SAC2200

Quality Changes the World
Operation and
Maintenance
Manual
SAC2200
All Terrain Crane

SAC2200
SAC2200 All Terrain Crane

Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the
machine decals. Failure to do can cause serious injury, death or property damage.
Keep this manual with the machine for reading and future reference.
SAC2200
SANY Group
SANY Mobile Machinery Co., Ltd.
Sany Industry Town,
SANY Industry Town, Changsha
Jinzhou Development Zone, Hunan, China
410600
http://www.sanygroup.com
Tel: 0086-21-58592902
Fax: 0086-21-58596210
WARNING
© 2010 by Sany Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as
described herein. All information included within this publication was accurate
at the time of publication. Product improvements, revisions, etc., may result in
differences between your machine and what is presented here. Sany Group assumes no
liability. For more information, contact Sany Group.
Table of Contents
SAC2200
Table of Contents
0 Introduction
0.1 Overview...................................................................................................................0-2
0.2 Your Documentation Package.................................................................................... 0-4
0.2.1 Recommendations on Using the Documentation.............................................0-5
0.2.2 Documentation Storage....................................................................................0-5
0.2.3 Operation Manual Organization........................................................................ 0-6
0. 3 Your Sany Machine.................................................................................................... 0-8
0.3.1 Breaking in a New Machine............................................................................... 0-8
0.3.2 Directional Reference of the Machine............................................................... 0-9
0.3.3 Machine information........................................................................................ 0-10
0.3.4 Table for Serial Number and Distributor Info................................................... 0-14
0.4 Contact Information.................................................................................................. 0-14
1 Description of Crane
1.1 Terminology...............................................................................................................1-2
1.1.1 Crane Chassis................................................................................................... 1-2
1.1.2 Crane Superstructure........................................................................................ 1-2
1.1.3 Tlescopic Boom (T)........................................................................................... 1-2
1.1.4 Additional Boom................................................................................................ 1-5
1.2 Product Description...................................................................................................1-6
1.2.1 Crane Chassis................................................................................................... 1-6
1.2.2 Crane Superstructure........................................................................................ 1-8
1.2.3 Additional Equipment....................................................................................... 1-10
1.3 Technical Data.........................................................................................................1-11
2 Safety
Foreword.........................................................................................................................2-2
2.1 Traffic Regulations...................................................................................................2-10
2.2 Crane Break-in Specifications.................................................................................2-11
2.3 Planning Crane Operation.......................................................................................2-13
2.4 Safety-Technical Regulation....................................................................................2-14
2.4.1 Requirements of the Crane Operator.............................................................2-14
2.4.2 Selecting an Operating Site............................................................................2-18
2.4.3 Maintenance Work on the Crane Superstructure or Boom.............................2-20
2.4.4 Obligations of the Crane Operator..................................................................2-21
2.4.5 Selecting the Location....................................................................................2-24
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2.4.6 Slopes and Ditches.........................................................................................2-26

2.4.7 Permissible Ground Pressure.........................................................................2-30
2.4.8 Supporting......................................................................................................2-34
2.4.9 Crane Operation with A Load..........................................................................2-38
2.4.9.1 Counterweight.......................................................................................2-39
2.4.9.2 Hoist Gear, Hoist Rope..........................................................................2-39
2.4.9.3 Crane Operation....................................................................................2-40
2.4.10 Grounding the Crane....................................................................................2-42
2.4.11 Safety Instructions for External Power Supply (230 V Ac)............................2-47
2.4.12 Endangering Air Traffic................................................................................2-48
2.4.13 Joint Lifting of a Load by Numerous Cranes................................................2-49
2.4.14 Working in the Vicinity of Transmitters.........................................................2-50
2.4.15 Hand Signals for Guidance...........................................................................2-56
2.4.16 Consideration of Wind Conditions................................................................2-58
2.4.17 Interruption of Crane Work..........................................................................2-60
2.5 Warning Signs.........................................................................................................2-65
2.6 Operation of Crane Superstructure.........................................................................2-66
2.6.1 Technical Safety Instructions for Working with Loads....................................2-66
2.6.2 Checking before Starting to Work with the Crane..........................................2-68
2.6.2.1 Visual Check for Damage......................................................................2-69
2.6.2.2 Telescopic Boom Distortion Because of Sunshine on one Side............2-70
2.7 Taking on a Load.....................................................................................................2-71
2.7.1 Lifting the Load...............................................................................................2-71
2.7.2 Diagonal Pulling..............................................................................................2-73
2.7.3 Breaking away Fixed Loads...........................................................................2-73
2.8 Crane Operation.....................................................................................................2-74
2.8.1 General...........................................................................................................2-74
2.8.2 Guiding the Load............................................................................................2-75
2.8.3 Carrying People..............................................................................................2-75
2.8.4 Danger of Crushing........................................................................................2-76
2.8.5 Working in the Vicinity of Electricity Transmission Lines................................2-76
2.8.6 Ram Work or Pulling Sheet Piles...................................................................2-78
2.9 Equipment...............................................................................................................2-79
2.9.1 Checking the Retaining Elements..................................................................2-79
2.9.2 Checking the Ropes.......................................................................................2-79
2.9.3 Attaching a New Hoist Rope..........................................................................2-80
2.9.4 Inspection Procedures....................................................................................2-81
2.9.5 Dangerous Conditions without Shut Off.........................................................2-83
2.9.5.1 Block Position of Relapse Cylinders when Setting Down a Load..........2-83
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SAC2200
2.9.6 Transporting Components..............................................................................2-84

