Safety Instructions 1

1 Safety Instructions

1.1 General

This Section entitled ”Safety Instructions” gives a concise and

general view of the dangers which may occur when the crane su-
perstructure and crane chassis are operated.
Where necessary, these safety instructions are mentioned again
and put in concrete terms in the relevant Sections of the operat-
ing instructions.
A cross reference to this section is given in Section 1 entitled
”Safety Instructions” of the operating instructions for the crane
chassis (Part 2 of this documentation).

The safety instructions for all lubrication, service and mainte-

nance tasks are given in Part 3 of this documentation.

1.2 Intended Use

The crane is intended solely for erection operation. The crane is

not intended for any other use, e.g. piece goods or clamshell op-
eration. The manufacturer accepts no liability for any damage re-
sulting from improper use. The crane user is fully responsible.

Pulling out jammed loads is not permitted !

The crane operator is responsible for using any additional equip-

ment which is not included in the delivery from the crane
manufacturer (e.g. personnel cages) in accordance with the
safety and accident prevention regulations applicable.

The use of two hoists to raise a load (two hook operation) is not
permitted.
Corresponding special load cases are, however, permitted if ap-
proved by the crane manufacturer.

The capacity charts, operating instructions, and in particular the

stipulated erecting sequence, and the lubrication and mainte-
nance conditions must be observed to ensure the crane is oper-
ated as intended.

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1.3 Operating Conditions and Calculated Design of the

Crane

1.3.1 General

The crane has been constructed in accordance with state of the

art technology and all recognized safety regulations. During use,
however, danger to life and limb for the operator or any third party
may occur and the crane and any other material assets may be
impaired.

The crane must only be operated when in full technical working

order. It must always be operated correctly and with safety in
mind, and in accordance with the operating instructions. In partic-
ular, immediately eliminate, or have eliminated, any malfunctions
which may impair the safety of the crane.

The term ”operating instructions” covers both the operating

instructions and the lubrication and maintenance instructions.

The construction engineer has assumed certain operating condi-

tions in calculating and dimensioning the winches on your crane.
The winches on your crane are classified as follows (ISO 4301/1,
FEM 1.001, DIN calculation principles for power units):
Power unit group: M........
Load spectrum: Q....... (L.......)
Load spectrum factor: km = ..........

Please take the applicable values given in the table entitled

”Monitoring the Winches” given in the crane certification log.

All important crane components have been designed and

manufactured for normal erection operation. This presupposes
that all operations with maximum utilization of the crane and with
lower utilization and interruptions in operation are in a ratio typical
for an erection crane. More severe operating conditions automat-
ically lead to a reduction in the service life of the crane.

Operating conditions or applications other than those for erection

operation require authorization from the manufacturer and usu-
ally lead to a reduction in load capacities.

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Z 31 305

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1.3.2 Working Environment Ergonomics

The following sound levels can be expected for the crane opera-
tor’s working environment in the superstructure cab:
-- Engine idle speed (1000 rpm) < 75 dB(A)
-- Max. engine speed, without load (2200 rpm) < 85 dB(A)
-- Engine speed at highest engine torque,
without load (1400 rpm) < 80 dB(A)
Measurements were taken using a sound level measuring device
and a measuring microphone positioned near the ear of the crane
operator. The equivalent continuous A--value for sound pressure
at the driver’s seat, averaged over an 8 hour shift, is less than
70 dB(A). In this instance, measurements were taken using do-
simeters when operating on construction sites.

The crane operator is protected against any mechanical vibra-

tions by a swing seat which can be adjusted according to the op-
erator’s weight. The crane operator’s seat can be continuously
adjusted with regard to seating height and angle and the back
and arm rests. An optimal working position can therefore be set
for each crane operator.

