Fixed Fly Jib 20

650--1200--033_en 1/73
20

52
73

Z 40 216

2/73 650--1200--033_en
 Fixed Fly Jib 20

20 Fixed Fly Jib

-- The fixed fly jib is marked with the construction num-

ber of the crane. It may only be fitted to the crane with
this construction number.
Exceptions are only permitted if this is expressly
stated in the crane papers (e.g. crane log book).
-- The fly jib may only be fitted and removed by trained
and qualified personnel.

20.1 Important Information

- The fixed fly jib comprises components of the luffing fly jib, but
differs from this in that it is connected in a fixed position to the
main boom head. For this reason, only hoist 1 is required for
work with the fixed fly jib.

The crane can be operated with a fixed fly jib under an angle
of 0°, 20°, or 40°. The angle is adjusted by means of tension
rods on the intermediate section (8, Z 40 216). These tension
bars (73) must be inspected at least once a year by a quali-
fied engineer (in accordance with accident prevention regu-
lations for load handling equipment in lifting operations
(VBG 9)”. In addition they must be checked by a specialist
between these intervals if required by the operating and site
conditions.
The inspection intervals are generally determined by the op-
erating and site conditions. This means that the more the
equipment is used, the shorter the inspection intervals
should be.

Records should be kept of when these inspections are car-

ried out (e.g. in the examination log book for the crane).

The following checks should be carried out:

* Checking for cracks

* Checking length
* Checking wear
* Checking paintwork
* Checking plastic deformation

Instructions on carrying out the inspection can be found in

part 3, ”Lubrication and Maintenance Instructions of the Su-
perstructure”.

650--1200--033_en 3/73
20

51

Z 47 346 Z 39 374

Z 47 347 Z 39 370

4/73 650--1200--033_en
 Fixed Fly Jib 20

- The fixed fly jib may only be fitted, removed and operated
when the crane is supported with its outriggers fully extended
(support area “12 x 12.2 m”).

- The fixed fly jib should be assembled so that the intermediate

sections can be bolted in the horizontal position (Z 47 346).

- To fit and remove the fixed fly jib the superstructure must be
turned so that the boom is positioned to the rear or the side
(90°).

- The fixed fly jib can only be fitted and removed with the help
of an auxiliary crane.

- Check to make sure that the tubular structures of the lattice

mast components of the fly jib are free of damage. If you dis-
cover any damaged tubes during the visual inspection, all
work with the fly jib must be stopped immediately.

- Pay attention also to the safety instructions in section 1.4.8

on ”Assembling and Dismantling Crane Components”.

- When bolting the jib top section (9) with the intermediate sec-
tions (8), (11) or (55) the diameter of the top bolts equals 55
mm and the diameter of the lower bolts 65 mm at a length of
536 mm. These biconical bolts are each secured with 2 pin
locks. Before inserting these pin locks, a distance washer
must be pushed over the biconical bolt on both sides (Z 47
347).

-- The biconical bolts and the corresponding distance plates are

located on the jib top section (9) in the parking position (Z 39
370).
-- Information on the combination of the lattice mast compo-
nents can be found in Sect. 20.2.1 of these operating instruc-
tions.

- The head connecting piece (51) is bolted to the main boom

head by means of 4 biconical bolts with different diameters
(top bolt: ∅ 55, bottom bolt: ∅ 65). The bolt length is 536 mm
(Z 39 374).

650--1200--033_en 5/73
20

41

41b

9 52
51

Z 45 002 Z 45 004

41b

41a

Z 45 003

6/73 650--1200--033_en
 Fixed Fly Jib 20

- The counterweight required for operation of the crane must

be fitted before the fly jib is fitted on the superstructure.

- If the crane is equipped with a hinged head sheave, the

sheave must be removed before the fixed fly jib is fitted.

- The crane is operated with a 20m fly jib only below a fly jib
angle of 0°.
The rope is guided to the jib top section (9) via a height--ad-
justable rope idler.
This rope idler (41) is fitted on the jib top section (9) and must
be bolted in the middle hole (Z 45 002).

- There are 2 different types of rope idler (41) (Z 45 003):

-- fixed design (41a)
-- hinged design (41b)
The design of this rope idler does not affect its folding height.
The fold--up rope idler (41b) is only used for drawing forward
the flying bridle with rope “hoist 1”.
In this case the hoist rope is fed through the sheave
(Z 45 004).
This step is carried out when fitting the luffing fly jib.

650--1200--033_en 7/73
20

”A”--74 73 ”B” ”C”-- 74

41

”A” 73 ”C”

0
75
75

8 52
41

”B”
X
73

52
8
41

8 41
”A”
73

52

Z 40 218

8/73 650--1200--033_en
 Fixed Fly Jib 20

- The crane can be operated with a 26 m to 50 m fly jib with the

fly jib at an angle (see the corresponding load tables). The
angle equals 20° or 40° and is set by means of tension bars
on the intermediate section (8) (Z 40 218).
For crane operation with 0° ,20° or 40° fly jib angle, the rope
is guided to the jib top section (9) via a height--adjustable rope
idler (41) on the intermediate section (8).