2.9.6.1 Transporting Lattice Components..........................................................2-84
2.9.7 Pneumatic Springs for Assembly Support of Components.............................2-85
2.9.8 Weights...........................................................................................................2-86
2.9.9 Reduction of Load Carrying Capacity with Placed Guy Posts........................2-86
2.9.10 Bypassing the Overload Protection..............................................................2-87
2.9.10.1 Bypassing Overload Protection...........................................................2-88
2.9.10.2 Bypass of Hoist-Top Switch-Off...........................................................2-89
2.9.11 Assembly / Dismantling.................................................................................2-90
2.9.11.1 Assembly/Disassembly of the Booms.................................................2-93
2.9.11.2 Assembly of Lattice Components for Cranes with Telescopic Booms.2-96
2.9.11.3 Bypassing during Assembly and Dismantling....................................2-104
2.9.11.4 Assembling/Dismantling the Hydraulic Lines.....................................2-105
2.9.12 Setting-Up and Taking-Down.....................................................................2-106
2.9.12.1 Checking the Preconditions...............................................................2-106
2.10 Inspection of Cranes...........................................................................................2-107
2.10.1 Periodic Inspection on Crane.....................................................................2-107
2.10.1.1 General..............................................................................................2-107
2.10.1.2 Inspecting Load-Bearing Steel Structures.........................................2-110
2.10.2 Inspecting the Rims....................................................................................2-120
2.10.3 Inspecting the Hoist and Luffing Winches..................................................2-121
2.10.3.1 Inspections........................................................................................2-121
2.10.3.2 Requirements for Monitoring the Winches........................................2-124
2.10.4 Inspecting the Load Hooks.........................................................................2-139
2.10.4.1 Inspection and Monitoring Procedure................................................2-139
2.10.5 Inspection of the Rope Feed Mechanics in the Telescopic Boom..............2-140
2.10.6 Inspecting the Operation of the Inner and Outer Interlocking Systems Of The
Telescopic Boom...................................................................................................2-140
2.10.7 Inspecting the Safety Switching on the Relapse Supports.........................2-140
2.10.8 Inspecting the Nitrogen Storage Tank........................................................2-140
2.10.9 Inspecting the Rope Pulleys.......................................................................2-141
2.10.10 Testing Overload Protection Operation.....................................................2-141
2.10.11 Inspecting the Mounting of the Load Bearing Equipment.........................2-142
2.10.12 Inspecting the Oil and Fuel Reservoirs.....................................................2-143
2.10.13 Inspection of the Auxiliary Reeving Winch, Towing Winch and Spare Wheel
Winch.....................................................................................................................2-143
2.10.14 Appendix...................................................................................................2-143
2.10.14.1 Inspection Recommendations for Periodic Inspections of Sany Cranes..
........................................................................................................................2-144
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SAC2200
2.10.15 Inspection on Wire Rope..........................................................................2-154

2.10.15.1 Introduction......................................................................................2-154
2.10.15.2 Wire Rope........................................................................................2-154
2.10.15.3 Operating Behavior of Steel Ropes.................................................2-168
2.10.15.4 Condition of Equipment that is Functionally Associated with the Rope....
........................................................................................................................2-168
2.10.15.5 Rope Checking Log.........................................................................2-169
2.10.15.6 Rope Storage and Marking..............................................................2-169
2.10.15.7 Wire Ropes and Rope end Connections.........................................2-169
2.10.15.8 Twisting Caused by Stretching in Non-Twisting Ropes and Remedying
Thereof............................................................................................................2-172
2.10.15.9 Appendix 1.......................................................................................2-174
2.10.15.10 Appendix 2.....................................................................................2-177
2.10.15.11 Appendix 3.....................................................................................2-179
2.11 General Notes......................................................................................................2-182
2.11.1 Daily Checking............................................................................................2-182
2.11.2 Repair and Maintenance Tasks..................................................................2-183
2.11.3 Important Servicing.....................................................................................2-184
2.11.4 Maintenance Notes for Replacement Parts................................................2-184
2.11.5 Instructions for Travel Operation.................................................................2-185
2.11.6 Disposal of Service Fluids and Lubricants..................................................2-185
2.11.7 Tires............................................................................................................2-186
2.11.7.1 Wheel Checks....................................................................................2-186
2.11.7.2 Tire Changes.....................................................................................2-187
2.11.7.3 Wheel Changes.................................................................................2-187
3 Crane Chassis Operation