Crane operator’s seat

(Z 31 305)
(1) -- Hand wheel for weight setting
(2) -- Lever for horizontal setting of seat
(3) -- Lever for horizontal setting of seat
(4) -- Lever for folding the control platform, left--hand side
(5) -- Lever for folding the control platform, right--hand side
(6) -- Lever for setting back rest
(7) -- Lever for setting height and angle of seat
(8) -- Control knob for setting angle of arm rests
The actual weighted acceleration value to which the upper body
is exposed is less than 2.5 m/s2.
The actual weighted acceleration value to which the body (feet
or rear) is exposed is less than 0.5 m/s2.
Both these values are below the legal stipulations.

1.3.3 Loading and Utilization of the Crane

The capacity charts supplied with the crane stipulate limit values
which must not be exceeded.
The load capacity limits of the winches are reached, in principle,
when the rope force has reached its maximum permissible value.
Low loads with smaller reeving may therefore place severe strain
on a winch.

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1.3.4 Obligatory Ambient Conditions

The permissible temperature range for crane operation is --20°C

to +40°C, provided the maximum and minimum temperatures oc-
cur only a few days each year.

Additional equipment for use with other applications can be sup-

plied.

The crane may be operated at full load up to a height of 1000 m

above mean sea level. Operation is not hazardous up to a height
of 2000 m above mean sea level.

The crane can also be operated at a higher / lower relative

humidity level without operation becoming hazardous.

Continuous operation in hostile environments (e.g. seaports,

chemical industries, steelworks etc.) together with higher relative
humidity levels may require the use of an adapter kit / special
equipment.

Filters must be replaced more frequently if dust concentrations

are high. The permissible short--term dust concentration can be
35 mg/m3.

Observe the corresponding regulations given in the lubrication

and maintenance instructions, Parts 3 and 4.

The crane operator must observe all regulations given in the op-
erating instructions when wind is expected. See Section 11 in the
operating instructions for the superstructure, ”Working Instruc-
tions”.

The ground on which the crane is supported, or over which the

crane is driven under load, must be of sufficient load--bearing
capacity.

The crane may only be operated in a potentially explosive at-

mosphere or in cases where combustible gas may be inducted
once it has been correspondingly converted.

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1.3.5 Service Life of the Power Units

In determining the service life for the power units of the crane
used for erection operation, the following operating conditions
are assumed:
-- The crane is operated for approximately equal periods at
high, medium and low utilization.
-- The time during which an important crane component is sub-
jected to load in this fashion is on average one hour per day.
-- The crane is in operation for an average of 210 days per year.

Under these conditions, and with servicing work carried out as

prescribed, the theoretical life--span can be more than 20 years.

The regulations for determining the theoretical remaining

service life of the winches detailed in Part 3, Section 1.8 of
the lubrication and maintenance instructions, must be ob-
served.

The same service life can, of course, also be reached if the num-
ber of operating hours per day is higher and the number of oper-
ating days per year is correspondingly lower.

Under no circumstances must the crane be used for operations

similar to those for piece goods or clamshell operation. In particu-
lar, this can lead to rapid wear and failure of the power unit com-
ponents (drive units, winches, etc.).

1.3.6 Standards and Calculation Regulations

The above information regarding service life, loading and utiliza-

tion of the crane is based on the standards DIN 15018/Part 3 and
DIN 15020 and the corresponding FEM standards.

Service life calculations may be carried out specially for countries

in which other standards and calculation regulations apply. If re-
quired, the crane operator must have these calculations carried
out specially. The operating conditions for the crane are not af-
fected as a result, but lifting capacities may have to be reduced.

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1.3.7 Hazards to Air Traffic

Work with cranes is sometimes carried out at great heights. This

may create a hazard to air traffic.
Therefore, especially when operating the crane in the vicinity of
airports, runways and air traffic control installations (so--called
protected areas) permission must first be gained from the ap-
propriate authorities (e. g. Federal Aviation Agency, military dis-
trict administration, in Germany -- Deutsche Flugsicherung
GmbH).

