /
dummy axle.
ABS circuit 2
is simply axle 4 of the vehicle.
The function is monitored by the preheating indicator (B27).
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 sustained−action brake is automatically
switched off. However, the indicator light (38) does not go out.
Afterwards, the operating mode most recently activated is swit-
ched on.
RISK OF ACCIDENTS!
ABS does not release you from driving in a way that is adap-
ted to the traffic and road conditions. Track and steerability
of the vehicle are improved.
For example, ABS is not able to prevent the consequences
of keeping too small a safety distance or of increased curve
speeds.
200−1−2080−247_en 23/29
8
31 32 35 36 38 39
B27
B29
43
3 104
B30
38
36
35
12
18 13 32
19 14
31
Z 52 137
24/29 200−1−2080−247_en
Brakes 8
8.7.1 ABS: Full Function / Off−road Mode
ABS is always active, however, the driver can switched it to ”Ter-

rain mode” using key (104).
ABS in ”Terrain mode” is indicated by the flashing of the indicator
light (32).
The brake path can be reduced on terrain or unpaved roads (i.e.

soft or extremely bumpy surfaces as well as sloping roads) by
switching ABS over to ”Terrain mode”.
The control is speed−dependent; at higher speeds the ABS con-
trol also switches to full function when in ”Off−road 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 on terrain,
switch ABS over again.
In the 6−axle basic unit, only the ABS circuit 1 is switched over
to terrain mode due to the system. The ABS circuit 2 cannot be
switched over.
Terrain mode may not be used on public roads.
8.7.2 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 indicator light (B27, B29, B30) is only displayed in case of da-
mage (indicator light B27 only exists in the 6−axle basic unit).
The functions check is finished after the two check signals (ap-
prox. 30 sec.) have sounded.
200−1−2080−247_en 25/29
8
31 32 35 36 38 39
B27
B29
43
3 104
B30
38
36
35
12
18 13 32
19 14
31
Z 52 137
26/29 200−1−2080−247_en
Brakes 8
The indicator lights (31, 32) must light up for a short period
of time and must have gone out after the acoustic check si-
gnal.
Blocking protection is not ensured if the displays for func-
tions check do not light up or do not go out after the check
signal.
The preheating indicators (B27, B29, B30) may not be illumi-

nated. (Indicator light B27 only exists in the 6−axle basic
unit)
If it lights up, locking protection is not ensured at each axle.
RISK OF ACCIDENTS!
If an ABS fault is displayed, (”CAUTION” (35) would light up
at the same time), braking behaviour of the vehicle can
change.
Drive especially carefully.
Have the fault rectified immediately in a specialist garage.
8.7.3 Braking with ABS
− In case of danger, fully activate the brake pedal. This ensures

that all wheels are monitored and optimum delay of vehicle
is achieved.
− During ABS control, the sustained−action brake is automati-
cally switched off. However, the indicator light (38) does not
go out.
− If you drive with a dolly without ABS, it can lock up if you have
to make an emergency stop. In this case, the driver must ob-
serve the towed vehicle in the rearview mirror. The towing ve-
hicle 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 lock up. In this case, the driver must observe the to-
wed 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
“Terrain mode”.
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8
2 1 5 4 3
Z 200 225
28/29 200−1−2080−247_en
Brakes 8
8.7.4 ABS with Dolly Operation
(Z 200 225)
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 7−pole)
When using a dolly, the relevant regulations must be observed

(e.g. if for example ABS is required due to the number of axles).
200−1−2080−247_en 29/29
Steering 9
9 Steering
9.1 General System Description
The steering of the crane chassis consists of a hydraulic

two−circuit steering system and electro−hydraulic rear−axle
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 electro−hydraulically, depending on the speed.
A computer monitors the control of the electro−hydraulic

rear−axle 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

engine−dependent driven steering pumps and a
driving−dependent 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.
200−1−2090c_en 1/57
9
2/57 200−1−2090c_en
Steering 9
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.
200−1−2090c_en 3/57
9
4/57 200−1−2090c_en
Steering 9
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 crossties.
Always ensure that you have sufficient space for safe
movement.
Unauthorised persons must stay well clear of the turning

area of axles, wheels and crossties.
For maintenance work in the turning area of axles, wheels

and crossties, 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

transducers), particular caution is required.
It must be ensured that no movements can occur on axles,
wheels, or crossties. This can be achieved by switching off
the engine or removing the connector at the corresponding
non−return valves.
Caution following servicing work!

Errors in the steering system can lead to axle movements.
Keep a distance from the axles when starting the engine;
no−one may be in the slewing range of the axles, wheels or
crossties.
Caution with the manual emergency steering control!

Particular care is required in case of manual emergency
steering. When actuating the valves for manual emergency
steering, the crossties and the wheels on the affected axle
will turn.
200−1−2090c_en 5/57
9
35 36 B2
43
B8
B9
B10
35
36
Z 52 123
6/57 200−1−2090c_en
Steering 9
(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
electric−hydraulic rear−axle steering) are monitored
electronically.
Faults are displayed on the “driver’s information” screen (43) by

means of the following indicator lights:
B2 Fault electric−hydraulic rear−axle 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 different colours is described in detail in
section 4 (driver’s cab) under “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.
If there is a pink−coloured message, the function cannot be

monitored as there is an error in the corresponding connection;
i.e. a short circuit or a disruption.
In the case of pink−coloured 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 fault and rectify 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.
200−1−2090c_en 7/57
9
35 36 B2
43
B8
B9
B10
35
36
Z 52 123
8/57 200−1−2090c_en
Steering 9
(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 through−feed
B9: Steering circuit 2 (”main pump 2”) no through−feed
B10: Steering circuit 3 (emergency steering pump) no

through−feed
In case of error ”no flow on the emergency steering pump”

(indicator light B10) will only be displayed by the system at driving
speeds > approx. 8 km/h (5 mph).
The indicator lights (B8, B9 and B10) must not light up as

a rule.
If one of these indicator lights lights up red (at the same
time “STOP” (36) is displayed), there is a dangerous 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 pink−coloured 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 pink−coloured
indicator lights / changing displays.
200−1−2090c_en 9/57
9
35 36 B2
43
B8
B9
B10
35
36
Z 52 123
1
12 t 12 t 12 t 12 t 12 t 12 t 12 t
Z 200 247
10/57 200−1−2090c_en
Steering 9
(Z 52 123)
9.3.2 Monitoring the electro−hydraulic rear axle steering
The function of the electric−hydraulic rear−axle steering is

monitored during driving by an alarm buzzer and the indicator
light (B2).
The indicator light (B2) signalises an error in the

electric−hydraulic rear−axle steering of the basic unit or an error
in the electric−hydraulic steering of the optional additional axle
(1, Z 200 247).
The warning buzzer sounds additionally for each new fault and
in the event of maloperation during a program change.
The indicator light (B2) must not light up.

If it lights up in red (“STOP” (36) would be indicated at
the same time), there is a dangerous error in the
electric−hydraulic rear−axle steering of the basic unit or
the optional additional axle.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!
In the case of a pink−coloured 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.
200−1−2090c_en 11/57
9
92
43
A6
Z 52 124
12/57 200−1−2090c_en
Steering 9
(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/h (3 mph) 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) “Driver’s information”. A white indicator light shows a
preselected steering programme; a yellow indicator light shows
the currently active steering programme.
200−1−2090c_en 13/57
9
92
43
A6
75 B2
Z 52 125
”A”
”B”
”C”
Z 200 274
14/57 200−1−2090c_en
Steering 9
9.4.2 Steering program “road travel”
(Z 52 125)
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.
5−axle−basic unit (Z 200 274, A)
− Rear axles 4 and 5 using the electric−hydraulic rear−axle

steering (depending on the driving speed).
(Axle 3 cannot be steered = rigid axle).
6−axle−basic unit (Z 200 274, B)
− Rear axles 5 and 6 using the electric−hydraulic rear−axle

steering (depending on the driving speed) (axle 3 cannot be
steered = rigid axle; axle 4 is hydraulically locked in the
straight−ahead position).
Basic unit with fitted additional axle (Z 200 274, C)
− Axles of the basic unit: for function of steering, see

corresponding description of the basic unit.
Axle of the additional axle: electric−hydraulic.
− Axle of the additional axle: electric−hydraulic.
For driving speeds < 20 km/h (12 mph), the steered rear axles
steer around the steering centre of the front axles.
For driving speeds > 20 km/h (12 mph) 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
(28 mph).
200−1−2090c_en 15/57
9
35 36 B2
43
B8
B9
B10
35
36
Z 52 123
”A” ”B”
A6
92
A3
85
86 87 88 89
Z 200 275
16/57 200−1−2090c_en
Steering 9
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 electric−hydraulic
rear−axle steering” must not light up.
Caution RISK OF ACCIDENTS !

When one of the indicator lights (A6 or B2) lights up
together with the “STOP” display (35) and the warning
buzzer sounds, the operational reliability of the steering
is no longer guaranteed.
Stop vehicle immediately; there is a great risk of
accidents. Never drive with a defective steering system!
9.4.2.1 “Narrow cornering” for road travel
(Z 200 275)
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 / 12 mph) .
5−axle−basic unit (Z 200 275, A):
− In the steering programme, “Narrow cornering”, the 4th axle

steers more strongly than during normal road travel (as
soon as >85% has been achieved in the steering angle at
axle 1).
6−axle−basic unit (Z 200 275, B)
− In the steering programme “Narrow cornering”, the 5th axle

steers more strongly than during normal road travel (as
soon as > 85% has been achieved in the steering angle at
axle 1). The 4th axle aligns itself correctly in the geometric
sense to the new steering centre.
This achieves a smaller turning radius − albeit with increased tyre

wear.
200−1−2090c_en 17/57
9
”A” ”B”
A6
92
A3
85
86 87 88 89
Z 200 275
18/57 200−1−2090c_en
Steering 9
Switch on steering program “tight cornering”:
− Reduce driving speed to < 20 km/h (12 mph).
− Press button (86) (”Narrow cornering” is preselected).

The indicator light (A3) appears (first in white).
− Continue to reduce driving speed to < 5 km/h (3 mph).

The selected programme becomes active;
the indicator light (A3) changes from the colour white to
yellow.
If the driving speed is not reduced to < 5 km/h (3 mph) 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).
− Usually while the unit is rolling, the steering angle of axle 4

(5−axle−basic unit) or axle 5 (6−axle basic unit) is
automatically synchronised with the other steering axles
after a short stretch.
− As soon as the synchronised position has been achieved,

the indicator light (A3) goes out.
Even when driving speeds > 20 km/h (12 mph) have been
achieved, “Narrow cornering” is automatically switched off again;
indicator light (A3) goes out.
200−1−2090c_en 19/57
9
”A” ”B” ”C” ”D”
Z 200 276
”A” ”B” ”C” ”D”
Z 200 277
20/57 200−1−2090c_en
Steering 9
9.4.3 Steering program “construction site mode”
(Z 200 276, Z 200 277)
Depending on the selected programme, the steered rear axles

are steered by the monitoring programme, corresponding with
the front axles (axles 1 and 2) (computer−controlled separate
hydraulic circuit).
The non−steered 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:
5−axle−basic unit (Z 200 276); 6−axle−basic unit (Z 200 277)
(Z 200 276: 5−axle−basic unit; Z 200 277: 6−axle−basic unit)
− “Manual rear−axle 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 / non−public highways
− if the crane is in the transportation state

(boom set down, axle loads max. 17 t / 37.5 kip)
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 / 37.5 kip) and the overall weight.
200−1−2090c_en 21/57
9
35
B2
43
6 9 35
Z 52 128
5
6
7
8
9
10
Z 52 134
22/57 200−1−2090c_en
Steering 9
(Z 52 128)
The indicator light (B2) “fault electric−hydraulic rear−axle

steering”, with which the electric−hydraulic rear−axle
steering is monitored, must not light up.
When it lights up together with the “STOP” display (35)
DRIVING IS PROHIBITED!
(Z 52 134)
Remember when using the steering programme

“Construction site operation”:
Raising the “lift axle” inevitably leads to increased axle

loads on the axles remaining on the ground.
After the ”lift axle” is raised − with the vehicle stationary − a

pressure of 260 bar (3771 psi) 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

“four−circuit system”.
The differential locks must not be actuated in the steering

figures “manual rear−axle 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

/ 3 mph).
200−1−2090c_en 23/57
9
92
43
A6
Z 52 124
24/57 200−1−2090c_en
Steering 9
9.4.3.1 Shared characteristics of all steering programs for

the “construction site mode”
(Z 52 124)
− The basic release of the various steering programmes

“Construction site operation” is done by pressing the switch
(92) at speeds < 5 km/h (3 mph).
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 (12 mph) 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 during slow driving
(V < 5 km/h / 3 mph); they only become active when all
axles are synchronised.
− Normally “lift axle” (axle 4) 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” when the steering
/ wheel angles are within the permissible range (for state ”lift
axle” not raised); otherwise reduce the steering angles by,
for example, turning the steering wheel (wheels straight
ahead).
− When the “lift axle” is raised, speed is limited to < 20 km/h
(12 mph).
− If the “lift axle“ remains on the ground, the steering angles
are limited at the steering figures at which the rear axles are
automatically steered, i.e. they are not limited for “Manual
rear−axle 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.
200−1−2090c_en 25/57
9
”Af” ”As”
85 A6
92
A18
A2
86 87 88 89
Z 200 278
26/57 200−1−2090c_en
Steering 9
(Z 200 278)
9.4.3.2 “Manual rear−axle steering” (steering figure “A”)
(Af: Principle sketch of the 5−axle−basic unit; As: Principle sketch

of the 6−axle−basic unit)
The front axles are steered with the steering wheel.

The lift axle (non−steered) remains on the ground, but it 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 of the steering angles to protect against
increased tyre wear (steering error); not even when the “lift axle”
remains on the ground.
Switch on the steering program “Manual rear−axle steering”
− Press switch (92) “Release steering programmes“.

The indicator light (A6) lights up.
Speed lock (20 km/h / 12 mph) is effective and indicator
light (A18) lights up.
− Press button (85) “Manual rear−axle steering”.

After the wheels have been synchronised, the selected
programme becomes active.
The indicator light (A2) changes from white to yellow.
− Using button (85), the rear axles can now be steered:

Press left button = wheel turn to the left
Press right button = wheel turn to the right
Switch off the steering program “manual rear−axle 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.
200−1−2090c_en 27/57
9
”Bf” ”Bs”
85 A6
92
A18
A3
86 87 88 89
Z 200 279
28/57 200−1−2090c_en
Steering 9
(Z 200 279)
9.4.3.3 “Tight cornering” (steering figure “B”)
(Bf: Principle sketch 5−axle−basic unit; Bs: Principle sketch

6−axle−basic unit)

The “lift axle” (non−steered) remain on the ground, but it can be
The rear axles are steered analogous to the front axles by means
of the electric−hydraulic rear−axle steering. At the end axle 4
(5−axle−basic unit) or axle 5 (6−axle−basic unit) steer more
strongly than during normal road travel.
In the 6−axle−basic unit the 4th axle aligns itself correctly in the
geometric sense to the new steering centre.
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”
− Activate switch (92) “Release steering programmes“.

− Press button (86) (”Narrow cornering” is preselected).

After the wheels are synchronised, the selected
programme remains active.
The indicator light (A2) changes in colour from white to
yellow.
Switch off the steering program “tight cornering”

The indicator light (A3) changes from the colour yellow to
white.