− Fly jib not angled (0° position).

With a straight fly jib:
∗ bolts (74) are inserted in the draw bars (73) at points “A”
and “C”.
∗ the rope idler (41) is bolted in the middle hole.
− Fly jib at an angle of 20°.
With a fly jib at an angle of 20°:
∗ bolts (74) are inserted in the draw bars (73) at point “B”.
The 2 remaining bolts must be inserted in the transport
receptacle (point ”X”) and secured.

To avoid damage, the pins in point ”A” must be removed.

∗ the rope idler (41) is bolted in the middle hole.

− Fly jib at an angle of 40°.
With a fly jib at an angle of 40°:
∗ bolts (74) are inserted in the draw bars (73) at point “A”.
The 2 remaining bolts must be inserted in the transport
receptacle (point ”X”) and secured.
∗ the rope idler (41) is bolted in the middle hole.

The bolts (74) must be inserted from the inside outwards and
secured with pin locks. Each bolt has two washers (75)
which must be fitted on either side when the bolts are in-
serted.

650--1200--033_en 9/73
20

10/73 650--1200--033_en
 Fixed Fly Jib 20

20.2 Fly Jib Combinations

20.2.1 Combinations of the Lattice Mast Components

The fixed fly jib can be used for the following lengths:
− at an angle to the main boom of 0°:
from 20 m to 50 m / 65.6 to 164.0 ft
− at an angle to the main boom of 20°:
from 26 m to 50 m / 85,3 to 164,0 ft
− at an angle to the main boom of 40°:
from 26 m to 50 m / 85,3 to 164,0 ft

The possible combinations are shown in the drawing (Z 42 359).

The number of lattice mast components in relation to the fly jib
length can be taken from the picture (Z 42 359) and the following
table.
Part no.
Fly jib length
8 9 11 51 52 55
20 m / 65,6 ft ./. 1x ./. 1x 1x ./.
26 m / 85,3 ft 1x 1x ./. 1x 1x ./.
32 m / 105,0 ft 1x 1x ./. 1x 1x 1x
38 m / 124,7 ft 1x 1x 1x 1x 1x ./.
44 m / 144,4 ft 1x 1x 1x 1x 1x 1x
50 m / 164,0 ft 1x 1x 1x 1x 1x 2x

The lattice mast components are marked as follows (see detail

”X”, Z 42 359).
Parts Marking Ident. no.
no.
8 1411--10--11 110 232 12
9 1411--5--11 110 233 12
11 1411--5--11 110 235 12
51 ./. 110 796 12
52 1421--8--11 113 800 12
55 1411--6--11 110 690 12

650--1200--033_en 11/73
20

12/73 650--1200--033_en
 Fixed Fly Jib 20

The length and weight of the individual lattice mast components

can be taken from the adjacent picture (Z 42 360) and the follow-
ing table.
Parts Designation Lgth. (mm) Approx.
no. weight
8 Intermediate sec- 6 000 1.6 t
tion
9 Jib top section 5 470 1.4 t
11 Intermediate sec- 12 000 1.4 t
tion
51 Head connection 2 125 1.4 t
52 Adapter 12 000 2.5 t
55 Intermediate sec- 6 000 0.8 t
tion

650--1200--033_en 13/73
20

14/73 650--1200--033_en
 Fixed Fly Jib 20

20.2.2 Bolting Table

The fly jib is attached to the main boom and the lattice mast com-
ponents are connected together by driving in bolts.
The number of these connecting elements can be taken from the
picture (Z 48 866) and the following table.

Legend:
(45) : Biconical bolt ∅ 65 x 536 -- Ident. no.: 110 961 12
(46) : Biconical bolt ∅ 55 x 536 -- Ident no.: 110 962 12
(47) : Biconical bolt ∅ 65 x 506 -- Ident no.: 113 041 12
(48) : Biconical bolt ∅ 55 x 506 -- Ident no.: 113 040 12
(76) : Washer ∅ 135 / 66 x 15 thick -- Ident no.: 117 093 12
(77) : Washer ∅ 135 / 57 x 15 thick -- Ident no.: 117 094 12
(HA) : Main boom head

Pin stop Connection of Connecting elements

A (51) with (HA)
B (52) with (51)
C (9) with (52)
d (8) with (52)
E (9) with (8)
F (55) with (8)
G (9) with (55)
H (11) with (8)
I (9) with (11)
K (11) with (55)
L (55) with (55)
2 x (45) + 2 x (46)
2 x (45) + 2 x (46)
2 x (45) + 2 x (46)
2 x (45) + 2 x (46)
2 x (45) + 4 x (76)
2 x (46) + 4 x (77)
2 x (47) + 2 x (48)
2 x (45) + 4 x (76)
2 x (46) + 4 x (77)
2 x (47) + 2 x (48)
2 x (45) + 4 x (76)
2 x (46) + 4 x (77)
2 x (47) + 2 x (48)
2 x (47) + 2 x (48)

650--1200--033_en 15/73
20

Z 39 376 Z 39 377

16/73 650--1200--033_en
 Fixed Fly Jib 20

20.3 Fitting the Fixed Fly Jib

-- There is a risk of crushing when the lattice mast sec-

tions of the fly jib are being assembled or dismantled:
* when connecting / disconnecting between the indi-
vidual lattice mast components !
* between the main boom head and head connect-
ing piece.