Further details available from:

Deutsche Flugsicherung GmbH (DFS)
Kaiserstraße 29--35
D--63067 Offenbach a. M.
Tel. 069/8054--0

These regulations apply for the Federal Republic of Germany. In

other countries, the corresponding national regulations must be
observed.

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Z 31 306

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1.4 Safety Regulations

1.4.1 Organizational Measures

In addition to the operating instructions, all applicable national

specifications and other mandatory regulations concerning acci-
dent prevention and environmental protection must be observed
and carried out. The operating instructions are to be supple-
mented by these regulations.

Responsibilities of such kind may also include, for example, use

of hazardous material, the provision / wearing of personal protec-
tive equipment or road traffic regulations.

In addition to the operating instructions and the mandatory acci-

dent prevention regulations applicable in the country of use and
at the operating site, the recognized technical regulations regard-
ing the safe and specialist operation of the crane must be ob-
served.

In addition to the operating instructions, instructions should be

given which cover supervisory responsibilities and the reporting
of operational peculiarities, for example in view of work organiza-
tions, operational procedures, personnel employed, etc.
(Z 31 306)
Ensure that all safety and warning signs on the crane are com-
plete and legible.

Familiarize yourself with the location and operation of the fire

extinguishers.

The fire extinguishers supplied are located beside the driver’s

seat in the crane chassis cab.
The first aid box (and any other accessories according to national
motor vehicle safety standards) must be taken from the range
supplied and kept in the crane chassis cab.

If visibility is poor or it is too dark, the area immediately in front of

the crane operator’s cab, the outriggers and winches must be lit
using the spot lights located on the crane (rear exterior lighting,
front exterior lighting, side exterior lighting). The side exterior
lighting can be operated from either the crane operator’s cab or
the driver’s cab.
The surrounding area (load, path of load, slewing range, track,
etc.) must be lit using suitable equipment independently of the
crane. The crane operator is responsible for such lighting.

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1.4.2 Selection and Qualifications of Personnel

A thorough training course is required for the crane operator and

all maintenance, erecting and dismantling personnel, in order to
optimize use of the crane without placing too great or too small
a strain upon it.

Employ only reliable personnel who have received training or

instruction for work on or with the crane.
Ensure that only the personnel appointed are employed.
Observe the minimum legal age permitted.

Assign the areas of responsibility clearly:

− for operation, erection and maintenance.
− for the crane operator, also concerning responsibility regard-
ing road traffic regulations. Allow him to refuse to carry out
orders from third parties which go against safety regulations.

Personnel who are to be trained, instructed or shown the job, and

those who are following a general training course, may only work
with the crane if kept under the constant supervision of an experi-
enced person.

Personnel who are assigned to work with the crane must have
read the operating instructions, and in particular this Section en-
titled ”Safety Instructions”, before starting work.
It is too late once work has begun.
This applies in particular to personnel who work only occassion-
ally with the crane, e.g. during erection and maintenance work.

Check, at least now and again, that personnel are working safely
and carefully and in accordance with the operating instructions.

No employees may wear their hair long and loose, nor wear loose
clothing or jewellery, including rings. Injuries may be caused
otherwise, e.g. by getting caught up or dragged into the equip-
ment.

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1.4.3 Particular Hazards

1.4.3.1 Electrical Energy

High voltage

Keep the crane at a sufficient distance from overhead electrical

power lines. When operating the crane near overhead power
lines, do not allow the equipment to come close to the power
lines, as this is extremely hazardous.
Keep the crane at a distance of at least 10 m from the lines. If this
is not possible, you must consult the electricity supply company
responsible and find out what safety distances are to be ob-
served.

This safety distance is difficult to estimate with extremely long

equipment. Increase the distance to 20 m for the sake of safety.

If, however, the crane equipment does come into contact with
high voltage power lines:
− Do not leave the crane.
− Slew the crane out of the danger zone.
− Warn those outside not to come too near or to touch the
crane.
− Ensure the power is switched off.
− Leave the crane once you are sure the current in the con-
tacted or damaged power line is switched off.