200−1−2090c_en 29/57
9
”Cf” ”Cs”
85 A6
92
A18
A4
86 87 88 89
Z 200 280
30/57 200−1−2090c_en
Steering 9
(Z 200 280)
9.4.3.4 “Driving away from the wall” (Steering figure “C”)
(Cf: Principle sketch 5−axle−basic unit; Cs: Principle sketch

The steering centre is at the vehicle rear, the rear end does not
swing out.
The “lift axle” (non−steered) remains on the grounds, but it can
be raised by the driver.
The rear axles are steered analogously to the front axles by
means of the electric−hydraulic rear−axle 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”

− Press button (87) (”Driving away from the wall” is

preselected).
The indicator light (A2) changes from white to yellow.
Switch off the steering program “Driving away from the wall”

200−1−2090c_en 31/57
9
”Df” ”Ds”
85 A6
92
A18
A5
86 87 88 89
Z 200 281
32/57 200−1−2090c_en
Steering 9

(Z 200 281)
9.4.3.5 “Diagonal steering” (steering figure “D” (crab travel))

(Df: Principle sketch 5−axle−basic unit; Ds: Principle sketch
The rear axles are steered analogous to the front axles and with
the same angle (parallel). The steering lock is determined by the
steering wheel.
The “lift axle” (non−steered) remains on the ground but can be
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”

− Press button (88) (”Diagonal steering” is preselected).
the indicator light (A2) changes from white to yellow.
Switch off the steering program “diagonal steering”

200−1−2090c_en 33/57
9
34/57 200−1−2090c_en
Steering 9
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 (1 mph).
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
− Button activation while at a standstill
Continuos activation of the corresponding steering
programme button while at a standstill; the axles move
independently into the corresponding desired position as
long as the button remains pressed.
When changing back into 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 straight−ahead 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 so−called ”capture” of the
electric−hydraulic 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.
200−1−2090c_en 35/57
9
36/57 200−1−2090c_en
Steering 9
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.
200−1−2090c_en 37/57
9
5
6
7
92 A6
8
9
10
102 A14
Z 52 133 Z 52 134
I II III
”A”
IV V VI
I II III
”B”
IV V VI
Z 200 282
38/57 200−1−2090c_en
Steering 9
9.4.5 Raising/Lowering the “Lift Axle”
(Z 52 133, Z 52 134, Z 200 282)
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
(12 mph).
9.4.5.1 Raise the “Lift Axle”
1. Stop vehicle; apply retaining brake; transmission in “neutral”!
2. Set the engine speed to approx. 1500 U/min (rpm) .

3. Actuate switch (92) “enable steering programs“.
4. Activate switch “Raise lift axle” (102) (unlock); this raises the
“lift axle” (axle 3) to the top final position.
The pressure gauges 6 and 9 display no pressure.
5. 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 the steering and wheel
angles are within the permissible range (for state “lift axle” not
raised); otherwise reduce steering angles by, for example,
reducing the steering wheel turns (wheels straight ahead).
1. Stop vehicle; apply retaining brake; transmission in “neutral”!
2. Switch off the switch “raise lift axle” (102) (lock).

The raised “Lift axle” is lowered to the ground again.
(Z 200 282)
3. If the “Lift axle” is on the ground, a pressure of 105 bar

(1523 psi) 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).
(Z 200 282, A: 5−axle−basic unit; Z 200 282, B: 6−axle−basic
unit)
4. The overall level must be checked for road travel (relevel if

required).
200−1−2090c_en 39/57
9
F1 F2 F3 F4
Z 52 116
40/57 200−1−2090c_en
Steering 9
9.5 Steering Computer / Fault Diagnosis / Fault List
The steering computers are in the floor of the driver’s 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.
200−1−2090c_en 41/57
9
35 36
B2
43
35
36
Z 52 117
F1 F2 F3 F4
Z 52 116
42/57 200−1−2090c_en
Steering 9
(Z 52 117, Z 52 116)
9.5.2 Registration of a fault
The electric−hydraulic rear−axle steering has a self−diagnosis

system.
When the system recognises a fault, this is displayed to the driver
on the display (43) “driver’s information” by the indicator light (B2)
and additionally signalled by the warning buzzer.
At the same time, all faults are displayed on the corresponding

steering computer, however, the driver cannot see this during
driving (main steering computer: display A ; steering computer
without display: two−digit 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) “driver’s

information”
Caution !
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 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.

When the indicator light (B2) lights up together with the
“STOP” display (35) and the alarm buzzer sounds, the
operational reliability of the steering is no longer
guaranteed.
Stop vehicle immediately; there is a great risk of
accidents. Never drive with a defective steering system!
200−1−2090c_en 43/57
9
Z 52 118
Z 52 119
44/57 200−1−2090c_en
Steering 9
See also section 6 “Displays on the Driver’s information display

(43)”.
9.5.2.2 Fault display on screen (A) of the steering computer
Display in the fault−free 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 fault location: 10
− Example fault type: 07
− Example fault 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
fault−free state (”no error”, “ >” symbol).
200−1−2090c_en 45/57
9
F1 F2 F3 F4
3 sec.
Z 52 120
Z 52 121 Z 52 122
46/57 200−1−2090c_en
Steering 9
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 menu special functions:

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”.
Continue to menu point “error memory”:

By pressing the PLUS key (F 3) you change from the “i/o data
display” to the “error memory”.
Activate error memory:

By pressing the ENTER key (F4) the error memory function is
activated. The display changes to the first fault that is stored.
(Z 52 121)
Read out fault 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.
200−1−2090c_en 47/57
9
F1 F2 F3 F4
Z 52 116
LCD
Z 53 001
48/57 200−1−2090c_en
Steering 9
(Z 52 116, Z 53 001)
Remote−controlled operation:
Individual steering computers of the system do not have their own
display. The faults of all steering computers are read off centrally
on display screen (A) of the main steering computer.
To this end, 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 selecting the desired steering computer the display
changes constantly between “choose SLC: ?? and the
display contents 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. Activating / reading out the selected steering computers:

Carry out process “Activating / reading out error memory” (as
described on the previous page).
7. Exiting the selected steering computer:

By switching the ignition off.
9.5.3.2 Delete error memory
The error memory may only be deleted in consultation with our

customer service department.
200−1−2090c_en 49/57
9
35 36
B2
43
35
75
36
12
18 13
19
Z 52 117
50/57 200−1−2090c_en
Steering 9
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 on display (43): No

reaction of the steering system: warning; steering behaviour
is not limited.
Effect: unlimited driving operation is possible.
Fault category 1
Display on display (43): indicator light (B2) + “caution” (36) +

single warning signal.
Reaction of the steering system: steering of the axles / of the
system up to the next straight−ahead position.
Effect: speed lock partially effective.
Fault category 2
Display on display (43): indicator light (B2) + “caution” (36) +

single warning signal or indicator light (B2) + “STOP” (35) +
multiple warning signal.
Reaction of the steering system: independent steering in the
straight−ahead position.
Effect: speed lock effective.
Fault category 3
Display on display (43): indicator light B2 + “STOP” (35) +

multiple warning signal.
Reaction of the steering system: self−centring or locking of the
axle (safe state).
Effect: speed lock effective.
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)
200−1−2090c_en 51/57
9
Z 200 283
Y1 ”A” ”B” Y2
X1 X2
Z 200 284
52/57 200−1−2090c_en
Steering 9
(Z 200 283, Z 200 284)
9.6 Manual emergency steering
Caution, increased risk of crushing!

When the valves for the manual emergency steering
control are actuated the crossties and the wheels move
on the affected axle. In the case of manual emergency
steering, particular caution is therefore required.
Make sure that you have sufficient space to move in
freely.
If the steering computer fails, all valves are without current; i.e.
the steered rear axles are locked in the 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 non−return 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 non−return 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.
There are two types of manual emergency activation devices of

the non−return valve:
Type A:
activating the non−return valve (Y) by pressing the key (Y1) in the
blue anodised knurled nut. After the key has been released, the
key jumps back into its original position.
Type B:
activating the non−return valve (Y) by pressing the turning the
black plastic rotating knob. The rotating knob locks into the
activated position.
After manual emergency activation of the axle the rotating knob
must be brought back into its original position manually. To do so,
the rotating knob is pressed and turned back at the same time.
200−1−2090c_en 53/57
9
Y1 ”A” ”B” Y2
X1 X2
Z 200 284
54/57 200−1−2090c_en
Steering 9

For normal operation, the non−return valves must not be
actuated manually.
It may only be used in case of emergency, e.g. in order to
move the vehicle from a dangerous area. The non−return
valves must then spring back into their original position
immediately (type A) or turned back (type B).
If the non−return valves do not spring back into their
original position or are not turned back because they are
blocked, for example, the steering system is no longer
safe. The axles can change position in an uncontrolled
fashion. Safety risk!
(Z 200 284)
Steps for positioning an axle
Type A:
1. Stop vehicle; apply retaining brake; secure against rolling

away; transmission in “neutral”; running engine.
2. Unlock axle:
activate non−return valve (Y) by pressing the key (Y1) in the
blue anodised knurled nut; hold button down.
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 the
straight−ahead position):
∗ Release the valve tappet (X1 / X2).
The axle no longer moves.
∗ Release the button (Y1); the valve rotor springs back into
its original position.
The axle is locked again.
200−1−2090c_en 55/57
9
Y1 ”A” ”B” Y2
X1 X2
Z 200 284
56/57 200−1−2090c_en
Steering 9
(Z 200 284)
Type B:
1. Stop vehicle; apply retaining brake; secure against rolling

away; transmission in “neutral”; running engine.
2. Unlock axle:
activate non−return valve (Y) by pressing and turning the
black plastic rotating knob at the same time. The rotating
knob locks into the activated position.
The axle is no longer locked as long as the rotating knob is
locked in place.
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 the
straight−ahead position):
∗ Release the valve tappet (X1 / X2).
The axle no longer moves.
∗ Bring the rotating knob (Y2) back into its original position:
to do so the rotating knob is pressed lightly and turned
back at the same time.
200−1−2090c_en 57/57
Differentials / Differential Locks 10
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

An additional longitudinal differential is fitted in axle 4 (5−axle
basic unit) and / or in axle 5 (6−axle basic unit).
Activation axle 3:
When the longitudinal differential locks are set, axle 3 is
activated.
− Transverse differential
Transverse differentials are fitted in the drive axles 2, 3, 4, 5
(5−axle basic unit) and / or 2, 3, 5, 6 (6−axle basic unit).
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 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 rear−axle steering” and “Diagonal
steering”.
200−1−2100A_en 1/7
10
2/7 200−1−2100A_en
You must avoid activating the differential locks during

steering figures “Narrow cornering” and “Driving away from
the wall”.
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.
200−1−2100A_en 3/7
10
94 95
A9
A10
Z 52 140
4/7 200−1−2100A_en
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
(5−axle basic unit) and / or in axle 5 (6−axle basic unit) are
switched on and axle 3 is activated.
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
(5−axle basic unit) and / or in axle 5 (6−axle basic unit) are
switched off and axle 3 is switched off.
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.
200−1−2100A_en 5/7
10
94 95
A9
A10
Z 52 140
6/7 200−1−2100A_en
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 in the drive axles 2, 3, 4, 5 (5−axle basic
unit) and / or 2, 3, 5, 6 (6−axle basic unit) are switched on
together.
3. The display (A10) lights up.
Switch off the transverse locks as follows:
2. Press switch (95) again.

The transverse locks in the drive axles 2, 3, 4, 5 (5−axle basic
unit) and / or 2, 3, 5, 6 (6−axle basic unit) 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.
200−1−2100A_en 7/7
Hydraulic Suspension 11
200−1−2110c_en 1/27
11
99
43
A6
Z 52 145
Z 200151
2/27 200−1−2110c_en
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 three−circuit system to improve road handling.
You switch to the three−circuit system by pressing the lockable

switch (99).
When indicator light (A6) comes on, the suspension is in the
three−circuit system.
Driving with the three−circuit system means less lateral

stability. The max. road speed should therefore not exceed
15 km/hour (9 mph).
When the crane’s equipment is erected, it must be driven

with the four−circuit 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 no−one is in the danger zone of the
vertically extending / retracting suspension cylinders.
200−1−2110c_en 3/27
11
5 6 7
8 9 10
Z 53 784
I II III
’A’
IV V VI
I II III
’B’
IV V VI
I II III
’C’
IV V VI
I II III
’D’
IV V VI
Z 200 371
4/27 200−1−2110c_en
(Z 53 784, Z 200 371)
11.1 Distribution of the suspension circuits / assignment

of the pressure gauge
11.1.1 Normal case: 4−way system
The figure ’A’ in figure Z 200 371 shows a principle sketch of the
distribution of the suspension circuits of the 4−way system in the
5−axle basic unit.
The figure ’B’ in figure Z 200 371 shows a principle sketch of the
distribution of the suspension circuits of the 4−way systems in the
6−axle basic unit. In the 7−axle design the suspension cylinders
of the additional axle are added to the individual rear suspension
circuit of the basic unit.
− Suspension circuit 1:
axles 1 and 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:
axles 4 to 5 (5−axle basic unit),
axles 4 to 6 or 7 (6−axle basic unit or 7−axle basic unit):
rear right
pressure gauges III (7) + II (6)
− Suspension circuit IV:
axles 1 and 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:
axles 4 to 5 (5−axle basic unit), axles 4 to 6 or 7 (6−axle basic
unit or 7−axle basic unit):
rear left
pressure gauges VI (10) + V (9)
200−1−2110c_en 5/27
11
5 6 7
8 9 10
Z 53 784
I II III
’A’
IV V VI
I II III
’B’
IV V VI
I II III
’C’
IV V VI
I II III
’D’
IV V VI
Z 200 371
6/27 200−1−2110c_en
∗ 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 Special case: 3−way system
(Z 200 371)
The figure ’C’ in figure Z 200 371 shows a principle sketch of the
distribution of the suspension circuits of the 3−circuit system in
the 5−axle basic unit.
The figure ’D’ in figure Z 200 371 shows a principle sketch of the
distribution of the suspension circuits of the 3−circuit system in
the 6−axle basic unit. In the 7−axle design the suspension
cylinders of the additional axle are added to the individual rear
suspension circuit of the basic unit.
− Suspension circuit I + IV:
axles 1 to 2, front right and left
pressure gauge I (5) / IV (8)
− Suspension circuit III:
rear right
pressure gauges III (7) + II (6)
− Suspension circuit VI:
rear left
pressure gauges VI (10) + V (9)
200−1−2110c_en 7/27
11
76 77
78 79
80 81
Z 35 554 Z 52 148
100 101 102
9/19
A12 A13 A14 A15
Z 51 302
8/27 200−1−2110c_en
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).
The clearance between the fastening eyes on the suspension
cylinder (dimension ”X”) is then 630 mm (24.8 in). Only in this
condition can it be guaranteed that there is sufficient suspension
travel available for driving operation.
At road travel level the suspension travel is + 110 / −110 mm (110
mm upward / 110 mm downward) or + 4.3 / − 4.3 in (4.3 in upward
/ 4.3 in downward).
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 is − 110 / +110 mm (+ 4.3 / − 4.3
in).
The requirement for smooth functioning is a level, even road

surface (no potholes, no lateral gradient).
200−1−2110c_en 9/27
11
76 77
78 79
B
80 81
Z 51 303
Z 200151
10/27 200−1−2110c_en
(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. Any level in the
entire range of suspension travel (between 0 and 220 mm or 0
and 8.6 in) is adjustable.
Manual level setting is only possible when standing still (parking
brake applied, transmission “in neutral”).
Starting position:
− Set the crane on level and even ground, apply the parking
brake; transmission in “neutral”!
− Set the engine speed to approx. 1500 U/min (rpm).
11.2.3.1 Function of the dual buttons (78, 79, 80, 81)
− Press dual button in pos. “A”: the corresponding suspension

circuit is raised
− Press dual button in pos. “B”: the corresponding suspension
circuit is lowered.
11.2.3.2 Setting the Suspension Circuits (Four−circuit 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 double button (79A):