The hazardous area must therefore be kept clear at all

times! Pay particular attention to the notes on hazards in
section 1.4.8 when ”Assembling and Dismantling Crane
Components” as well as the following instructions.
All assembly work is to be carried out with the help of
suitable equipment (ladders, hoist platforms, scaffolding,
auxiliary crane).
If work cannot be carried out using this type of equip-
ment or from the ground, assembly personnel must take
suitable precautionary measures to safeguard against
the RISK OF FALLING (e.g. safety belt).

During the fitting/removal procedure the area beneath

suspended loads or areas where there is a risk of falling
must be kept clear.

-- Select the auxiliary crane and lifting tackle so that the

lifting capacity clearly exceeds the weight of the fly jib
component which is to be fitted or removed and is suf-
ficient to lift the fly jib components at the required
working radius.

Proceed as follows:

1. Support the crane properly on outriggers and fit the counter-

weight required for operation of the crane (Z 39 376).

2. Prepare the main boom for fitting the fly jib. To this end:
− retract the main boom completely
− unreeve the hook block
− disconnect the shift weight of the hoist limit switch for
safety reasons and remove from the main boom head
(Z 39 377).

650--1200--033_en 17/73
20

52

51

Z 40 222

46

45

52 51

Z 47 355

18/73 650--1200--033_en
 Fixed Fly Jib 20

3. Using the auxiliary crane, connect the head connecting

piece (51) and adapter (52) on the ground. Support both fly
jib components on wooden blocks (Z 40 222).

-- head connecting piece (51): see transport unit X in Sect.

19.13.1.10 of these operating instructions.
-- adapter (52): see transport unit XI in Sect. 19.13.1.11 of these
operating instructions.
4. Remove the biconical bolt from the transport receptacles
and connect the fly jib components (Z 47 355).
Secure each biconical bolt with 2 pin locks.

Using biconical bolts ensures that the bolts can always be

hit FROM THE OUTSIDE -- both during assembly and disman-
tling.

650--1200--033_en 19/73
20

15.5 m
51
52

Z 47 356

20/73 650--1200--033_en
 Fixed Fly Jib 20

5. Attach four--stranded lifting tackle to the transport unit (com-

prising head connecting piece (51) and adapter (52)) and
hook up to the auxiliary crane.

This transport unit weighs approx. 3.9 t.

Pay attention to the centre of gravity!

Attach the lifting tackle so that the transport unit which is
to be lifted is neither slanted nor swings when it is
raised.

6. Lift the transport unit using the auxiliary crane and move to
the bolting position on the main boom head (Z 47 356).

Danger of crushing!
There is a risk of crushing between the main boom head
and head connection (51)! Proceed with appropriate cau-
tion.
The area beneath suspended loads or any areas where
there is a risk of falling must be kept clear at all times.

7. Connect the main boom and head connection by means of

four biconical bolts. Secure each bolt with 2 locking elements
each (Z 47 356).

-- The use of biconical bolts guarantees that the bolts

can always be hit FROM THE OUTSIDE during the fit-
ting and removing procedure.
-- Please observe the bolting table in section 20.2.2. for
bolting.

8. Release the lifting tackle from the transport unit.

650--1200--033_en 21/73
20

46
52
41

52
9

9
45

Z 47 357

22/73 650--1200--033_en
 Fixed Fly Jib 20

9. Assemble the desired fly jib length.

9.1 Fly jib length 20m

For a fly jib length of 20m, the jib top section (9) is now
fitted (Z 47 357).

9.1.1 To this end, attach the two ropes from the auxiliary
crane to the eyes provided. This transport unit can be
found in Sect. 19.13.1.8 of these operating instruc-
tions.

9.1.2 Raise the jib top section (9) using the auxiliary crane
and place in the bolting position with the adapter
(52).

Danger of crushing!
There is a risk of crushing between the jib top section
and adapter! Proceed with appropriate caution.
The area beneath the suspended jib top section must be
kept clear of personnel at all times.

9.1.3 Connect the jib top section (9) and adapter (52) using
four biconical bolts. Secure each bolt with 2 locking
elements.
-- The use of biconical bolts guarantees that the bolts
can always be hit FROM THE OUTSIDE during the fit-
ting and removing procedure.
-- Please observe the bolting table in section 20.2.2. for
bolting.

9.1.4 Disconnect the lifting tackle from the jib top section.

9.1.5 Reeve the hoist rope over the rope idler (41) and
guide to the head of the jib top section (9).

Due to the risk of falling, it is prohibited to walk on the

lattice mast components to draw forward the hoist rope,
this must be carried out from the ground.
Reeve the rope idler before fitting at the prescribed
height.