High--frequency radiation

The danger that the load limit device may be influenced by the
effect of high--frequency radiation is minimised by state of the art
technology (shielding). This danger cannot, however, be ruled
out completely, in particular under extreme conditions, e.g. when
near powerful transmitters.
Therefore observe the instructions given in Section 10, ”Safety
Equipment”.

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Lightning

If thunderstorms are gathering, dismantle the crane where pos-

sible and leave the crane.
If this is not possible, lower the load from the hook, switch off the
engine and leave the crane.

Only remain in the crane operator’s cab if the above cannot be

carried out in good time.

If this is the case, the crane operator must not, under any
circumstances, step into the vicinity of the crane or onto
the crane itself while the thunderstorm continues. Also
warn those outside accordingly.

The following must be checked if it is suspected that lightning has

struck:
-- Load limit device; if damaged, a fault message will appear on
the display.
-- Limit switches; ensure they are functioning correctly.
-- Inductive proximity switches; ensure they are functioning cor-
rectly.
-- Visually inspect the luffing and outrigger jacks for external
damage caused by flashover voltage or melting.
By retracting and extending several times, check the corre-
sponding jacks for any signs of internal leakage caused by
damaged seals.

1.4.3.2 Gas, Dust, Steam, Smoke

Only operate engines and fuel--driven heaters in sufficiently ven-

tilated areas. Check that there is sufficient ventilation before
starting in an enclosed space.

Follow the instructions applicable to the operating site.

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Z 29 800 Z 29 801

Z 29 802 Z 29 803

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1.4.3.3 Crushing / Shearing

(Z 29 802)

For additional, precise information on the following points please

refer to the corresponding sections in the operating instructions.
− Outriggers
− Counterweights
− Additional equipment (e.g. fly jib)
− Load or hook block (with uncontrolled movements)

1.4.3.4 Reeling / Derricking

(Z 29 801)

For additional, precise information on the following points please

refer to the corresponding sections in the operating instructions.
− Head sheaves and deflection rollers
− Hook blocks
− Winches

1.4.3.5 Crushing / Jolting

(Z 29 800)

For additional, precise information on the following points please

refer to the corresponding sections in the operating instructions.
− Hook block while slewing the superstructure

1.4.3.6 Dangers due to Slipping, Stumbling, Falling

(Z 29 803)

Only the catwalks and ladders stipulated here should be used.

They provide sufficient gripping points to hold on to and the cat-
walks are slip--free (e.g. sanding, checker--plating, etc.).

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1.4.4 Increased Danger due to More than One Crane

Operating in Unison

1.4.4.1 Operating Ranges of More than One Crane Overlap

If the operating ranges of different cranes overlap, there is a dan-

ger of collision.
The operator or his agent must:
-- lay down the operating procedure in advance,
-- ensure that the crane operators can communicate with other
clearly.

If the crane operators cannot communicate by means of calls or

visual signals, other suitable methods must be implemented, e.g.
use of walkie--talkies, banksmen etc.

If banksmen are to be employed, suitable signals must be agreed

between them and the crane operators. Please refer to Section
1.5 of this Section ”Safety Instructions”.

The crane operators should operate their cranes slowly and care-
fully to avoid collisions caused by uncontrolled movements.
They must be adequately trained and qualified to ensure this is
the case.

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1.4.4.2 Raising a Load Using More than One Crane

If a load is to be raised using more than one crane, the operating

procedure must be laid down in advance by the operator or his
agent and carried out in the presence of a foreman designated
by the operator.

Special care should be taken in the following instances:

-- Cranes do not have the same lifting capacities.

In this instance, the component to be raised must be attached so

that each crane is loaded within the limits of its load--bearing ca-
pacity.

-- The component to be raised is not symmetrical or the location

of the centre of gravity is not clear. If necessary, use only 75%
of the permissible load.
-- Dynamic influences may act on the load once raised.

The load must not be dragged at an angle under any

circumstances.