”raise level” (extend suspension cylinder)
− Press double button (79B):
”lower level” (retract suspension cylinder)
200−1−2110c_en 11/27
11
76 77
78 79
B
80 81
Z 51 303
Z 200151
12/27 200−1−2110c_en
(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.
Control: on the display (43) in menu point 4.1 Suspension level”.
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 (Three−circuit

System)
The suspension circuits are normally set in the four−circuit

system (road travel).
However, the setting can also be made in the three−circuit
system (off−road travel).
You must then make sure that both front circuits react together;
even if only one of the assigned dual buttons (78, 79) is pressed.
200−1−2110c_en 13/27
11
5
6
7
8
9
10
Z 52 147
B1
Z 53 786
14/27 200−1−2110c_en
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 5−10) in the
driver’s cab.
The desired value of the suspension pressure can only be

determined precisely after the suspension cylinders have been
levelled.
With a 12 t (26.4 kip) axle load, the suspension pressure should
be approximately 105 bar / approx. 1524 psi (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 in one of the suspension circuits

drops quickly during road travel, and / or the level changes
noticeably (display B1 is illuminated), then there is a
dangerous fault.
In this case you must stop the mobile crane, find the cause
of the fault and rectify it.
200−1−2110c_en 15/27
11
C 2 1 A
D B
Z 52 149
16/27 200−1−2110c_en
11.3.2 Level Control, Level Indicator

(Z 52 149)
Level control of the suspension circuits takes place on the display

(43) in the driver’s 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.
At the road travel level

the bar (1) is coloured green and the “piston” (2) is located in the
middle − in accordance with 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.
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11
100 101 102
9/19
A12 A13 A14 A15
Z 51 302
18/27 200−1−2110c_en
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 (3 mph)!
11.4.1 Activating the Suspension Block

. . . Before Driving in an Erect Mode
(Z 51 302)
Driving in the erect condition always means driving

without 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.
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11
100 101 102
9/19
A12 A13 A14 A15
Z 51 302
76 77
78 79
B
80 81
Z 51 303
20/27 200−1−2110c_en
(Z 51 302, Z 51 303)
Bring the crane into state ”Driving when configured”; to do

so:
Starting position:
The crane is supported on outriggers.
Switch (101) ”hold axles” is activated; display (A13) lights up.
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 (24.8 in).
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 left−hand side or (79A, 81A) for the
right−hand side.
The suspension may only be filled up to a maximum

suspension pressure of 270 bar (3919 psi).
An attempt to fill the suspension up to higher pressures
can cause the suspension to sag.
5. Then extend the outrigger cylinders until the crane is

standing free on its wheels; check that it is aligned
horizontally. Outrigger plates just above the ground!
200−1−2110c_en 21/27
11
Z 35 554
22/27 200−1−2110c_en
(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 (24.8 in).
The suspension pressure should be monitored continually.

If the pressure in one of the suspension circuits rises up to
300 bar (4354 psi), 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.
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11
24/27 200−1−2110c_en
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.
DRIVING PROHIBITED!
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.
200−1−2110c_en 25/27
11
92 93 94 95 96 97 98
”Y”
”X”
99 100 101 102 103 104

Z 56 500
26/27 200−1−2110c_en
11.9 Selection of the Operating Modes (Optional)

(”Axle Loads 12 t / 26.5 kip” or “Reduced Axle
Loads”)
(Z 56 500)
Due to special country regulations, it might be necessary to

reduce the axle loads under 12 t (26.4 kip) when driving on roads.
In the operating mode “Reduced axle loads” there might be

various driving states. Examples:
− driving without main boom
− driving without superstructure
− driving with different axle loads < 12 t / 26.5 kip
− driving with dolly (”dolly operation”)
Risk of accidents!
The suspension must always be set to the operating mode
in which the mobile crane is driven. The mode may only be
switched when the crane is at a standstill.
If this instruction is not adhered to, there is increased risk of
accidents.
When selecting the operating mode “Reduced axle loads”, only

the hydraulic suspension is set to the changed axle loads. All
other components (e.g. braking system and steering) remain
unchanged.
The operating mode is selected using a switch (96) that can be

unlocked.
If the switch is in the position “OFF” (switch position “X”), the

suspension is in the operating mode “Axle load 12 t / 26.5 kip”.
If the switch is in position “ON” (switch position “Y”), the

suspension is in operating mode “Reduced axle loads”.
After a new operating mode has been selected, the levels of
the suspension circuits must be checked. If required, the
level must be reset.
If the machine is driven in dolly operation mode, you must
follow the “Instructions on dolly operation” in section 6.
The suspension can be blocked in both operating modes (switch

100).
200−1−2110c_en 27/27
Outriggers 12
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.
− Only rotate the superstructure if the crane is stabilised
on outriggers.
− Before taking up the load, always support the crane on
outriggers.
− During the stabilising procedure the outrigger pads
need some space for shifting movements to the sides.
− Always extend the outrigger struts up to the correspon-
ding pinning position (colour or arrow marking) and pin.
− For reasons of safety, the outrigger struts can only be
extended on the same side as the corresponding switch
panel.
The crane operator can thus only extend outrigger struts
which he can observe continuously. The outrigger strut-
son one side can be activated at the same time.
Caution: risk of crushing and collision when the outrig-
gerstruts are driven at the same time!
The outrigger cylinders on the opposite, non−visible si-
demust be activated for levelling (see relevant section).
In order to avoid risk of crushing, the crane operator
mayonly drive an outrigger cylinder until the outrigger
plate ispositioned on the ground when he can directly
observean outrigger cylinder. This means that he may
only drivean outrigger cylinder if he is on the side where
therelevant cylinder is. However, before extending
theoutrigger cylinder further for supporting on outrig-
gers orfor levelling from one side he must make sure
that thereis no further risk of crushing or collision. If ne-
cessary,the crane operator must assign a banksman.
− Always keep both switch panels locked.
Only the switch panel that is needed directly for opera-
ting may be opened.
To prevent misuse, it must be closed again immediately
afterwards.
200−1−2120−120c_en 1/95
12
2/95 200−1−2120−120c_en
Outriggers 12
− After being put on outriggers (before beginning work

with the crane), the tyres must no longer touch the
ground.
− The maximum deviation after levelling is 0.15 (corres-
ponds to approx. 0.2 %).
− Make sure the ground is even and capable of carrying
the load before setting down the outrigger plates!
No foreign material (for example: stones, metal objects,
etc.) are permitted under the outrigger plates!
The max. surface pressure with standard outriggerpla-
tes:
− Outrigger plate, front ø 600 mm (23.6 in)
Surface pressure approx. 295 N/cm2 (428 lbs/
in2)
Outrigger force 834 kN (85 t / 187.4 kip)
− Outrigger plate, rear ø 700 mm (27.6 in)
Surface pressure approx. 255 N/cm2 (370 lbs/
in2)
Outrigger force 981 kN (100 t / 220.5 kip)
The surface may only be tilted by a maximum of 5*
(9%).
− Where there is insufficient load bearing capacity the soil
pressure in the area of the outrigger plate must be redu-
ced using rigid underlay plates (mats).
− The maximum permitted support forces must be obser-
ved.
− Only level the crane with counterweight and fitted
equipment by extending the vertical support cylinders.
See section Instructions on levelling with Counter-
weight“ .
− In order to protect the supporting cylinders from over-
loading, they must not be extended to the limit; there
must always be a remaining lift 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.
200−1−2120−120c_en 3/95
12
4/95 200−1−2120−120c_en
Outriggers 12
Extending and retracting the supports with a load attached

is not permitted. Risk of tipping!
In order to avoid damage to the outriggers as well as acci-
dents in the course of driving or operating the crane, take
special care to do the following:
− Unlock the supports before they are extended or retrac-
ted.
− Pin / secure the supports for work with the crane.
− Pinning / locking of the (retracted) struts in transport po-
sition.
− Secure the outrigger pads in transport position
There is a danger of accidents, if the prescribed outrigger
support area, specified in the load capacity table, is not
used.
No other outrigger support area is permitted − HIGH RISK
OF DAMAGE !
200−1−2120−120c_en 5/95
12
6/95 200−1−2120−120c_en
Outriggers 12
12.2 Notes on Levelling with 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 basis depending on required
configuration state.
− 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 ba-
lanced (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.
3. Check the levelling of the crane, if necessary repeat the pro-

cedure (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 support force must be distributed by
slightly adjusting / turning the superstructure / main
boom / equipment.
4. Rotate superstructure by 180° .
5. Repeat steps 2 and 3.
200−1−2120−120c_en 7/95
12
Z 47 962
8/95 200−1−2120−120c_en
Outriggers 12
12.3 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)
Pos. 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 ”Supporting cylinder, back right ”
3A: Retracting
3B: Extending
4 Rocker switch ”Supporting cylinder, back 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 Self−return rocker switch ”all outrigger cylinders toge-
ther”
8A: Retracting
8B: Extending
8B with key 10: Level automatically
9 Button ”raise all axles”
10 Button “caution” (safety key)
1.) “Boot data bus” (hold pressedapprox. 5 sec.)
2.) forwards / with button (7B) “engine start”
3.) forwards / with button (8B) with ”automatic level-
ling”
21 Display
with crane symbol left−hand side
The symbol on the push buttons always determines the function

of the outrigger cylinder.
200−1−2120−120c_en 9/95
12
1.5°
1.5°
3°
0°
0°
3°
Z 60 982
10/95 200−1−2120−120c_en
Outriggers 12
Switch panel right side:
(Z 60 982)
Pos. Function
11 Rocker switch ”Supporting cylinder, back left”
11A: Retracting
11B: Extending
12 Rocker switch ”Supporting cylinder, back right ”
12A: Retracting
12B: Extending
13 Rocker switch “outrigger cylinder front left”
13A: Retracting
13B: Extending
14 Rocker switch “outrigger cylinder front right”
14A: Retracting
14B: Extending
15 Rocker switch “outrigger strut back right”
15A: Retracting
15B: Extending
16 Rocker switch “outrigger strut front right
16A: Retracting
16B: Extending
17 Rocker switch “engine start/engine stop”
17A: Engine stop
17B: Engine start
18 Rocker switch ”Supporting cylinders together”
18A: Retracting
18B: Extending
18B with key 20: Level automatically
19 Button ”raise all axles”
20 Button “caution” (safety key)
1.) “Boot data bus” (hold pressedapprox. 5 sec.)
2.) forwards / with button (17B) “engine start”
3.) forwards / with button (18B) for “automatic level-
ling”
22 Level
The symbol on the push buttons always determines the function

of the outrigger cylinder.
200−1−2120−120c_en 11/95
12
21
F1 F2 F3 F4 F5 F6
M N O P Q
8 8
8 8
L
Z 200 434
12/95 200−1−2120−120c_en
Outriggers 12
12.4 Information System for the Outrigger Controls

(Z 200 434)
The information is shown on the display of the outrigger controls

(left on the chassis).
The system on the left 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 keys F1 − F6

F1 = Contrast
F2 = Brightness
F3 = Inverting
F4 = Support position for outrigger support area
display (optional)
F5 = Inclination
F6 = Support Forces
(L) Symbols for the function keys
(M) Support forces at the frontstruts (and support position
for the outrigger support area display (optional))
(N) Level
(O) Electronic level
(P) Crane symbol
(Q) Support forces at the rear struts (and support position
for the outrigger support area display (optional))
If the crane is not equipped with the optional outrigger support

area display, the corresponding space in the display is free.
200−1−2120−120c_en 13/95
12
”A”
O P
R
S1 S3
M1 18.0t 18.0t Q1
S2 S4
M2 18.0t 18.0t Q2
Z 200 435
14/95 200−1−2120−120c_en
Outriggers 12
12.4.1 Indicators on the Display
(Z 200 435)
Diagram ”A: (Level, support force,

support position (optional))
− Basic display with electronic level indicator / bubble and indi-
cation of supporting force.
When the supporting cylinders are operated, the moving direc-

tion is displayed in the form of an arrow, as well as the supports,
indicated as symbols.
200−1−2120−120c_en 15/95
12
”A”
O P
R
S1 S3
M1 18.0t 18.0t Q1
S2 S4
M2 18.0t 18.0t Q2
Z 200 435
”B”
P
X 0,1
O
N
0,1 Y
L1 L6
Z 58 808
16/95 200−1−2120−120c_en
Outriggers 12
(Z 200 435, Z 58 808)
Diagram ”A: (Level, support force,

support position (optional))
Diagram “B“ (Inclination)
Legend:

L1 = Exiting the display
L6 = Adjustment, menu asissted (results in diagram
”F”)
(M) Support forces on the front struts
M1 = Support force front right
M2 = Support force front left
(N) Level
(O) Electronic level
(P) Crane symbol
(Q) Support forces on the rear struts
Q1 = Support force rear right
Q2 = Support force rear left
(R) Retraction / extension movement of the outriggercylin-
ders
(S) Support position for outrigger support area display (op-
tional)
S1 = Support position, front right
S2 = Support position, front left
S3 = Support position, rear right
S4 = Support position, rear left
If the crane is not equipped with the optional outrigger support

area display, the corresponding space in the display is free.
(X) Tilt across the driving direction

(Y) Tilt in the driving direction
200−1−2120−120c_en 17/95
12
”C”
P
1 8. 0 t 1 8. 0 t Q1
M1
M2 1 8. 0 t 1 8. 0 t Q2
L1 L4
Z 58 809
”D”
P
S3
S1 , m , m
S4
S2 , m , m
L1 L6
Z 58 810
18/95 200−1−2120−120c_en
Outriggers 12
(Z 58 809, Z 58 810)
Diagram ”C” (supporting force)
Diagram ”D” (Support position of the strut, menu asis-

sted) (optional)
Legend:

L1 = Exiting the display
L4 = Support force (results in diagram ”D”)
L6 = Support position of the strut, menu asissted
(optional) (leads to depiction ”C”)
(M) Support forces on the front struts
M1 = Support force front right
M2 = Support force front left
(P) Crane symbol
(Q) Support forces on the rear struts
Q1 = Support force rear right
Q2 = Support force rear left
(S) Support position of the strut, menu asissted
S1 = Support position, front right
S2 = Support position, front left
S3 = Support position, rear right
S4 = Support position, rear left
200−1−2120−120c_en 19/95
12
”E”
Z 47 972
”F”
Z 47 973
”G”
Enter PIN−Code
Z 47 974
20/95 200−1−2120−120c_en
Outriggers 12
(Z 47 972, Z 47 973, Z 47 974)
Diagram ”E” (contrast), menu asissted
Modify contrast:
− Key F2 = darker
− Key F5 = lighter
− Key F1 (Exit) leads to view ”A” (level and support force)
Diagram ”F” (brightness), menu asissted
Modify brightness:
− Key F2 = darker (corresponding bar display)
− Key F5 = lighter (corresponding bar display)
− Key F1 (Exit) leads to view ”A” (level and support force)
Diagram ”G” (coding; only for service)
200−1−2120−120c_en 21/95
12
Z 47 962
”A”
O P
R
S1 S3
M1 18.0t 18.0t Q1
S2 S4
M2 18.0t 18.0t Q2
Z 200 435
22/95 200−1−2120−120c_en
Outriggers 12
12.4.2 Functions
(Z 47 962, Z 200 435)
Starting position:
− Crane parked in transport position