650--1200--033_en 23/73
20

Z 40 235

24/73 650--1200--033_en
 Fixed Fly Jib 20

9.1.6 Release the shift weight from the parking position

(detail “X”) and reeve the hoist rope on the head of
the jib top section (9) (Z 40 235).

Information on reeving the hoist rope on the head of the fixed fly
jib can be found in section 17.2 of these operating instructions.

During reeving there is a risk of becoming caught and

dragged into the equipment at the head sheaves and at
the hook block.
Proceed with appropriate caution and ensure that the
safety guards, for example the run--in guard, are fitted.
Risk of crushing !
Only hand le the hook block using the handrails provided
(see detail “Y”). Hands must be kept clear of the follow-
ing areas at all times:
* between the sheaves, side plates and covers.
* in the area of the fixing points (sometimes of a
folding/hinged design), the hook, the hook nut, the lifting
beam or the protecting cages.
Work may only be carried out on the hook block (reev-
ing) when it is resting on solid and firm ground.

650--1200--033_en 25/73
20

”A”-- 74 ”C”-- 74

Z 40 226

Z 40 227

26/73 650--1200--033_en
 Fixed Fly Jib 20

9.2 Fly jib length 26m to 50m / 85,3 ft to 164,0 ft

Proceed as follows to assemble the fly jib lengths

above 26m:

9.2.1 By drawing the bolts (74) at point “C”, set the inter-
mediate section (8) at an operating angle of 40°. The
two remaining bolts (74) remain inserted and se-
cured at point “A” (Z 40 226).

9.2.2 Connect the two ropes of the auxiliary crane to the

eyes provided on the intermediate section (8) (Z 40
227).

Intermediate section (8): see transport unit VII in Sect. 19.13.1.7

of these operating instructions.

650--1200--033_en 27/73
20

46
52

52
8

8
45

Z 47 358

28/73 650--1200--033_en
 Fixed Fly Jib 20

(Z 47 358)

9.2.3 Raise the intermediate section (8) using the auxiliary

crane and place in the bolting position with the
adapter (52).

Danger of crushing!
There is a risk of crushing between the intermediate sec-
tion and adapter! Proceed with appropriate caution.
The area beneath the suspended intermediate section
must be kept clear of personnel at all times.

9.2.4 Connect the intermediate section (8) and adapter

(52) by means of four biconical bolts. Secure each
bolt with 2 locking elements.
-- The use of biconical bolts guarantees that the bolts
can always be hit FROM THE OUTSIDE during the fit-
ting and removing procedure.
-- Please observe the bolting table in section 20.2.2. for
bolting.

650--1200--033_en 29/73
20

52

Z 40 229

30/73 650--1200--033_en
 Fixed Fly Jib 20

9.2.5 Using the auxiliary crane, lower the intermediate sec-

tion (8) until the end of the intermediate section is
resting on a wooden support which has been placed
ready in advance (Z 40 229).

There is a risk of crushing when the intermediate section

is lowered onto the wooden block. Proceed with ap-
propriate caution.

9.2.6 Disconnect the lifting tackle from the intermediate

section (8).

650--1200--033_en 31/73
20

”B”
”A”

8
8
9

11
55

11

Z 47 359

32/73 650--1200--033_en
 Fixed Fly Jib 20

(Z 47 359)
9.2.7 Hook up the jib top section (9), intermediate section
(11) and intermediate section (55) to the auxiliary
crane.
-- Above a fly jib length of 26m, the jib top section (9) is now
fitted.
Connection points: see transport unit VIII in Sect. 19.13.1.8
of these operating instructions.
-- For a fly jib length of 38m, the intermediate section (11) is now
fitted. Attachment points: see transport unit IX in Sect.
19.13.1.9 of these operating instructions.
-- For the fly jib lengths of 32m, 44m and 50m, the intermediate
section (55) is now fitted.
Attachment points: see transport unit XII in Sect. 19.13.1.12
of these operating instructions.
9.2.8 Using the auxiliary crane, raise the corresponding
lattice mast component so that it can be fitted on the
intermediate section (8). First insert a biconical bolt
in each of the top pin stops and secure the bolts with
two pin locks (Z 47 359--”A”).
When the upper bolting points have been bolted and
locked, lower using the auxiliary crane and discon-
nect the lifting tackle.

-- There is a risk of crushing between the individual lat-

tice mast components. Proceed with appropriate cau-
tion.

-- For bolting specifications, please refer to the bolt-

ing table in section 20.2.2.

9.2.9 To close the bottom pin stop, connect 2--stranded lift-

ing tackle on both sides of the intermediate section
(8) (Z 47 359--”B”). To avoid damage, securing straps
should be used. Raise slightly using the auxiliary
crane. The lower pin stop is closed and can be bolted
and locked like the upper bolt connection. Place a
wooden block beneath the end of the intermediate
section to provide support.

To close the lower pin stops the auxiliary crane must al-
ways be hooked up to the component part which is posi-
tioned nearer the main crane.

9.2.10 Disconnect the lifting tackle from the intermediate

section (8).