Note that an individual crane can also become over-

loaded when lowering the load.

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1.4.5 Before Operating the Crane

Before commencing work on site, take time to survey the operat-

ing area. This includes, for example, obstructions to operations
and traffic, load--bearing capacity of the ground and the neces-
sary safety measures to isolate the construction site from general
traffic.
The crane may only be operated when the crane itself, the load
and the load path can be seen clearly.

The necessary measures should be taken to ensure that the

crane is operated in a safe and fully functional condition.

The crane may only be operated when all safety devices and
equipment are fitted and in full working order.

Note that all mobile jib cranes may be used on firm ground only.

Check the effectiveness of the brakes, steering, signal and light-

ing equipment, limit switches and the overload cut--off device
daily, or before starting work (or driving) in the case of cranes in
infrequent use.

Before starting work (or starting to drive, respectively), ensure

that no--one is standing in the danger zone of the crane. Give a
warning signal if necessary (sounding the horn is recommended
before starting the engine ).

Before starting work, check that all crane movements are func-
tioning correctly.

Always have a suitable container and binding agent to hand

when carrying out maintenance and assembly work, as oil may
sometimes leak.

Where necessary and in accordance with the regulations, per-

sonnel must use individual protective equipment (e.g. safety har-
nesses, safety clothing, goggles, face masks, etc.).

Even protective equipment cannot provide 100% protec-

tion. A helmet can perhaps provide protection against
small falling objects, but not against a falling load.
Always remain fully alert and safety conscious.

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Before driving the crane, always check that the accessories are
stored safely.

When driving on public streets, roads and squares, please ob-

serve the applicable traffic regulations and, if necessary, ensure
that the crane is in a permissible state with regard to traffic law
before it is driven.

As regards axle loads, a distinction must be made between the

technically possible axle load and the maximum axle load per-
mitted by the local road traffic regulations.
”Technical driveability” is only permissible on construction sites
and private roads (with the exception of countries where axle
loads of greater than 12 t are permitted).

Axle loads of more than 12 t are not permitted when driving on

public roads in countries in which EEC regulations (or reduced
axle loads) apply. If the crane is driven on public roads with axle
loads over 12 t, the crane operator is responsible for any conse-
quences. All components and equipment are designed and cal-
culated for an axle load of 12 t at maximum speed.
If the 12 t axle load is exceeded, this will lead to a reduction in the
service life of axles, wheel hubs, bearings, suspension cylinders
and brakes. In particular, wear on brake linings and the danger
of brakes overheating and fading is increased.
Deceleration for the brakes (EEC: 50 %) is reduced in proportion
to the increase in axle load or to the transport weight of the crane.

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1.4.6 During Operation of the Crane

Only the crane operator is permitted on the crane during

power--driven operating, erection or assembly proce-
dures (and only in the crane operator’s cab). No other
personnel are permitted on the crane or in the danger
zone of the crane.
An exception is only permitted when erecting the coun-
terweight with the aid of a slinger. This must, however,
leave the slewing range as soon as the erection proce-
dure is completed.

To allow rapid reaction to outside influences working on the

crane, the drive mechanism of the crane must never be switched
off, nor the crane operator’s cab be left unoccupied, when a load
is still attached to the crane.

An exception is only permitted in an emergency. In order

to prevent dangerous situations, the drive (diesel engine)
can, as a last resort, be switched off using the emer-
gency stop button in the crane operator’s cab. If pos-
sible, any movements already started should be com-
pleted using the control levers beforehand.

The superstructure may only be operated if the crane chassis en-

gine is switched off, the driver’s cab is closed and the control pa-
nels for the outriggers are locked.

The erected crane may only be left without supervision by a trai-

ned crane operator if certain conditions are fulfilled (see opera-
ting instructions for the crane chassis, Sect. 14 ”Parking”).

Only hook blocks referred to by Mannesmann Demag Baumas-

chinen may be used.
The use of other hook blocks is only permitted after consulting
Mannesmann Demag Baumaschinen and obtaining the ap-
propriate authorization.