− parking brake applied
− Ignition switch in position ”0” (external start standby)
”Boot” data bus:
Press key ”caution” (10 / 20) approx. 5 secs.
External engine start:
Press key ”caution” (10 / 20) before / with key ”engine start” (7B
/17B) until the 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 diagram ”A” (Z 200 435)
− Key F1 = diagram ”E” (contrast) (Z 47 972)
− Key F2 = darker
− Key F5 = lighter
− Key F1 = Quit, back to diagram ”A” (Z 200 435)
200−1−2120−120c_en 23/95
12
Z 47 962
”A”
O P
R
S1 S3
M1 18.0t 18.0t Q1
S2 S4
M2 18.0t 18.0t Q2
Z 200 435
24/95 200−1−2120−120c_en
Outriggers 12
(Z 47 962, Z 200 435)
Modify brightness:
− Key F2 = diagram ”F” (brightness) (Z 47 973)
− Key F2 = darker (corresponding bar display)
− Key F5 = lighter (corresponding bar display)
Inverting
− Key F3 = Inverting
Inclination indicator
− Key F5 = diagram ”B” (inclination) (Z 58 808)
Support pressure display

− Key F6 = diagram ”C” (supporting force) (Z 58 809)
200−1−2120−120c_en 25/95
12
Z 47 962
O P
R
S1 S3
M1 18.0t 18.0t Q1
S4
”A”
S2
M2 18.0t 18.0t Q2
L
Z 200 435
”C”
P
1 8. 0 t 1 8. 0 t Q1
M1
M2 1 8. 0 t 1 8. 0 t Q2
L1 L4
Z 58 809
26/95 200−1−2120−120c_en
Outriggers 12
12.4.3 Support Pressure Display
(Z 47 962, Z 200 435, Z 58 809)
The support force is determined by pressure contacts in the four

outrigger cylinders and shown in the outrigger control display.
Monitor the supporting forces at every support procedure

with the help of the support pressure display.
Displaying supporting force:

− Call up diagram ”A”
− Key F6 = diagram ”C” (supporting force)
− Key F1 (L1) = Quit, back to diagram ”A”
The following supporting force values must not be excee-

ded:
85 tons (187.4 kip) at the front supporting cylinders.
100 tons (220.5 kip) at the rear supporting cylinders.
Important note on complying with limit values:

The limit values to be followed are not monitored automati-
cally.
The support pressure display shows tolerance values. The

display value can differ from the actual value by up to ap-
prox. 10% (plus / minus).
Keep this in mind, e.g. in relation with limited load−carrying
capacity of the ground.
While the crane is in operation, the support pressure display is

supplied with power from the superstructure via an electrical swi-
velling connection.
200−1−2120−120c_en 27/95
12
Z 47 962
O P
R
S1 S3
M1 18.0t 18.0t Q1
S4
”A”
S2
M2 18.0t 18.0t Q2
L
Z 200 435
”B”
P
X 0,1
O
N 0,1 Y
L1 L6
Z 58 808
28/95 200−1−2120−120c_en
Outriggers 12
12.4.4 Inclination Indicator
(Z 47 962, Z 200 435, Z 58 808)
The inclination of the crane is detected by an electronic inclina-

tion transmitter and displayed at the switch panels of the outrig-
ger 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 is used for basic orientation; the numerical values are
definitely the decisive values.
Display of inclination
− Key F5 = diagram ”B” (inclination)
− Key F1 (L1) = Quit, back to diagram ”A”
The inclination indicator must be observed during the level-

ling procedure.
Deviations must not exceed 0.1 degrees (equivalent to ap-
prox. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.
200−1−2120−120c_en 29/95
12
1
Z 200 430 Z 200 436
”D”
P
S1 , m , m S3
S2 , m , m S4
L1 L6
Z 47 962 Z 58 810
O P
R
S1 S3
M1 18.0t 18.0t Q1
S4
”A”
S2
M2 18.0t 18.0t Q2
L
Z 200 435
30/95 200−1−2120−120c_en
Outriggers 12
12.4.5 Outrigger Support Area Display (Optional)
(Z 200 430, Z 200 436, Z 47 962, Z 58 810, Z 200 435)
If the crane is equipped with an outrigger support area display,

there is a length measuring device (1, Z 200 430) fitted to each
strut in order to determine the support position (outrigger width
B, Z 200 436) of each strut.
The values shown under S1 to S4 in the basic display “A”
(Z 200 435) or the outrigger support area display “D” (Z 58 810)
indicate the pinning position of the individual struts.
The strut length (L, Z 200 436) is always the same in a crane with
H−shaped outriggers (as in this type of crane).
Risk of overturning!
The support position of each strut is ONLY displayed.
The value which corresponds to the support position is
not passed on the LLD.
There are NO instructions and there is NO shut−down if
the displayed outrigger support area does not corres-
pond with the outrigger support area set in the IC−1.
Show outrigger support area display:

− Key F4 = Depiction ”D” (strut width)
− Key F1 (L1, = Quit, back to diagram ”A”

Z 58 810)
Observe the instructions and warnings on the outrigger sup-

port area display on the following page!
200−1−2120−120c_en 31/95
12
32/95 200−1−2120−120c_en
Outriggers 12
Instructions on display of the support position (S1 to S4):

− The support position of the strut is only displayed if the
current extension length of the outrigger strut corresponds
with a permitted strut variant (8.2 m (26.9ft); 6.85 m
(22.5 ft); 5.7 m (18.7 ft) and 2.8 m (9.2 ft)).
If the outrigger strut is in a state of extension which does
not correspond with any permitted strut variant, the num-
ber ”0” appears at the corresponding strut.
− For this crane type, two outrigger struts are moved within
each other at each strut in order to achieve the required
strut width.
The correct position of both outrigger struts in relation to
each other − dependent on the desired strut width − is
described in the section “Strut variants” (section 12.9).
The optional length measuring device for the display of
the support position only recognises the strut’s extension
length.
The length measuring device does not recognise when
both outrigger struts are in an “incorrect” position to each
other or when the outrigger struts are not pinned to each
other.
Risk of tilting and breaking!

The correct position of the outrigger struts in relation to
each other must be observed, in particular with reduced
outrigger support areas.
The optional “Outrigger support area display” does not
recognise when the crane is supported on outriggers
with a permitted strut width but both outrigger struts are
not in the correct position in relation to each other.
If required, the correct support on outriggers must be
monitored manually.
Risk of accidents!
The required insertion / pinning of the struts is not monito-
red and is the responsibility of the operating personnel.
The corresponding instructions in section 12 of the opera-
ting instructions of the crane chassis must be observed.
200−1−2120−120c_en 33/95
12
Z 47 962
3°
1.5°
0°
0°
1.5°
3°
Z 60 982
”B”
P
X 0,1
O
N 0,1 Y
L1 L6
Z 58 808
34/95 200−1−2120−120c_en
Outriggers 12
12.5 Automatic Levelling
(Z 47 962, Z 60 982, Z 58 808)
The crane can also be levelled automatically (by extending the

outrigger cylinders together). This is only possible when ”Exten-
ding” (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 cylinders
that cannot be seen from the switch panel. It must be ensu-
red that no−one is in the hazardous area.
Starting position:
− Crane parked in transport position
− parking brake applied
− outrigger struts extended / pinned / locked (outrigger pads
are fitted)
− display: Diagram ”B” (inclination)
Steps for automatic levelling:
1. Press key ”caution” (10 / 20) and key ”extend all outrigger cy-
linders together” (8B / 18B) together.
Inverse display during ”Automatic operation”.
The engine runs at increased speeds so that the required
pressure oil quantity is made available by the hydraulic
pump.
The outrigger cylinders are extended to a check support force.
This ensures that all outrigger cylinders have contact with 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.
The speed increase of the engine is reduced when fine levelling

begins.
200−1−2120−120c_en 35/95
12
Z 47 962
3°
1.5°
0°
0°
1.5°
3°
Z 60 982
”B”
P
X 0,1
O
N 0,1 Y
L1 L6
Z 58 808
36/95 200−1−2120−120c_en
Outriggers 12
(Z 47 962, Z 60 982, Z 58 808)
3. As soon as the crane is level (angle tolerance value 0.1 de-

grees), the procedure is automatically stopped.
The information on the display is shown in standard format
again.
After the procedure, the system might change the displayed incli-
nation value from 0.1 to 0.2.
This however has no negative effect on the required precision.
4. Let go of key (10 / 20).
Make sure there is a remaining lift (2 to 3 cm / 0.8 to 1.2 in) in the

supporting cylinders; Compare supporting forces.
The system does not automatically take the remaining lift into
consideration.
If re−levelling is necessary:
Hold button „Caution“ (10 / 20) and press „Extend all outrigger cy-
linders“ button shortly (8B / 18B).
Levelling is carried out as already described.
Combined retraction of all supporting cylinders:

Press the button ”caution” (10 / 20) and key ”retract all outrigger
cylinders” (8A / 18A) together.
200−1−2120−120c_en 37/95
12
Z 200 050
38/95 200−1−2120−120c_en
Outriggers 12
12.6 ”Hold Axles” / ”Raise Axles” Functions
(Z 200 050)
When the crane is on outriggers, the wheels must not touch the
ground. The “Hold axles” or “Raise axles“ functions are availa-
ble 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”.
12.6.1 ”Hold Axles” Function
“Hold axles” is selected before the crane is stabilised.
All axles are fixed in the starting position (horizontally aligned and
suspension cylinders in the middle position).
If the crane is lowered back on to the wheels for moving (by re-
tracting the supporting cylinders), then it does not have to be rele-
velled.
It is aligned horizontally and the suspension cylinders are in the
middle position.
12.6.1.1 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 switch (101, S4428) ”hold axles”. Message (A38.6)

lights up .
If ”hold axles” is switched on, the crane must not be moved

as ”R I S K O F B R E A K A G E” !
3. Support the crane (see section ”Extend the back stop”)
Extend the support until no wheel is in contact with the ground.
200−1−2120−120c_en 39/95
12
6 8
7 10
9 11
Z 200 022
Z 200 050
40/95 200−1−2120−120c_en
Outriggers 12
12.6.1.2 Switching on ”Hold Axles” after

”Driving in the Configured State”− Suspension Lok-
ked
(Z 200 022, Z 200 050)

brake.
− the crane is aligned horizontally,
− suspension cylinder in the middle position.
2. Extend horizontal support.
3. Extend the outrigger cylinder, until the outrigger pads are

pressed to the ground. Set the contact pressure so that the
suspension pressure is at approximately 100 bar (1450 psi).
Pressure check on pressure gauges (6, 9), (8, 11) and (7,
10).
The clearance between the mounting eyelets on the suspension

cylinders equals 630 mm (24.8 in) (compare section ”Extending
the outriggers”).
4. Switch off the suspension locking using switch (100, S4401).

Message (A38.5) goes out.
5. Actuate switch (101, S4428) ”hold axles”. Display (A38.6)

lights up.
6. The supporting cylinders are extended further and the crane

is stabilised (see section ”Extend the back stop”).

Keep to the sequence!
200−1−2120−120c_en 41/95
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6 8
7 10
9 11
Z 200 022
Z 200 050
42/95 200−1−2120−120c_en
Outriggers 12
12.6.1.3 Switching off ”Hold Axles” for ”Moving on the Road”

− Suspension Not Locked or Switching to
ked
(Z 200 022, Z 200 050)
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 section ”Retracting outriggers”)
2. Lock the switch ”hold axles” (101, S4428) in the ”off” position.
If the crane is now to be ”driven in the erect mode”, switch on the

suspension lock using switch (100, S4401).
The message (A38.5) lights up.
In ”Driving in a configured state“, the outriggers (outrigger sup-
port area 8.4 m x 8.2 m / 27.6 ft x 26.9 ft) remain right above the
ground with fittedoutrigger plates.
”Driving in a configured state“ is only permitted when the ground-
conditions correspond to those described in section 6, ”Drivingin
a configured state“.
3. Continue to retract supporting cylinder / retract outrigger ent-

irely and lock.
4. For ”Moving the crane in transport position” (on−road driving,

axle load max. 12 t / 26.4 kip) see section 6 of the operating
instructions for the carrier.
200−1−2120−120c_en 43/95
12
Z 200 050
9/19
Z 200 051
44/95 200−1−2120−120c_en
Outriggers 12
12.6.2 ”Raise Axles” Function
(Z 200 050, 200 051)
The ”axles are raised” after the crane is supported on outriggers.
Switch on “Raise axles”:
2 work steps are required for ”Raise axles”.

Between the two steps, the crane must be stabilised.
1. Press switch ”hold axles” (101, S4428) in the driver’s cab.

Message (A38.6) lights up .
The axles remain in the middle position (on the ground).
The crane must now be supported on outriggers (cf. support pro-

cedure).
If the axles still have contact with the ground:
2. Press/hold button (9 / 19) on the outrigger control. All axles

are raised as long as the button is pressed.
DRIVING IS FORBIDDEN if „Axles raised“ is activated(signal

A38.6 appears and stop light A30 is illuminated).
Switch off ”raise axles”:
When switch (101, S4428) is switched off in the driver’s cab, allw-
heels are lowered to the ground again.
Before being driven the crane must be levelled again (aligned ho-
rizontally and the spring actuators placed in the middle position).
When the suspension is locked (locking switch 100, S4401 on,

message A38.5 appears), ”Raise axles” or ”Hold axles” is not
possible.
200−1−2120−120c_en 45/95
12
Z 200 050
9/19
Z 200 051
46/95 200−1−2120−120c_en
Outriggers 12
(Z 200 050, Z 200 051)

”Moving on the Road” − Suspension is Not Locked.
If the crane is in ”On−road driving” position before being stabili-

sed, then raise the axles as described in the following:

brake.
Message (A38.6) lights up.
3. Support the crane (see section ”Extend the back stop”)
If the wheels still have contact with the ground:
4. Press/hold the button ”raise axles” (9 / 19) on the outrigger

controls.
All axles are raised as long as the button is pressed.