650--1200--033_en 33/73
20

8
41

8
8
73

Z 40 231

34/73 650--1200--033_en
 Fixed Fly Jib 20

9.2.11 Depending on the desired length of the fly jib, fit the
required lattice mast components as previously de-
scribed.
Once the required fly jib length has been assembled,
checks must be made to ensure that all the pin stops
are connected with the correct biconical bolts and
that each bolt is additionally locked with two pin
locks.

-- The lattice mast component combinations can be found in

section 20.2.1 of these operating instructions.
-- The bolting table for connecting the lattice mast components
can be found in Sect. 20.2.2 of these operating instructions.

Where the upper pin stop has already been closed, the lattice
mast component nearest the crane must be raised to close
the lower pin stop. If shackles are not available, the two
strands of the lifting tackle must be connected to the two up-
per tubes of the corresponding part.

9.2.12 Guide the hoist rope over the rope idler (41) on the
intermediate section (8) and, for the purpose of sub-
sequent reeving, feed to the head of the jib top sec-
tion (9) (Z 40 231).

Due to the risk of falling, it is prohibited to walk on the

lattice mast components to draw forward the hoist rope,
this must be carried out from the ground.
Reeve the rope idler before fitting at the prescribed
height.

9.2.13 The fly jib is prepared for crane operation at a work-

ing angle of 40°.
If you plan to operate the crane with a fly jib angle of
0° or 20°, you should now proceed as follows:
− Hook up the auxiliary crane to the eyes provided
on the jib top section (9).
− Raise the front lattice mast combination and, as
described in section 20.1, bolt the shackles (73)
on the intermediate section (8) accordingly
(Z 40 231).

650--1200--033_en 35/73
20

Z 40 236

36/73 650--1200--033_en
 Fixed Fly Jib 20

9.2.14 Release the shift weight from the parking position

(detail “X”) and reeve the hoist rope on the head of
the jib top section (9) (Z 40 236).

Information on reeving the hoist rope on the head of the fixed fly
jib can be found in section 17.2 of these operating instructions.

During reeving there is a risk of becoming caught and

dragged into the equipment at the head sheaves and at
the hook block.
Proceed with appropriate caution and make sure that the
safety guards, for example the run--in guard, are fitted.
Risk of crushing !
Only touch the hook block using the handrails provided
(see detail “Y”). Hands must be kept clear of the follow-
ing areas at all times:
* between the sheaves, side plates and covers.
* in the area of the fixing points (sometimes of a
folding/hinged design), the hook, the hook nut, the lifting
beam or the protecting cages.
Work may only be carried out on the hook block (reev-
ing) when it is resting on solid and firm ground.

650--1200--033_en 37/73
20

82

83

Z 39 388 Z 39 389

94

Z 40 232

38/73 650--1200--033_en
 Fixed Fly Jib 20

10. Attach the mounting pipe with the fitted rotor of the anemom-
eter and the aircraft warning light on the jib top section (9) (Z
39 388).

11. Connect the electrical safety chain on the distribution boxes

(82, “X550”) and (83, “X552”) on the main boom head (Z 39
389) and on the distribution box (94, “X570”) in the jib top
section (9, Z 40 232).

650--1200--033_en 39/73
20

86

82

83
1

Z 39 391

92

9
Z 42 355

40/73 650--1200--033_en
 Fixed Fly Jib 20

11.1 Connect the safety chain on the main boom head

The sockets on the distribution boxes (82) and (83) on the main
boom head should be assigned as follows:
(Z 39 391 and Z 42 355)
− Distribution box (82, “X550”)
∗ Socket (1, “Q4”)
Shut off with protective cap
∗ Socket (2, “Q5”)
Plug connection to cable drum (92) in the jib top section (9)
(connection for distribution box “X570”).
− Distribution box (83, “X552”)
∗ Socket (3, “Q2)
sealed with protection cap.
∗ Check to make sure that there is a connection to the angle
transmitter (86) on the main boom head.

650--1200--033_en 41/73
20

92

”S2D”

9
Z 42 355 Z 42 356

94
90 91

4 5

Z 39 702 Z 39 703

42/73 650--1200--033_en
 Fixed Fly Jib 20

11.2 Connect the safety chain on the jib top section

− Make the connection between the cable drum (92) and dis-
tribution box (94, “X570”) in the jib top section (9) (connection
for anemometer, aircraft warning light and hoist limit switch),
(Z 42 355 and Z 39 702).
− Make the connection between socket (4, “Q5N”) in the dis-
tribution box (94) and rotor (90, “G7”) of the anemometer on
the jib top section (9) (Z 39 702 and Z 39 703).
− Make the connection between socket (5, “Q4N”) in the dis-
tribution box (94) and aircraft warning light (91, “H115.1/2”)
on the jib top section (9) (Z 39 702 and Z 39 703).
− Check that the connection between the hoist limit switch
“S2D” on the jib top section and the distribution box
(94,”X570”) has been made (Z 39 702 and Z 42 356).

650--1200--033_en 43/73
20

”S2D”

Z 40 237

1 2 3

Z 39 718

44/73 650--1200--033_en
 Fixed Fly Jib 20

12. To ensure that the hoist limit switch “S2D” on the jib top sec-
tion (9) can function properly, the hoist limit switch “S1” on the
main boom head must be bridged, the restraint must be
placed in the locking position (Z 40 237).