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Passengers may only travel in the crane chassis cab on the stan-
dard seats provided for this purpose.

Transportation of persons on the load or the load--handling

equipment is prohibited.

Transportation of persons on personnel--carrying equipment and

the carrying out of work from this equipment is permitted only if
the operator gives written notice in advance to the Employer’s Li-
ability Insurance Association, detailing the work planned and the
safety measures to be undertaken (see for instance the ”Safety
Regulations for Extendable Personnel--Carrying Equipment”, ZH
1/461).

The crane may only be boarded or left once the crane operator
has been informed and whilst the crane is stationary.

Observe all safety and warning signs on the crane.

Fixed, mechanical safety guards must not be opened or removed

while the crane is in operation.

Do not carry out any operation which may be unsafe (e.g. opera-
tions which may endanger the stability of the crane).

Keep the crane operator’s cab and driver’s cab windscreens

clean to ensure good visibility.

No personnel are permitted in the slewing range of the crane.

Work should be stopped if persons fail to leave the danger zone
in spite of warnings.

Only start the crane engine from the operator’s seat. Only oper-
ate control equipment from the cab.

To prevent unintentional movements being triggered, both con-

trol levers have an additional switch (”28”, ”30”, dead man’s
switch).
Crane movements can only be carried out while one of these
switches is being pressed.

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Z 27 796

Z 27 797

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Keep the control units within reach whilst a load is suspended

from the crane or the crane is being driven under load.

If operation of the equipment (or danger zone) cannot be ob-

served from the crane operator’s cab (or driver’s cab), a banks-
man should be employed (see Section 1.5).
This also applies when normal communication by speech is not
possible due to an increased noise level.

Particular attention should be paid to the load during all crane op-
erations, and to the load--handling equipment and the boom top
section when raising without load. Also monitor the swing of the
counterweight etc.

It is prohibited to use the crane to pull loads at an angle or to drag

loads.

Do not jump from the crane. Use the ladders and handrails.

Secure the doors to prevent them flying open or slamming shut.

Check the crane for any externally visible damage or shortcom-

ings at least once during a shift period. Inform the authority / per-
son in charge immediately of any changes which arise (including
the operational behaviour of the crane). If necessary, stop work
immediately and secure the crane.

In the case of maloperation, shut down the crane immediately

and secure it safely. Have any faults rectified immediately.

Observe the procedure for starting and switching off the crane
and the function of the indicator displays as laid out in the operat-
ing instructions.

Always switch on the exterior lighting on the crane when visibility

is poor or when in darkness. The interior lighting should then be
switched off to ensure that the load and the area surounding the
crane can be seen clearly.
(Z 27 796, Z 27 797)
Always keep the operating instructions at hand at the operating
site in the retainers provided. These are located on the rear wall
of the superstructure and in the driver’s door on the crane chas-
sis.

Observe the availability of fire warning and fire fighting equip-

ment.

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Keep a safe distance from banks and ditches.

Do not park the crane on embankments or near the edges of

ditches.

Set the computer of the load limit device in accordance with the
capacity charts provided.

Observe the permissible wind speeds.

The superstructure may only be slewed if the crane is supported

on outriggers. Please note that slewing is also only then per-
mitted for certain crane configurations (e.g. with regard to outrig-
ger support area, counterweight, etc.). Always observe the val-
ues given in the capacity charts.

It is generally prohibited to slew the superstructure in the over-

load range (load limit device has shut down).

The crane has two emergency exits. These are the wide--open-
ing front window on the superstructure and the passenger door
on the crane chassis.

When driving on the road, the boom must be locked to the travel
rest in the transport position and the telescopic sections must be
pin locked.

When driving downhill, always drive the crane at a speed suitable

for the prevailing ground conditions. Always change down into
the lower gear before reaching the hill, and never change down
when on the hill.