”Driving in the Configured State” − Suspension Lok-
ked
If the crane is in ”Driving in the configured state” 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 so that the
suspension pressure is at approximately 100 bar (1450 psi).
10).
3. Switch off the suspension locking using switch (100, S4401).
5. Keep the crane stabilised.
6. If necessary: Press/hold button ”hold axles” (9 / 19) on the
outrigger controls until all wheels are free of the ground.
200−1−2120−120c_en 47/95
12
Z 200 050
48/95 200−1−2120−120c_en
Outriggers 12
12.6.2.3 Switching off ”Raise Axles” for

”Driving on the Road” − Suspension Not Locked
or Switching to
ked
(Z 200 050)
The procedure ”Raise Axles” is switched off using switch (101,

S4428) ”Hold axles” in the cab. All wheels are then lowered to the
ground.
1. Switch off switch ”Hold Axles“ (101, S4428) in the dri-

ver’scab.
When switch (101, S4428) is switched off in the driver’s cab,
allwheels are lowered to the ground again.
2. Actuate button (76 or 77). Fill all suspension circuits to ap-

prox. 100 bar (1450 psi) (see section 11).
Monitor the rise in pressure on pressure gauges (6 to 11).
3. Retract supporting cylinders; reset the 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 ”lok-

ked”. Driving is not permitted in this condition. Damage to
undercarriage!
200−1−2120−120c_en 49/95
12
12
14
2
1 3
Z 200 052
50/95 200−1−2120−120c_en
Outriggers 12
12.7 Measures before Stabilising:
(Z 200 052)
1. Apply parking brake (14).
On sloping ground in the longitudinal direction of the vehi-

cle, the vehicle must be prevented from rolling away by pla-
cing wheel chocks at the axle last released.
2. Shift the transmission to the neutral position (12).
3. Lock the slew gear brake in the superstructure cab.
The superstructure may only be slewed in the supported

condition!
4. Start crane chassis engine.
The engine can also be started at the switch panels of the outrig-
ger controls. The ignition switch (4) must then be in the position
” 2” (external ignition standby).
When the outriggers are operated, an engine speed of 1200 rpm

is automatically set.
200−1−2120−120c_en 51/95
12
A/B
A/B
I A/B
A/B
A
4 J B/C
5
E
F
6
G
H
I B
Q
5
4 6
J H
Z 200 053
52/95 200−1−2120−120c_en
Outriggers 12
12.7.1 Pinning Positions of the Outrigger Struts
(Z 200 053)
(1) = Inner outrigger strut

(2) = Outer outrigger strut
(3) = Chassis frame / outrigger box
(4) = Driving bolt
(5) = Bolt for transportation state and pinning of the chas-
sisframe to the outer outriggers
(6) = Bolt for pinning the inner outriggers to the outerou-
triggers
(A) = Marking point on chassis frame for driving bolt (4)
(B) = Marking point on chassis frame for transportation po-
sitionof the outriggers and all outrigger support areas
(C) = Marking point on outer outrigger strut (2) for outrig-
gersupport area 8.2 m (26.9 ft)
(D) = Stop outrigger support area 6.85 m (22.5 ft)
(E) = Marking point on outer outrigger strut (2) for outrig-
gersupport area 6.85 m (22.5 ft)
(F) = Stop for outrigger support area 5.7 m (18.7 ft)
(G) = Marking point on outer outrigger strut (2) for outrig-
gersupport area 5.7 m (18.7 ft), transportation posi-
tion of outriggersand outrigger support area 2.8 m
(9.2 ft).
(I) = Support point for bolts (5)
(J) = Support point for driving bolt (4)
(X) = Support surface on inner outrigger strut (1) fortran-
sportation safety lock
Bolt (5) is used for pinning the outriggers and the chassisframe
in the transportation position and / or in the 4 outriggerwidths. In
the transportation position, bolt (5) is then flush with surface (X)
of the inner outrigger strut (1).
The pin (4) is used for driving the stops (D / F) for the support base
areas 5.7 m (18.7 ft) and 6.85 m (22.5 ft).
The marking points (A / B) are located on the separating plates
of the front or rear outrigger box sets.
200−1−2120−120c_en 53/95
12
A/B
A/B
I A/B
A/B
A
4 J B/C
5
E
F
6
G
H
I B
Q
5
4 6
J H
Z 200 053
54/95 200−1−2120−120c_en
Outriggers 12
12.7.2 Transportation State of the Outrigger Struts
(Z 200 053, detail Q)
− Outriggers completely retracted

− Bolt (5) fitted into point (B) in the chassis frame (Bolt (5) is fit-
ted through the outer outrigger box and is flushwith surface
(X) in the inner outrigger box.)
− Driving bolt (4) is set down on point (J) or fitted into point
(A)(must be removed first when setting on outriggers.)
− Bolt (6) set down on point (H).
200−1−2120−120c_en 55/95
12
2
2
3
1 1
Z 200 054 Z 200 055
A/B
A/B
I
A/B
A/B
4 J A B/C
5
E
F6
G
H
I B Q
4 5
6
J H
Z 200 053
56/95 200−1−2120−120c_en
Outriggers 12
12.8 Stabilising Procedure
12.8.1 Extending the Outriggers

(Outrigger Support Area 8.40 m x 8.20 m / 27.6 ft x
26.9 ft)
(Z 200 054, Z 200 055, Z 200 053)
When the crane is on outriggers, the wheels must not touch the
ground (”Hold axles” / ”Raise axles” functions).
Once you have convinced yourself that no obstacles or persons

are present in the extension area for the stabilisers and that all
notes on dangers in section 12.1 have been observed, then pro-
ceed as described in the following.
1. Bring outrigger pad in operating position

(Z 200 054, Z 200 055)
Clean the bottom of the outrigger cylinder’s piston rod and
the top of the outrigger plate (if contaminated), remove the
forelocks (3), remove the socket pins (2), pull the outrigger
plates (1) into the support position.
Attach plug bolts and forelock again.
Risk of accidents!
The contact surface between the outrigger cylinder’s
piston rod and the outrigger plate must be clean. In particu-
lar, no foreign matter is permitted (for example: stones,
sand, etc.).
2. Remove safety bolts (5) from 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, di-
rectly after use !
200−1−2120−120c_en 57/95
12
Z 47 962
3°
1.5°
0°
0°
1.5°
3°
Z 60 982
58/95 200−1−2120−120c_en
Outriggers 12
(Z 47 962, Z 60 982)
3. Extending the outrigger struts

Left side: press self−return rocker switch 5B or 6B
(Z 47 962)
Right side: press self−return rocker switch 15B or 16B
(Z 60 982)
The outrigger struts can only be extended / retracted (horizon-

tally) at the switch panel of the corresponding side.
Extend the outrigger struts one at a time up to the coloured mar-
king.
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 !
4. Fit and secure locking bolts (5) and (6) between the chassis-
frame and the outer outrigger strut, or between the outrigger-
struts.
200−1−2120−120c_en 59/95
12
Z 47 962
3°
1.5°
0°
0°
1.5°
3°
Z 60 982
60/95 200−1−2120−120c_en
Outriggers 12
(Z 47 962, Z 60 982)
5. Extending the outrigger cylinders
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 operator’s view at the switch panel.
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!
Switch panel left side: press self−return rocker switch 1B,

2B, 3B or 4B.
Switch panel right side: press self−return rocker switch 11B,
12B, 13B or 14B.
In order to protect the supporting cylinders from overloa-

ding, they must not be extended to the limit; a remainder 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.
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.
6. Attach counterweight (see load capacity table and operating

instructions for the superstructure, section 9).
7. Position superstructure in the direction of travel and thereby

position counterweight above the rear outrigger.
8. Move boom to steep position.
The slew gear brake must be released at points 5 and 6.

Now reinsert it.
200−1−2120−120c_en 61/95
12
Z 200 050
1.5°
1.5°
3°
0°
0°
3°
Z 47 962 Z 60 982
62/95 200−1−2120−120c_en
Outriggers 12
(Z 200 050, Z 47 962, Z 60 982)
9. ”Raise axles” now

”Raise axles” consists of two steps:
9.1 Press switch ”hold axles” (101, S4428) in the driver’s
cab.
The axles are still on the ground.
9.2 Press and hold down the key (9/19) at the outrigger
controls.
All axles are raised.
Raise the axles until all wheels are free of the ground.
If ”hold axles” is selected before the crane is supported on outrig-
gers, message (A38.6) lights up, the axles are no longer raised.
It must be ensured however that all wheels are free of the ground.
When putting the crane on outriggers, make sure that the

ground has sufficient load bearing capacity.
The individual support forces are displayed on the screen of
the outrigger controls (left and right on the chassis) and on
the PDC system of the superstructure.
Only the current supporting forces are displayed; not those
that will occur when a load is picked up.
10. Extend rear supporting cylinder, until the lateral axis is balan-
ced.
Switch panel left side: press self−return rocker switch 3B /
4B.
Switch panel right side: press self−return rocker switch 11B
/ 12B.
11. Extend the supporting cylinders at the front, in order to also
bring the longitudinal axis in the balance.
Switch panel left side: press self−return rocker switch 1B /
2B.
Switch panel right side: press self−return 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 suppor-

ting forces, the supporting cylinders at the front should fi-
nally be briefly pressed further together and then the same
applies to the supporting cylinders at the rear. Make sure
that all outrigger cylinders are loaded equally.
200−1−2120−120c_en 63/95
12
64/95 200−1−2120−120c_en
Outriggers 12
12. Check the set level once more.
If the transverse axis has come out of alignment, the levelling pro-
cedure must be repeated.
a.) Level the rear transverse axle.
b.) Retract the front support cylinders slightly and then

extend to level the longitudinal axis.
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 neces-

sary to operate all supporting cylinders from the switch pa-
nel on one side. In this case be particularly careful, espe-
cially when the supporting cylinders are operated that are
not in the direct line of view.
Immediately afterwards, lock the switch panel !
200−1−2120−120c_en 65/95
12
”B”
P
X 0,1
O
N
0,1 Y
L1 L6
Z 58 808
66/95 200−1−2120−120c_en
Outriggers 12
12.8.2 Checking the Level at the Chassis
(Z 58 808)
After each new configuration, the level of the crane must be re-
checked (see ”Inclination indicator”).
Careful levelling is essential for safe working with the crane.

Deviations must not exceed 0.1 degrees (equivalent to ap-
prox. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.
200−1−2120−120c_en 67/95
12
Z 200 050
68/95 200−1−2120−120c_en
Outriggers 12
12.8.3 Retracting the Outriggers
The outriggers are retracted analogously in the reverse order of

their extension.
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.
− Retracting the outrigger supports when a load is atta-
ched to the crane is prohibited. Risk of tipping!
− The struts may only be retracted if the superstructure
isin the transportation position or in position 05 to the
rear for mobile operation. Risk of tipping!

. . . .for ”Driving in Transport Position”
(Z 200 050)
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 supporting
cylinders, crushing movements between tyres and ground
space are possible. Watch your feet!
It must be ensured that no persons are present in the dan-
ger zone.
3. Lock the switch ”hold axles” (102, S4427) in the ”OFF” posi-
tion.
The axles are lowered.
200−1−2120−120c_en 69/95
12
1.5°
1.5°
3°
0°
0°
3°
Z 47 962 Z 60 982
70/95 200−1−2120−120c_en
Outriggers 12
(Z 47 962, Z 60 982)
If ”hold axles” was switched on, this point does not apply.
4. Pressing down the wheels

Press button (78 / 79 / 80 / 81) or button (76 or 77) until thew-
heels of all axles are pressed down on the ground.
The outrigger cylinders must be retracted if the outrigger height

isgreater than the suspension cylinder hoist.
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 outrigger cylinders completely!
When retracting the supporting cylinders on slopes in the

longitudinal direction of the vehicle, the vehicle must be se-
cured with support blocks at the axle that is to touch the
ground first.
6. Retracting the outrigger struts:

Left side: press self−return rocker switch 5A
or 6A
Right side: press self−return rocker switch 15A
or 16A
Retract all outrigger struts individually and completely!
It is forbidden to retract or extend the cylinders with hangin-

gload or if the superstructure is not in the transportationpo-
sition or in position ”mobile operation“. RISK OFTILTING!
Risk of crushing and reeving !

When retracting the outrigger struts, reeving and crushing
movements around the retracting parts and the carrier
frame are possible.
Make sure that there is no−one in the danger zone!
200−1−2120−120c_en 71/95
12
2
2
3
1 1
Z 200 054 Z 200 055
A/B
A/B
I B
5
A/B
J
A/B
Z 200 136
72/95 200−1−2120−120c_en
Outriggers 12
(Z 200 054, Z 200 055, Z 200 136)
(Z 200 136)
Secure the outrigger boxes which have been pushed in-
toeach other, using bolt (5) in point (B) in the chassis frame
(3). The bolt (5) is fitted through the outer bumper brace and
isflush with the inner bumper brace on surface (X). Thedri-
ving bolt (4) is inserted in point (A) in the chassis frame orfit-
ted in point (J).
The marking points (A) and (B) can be found on thebulk-
heads of the front and rear outrigger box pairs.
7. Bring the outrigger plates into the transport position

(Z 200 054, Z 200 055)
Remove the fore locks (3), remove the socket pins (2), pull
the outrigger plates (1) into the transport position.
Attach plug bolts and forelock again.
8. If ”Raise axles” was actuated:
Press button (76, S441 or 77, S4424) to level all axles. See
section 11 ”Adjusting for driving in the transport position”.
Or
9. If ”Hold axles” was actuated:
Lock switch (101, S4428) ”hold axles“ in the ”OFF” position.
Driving in the ”Hold axles” condition is prohibited.

Damage to undercarriage!

. . . . for ”Driving in the Configured State”
See section 11.4, ”Switch on the suspension locking system −

. . . . Before driving in the configured state”.
Before lowering the crane on to the wheels (for subsequent

”Driving in the configured state”), always pay attention to
the permitted axle loads relating to rigging mode, counter-
weights, superstructure position, main boom length and an-
gle (see section 6 ”Driving in the configured state”).
When lowering the crane onto the wheels, the suspension
pressure is monitored on the pressure gauges (6) to (11) in
the driver’s cab.
It must not exceed 270 bar (3916 psi).
200−1−2120−120c_en 73/95
12
1345 mm 1355 mm
(4.4 ft) (4.5 ft)
5 B,C 2 6 G 1
8200 mm
(26.9 ft)
Z 200 416
670 mm 1355 mm
(2.2 ft) (4.5 ft)
A 4 5 B,E 2 6 G 1
6850 mm
(22.5 ft)
Z 200 417
74/95 200−1−2120−120c_en
Outriggers 12
12.9 Supporting Variants
12.9.1 Outrigger Support Area 8.40 m x 8.20 m

(27.6 ft x 26.9 ft) (Standard Outrigger Support Area)
(Z 200 416)
Outrigger struts (1) and (2) are fully extended for theoutrigger
support area 8.40 m x 8.20 m (27.6 ft x 26.9 ft).
The bolt (5) pins the chassis frame (fitting point B) to theouter ou-
trigger strut (2) in point (C).
The bolt (6) pins the outer outrigger strut (2) to the inneroutrigger
strut (1) in point (G).
Working with the crane is permitted only with the load capa-
city tables supplied with the crane. The crane’s construc-
tion number is noted on the load capacity tables.
If there are no specifications for the outrigger support area
in the load capacity tables, then the outrigger struts must
be extended completely and pinned.
12.9.2 Outrigger Support Area 8.40 m x 6.85 m (27.6 ft x

22.5 ft)
(Z 200 417)
Outrigger strut (1) is fully and outrigger strut (2) is partially exten-
ded for the outrigger support area 8.40 m x 6.85 m
(27.6 ft x 22.5 ft).
The measurement from the outer edge of the chassis frame to the
outer edge of the outrigger strut (2) is 670 mm (26.4 in)
The extension length of 670 mm (26.4 in) is colour marked on

theoutrigger strut (2).
If the outriggers are to be driven from the ”normal“ outriggerbasis
to reduced outrigger basis, pin bolt ”B“ in the lockingposition for
driving.
If the outrigger support area is reduced, then only certain co-

unterweights / main boom lengths / equipment are permit-
ted.
Details of these can be found in the corresponding load ca-
pacity tables.
Only the combinations specified there are permitted.
Drive the outrigger support area as follows:

− Remove bolt (5) from point (B)
(remove transportation safety lock)
200−1−2120−120c_en 75/95
12
670 mm 1355 mm
(2.2 ft) (4.5 ft)
A 4 5 B,E 2 6 G 1
6850 mm
(22.5 ft)
Z 200 417
1355 mm
(4.5 ft)
2
1
A 4 5 B
5700 mm
(18.7 ft)
Z 200 418
76/95 200−1−2120−120c_en
Outriggers 12
(Z 200 417)
− Extend strut until the pinning hole (G) on the outer outrigger-
strut (2) is visible.
− Insert driving bolt (4) in point (A) on the chassis frame andse-
cure.
− Extend strut until stop (D) of the outer outrigger strut (2) is
flush with the driving pin (4) and the inner outrigger strut (1)
is completely extended.
− Pin the chassis frame (fitting point B) to the outeroutrigger
strut (2) using bolt (5).
− Pin the outer outrigger strut (2) (fitting point G) to theinner ou-
trigger strut (1) using pin (6).