To switch the restraint from the storage position into the locking
position proceed as follows (Z 39 718):

12.1 Push the restraint to the left 1 to release it from the

storage position.

12.2 Pull the hoist limit switch cable downwards, then bend
backwards parallel to the boom and hold in this posi-
tion 2 .

12.3 Starting from the left, push the slit of the restraint be-
tween the switch and the attached cable stop over the
cable 3 . Now press up against the guide of the hoist
limit switch ”S1” 4 .

12.4 Pull the cable down again, guiding the slit of the re-
straint into position, and release 5 .

12.5 Turn the flag of the restraint to where it can best be

seen by the crane operator 6 .

13. On the ECIS console, enter the code no. (DS) for the desired
operating mode (operation of fixed fly jib) and the length
code no. (LK) for the desired operating length of the main
boom.

These entries must be made in accordance with the applica-

ble load capacity table.
The computer of the load limit device is then set for opera-
tion with the fixed fly jib. On the ECIS display, the crane sym-
bol is shown with a fixed fly jib fitted. The current values for
the crane geometry are now displayed.

Due to the risk of tipping, the code numbers that have

been entered (DS) and (LK) for the corresponding load
capacity table and the fitted counterweight must be
checked again!

650--1200--033_en 45/73
20

46/73 650--1200--033_en
 Fixed Fly Jib 20

14. Using key--operated pushbutton (126), bridge the hoist limit

switch. Indicator light (125) lights up.

15. Using the luffing gear, raise the main boom until the hook
block is hanging free and deactivate the bridged condition of
the hoist limit switch. Switch key--operated pushbutton (126)
to the operating position to do this. Indicator light (125) goes
out.

16. Check the function of the hoist limit switch on the fly jib head.

When the hoist limit switch is activated, “raise hoist 1” must be

shut down. The hoist limit symbol appears in the top line of the
ECIS display. Indicator light (145) with the hoist limit symbol lights
up and an alarm buzzer sounds.

650--1200--033_en 47/73
20

52
73

Z 40 216

48/73 650--1200--033_en
 Fixed Fly Jib 20

20.4 Erecting

20.4.1 Checks Before Erecting

Before raising the fly jib and moving to the operating length
check:
-- that the fixed fly jib and main boom head are correctly
locked together.
-- that all bolts/pins are seated correctly and secured.
-- that all connecting bolts have been secured with func-
tioning locks in accordance with regulations.
-- that no tubular damage has occurred on the lattice mast
components. If damaged tubes are found during inspec-
tion, further work with the fly jib is prohibited.
-- that the main boom is well lubricated. This is especially
important for long fly jib lengths. Before all operations,
the slides and the rear linings must be well lubricated.
-- that the load limit device is set to the load program to be
driven for ”fixed fly jib” operation (see Sect. 10 of these
operating instructions and the corresponding load
table).
-- that the main boom is retracted.
-- that the fitted counterweight corresponds to the one spe-
cified in the corresponding load table.
-- that the tension brackets (73) on the intermediate section
(8) are correctly bolted in relation to the fly jib angle (Z 40
216). Information on the angle settings can be found in
section 20.1.

650--1200--033_en 49/73
20

Z 40 238

50/73 650--1200--033_en
 Fixed Fly Jib 20

20.4.2 Erection Procedure

Proceed as follows to erect to the operating position (Z 40 238):

1. Using the luffing gear, raise the main boom into the high
position (83°).

Move briefly against the safety pressure of the luffing gear

to make sure that the main boom is secured firmly in place.

2. Paying attention to the instructions of the telescoping infor-

mation system, telescope out to the main boom length in ac-
cordance with the load capacity table.

Two main boom lengths are available for operation of the crane
with the fixed fly jib: 50.5m and 55.5m.
The length code (LK number) required to configure to these oper-
ating lengths and the extension lengths of the telescopic sections
for the corresponding main boom lengths can be taken from the
following table.

Main boom Extension length of the individual telescopic sec-

p g
operating tions
l
length
th (m
( / ft) Code no.
Tele 1 Tele 2 Tele 3 Tele 4
LK
50,5 / 165,7 90 % 90 % 90 % 45 % 73
55,5 / 182,1 90 % 90 % 90 % 90 % 83

If the main boom has been extended to its final operating

length and pinned, the LPU is completely retracted.

650--1200--033_en 51/73
20

Z 40 239 Z 40 240

52/73 650--1200--033_en
 Fixed Fly Jib 20

20.5 Lowering Procedure

20.5.1 Lowering procedure at 20 and 40 degrees fly jib angle

Proceed as follows to lower the fixed fly jib:

1. Move the main boom with the luffing gear into the high posi-
tion (83°) (Z 40 239).

2. Enter the LK no. “00” on the ECIS display for complete retrac-
tion of the main boom.

3. Telescope in the main boom completely while observing the

telescoping information system (Z 40 239).