Always ensure that enough clearance is available when passing

under underpasses, bridges, tunnels, overhead power lines,etc.

Please observe the specified transport position, the permissible

speed and route when towing.

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1.4.7 After Crane Operation

When leaving the crane, ensure that:

∗ the load has been detached from the crane hook or placed
on the ground;
∗ the engine is switched off and all control levers are returned
to the ”Off or ”Locked” position;
∗ the heating is switched off;
∗ the parking brake for the crane chassis is applied;
∗ the crane is locked to prevent unauthorized use of the crane
and to prevent the crane from rolling.

If the crane is parked on a slope, the chassis must be secured by

chocks, the slew brake must be applied and the boom secured.

Always lock all control stands which are equipped with a lock
when they are not in use or when the control is being operated.

When parking the crane, please observe the permissible wind

speeds. If necessary, retract and set down the boom.

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1.4.8 When Mounting and Dismantling Crane Components

In addition to the instructions already given in this section, the

instructions detailed below apply specifically to mounting and dis-
mantling operations.

These operating instructions describe the standard mounting se-

quence.

The reverse of the mounting procedure must be followed exactly

when dismantling (unless otherwise specified).

The crane components must not be mounted or dismantled by

untrained personnel under any circumstances.
Incorrect mounting would lead to extremely dangerous situa-
tions.

Owing to the hazard of slipping, stumbling and falling it is prohib-

ited to step on the boom and equipment (or their components).
All mounting work must be carried out using suitable aids (lad-
ders, lifting stages, scaffolds, auxiliary cranes, etc.).

Exceptions are only permitted where provision is made for

personnel to climb on the equipment. In this case, however,
additional safety gear must be used.

Standard mounting requires that all component parts which are

transported separately are transported close to the ground by
means of suitable auxiliary cranes and load--handling equipment
(ropes) and are secured reliably to the basic crane.

Before mounting personnel approach suspended loads such as

counterweights, outriggers, intermediate sections, boom foot
sections and top pieces, luffing masts or fly jibs, these loads
must be lowered onto the ground or onto trestles or other sup-
ports of sufficient load--bearing capacity.

Any persons standing in the vicinity of suspended loads

may be jolted or crushed when loads move laterally.

During the mounting procedure, personnel must never stand in

areas into which loads might fall or under suspended loads be-
fore the loads have been secured in accordance with the speci-
fied procedure.

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A securing procedure is not completed until the suspended load

has been secured firmly to the stable part of the crane, e.g. by
driving home pins into an intermediate section or by tightening all
bolts of a threaded connection to the specified torque, etc.

A safe distance must be kept from areas where crushing and

shearing may be unavoidable, in particular near outriggers, be-
tween the superstructure and the crane chassis, near cylinders,
on the telescopic boom and on the entire lattice mast fly jib while
any part is suspended in the air during mounting and / or is not
firmly secured or the engine of the crane or the mounting auxiliary
crane is still running.

Connecting pins for the mounting of fly jibs must be driven home
from the outside inwards unless otherwise expressly stated in the
operating instructions. Guarding using auxiliary pins and clip pins
can be carried out once all pins of a component have been driven
home.

When fly jib components or other parts are being dismantled,

connecting pins may only be driven out when all individual com-
ponents are reliably supported symmetrical to the component
centre of gravity. Before components can be released, the shift
foreman must establish the likelihood of components falling or
folding unexpectedly as a result of their being released. A Man-
nesmann Demag customer service representative must be con-
sulted if in any doubt.

The driving out of pins must be planned with particular care. It

must be ensured that no persons are standing within the fly jib,
where they may be at risk of being crushed. Suitable measures
must be planned and taken to prevent pins from falling when
driven out, ropes from falling when released or any other compo-
nent falling.

Ensure that no tools are left behind once work has been com-
pleted, as tools which fall or are flung from the crane can prove
extremely dangerous.

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1.5 Hand Signals

If the crane operator cannot observe operation of the equipment

(or danger zone) from the crane operator’s cab (or driver’s cab),
a banksman should be employed.
This also applies when normal communication by speech is not
possible due to an increased noise level.