18.7 ft)
(Z 200 418)
The inner outrigger strut (1) is completely extended and the outer
outrigger strut (2) is not extended for the outrigger support area
8.40 m x 5.70 m (27.6 ft x 18.7 ft).
Drive the outrigger support area as follows:

− Remove bolt (5) from point (B)
(remove transportation safety lock)
− Insert driving bolt (4) in point (A) on the chassis frame andse-
cure.
− Extend strut until the inner outrigger strut (1) is completely ex-
tended.
− Pin the chassis frame (fitting point B) to the strut using bolt (5).
− The pin (5) is then pinned by the retracted outer outrigger
strut (2) in the inner outrigger strut (1).
If the outrigger support area is reduced, then only certain

counterweights / main boom lengths / equipment are per-
mitted.
pacity tables.
200−1−2120−120c_en 77/95
12
2800 mm
(9.2 ft)
Z 200 419
78/95 200−1−2120−120c_en
Outriggers 12

9.2 ft)
(Z 200 419)
This outrigger support area is similar to the transportation state

of thestruts. The outrigger struts are completely retracted.
Bolt (5) is fitted in point (B) in the chassis frame. Only theoutrigger
cylinders are extended.
If the outrigger support area is reduced, then only certain

counterweights / main boom lengths / equipment are per-
mitted.
pacity tables.
200−1−2120−120c_en 79/95
12
5 ”B” 2
Z 200 432
E R 12 15 P Q
Z 200 433
80/95 200−1−2120−120c_en
Outriggers 12
12.10 Fitting and Removing the Outrigger Struts (Optional

Equipment)
12.10.1 Removing the Outrigger Struts
(Z 200 432, Z 200 433)
An auxiliary crane is required to remove and fit the outrigger

struts. The weight is marked on plates on the sides of the struts.
Observe the centre of gravity when fitting the attachmente-

quipment for dismantling the outrigger struts. Risk of tip-
ping!
The quick disconnect couplings on hydraulic lines ”R”, ”E” and ”P”
are marked with plates.
If there are no plates on the quick−release couplings, the

couplings must be marked before they are disconnected.
Connection „R“ = extending the horizontal cylinders:

The outer connection to the piston rod of
the horizontal cylinder on outrigger strut
(2) without ”T−union”
Connection ”E“ = retracting the horizontal cylinders and
thevertical cylinders :
The inner connection to the piston rod of
the horizontal cylinder on outrigger strut
(2) with ”T−union”
Connection ”P“ = extending the vertical cylinder
200−1−2120−120c_en 81/95
12
5 ”B” 2
Z 200 432
E R 12 15 P Q
Z 200 433
82/95 200−1−2120−120c_en
Outriggers 12
(Z 200 432; Z 200 433)
To remove the outrigger struts, proceed as follows:
1. Remove locking bolt (5) at position (B).

The inner outrigger strut (1) (with fitted outrigger cylinder) is
completely retracted.
2. Extend outrigger struts (2) completely.
3. Disengage the quick−release couplings of the hydraulic lines

”R”, ”E”, ”P” and the electrical line.
When disconnecting or connecting the quick disconnect

couplings, all buttons on the outrigger control panel must be
off.
4. Remove connecting bolt (15) from the piston rod of the hori-
zontal cylinder (12).
Disconnect plug ”Q” of the support pressure display.
Depending on the friction conditions, it could be necessary to

firstcompletely extend the struts and then to retract the innerou-
trigger struts:
After the strut has been extended, bolt (5) must be fitted in point
(B) in the chassis frame in such a way that the outer outriggerstrut
(2) is pinned to the chassis frame, but has not been fittedthrough.
The inner outrigger box is then mobile. Then theinner outrigger
strut must be retracted.
200−1−2120−120c_en 83/95
12
5 ”B” 2
Z 200 432
E R 12 15 P Q
Z 200 433
84/95 200−1−2120−120c_en
Outriggers 12
(Z 200 432, Z 200 433)
5. Connect extension hoses to the quick disconnect couplings

ofthe hydraulic leads „R“ and „E“. Clean the quick disconnect
couplings before assembling.
Check the O−rings for sealing the quick disconnect coupling.
The quick disconnect couplings should be screwed in up to

the stop.
The hydraulic lines must not be mixed up.
The non−return valve in the quick disconnect coupling can
open only if the coupling is screwed in up to the stop. Closed
or only partially open non−return valves can cause damage
to the hydraulic system.
Mixed−up hydraulic lines can also damage the hydraulic sy-
stem and cause malfunctions.
6. Connect the extension cable for activation of the hydraulic

valves.
7. Retract the horizontal cylinder. Disconnect the connection

hoses on the quick disconnect couplings of hydraulic lines
”R” and ”E” on the chassis.
8. Attach auxiliary crane to the outer outrigger struts (2) using

suitable lifting tackle.
9. Unscrew rollers (4) on both sides and extend outrigger strut

(2) horizontally using the auxiliary crane.
10. Disconnect the connection hoses on the quick disconnect

couplings of hydraulic lines ”R” and ”E”.
Place dust caps on all quick disconnect couplings. Remove
the electrical cable.
Load outrigger struts on an adequate transport vehicle and
secure.
200−1−2120−120c_en 85/95
12
86/95 200−1−2120−120c_en
Outriggers 12
12.10.2 Installation of the Outrigger Struts
The outrigger struts are fitted analogously in the reverse order.

Please observe the cautionary notes for the corresponding wor-
king steps.
Before fitting : clean and grease the sliding surfaces on theoutrig-

ger struts and on the chassis.
After fitting and before extending the struts: ensure that the hy-
draulic lines can move freely.
200−1−2120−120c_en 87/95
12
Z 41 654
88/95 200−1−2120−120c_en
Outriggers 12
12.11 Supporting the Outrigger Plates Due to Insufficient

Load−bearing Capacity of the Ground
The load−bearing capacity of the ground must be sufficient to ab-

sorb 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 ma-
terials 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.
You must also check whether channels, covered pits or cel-

lars are in the vicinity of the scheduled crane location and
how they are laid out. You must also take hidden dangers
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.
200−1−2120−120c_en 89/95
12
90/95 200−1−2120−120c_en
Outriggers 12
12.11.1 Permitted Ground Pressure
The permitted loading of the ground is determined by type and

condition of the ground. Instructions on permitted ground pressu-
res can be found for example, in the standard DIN 1054 “Permit-
ted loading of the construction ground” (for excerpt see the follo-
wing table).
Permitted ground pres-
Type of ground
sures
N/cm2 psi
1. Organic ground in general:
Peat, sludge, bog soil 0 0
2. Non−compressed rubble: Construction site rubble,
etc. 0 − 10 0 − 15
3. Non−cohesive ground:
Sand, gravel, stones and mixtures thereof 20 29
4. Cohesive grounds:
a) Course clay, mixed with e.g. topsoil 12 17
b) Coarse clay, consisting of all−weather clay and 13 19
clay from slopes
c) Rich clay, consisting of clay and fillers
stiff 9 13
semi−firm 14 20
firm 20 29
d) Mixed granular ground: Clay to sand, gravel and
stone areas
stiff 15 21
semi−firm 22 32
firm 33 47
5. Consistently firm rock:
− cracked with weather wear 150 217
− not cracked 400 580
If doubts exist with regard to the load−bearing capacity of

the ground, an examination of the ground must be carried
out (e. g. with a pile sensor).
200−1−2120−120c_en 91/95
12
p [N/cm 2] 4 10 15 20 40 150
p [psi] 6 15 21 29 58 217
1 2 3 4 5 6
Fs (kip) Fs (t)
242.5 110
6 5 4 3
220.5 100 2
198.4 90
176.4 80
154.3 70
132.3 60
110.2 50
88.2 40
1
66.1 30
44.1 20
22.0 10
As/(m2)
6,6
0 0,5 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0
As/(ft 2)
5.4 10.8 21.5 32.3 43.1 53.8 64.6 75.3 86.1 96.9 107.6
Z 200 617
92/95 200−1−2120−120c_en
Outriggers 12
12.11.2 Determining the Required Support Area
For this type of machine, the maximum support forces vary at the
front and rear supports.
The maximum support force is 100 t (220.5 kip) at the rear sup-
ports and it is 85 t (187.4 kip) at the front supports.
The rear outrigger plates have a diameter of 700 mm (27.6 in)
(support surface of 0.4 m2 / 4.3 ft2).
The front outrigger plates have a diameter of 600 mm (23.6 in)
(support surface of 0.3 m2 / 3 ft2).
Procedure
(Z 200 617)
The permitted ground pressure “p” for the type of ground on

which the supporting procedure is to be carried out can be found
in the table in segment “12.11.1 Permitted ground pressure”
(page 91).
The corresponding curve (1 to 6) must then be selected for the

assigned graph out of the table in figure (Z 200 617 top).
The support force FS is depicted on the y−coordinate (ordinate)

in the graph in figure (Z 200 617 bottom).
The required support surface AS is noted on the x−coordinate
(abscissa).
Curves 1 to 6 show the relation between the support force FS and
the required support area AS with regard to the permitted ground
pressure “p”.
Example
For a “stiff” mixed−granular ground (clay to sand, gravel and

stone areas) (p=15 N/cm2 (21 PSI)) in accordance with the table
“Permitted ground pressure” in segment (12.11.1), the following
values can be taken for the adjacent diagram:
For p=15 N/cm2 (21 PSI), the values of the curve 3 are the deci-
sive ones (see table (Z 200 617 top).
The support surface (As= 6.6 m2 / 71.0 ft2) required for the outrig-
ger plates is calculated from this with a maximum support force
(Fs = 100 t / 220.5 kip) at the rear supports.
In order to increase the outrigger pad’s support surface area −

which is too small in this example − to the required support sur-
face area, suitable supports (f.e: timber planks) must be laid un-
derneath.
200−1−2120−120c_en 93/95
12
Z 170 688
94/95 200−1−2120−120c_en
Outriggers 12
12.12 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

(6.6 ft).
A general rule is:

− For loose or backfilled soils the safety distance (a) must bet-
wice the size of the ditch depth (b)
The slope angle a must be < 30 °.
− for natural, firm soils the safety distance (a) must be as large
as the ditch depth (b).
The slope angle a must be < 45 °.
Thesafety distance is measured starting at the base of the pit (C).
200−1−2120−120c_en 95/95
Parking 13
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

engine−independent heating).
5. Telescopic sections must be pinned;

the LPU must be ready for road travel (see ”Operating
instructions of the Superstructure”, part 1, section 12).
6. Position all control levers in the off or middle position (neutral

position).
7. Pull out ignition key (superstructure and crane chassis).
If the crane is equipped with an engine−independent heater,

wait one or two minutes before switching off the ignition
switch.
(After−run time of the heater fan for cooling off the heating).
8. Lock the driver’s cab and crane operator’s cab.
200−1−2130A_en 1/3
13
”O”
”2”
Z 45 197
2/3 200−1−2130A_en
Parking 13
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 operator’s
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. Position all control levers in the off or middle position (neutral

position).
5. Switch off the engine.
6. Switch off the heating if it is on.
7. Pull out ignition key (superstructure and crane chassis).
(Z 45 197)
If the aircraft warning light is to remain switched on while parking,
the ignition key in the crane operator’s cab of the superstructure
must not be pulled out, but must be switched to position ”P”. 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 engine−independent heater,

wait one or two minutes before switching off the battery
switch or ignition key (after−run time of the heater fan for
cooling off the heater).
8. Lock the driver’s cab and crane operator’s cab.
Observe the permitted wind speeds!

If necessary, the boom or equipment must also be lowered!
200−1−2130A_en 3/3
Tow−starting and Towing the Crane 14
200−1−2140b_en 1/15
14
1 2 4 5 7 3 6
Z 200 092
2/15 200−1−2140b_en
14 Tow−starting and Towing the Crane
Figure Z 200 092 shows the drive line of the 5 axle model. With
the 6−axle design, an additional non−driven axle is added in the
same way between the third and fourth axle of the 5−axle design.
14.1 Towing start
The engine cannot be started by tow−starting the crane.

If the batteries are dead the engine can be started with the help
of jump−start cables and the batteries of another vehicle.
(Information pertaining to this can be found in section 4.)
14.2 Towing away
14.2.1 Important General Instructions
The trailer coupling on the front frame is designed for

manoeuvring and towing the crane.
The towing vehicle must be sufficiently dimensioned (brakes,

engine 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 when there is damage to the engine / transmission.
There are more detailed instructions in section 14. 2. 6.
Failure to observe this regulation will unavoidably result in

damage to the crane.
200−1−2140b_en 3/15
14
1 2 4 5 7 3 6
Z 200 092
M16x1.5
1 ”L”
B3
3 ”R”
B4
35
Z 51 301 Z 200 320
4/15 200−1−2140b_en
14.2.3 Towing with Engine Damage
(Z 200 092, Z 51 301, Z 200 320)
First possibility:
− 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 possibility:
Under certain conditions (max. 30 km (18.6 miles) at 30 km/h
(18.6 mph)), you can avoid removing the universal joints for
towing. In this case, the distributor gear must be switched to the
neutral position instead (for information pertaining to this see
“Neutral position of the distributor gear” in this section).
− Ignition on.
For both possibilities the following must apply:

− The braking system of the mobile crane must be supplied with
pressured air using a hose from the towing vehicle. To do so,
there is a combined exterior filling and tyre filling connection
with thread M 16 x 1.5 on the right−hand side of the chassis.
However, the connection of the filling tube may only be
screwed onto the connection of the combination connection
so that the cylindrical component is pressed in approx. 1 mm
(0.04 in) (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 (0.12 in) (position R).
If the air pressure in the supply tanks falls below 5.5 bar
(79.8 psi) (indicator 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
accord, 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.
200−1−2140b_en 5/15
14
1 2 4 5 7 3 6
Z 200 092
35 36 B4
B3
43 B8
B9
B10
35
36
Z 52 142
6/15 200−1−2140b_en
The spring accumulator brake cylinders may only be

released once the vehicle has been secured to prevent it
rolling.
(Z 200 092, Z 52 142)
Following towing with the spring accumulators − brake cylinders

released, the braking action of the parking brake must be
restored before the crane is placed back in operation.
The compressed air must first be raised to a pressure of 8 bar
(116 psi) with the engine running. The displays (B3 / B4) go out
at 5.5 bar (79.8 psi).
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 travel of the brake cylinder
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 starts moving
does the emergency steering pump connected to the drive
rope (distributor gear) start to turn and supplies the
(speed−dependent) 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
increased 3− to 4−fold.
∗ 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
moment. This is indicated during towing by red indicator
lights (B8, B9) in combination with “Caution” (36).
∗ During towing the indicator light (B10) must be observed.
200−1−2140b_en 7/15
14
35 36 B4
B3
43 B8
B9
B10
35
36
Z 52 142
1 2 4 5 7 3 6
Z 200 092
8/15 200−1−2140b_en
(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.
Depending on the system, in case of the fault ”No through−feed