When telescoping, the information on the ECIS display

should always be followed.
A precise description of the actual telescoping procedure
can be found in Sect. 12 ”Telescoping”.

4. Slew the superstructure so that it is positioned to the rear or

to the side (if there are no restrictions in this respect in the
corresponding load capacity table).

For dismantling using an auxiliary crane, the forward--facing

position is also possible if the following conditions are met:

-- no limitations in this respect in the corresponding load

capacity table.
-- The main boom must not be resting on the transport rest
of the crane chassis, i.e. the luffing cylinders must not be
fully retracted, in order to take up the resulting forces.

5. Lower the main boom using the luffing gear until the jib top
section (9) is resting on the ground (Z 40 240).

650--1200--033_en 53/73
20

Z 40 241 Z 40 242

54/73 650--1200--033_en
 Fixed Fly Jib 20

20.5.2 Lowering Procedure with a 0 Degree Fly Jib Angle

Proceed as follows to lower the fixed fly jib:

1. Move the main boom with the luffing gear into the high posi-
tion (83°) (Z 40 241).

2. Enter the LK no. “00” on the ECIS display for complete retrac-
tion of the main boom.

3. Telescope in the main boom completely while observing the

telescoping information system (Z 40 241).

When telescoping, the information on the ECIS display

should always be followed.
A precise description of the actual telescoping procedure
can be found in Sect. 12 ”Telescoping”.

4. Slew the superstructure so that it is positioned to the rear or

to the side (if there are no restrictions in this respect in the
corresponding load capacity table).

For dismantling using an auxiliary crane, the forward--facing

position is also possible if the following conditions are met:

-- no limitations in this respect in the corresponding load

capacity table.
-- The main boom must not lie on the transport rest of the
crane chassis, i.e. the luffing cylinders must not be com-
pletely retracted, in order to take up the resulting forces.

5. Lower the main boom to the horizontal using the luffing gear
(Z 40 242).

6. Hook up the two ropes of the auxiliary crane to the eyes pro-
vided on the jib top section (9) (Z 40 242).

650--1200--033_en 55/73
20
52
”C”--74

8
9

Z 40 243

56/73 650--1200--033_en
 Fixed Fly Jib 20

7. Raise the jib top section (9) slightly using the auxiliary crane
to relieve the strain on bolt (74) at point “C” on the intermedi-
ate section (8) (Z 40 243--”A”).

8. Remove both bolts (74) at point “C” (1 x left and 1 x right)

9. Using the auxiliary crane, lower the front part of the fly jib until
the jib top section (9) is resting on the ground (Z 40 243--”B”).

650--1200--033_en 57/73
20

58/73 650--1200--033_en
 Fixed Fly Jib 20

20.6 Removing the Fixed Fly Jib

-- There is a risk of crushing when the lattice mast sec-

tions of the fly jib are being assembled or dismantled:
* when connecting / disconnecting between the indi-
vidual lattice mast components !
* between the main boom head and head connect-
ing piece.

The hazardous area must therefore be kept clear at all

times! Pay particular attention to the notes on hazards in
section 1.4.8 when ”Assembling and Dismantling Crane
Components” as well as the following instructions.
All assembly work is to be carried out with the help of
suitable equipment (ladders, hoist platforms, scaffolding,
auxiliary crane).
If work cannot be carried out using this type of equip-
ment or from the ground, assembly personnel must take
suitable precautionary measures to safeguard against
the RISK OF FALLING (e.g. safety belt).

During the fitting/removal procedure the area beneath

suspended loads or areas where there is a risk of falling
must be kept clear.

-- Select the auxiliary crane and lifting tackle so that the

lifting capacity clearly exceeds the weight of the fly jib
component which is to be fitted or removed and is suf-
ficient to lift the fly jib components at the required
working radius.

650--1200--033_en 59/73
20

82

83

Z 31 823 Z 39 389

Z 42 976

60/73 650--1200--033_en
 Fixed Fly Jib 20

As the fly jib has now been lowered, as described in Sect. 20.5.1
and 20.5.2, and the tension bars on the intermediate section (8)
are set to the 40°--operating angle, the system can be dismantled
further as follows.

1. Release the shift weight on the hoist rope and insert in the
parking position on the jib top section (Z 31 823).

2. Unreeve the hook block and reel the hoist rope onto the rope
drum.

When unreeving there is a risk of persons becoming

snagged and dragged into equipment at the head
sheaves and the hook block.
Proceed with appropriate caution!
Risk of crushing !
Only touch the hook block using the handrails provided
(Z 42 976). Hands must be kept clear of the following
areas at all times:
* between the sheaves, side plates and covers.
* in the area of the fixing points (sometimes of a folding/
hinged design), the hook, the hook nut, the lifting
beam or the protecting cages.
Work (unreeving) may only be carried out on the hook
block when it is positioned in a stable and secure
place on firm ground.

3. Disconnect the electric lines to the fly jib on the distribution

boxes (82, “X550”) and (83, “X552”) on the main boom head
(Z 39 389).