Only reliable persons who are familiar with the symbols

may be employed as banksmen.

The banksman should stand in a safe position from

which he can SEE THE LOAD and BE SEEN clearly by
the crane operator.

The operator must be able to identify the banksman eas-

ily. The banksman must use one or more suitable identifi-
cation markings, e.g. jacket, helmet, cuffs, armbands,
signalling discs.
These identification markings should be of a
distinctive colour, preferably uniform, and must be re-
served for the banksman.

Should the operator not understand a signal fully, he should

not carry out any movement with the crane. The operator and
the banksman should agree a suitable means of commu-
nication for such an instance before starting work.

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1.5.1 General Hand Signals

(Z 26 024)

1. START
Attention, hand signals follow.

Arms extended horizontally each side, palms forwards.

2. STOP !
Interruption, end of a movement.

Right arm raised, palm of right hand forwards.

3. END
of a movement.

Hands clasped at chest level.

4. DANGER !
Emergency stop.

Both arms raised, palms forwards.

RAPID MOVEMENT
Coded hand signal for movements carried out rapidly.

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1.5.2 Hand Signals for Working Movements

(Z 26 026)

1. RAISE load
Right arm pointing upwards, palm of the right hand facing for-
wards, make slow circular movements with the index finger.

2. LOWER load
Right arm pointing downwards, palm of the right hand facing
inwards, make slow circular movements with the index fin-
ger.

3. RAISE boom
Signal with one hand. Right arm stretched out, thumb point-
ing upwards.

4. LOWER boom
Signal with one hand. Right arm stretched out, thumb point-
ing downwards.

5. TELESCOPE boom OUT

Signal with both hands. Thumbs pointing outwards.

6. TELESCOPE boom IN
Signal with both hands. Thumbs pointing inwards.

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1.5.3 Hand Signals for Driving Movements

(Z 26 025)

1. Drive FORWARDS
Arms bent; palms facing inwards; forearms move slowly to-
wards body.

2. Drive BACKWARDS
Arms bent; palms facing outwards; forearms move slowly
away from body.

3. Drive to the RIGHT (as seen by banksman)

Right arm stretched out more or less horizontally, palm of
right hand facing downwards, small movements in the direc-
tion indicated.

4. Drive to the LEFT (as seen by banksman)

Left arm stretched out more or less horizontally, palm of left
hand facing downwards, small movements in the direction
indicated.

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1.6 Power Failure

General

In case of power failure, all movements are stopped. Movements

cannot be started up again unintentionally. When the diesel en-
gine stops, the driven hydraulic pumps are stopped automati-
cally. The oil contained in the circuit also stops. As soon as the
control pressure reaches zero, all sliders return, spring--loaded,
to the neutral position irrespective of the position of the pilot con-
trol lever on the associated control device.

In those hydraulic circuits which affect the safety of the crane, the
winches and cylinders can be additionally braked by bringing
them into the locked position or by applying the retaining brake.

Winches and cylinders

The oil column on the raising side of the winch motors and cylin-
ders is protected by brake valves which are independent of the
load (lowering brake valves). Winches and cylinders can no
longer be moved following power failure. The lowering brake
valves are fitted directly onto the winch motors and cylinders (no
hoses).

As the case described is extremely rare, there is no possibility of

lowering a load suspended from the hook.
In such a case, customer services must be informed.

A burst oil pipe or hose will not therefore cause any hazardous
crane movements.

In addition, the hydraulically released disc brake for the slew gear
is applied.

Driving the crane erected

When driving the crane erected, the load rests on the suspension
cylinders. In order to guarantee perfect suspension when driving
the crane, these cylinders are not equipped with pipe burst
valves. The details given in the operating instructions of the crane
chassis, Section 6.4.2, ”Driving in Erect Mode” must be strictly
observed in order to avoid hazardous situations.

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