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.
14.2.4 Towing with Damage to the Drive Gearbox
(Z 200 092)
First possibility:
− The drive shaft (4) must be disconnected between the drive

gearbox (2) and the distributor gear (3).
− Distributor gear in road travel position.
Second possibility:
Under certain conditions (max. 30 km (18.6 miles) at 30 km/h

(18.6 mph)), you can avoid removing the universal joints for
towing. In this case, the distributor gear must be switched to the
neutral position instead (for information pertaining to this see
“Neutral position of the distributor gear” in this section).
For both possibilities the following must apply:
− Start the engine of the chassis and set the speed at 1200 U/
min (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 case of engine damage.
200−1−2140b_en 9/15
14
1 2 4 5 7 3 6
Z 200 092
B8
B9
B10
36
Z 51 300
10/15 200−1−2140b_en
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 at 1200 U/
min (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
possible 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
towing (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 (5mph).
200−1−2140b_en 11/15
14
A8
1
2
Z 52 143
93 A7
Z 52 144 Z 200 321
12/15 200−1−2140b_en
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

driver’s 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

position if the journey is no longer than 30 km (18.6 miles) and
speeds do not exceed 30 km/h (18.6 mph).
Avoid longer towing journeys (the lubricating oil pump does not
work).
If the max. towing journey (30 km / 18.6 miles) and / or the

max. towing speed (30 km/h / 18.6 mph) is not adhered to, it
will always lead to consequential damage.
The neutral position is switched on via a manually activated

pneumatic valve (1) (key function).
The button is on the right−hand side of the machine in the outer

covering under the rubber sheeting (Z 200 321).
In order to carry out a switching procedure, a pressure supply of

7 bar (101.5 psi) is required.
The valve is in the direct vicinity of the distributor gear within the
frame and can be accessed from below via the fitting openings
there.
Steps for neutral position of the distributor gear
1. Stop vehicle; apply the retaining 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
distributor gear by pressing the dual button (93). The
indicator light (A8) goes out.
No resetting is required at the actual pneumatic valve.
200−1−2140b_en 13/15
14
93 A7
Z 52 144
14/15 200−1−2140b_en
Make sure that the dual button (93) is not pressed during
towing (not even by accident).
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 on 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 which 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

deflection point may need to be set up between the crane and the
recovery vehicle. Make sure that there is sufficient air in the
braking system.
200−1−2140b_en 15/15
Heating and Ventilation 15
200−1−2150−076b_en 1/33
15
105 106 107 115
114
113
24V
112
5A
108 109 110 111
Z 53 019
2/33 200−1−2150−076b_en
15 Heating and Ventilation
15.1 General
The chassis cab is equipped with a hot−water heater that is de-
pendent on the coolant temperature of the chassis engine.
Optionally, the chassis can be equipped with an engine−inde-
pendent radiator preheater.
With the help of this radiator preheater, the chassis cab can be
heated with the chassis engine at a standstill.
In addition, the coolant can be preheated before the engine is
started.
At low ambient temperatures (up to −20 °C ( −4 °F)) the coolant
preheating makes it easier to start the engine.
Below −20 °C ( −4 °F) the coolant must be preheated.
15.2 Cab heater arrangement (engine−dependent)

(Z 53 019)
This heating is dependent on the coolant temperature of the en-

gine.
When the cooling water is warm, the temperature in the driver’s

cab can be regulated using rotary knob (113).
Using the rotary switch (114) a fan can additionally be activated

to allow air to be circulated around the driver’s cab more quickly
and/or to continue to feed warm air into the cab when the crane
is at a standstill.
Using the knob (111) the airflow can be switched to “front window”
or ”driver’s cab”.
Using control knob (115) an air flap can be set to fresh air or venti-
late.
200−1−2150−076b_en 3/33
15
105 106 107 115
114
113
24V
112
5A
108 109 110 111
Z 53 019
4/33 200−1−2150−076b_en
15.3 Engine−independent heating with radiator preheater

(optional)
In addition, observe the operating instructions of the manu-

facturer in part 5 of this documentation.
These are much more detailed and contain additional areas
(for example fitting, safety devices etc.).
The mobile crane is optionally equipped with an engine−indepen-

dent radiator preheater for the chassis engine. At low outside
temperatures of up to −20°C ( −4 °F) it facilitates starting the
engine.
Below −20°C ( −4 °F) the coolant must be preheated. To operate
the system there is a timer in the crane operator’s cab (109).
The heater may only be used for the purpose specified by the
manufacturer, and all operating instructions supplied must
be observed.
Operation is not permitted:
− where flammable fumes or dust can be produced
(i.e. near fuel, coal dust, wood dust, wheat depots, or
similar places)
− in enclosed spaces (e.g. garages) due to
the risk of poisoning.
− when refuelling.
When carrying out electric welding work on the vehicle, the

positive terminal must be disconnected from the battery to
protect the control unit and connected to ground.
If the coolant has been replaced, or if large quantities of coo-

lant have been added, before switching on the engine−inde-
pendent heater − the engine must be set to an operating tem-
perature of approx. 805 C (1765F) ( = opening point coolant
thermostat). The coolant circuit and the circuit for the en-
gine−independent heater assembly can then be vented auto-
matically.
200−1−2150−076b_en 5/33
15
105 106 107 115
114
113
24V
112
5A
108 109 110 111
Z 53 019
6/33 200−1−2150−076b_en
The coolant that has been preheated by the heater assembly can
be used to preheat the cab and/or engine.
First, up to a coolant temperature of approx. 45 °C (113 °F), the
heat of the auxiliary heating system is directed only into the dri-
ver’s cab = small circuit = rapid heating.
If the coolant temperature continues to rise, the
thermostat gradually switches over (fully switched at 60 °C
(140 °F)) to the large circuit = additional engine preheating.
15.3.1 Operating modes

(Z 53 019)
− Cab and engine preheating using preselected times
Set the heater regulator (control knob, 113) to the desired tempe-
rature and pre−program the start of heating operation using the
timer (109).
Once a certain coolant temperature has been reached, the fan

automatically starts at the level set by the control knob (114).
Control knob (114) must be set to the maximum position.
− only engine preheating using set times
Set the heater regulator (control knob 113) to the temperature po-
sition 0 and preprogramme the start of heating operation using
timer (109).
200−1−2150−076b_en 7/33
15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
8/33 200−1−2150−076b_en
15.3.2 Operating elements

(Z 36 772)
(1) − Time
(2) − Preselection
(3) − Heater
(4) − Backwards
(5) − Forwards
Display of the timer
(6) − Memory
(7) − Symbol for radio remote control
(8) − Week day / selected day
(9) − Current time / selected time
(10) − Temperature
(11) − Service indicator light
The heater should be switched on briefly (approx. 10 s) out-

side of the normal heating periods at least once a month.
This prevents the water pump and burner motor from seizing
up.
Before the heating period, a test run should be carried out

using the heater assembly. If strong smoke develops or if un-
usual burner noises or the smell of burning fuel occurs, the
heater must be switched off and placed out of operation by
removing the fuse. The equipment should only be restarted
once it has been tested by an authorised service outlet.
After interrupting the power supply the display of the heating

timer shows all signals flashing.
In this case a complete reset is required.
200−1−2150−076b_en 9/33
15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
10/33 200−1−2150−076b_en
15.3.3 Setting
(Z 36 772)
After connecting the power supply the display shows all signals
flashing − the timer must be completely set. In this condition, the
heater assembly cannot be switched on.
15.3.3.1 Setting the time and week day for the first time
Press briefly; time display flashes 12:00.

Set the current time.
Note: If two keys are shown next to each other, one or the
other must be pressed.
As soon as this stops flashing, it is saved. After this, the
weekday flashes.
Set the current week day.
As soon as this stops flashing, it is saved.
With the ignition “ON” the display remains set, with the igni-
tion “OFF” it goes out after 10 s.
15.3.3.2 Adjusting the time and day of week
Press longer until the time flashes. Now continue as descri-

bed above in section 15.3.3.1.
By pressing 2 x after setting the clock the adjustment op-
tion for the weekday can be skipped.
By pressing after setting the weekday the flashing of the
weekday can be shortened.
With the ignition switched on the time and week day are con-
stantly displayed. When the ignition is switched off the dis-
play goes out after 15 s.
Voltage interruptions are bridged by the heater timer.
After voltage interruptions, all signals on the display are
flashing. The system must be completely reset!
200−1−2150−076b_en 11/33
15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
12/33 200−1−2150−076b_en
15.3.4 Heating operation without pre−set times

(Z 36 772)
Before switching on the heating at the beginning of each

heating period, bring the superstructure engine to approx.
805 C (1765 F ) engine temperature so that the heating system
can be vented 100 %.
15.3.4.1 ... with the ignition ”OFF”
Switch on the heater

Heating symbol = observe the service indicator light.
Press briefly.
Display: Operation, heating time.
The heating time is set at a default of 120 minutes. It be changed

as a one−off or permanently.
Changing the heating time as a one off

Switch on the heating.
Press − shorten (min. 1 minutes) or lengthen (max. 120 mi-
nutes) heating time
Changing the heating time permanently

Do not switch on the heating
Press and hold approx. 3 s until the display appears and flas-
hes. Release briefly.
Press − shorten (min. 10 minutes) or lengthen (max. 120 mi-
nutes) heating time
When the display goes out, the new heating time is saved.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
200−1−2150−076b_en 13/33
15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
14/33 200−1−2150−076b_en
15.3.4.2 ... with ignition ”ON”

(Z 36 772)
Switch on the heater

Press briefly.
Display: Operation, time, day of week.
The heater remains in operation as long as the ignition is swit-

ched on. After switching off the ignition, 15 minutes residual hea-
ting time remains.
Changing the residual heating time

Switch on the heating.
Press − shorten (min. 1 minute) or lengthen (max. 120 minu-
tes) residual heating time.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
15.3.5 Heating operation with preselection

(Z 36 772)
Starting point: Neutral position, as long as the display is visible.

No memory activated.
Three starting times can be set within the next 24 hours or 1 star-
ting time within up to 7 days.
Only 1 starting time can be activated at once.
Before switching on the heating at the beginning of each

heating period, bring the superstructure engine to approx.
805 C (1765 F ) engine temperature so that the heating system
can be vented 100 %.
200−1−2150−076b_en 15/33
15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
16/33 200−1−2150−076b_en
15.3.5.1 Heating start within 24 hours
Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.
and is displayed as follows.
Press briefly and release. The selected time is shown flas-

hing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Press to select a memory again.
Set the preselected day

The preselected day is set automatically. It is therefore not
necessary to set it.
The selected time and day are stored as soon as the time
display goes out or switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The selected time of the displayed memory is displayed for
approx. 5 s. It then goes out or the time is displayed (with the
ignition ON).
Press once to call up the selected time and day (for 5 s)
200−1−2150−076b_en 17/33
15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
18/33 200−1−2150−076b_en
15.3.5.2 Heating start after 24 hours (max. 7 days)

(Z 36 772)
Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.
and is displayed as follows.
Press briefly and release. The selected time is shown flas-

hing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Set the preselected day

Approx. 5 s after setting the selected time the selected day is
shown flashing.
Press to set the preselected day for the heater.
The selected time and day are stored as soon as the time
display goes out or switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The selected time of the displayed memory is displayed for
approx. 5 s It then goes out or the time is displayed (with the
ignition ON).
Press once to call up the selected time and day (for 5 s).
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15
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
20/33 200−1−2150−076b_en
15.3.6 Rectifying faults

In case of faults or damage to the heater, an authorised service
outlet must be contacted to repair the damage using original
spare parts.
Repairs in house are therefore not permitted.
Proceed as follows:
− switch off and on (not more than twice)
− check main fuses
− check that the air flow is not blocked
− go to a workshop.
If a fault occurs when the heating is switched on and the diagno-

sis line is connected, the service indicator light flashes and
the code no. of the fault is displayed (contact garage).
200−1−2150−076b_en 21/33
15
105 106 107 115
114
113
24V
112
5A
108 109 110 111
Z 53 019
22/33 200−1−2150−076b_en
15.4 Air Conditioning Equipment, Standard, Optional

Equipment
(Z 53 019)
The air conditioning equipment works with the coolant R 134a

and therefore contains no ozone−destructive CFCs.
To operate the air conditioning, there are two rotary switches.
1. AC switch (110) (on/off)
2. Blower switch with 3 settings (114)
The air conditioning equipment only works when the engine is
running.
The air conditioning equipment is out of operation when the air
conditioning switch (110) is switched off.
If you want to switch on the air conditioning equipment, you must
set the blower switch (114) to at least position 1 by turning clock-
wise. With the temperature selection knob (113) you can now se-
lect the cooling temperature. By turning the knob in the clockwise
direction, the output of the air conditioning equipment is increa-
sed; the room temperature in the cab falls.
The higher the cooling output of the air conditioning as set with
the temperature switch, the higher the fan setting should be se-
lected.
If the cooling output of the air conditioning equipment is noticea-
bly lower with the setpoint value unchanged and the fan setting
lower, it is possible that the vaporiser has iced up. In this case,
switch off the air conditioning equipment − with the vaporiser fan
running − for approx. 3 minutes. The ice on the vaporiser will now
thaw.
To achieve the highest level of cooling in the cab, the
− temperature selection knob must be turned in the clockwise
direction up to the stop.
− the highest fan setting selected
− the heating switched off
− the window closed
On damp days the air conditioning unit can dehumidify the cab
air. With the vehicle heating the cooling effect is compensated for.
This then achieves a pleasant cab climate and prevents windows
fogging up.
The air−conditioning must be switched on at least once a month
for a brief period. This is necessary to lubricate the compressor.
For servicing of the air conditioning equipment, see part 3 ”main-

tenance and lubrication instructions of the superstructure“.
200−1−2150−076b_en 23/33
15
115
114
113
24V
112
5A
109 110 111

Z 57 679
205.1
205
Z 56 153
24/33 200−1−2150−076b_en
15.5 Auxiliary AC system (optional)

(Z 57 679, Z 56 153)
For special climate situations the cab can be equipped with an

additional AC system.
The housing (205) is then fitted in the cab.
The air conditioning equipment works like the standard AC only
when the engine is running and the fan switched on. The air con-
ditioning works permanently with maximum power.
Proceed as follows in order to operate the air conditioning unit:
1. Set switch (205.1) to the desired fan level.
2. Press luminous switch (110); the indicator light in the switch

lights up.
The auxiliary AC is then switched on with the same switch (110)

as the standard AC.
Whether and how the standard and auxiliary AC systems provide
cool air depends on the position of the fan switch.
When the fan is switched off, the corresponding AC does not pro-
vide a cooling function.
In order achieve maximum cooling in the cab:

− Set the fan to the highest level using switch (114) and (205.1)
− Turn switch (113) fully to the left (anti−clockwise) up to the
stop.
− Open the vent nozzles in the cab and housing (205) of the au-
xiliary AC system completely
− Press the switch (115) for circulation air mode
− Close windows and doors of the cab.
The instructions for operating the AC system in section 15.4 ap-

ply in the same way.
200−1−2150−076b_en 25/33
15
2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
26/33 200−1−2150−076b_en
15.6 Petrol gas heating (engine−independent), optional