650--1200--033_en 61/73
20

8
9

Z 40 244

62/73 650--1200--033_en
 Fixed Fly Jib 20

4. Remove the fly jib (Z 40 244).

The procedure for dismantling is practically the same as for fitting,

only in the reverse order. You should therefore read and follow
the instructions for assembly.

All pictures show the 26 m fly jib length as an example. The same
procedure is followed for other lengths.

4.1 Hook up the 2--strand lifting tackle on both sides on the

end of the intermediate section (8) on the upper mem-
bers. To avoid damage, securing straps should be
used.

For all fly jib lengths, the attachment must be made to

the component which is nearer to the main crane.

4.2 Raise using the auxiliary crane. It must take up the full
load, however without lifting the jib top section (9) off
the ground.

The pins of the lower pin stop may only be removed

when the components that are to be disconnected are
safely held by the auxiliary crane!
Otherwise, the lattice mast components can spring apart
suddenly when the lower pin stop is opened.
Risk to life and limb!

650--1200--033_en 63/73
20

52

52
8

8
9

Z 47 360

64/73 650--1200--033_en
 Fixed Fly Jib 20

4.3 Remove the bolts of the lower pin stop (Z 47 360--”A”).

Always knock out the biconical bolts from the outside

inwards!
The areas beneath and in the vicinity of suspended loads
must be kept clear of persons at all time!

These bolts must be easily knocked out. Otherwise the pin

connection is still under load!
For this reason, observe the pin when knocking it out and,
if necessary, relieve the pin stop by moving the auxiliary
crane accordingly.

4.4 When the hazardous area is clear, lower the auxiliary

crane so that the opened lower pin stop comes to rest
on the wooden blocks which have been laid ready and
the jib top section (9) rests on the ground (Z 47
360--”A”).

-- Risk of crushing between the lattice mast components

and the wooden supports. Proceed with appropriate
caution.

-- The upper pin stops may only be released when

both sections are lying on the ground.

4.5 Release the upper pin stop, hook up the auxiliary crane
to the eyes provided on the jib top section (9) and re-
move the jib top section (Z 47 360--”B”).

Attachment points on the jib top section (9): see transport unit VIII
in Sect. 19.13.1.8 of these operating instructions.

650--1200--033_en 65/73
20

73

52

”C”-- 74

Z 40 246

66/73 650--1200--033_en
 Fixed Fly Jib 20

4.6 Hook up the two rope strands of the auxiliary crane to

the eyes provided on the intermediate section (8) (Z 40
246--”A”).

Attachment points on the intermediate section (8): see transport

unit VII in Sect. 19.13.1.7 of these operating instructions.

4.7 Using the auxiliary crane, raise the intermediate sec-

tion (8) so that the tension bars (73) can be bolted in
the 0°--position (Z 40 246”A”).

4.8 On both sides, insert one bolt (74) at point “C” and lock
the bolts. The intermediate section (8) is bolted in the
0°--position (Z 40 246--”B”).

Information on setting the angle for the intermediate section (8)

can be found in section 20.1 of these operating instructions.

650--1200--033_en 67/73
20

46
52

52
8

8
45

Z 47 361

68/73 650--1200--033_en
 Fixed Fly Jib 20

4.9 Remove the top bolts (46) and bottom bolts (45) from
the pin stop connecting the intermediate section (8) /
adapter (52)(Z 47 361).

Always knock out the biconical bolts from the outside

inwards!
The areas beneath and in the vicinity of suspended loads
must be kept clear of persons at all time!

These bolts must be easily knocked out. Otherwise the pin

connection is still under load!
For this reason, observe the pin when knocking it out and,
if necessary, relieve the pin stop by moving the auxiliary
crane accordingly.

4.10 Remove intermediate section (8) (Z 47 361).

650--1200--033_en 69/73
20

51

51
51

52

52

Z 40 247

70/73 650--1200--033_en
 Fixed Fly Jib 20

4.11 Attach the 4--stranded lifting tackle to the transport unit

(comprising head connecting piece (51) and adapter
(52)) and hook up to the auxiliary crane
(Z 40 247--”A”).

This transport unit weighs approx. 3.9 t.

Pay attention to the centre of gravity!

Attach the lifting tackle so that the transport unit which is
to be lifted is neither slanted nor swings when it is
raised.

4.12 Remove the top bolts (46) and bottom bolts (45) from
the pin stop of the main boom head (Z 40 247--”A”).

Always knock out the biconical bolts from the outside

inwards!
The areas beneath and in the vicinity of suspended loads
must be kept clear of persons at all time!

These bolts must be easily knocked out. Otherwise the pin

connection is still under load!
For this reason, observe the pin when knocking it out and,
if necessary, relieve the pin stop by moving the auxiliary
crane accordingly.

4.13 Remove the transport Unit “adapter / head connecting

piece” (Z 40 247--”B”).

650--1200--033_en 71/73
20

Z 46 756

72/73 650--1200--033_en
 Fixed Fly Jib 20

20.7 Superlift Operation with Fixed Fly Jib

(Z 46 756)

Information on operation of the Superlift with the fixed fly jib can
be found in section 30.6 of these operating instructions.

650--1200--033_en 73/73