There is an operating panel for operating the liquid gas heating
system in the cab.
Depending on the design of the crane, operating panels with sli-
ding switches or a combined rotary switch are used.
Operating panel with sliding switches
(Z 56 140, principle drawing)
Set the desired room temperature at the control knob (1) of the
operating panel.
Using sliding switch (3), either operating modes “Heat” (C) and
“Ventilation” (E) can be set or the system can be switched off
(switch in middle position ’D’).
Using sliding switch (2), the heating performance can be set in
two stages.
Operating panel with combined rotary switch
(Z 56 138)
The upper part of the rotary switch is designed as a rotating knob

(1.1) and is used as a temperature selection switch.
The lower part (1.2) of the rotary switch is used to switch the sy-
stem on and off (d) and is used to set the two operating modes
“Heat” (c) and “Ventilation” (e).
The heater setting and ventilation output can be set in two sta-
ges.
Heating
Proceed as follows to switch on the heating:
1. If fitted, remove the flue cap.
2. Open the bottle valve and quick−closing valve in the gas.
3. Set the desired room temperature using the control knob (1,
Z 56 140 or 1.1, Z 56 138) of the operating panel.
4. Depending on the operating panel, set heating using the sli-

ding switch (2, Z 56 140) or, if the operating panel has a com-
bined rotary switch, set heating (”FULL, large flame” or ”1/2,
small flame”) using the lower part of the rotary switch (1.2).
At low ambient temperatures leave the heating running on
”FULL”.
200−1−2150−076b_en 27/33
15
2 C
4 D
E
3
Z 56 140
1.1
1.2
Z 56 138
28/33 200−1−2150−076b_en
Ventilation
If the operating panel has sliding switches, slide sliding switch (3)
to position (E) in order to activate the fan.
If the operating panel has a combined rotary switch, the lower

part of the rotary switch (1.2, Z 56 138) is set to the desired venti-
lation degree (”FULL” or ”1/2”) in order to activate the fan.
Notes on heating operation

(Z 56 140, Z 56 138)
If the system is activated, the green indicator light under the con-
trol knob must be illuminated. The fan is in operation.
If the control lamp is not illuminated, the fuse in the electronic con-
trol unit must be replaced (see maintenance and lubrication in-
structions).
If the heating is switched off after a heating phase, the green light
means that the fan is still running to use up the residual heat. The
ignition switch may therefore only be switched off once the fan
has come to a standstill.
When refuelling and in enclosed spaces (garage etc.) the heating

may not be operated.
Uninterrupted display of the red control lamp can, amongst other

things, point to a lack of gas, air in the gas line, heavily clogged
blower or malfunction in one of the safety units.
The fault can be deactivated by switching the heating off and
back on again.
Flashing of the red indicator lamp points to low operating voltage

for the heater.
Make sure that the exhaust flue and combustion air intake is al-
ways clear of clogging (slush, foliage etc.).
The cap for the flue must always be fitted when the heating is not
in operation.
For operation and servicing of your heater, see also the operating
instructions of the manufacturer in part 3.
Before carrying out any welding work, the corresponding fuse

breaker must be removed, switched off.
200−1−2150−076b_en 29/33
15
30/33 200−1−2150−076b_en
15.7 Instructions for winter operation
Starting the engine at ambient temperatures below −165 C

(3 5F)
If there is no engine oil or coolant preheating device, the engine

can be equipped for very low ambient temperatures with a flame−
starting system.
Information on this can be obtained from any DAIMLERCRYS-
LER Service Station.
Fuel
See operating instructions of the engine manufacturer
Engine oil for low temperatures
Coolant for low temperatures
Batteries
At ambient temperatures below −15 °C (5 °F) the batteries must

be heated or removed when the crane is at a standstill for longer
periods of time (e.g. overnight). Always ensure that the batteries
are well charged in the winter.
Discharged batteries freeze at −10° C (14 °F).
Transmission
At ambient temperatures below −20° C ( −4 °F) a warming−up

phase is required after starting the engine for the transmission.
The engine must run for at least 10 minutes until the gearlubricant
oil has warmed up; the vehicle should be stationary and the par-
king brake applied.
200−1−2150−076b_en 31/33
15
Z 2542
32/33 200−1−2150−076b_en
Bleeding the air tank

(Z 2542)
The air tank should be bled regularly using a manual drain valve.
By pulling or pushing on the bolt of the drain valve in the sideways
direction the tipping valve opens and the condensation water can
escape from the tank.
Windscreen washing assembly
The windscreen washing assembly should be checked at least

once a week to make sure that it is working properly. The supply
tank must always be filled with water. At low temperatures, an ap-
propriate amount of antifreeze suitable for the temperatures must
be added to the water.
The tank for the windscreen washing assembly is located in the
footwell of the driver’s cab.
200−1−2150−076b_en 33/33
Central lubricating system (optional) 16
200−1−2160b_en 1/15
16
Z 42 271
7
8
6 9
10
Z 29 548
2/15 200−1−2160b_en
16 Central lubricating system (optional)
(Z 29 548, Z 42 271)
16.1 Components
(1) Lubricating nipple for manual lubrication
(2) Grease containers
(3) Safety valve
(4) Filling nipple
(5) Sealing plug
After the sealing plug (5) has been removed, the control board
with the following details is visible:
(6) LED ”Battery voltage applied”

(7) Rotary switch ”Setting the interval times”
(8) Rotary switch ”Setting the operating time”
(9) LED ”Display of a lubrication procedure”
(10) Button for additional lubrication impulse
200−1−2160b_en 3/15
16
Z 42 271
7
8
6 9
10
Z 29 548
4/15 200−1−2160b_en
16.2 Function
(Z 42 271, Z 29 548)
The central lubricating system automatically supplies the

connected lubricating points via local sub−distributors with
grease.
It then operates in prescribed cycles, i.e. there areinterval and

operating times. These begin to run as soon as the ignition on the
chassis is switched on.
Interval time: Period in which no lubrication procedure occurs

(exceptions are possible with the additional
lubrication impulse)
Operating time: Period in which the lubrication procedure

occurs.
You will find an exact description of the interval and operating

times in section 16.3.
If there is a blockage in the system, lubricant will come out of the

pump safety valve (3).
You will find an exact description of the procedures to be followed

in the case of malfunctions in section 16.7.
A test run is possible for a functions check of system and

controls.
1. Switch on the ignition:

Light−emitting diode (6) must light up.
2. Press button (10) for additional lubrication for approx.

seconds (or button ”98” in the dashboard).
The interval time is then reduced and the normal lubrication
procedure follows; light−emitting diode (9) and indicating
lamp in the switch (98) light up.
200−1−2160b_en 5/15
16
7
8
6 9
10
Z 29 548
6/15 200−1−2160b_en
16.3 Setting the interval and operating times

(Z 29 548)
16.3.1 Generalinformation
The interval and operating times are controlled electronically.

As soon as the ignition is switched on, the interval timebegins.
When the interval time has expired, the operating time starts,
which is the actual lubrication procedure.
If, for example, an interval time of 6 hours was set, the interval
time that has passed up to that point is saved when the ignition
is switched off (e.g. 4 hours). When it is switched on again, there
are only two hours interval time remaining.
If the battery voltage is interrupted − for more than 4 days− a

complete interval time (6 hours) will first pass.
As long as the ignition is switched on, the operating time will

continue once it has been started.
If the operating time is interrupted by the ignition being switched
off, it will continue from the point it was interrupted at, when the
ignition is switched on again.
Each period is saved electronically.
Example: Expired operating time 3 min. −
remaining operating time 3 min.
The length of a lubrication cycle depends on the lubrication

requirements of the system. The interval / operating times of the
chassis are set ex works as follows:
− Interval time: 6 hours
Position of the rotary switch (7) = 6
− Operating time: 6 min.
Position of the rotary switch (8) = 3
This means that there is a lubrication procedure lasting 6 minutes

every 6 hours.
200−1−2160b_en 7/15
16
7
8
6 9
10
Z 29 548
8/15 200−1−2160b_en
16.3.2 Setting the interval time

(Z 29 548)
The pause time is set on rotary switch (7) in 15 increments.

Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
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.
This setting should be maintained in normal operating conditions.
16.3.3 Setting the operating time

(Z 29 548)
The operating time can be set using 15 settings on rotary switch

(8).
Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
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.
This setting should be maintained in normal operating conditions.
200−1−2160b_en 9/15
16
7
8
6 9
10
Z 29 548
4
41
5
Z 42 271 Z 47 997
10/15 200−1−2160b_en
(Z 29 548, Z 47 997, Z 42 271)
16.4 Additional lubrication impulses
When you are not within an automatic lubrication cycle, it is

possible to end the interval time prematurely and to introduce
additional lubrication procedures. 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;

light−emitting 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 the case of an emergency
If the lube pump fails, the lubricating pointscan also be lubricated

manually using grease.
To do so, grease is fed into the system via the lubricating nipple
(1) using a grease gun.
16.6 Filling the grease container
The grease container (2) is filled up to the “Max.” mark using the
filling nipple (4). This is done using a commercialgrease pump or
a lever type hand gun.
During filling, the pump must be set in motion (by first activating
the additional lubricating pulse).
The grease that is filled in must be free of any contamination

and must not lose its consistency with time.
Pay attention to the instructions on the prescribed lubricants

inthe „lubricating /maintenance instructions of the chassis“ (part
4).
200−1−2160b_en 11/15
16
12/15 200−1−2160b_en
16.7 Troubleshooting
Malfunction: Pump engine not running

Cause Remedy
Electricity supply interrupted. Check electricity supply / (safety) fuses.
Rectify malfunction / if required replace
(safety) fuses.
Malfunction: Pump is not pumping

Cause Remedy
Container is empty. Fill up container with clean grease, let pump
run (additional lubrication), until lubricant
emerges at all lubricating points.
Note: Depending on the ambient temperature
and / or the lubricant, the pump elements can
require up to 10 minutes in order to achieve
the full pumping capacity.
Air trapped in the lubricant. Carry out an additional lubricating pulse.
Remove exhaust screw from the safety valve.
The lubricant must emerge without any
bubbles.
Unsuitable lubricant used. Replace the lubricant, see lubricants table
(lubricating and maintenance instructions of
the chassis“, part 4).
Suction bore hole of the pump element Remove pump element, check suction bore
blocked. hole impurities and remove.
Pump piston worn. Replace the pump element.
Non−return valve in the pump element Replace the pump element.
defective or blocked.
Malfunction: Different lubricant quantity at the lubricating point

Cause Remedy
Corresponding valve body was fitted without a Remove valve body and check if there is a
clamping ring. clamping ring. If not, fit a clamping ring.
200−1−2160b_en 13/15
16
Z 29 549
14/15 200−1−2160b_en
Fault: Blockage in the connected progressive system (Z 29 549)

Cause Remedy
Bearing, lines or distributor Find and remove cause of blockage − as described in the
blocked. following example.
The malfunction can be 1. Let the pump run (additional lubrication impulse).
identified by the following 2. At the main distributor (B), remove all main lines (G) to
characteristics: the subdistributors one after the other. If, for example,
a) Grease emerging at the grease emerges when there is pressure on the exhaust
safety valve. (1) of the main distributor (B) you must search for the
b) Control pins at the distributor blockage in the lubrication circuit of the subdistributor (D).
pistons (if available) are not 3. Let the pump continue to run.
moving. 4. Remove all lubricating point lines (E) of the subdistributor
(D) one after the other. If, for example, grease escapes at
the exhaust (3) of the distributor (D) when pressure is
applied, you must search for the blockage in the line of
the exhaust (3) or in the connected bearing.
5. Replace safety valve A.
Note: In order to check the individual exhausts leave each
exhaust released for a longer period of time, as there is
only one stroke per pump rotation. However, several
strokes are required for a complete run of all distributors.
c) If a distributor is blocked, no Pump through blocked line / bearing using a hand pump.
lubricant emerges at any Replace distributor or clean as described in the following:
exhaust. 1. Remove all hose connecting screws.
2. Unscrew piston sealing screws.
3. If possible, drive the piston out using a soft mandrel
(∅ smaller than 6 mm (0,24 in)).
Caution: The pistons are fitted into the distributor bore
holes. After they have been removed, mark the fitting
position and direction of the pistons for refitting. They
must not be confused during fitting.
4. Clean distributor bodies thoroughly in a fat−dissolving
cleaner and blow out using compressed air.
5. Using a pin, press the sloped channels (ø 1.5 mm (ø
0.06 in)) through at the thread ends of the piston bore
holes.
6. Clean and blow out distributors again.
7. Assemble distributors.
8. Renew copper washers.
9. If possible, pump oil through the distributor several times
using a hand pump before screwing the hose connecting
screws in place. The pressure in the distributor must not
exceed 25 bar (362.8 psi).
If this happens, replace the distributor.
200−1−2160b_en 15/15

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Index

6 Driving the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6.4.8 Shorter maintenance intervals for Axle Loads

6.12 Attaching and Removing the Spare Wheel

7 Drive gearbox / distributor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10 Differentials / Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12.7.1 Pinning Positions of the Outrigger Struts . . . . . . . . . . . . . . . . . . . . . 53

14 Tow−starting and Towing the Crane . . . . . . . . . . . . . . . . . . . . . . . 3

15 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . . 3

Read this section thoroughly before beginning operation!

The AC 200−1 is available in different versions depending on

2.1 Technical Data

2.1.1 Dimensions, Weights

Total length of the crane vehicle

Turn radius “5−axle standard version (AC200−1)”

2.1.2 Road Performance

ZF−AS TRONIC type 16 AS 2601 IT

with road travel and terrain driving, fitted emergency steering

2.1.3.1 Axles, Drive: 5−axle version

∗ Axle A1: not driven, steered

2.1.3.2 Axles, Drive: 6−axle version

∗ Axle A1: not driven, steered

2.1.3.3 Axles, Drive: 7−axle version

∗ Axle A1: not driven, steered

2.1.4 Wheels / Tyres

385/95 R 25 445/80 R 25 445/95 R 25 525/80 R 25

Permitted speeds: see section 6 “Possible axle loads, permitted

2.1.5 Climatic Operating Conditions

Instructions in part 1, section 1 of this document.

2.2 Overview of the Crane Chassis

5 Front back stop

6 Wheels / tyres, axles 1−5 (or 1−6 for 6−axle design)

7 Rear back stop

8 Spare wheel (optional)

9 Additional axle (optional)

See part 1, operating instructions of the superstructure, section 2

2.4 Chassis and Construction Number

The construction number is to be found (punched):

The chassis and construction numbers are also engraved on the

2.5 Preparation for Emergency Control, Superstructure

The following hydraulic connections are located on the left side

1 Connection LUW (leakage)

2 Connection TUW (tank)

3 Connection PUW (pressure oil)

If the superstructure power units break down, a hydraulic

The hydraulic connections 1 − 3 may only be used with a

4.1 Operator’s Platform

No. Designation Function

* Separate (different) pressure display, when axle 3 is in its raised

No. Designation Function

4.2 Dashboard System

4.2.1 Instrument panel

No. Element Designation Function

No. Element Designation Function

4.2.2 Function buttons on the steering wheel

No. Element Designation Function

4.2.3 Switch on the instrument panel

No. Element Designation Function

* Display layout on the (75) “Transmission information” display,

No. Element Designation Function

* Function only possible, if the (92) “Steering program”

99 100 101 102 103 104