3.1 Chassis Control Devices and Instruments................................................................3-2
3.1.1 General Operating Instruments.......................................................................3-2
3.1.2 Indicator on Main Instrument Panel.................................................................3-8
3.1.3 Auxiliary Control Panel....................................................................................3-8
3.1.4 Side Control Panel.........................................................................................3-10
3.1.5 Support Control Unit......................................................................................3-12
3.1.5.1 Right Support Control Unit....................................................................3-12
3.1.5.2 Left Support Control Unit......................................................................3-14
3.2 Before Setting off.....................................................................................................3-16
3.2.1 General Checks Before Setting off.................................................................3-16
3.2.1.1 Checking Oil Level and Filters..............................................................3-16
3.2.1.2 Checking Fuel Level.............................................................................3-16
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SAC2200
3.2.1.3 Checking Coolant Level........................................................................3-16

3.2.1.4 Checking the Tires (Spare Wheel Included).........................................3-17
3.2.1.5 Checking the Crane General Transport Condition................................3-18
3.2.1.6 Checking the Lighting...........................................................................3-20
3.2.2 Driver’s Cab...................................................................................................3-21
3.2.2.1 Adjusting the Driver’s Seat...................................................................3-21
3.2.2.2 Adjusting the Mirror...............................................................................3-22
3.2.2.3 Adjusting the Steering Wheel...............................................................3-22
3.2.2.4 Turning Heater/Ventilation on...............................................................3-22
3.2.2.5 Putting on Seat Belt(49).......................................................................3-22
3.2.2.6 Checking Main Controls.......................................................................3-24
3.3 Axle Sprung /Axle Locking System..........................................................................3-26
3.3.1 Description.....................................................................................................3-26
3.3.1.1 Axle Sprung..........................................................................................3-26
3.3.1.2 Axle Locked .........................................................................................3-26
3.3.2 Axle Sprung/Axle Locking System..................................................................3-29
3.3.2.1 Road Driving/off-Road Driving..............................................................3-29
3.3.2.2 Level Control .......................................................................................3-29
3.3.3 Axle Locking System......................................................................................3-33
3.3.3.1 General.................................................................................................3-33
3.3.3.2 Switching on Axle Locking....................................................................3-33
3.3.3.3 Supporting the Crane...........................................................................3-33
3.4 Crane Driving Operation..........................................................................................3-34
3.4.1 Crane Driving Conditions................................................................................3-34
3.4.1.1 Axle Loads up to 12T............................................................................3-34
3.4.1.2 Axle Loads above 12T..........................................................................3-34
3.4.2 Starting and Stopping the Engine...................................................................3-36
3.4.2.1 Starting the Engine...............................................................................3-36
3.4.2.2 Checking the instruments after starting the Engine..............................3-36
3.4.2.3 Truning off the Engine.........................................................................3-37
3.4.3 Driving............................................................................................................3-38
3.4.3.1 Changing the Idling Speed...................................................................3-38
3.4.3.2 Parking Brake.......................................................................................3-38
3.4.3.3 Service Brake.......................................................................................3-38
3.4.3.4 Intarder................................................................................................3-40
3.4.3.5 Automated Shift Transmission..............................................................3-44
3.4.3.6 Transfer Case Operation......................................................................3-50
3.4.3.7 Creeper Gear........................................................................................3-50
3.4.3.8 Important Control Instruments While Driving�� 3-52
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3.4.3.9 Finishing Driving Operations................................................................3-54

3.4.4 Differential Locks...........................................................................................3-56
3.4.4.1 Turning the Differential Locks off..........................................................3-58
3.4.4.2 Addition of Longitudinal Differential Lock Axle 4+Transversal Differential
Lock Axle 4+Axle 5............................................................................................3-58
3.4.4.3 Addition of Transversal Differential Lock Axle 1+ Axle 2.......................3-60
3.4.5 Steering ........................................................................................................3-62
3.4.5.1 General.................................................................................................3-62
3.4.5.2 Changing Between Operating Modes...................................................3-66
3.4.5.3 Road Driving.........................................................................................3-68
3.4.5.4 All-wheel Steering.................................................................................3-68
3.4.5.5 Grab Steering.......................................................................................3-69
3.4.5.6 Reduced Swing-out Rate......................................................................3-69
3.4.5.7 Independent Steering...........................................................................3-70
3.4.5.8 Locked Rear Axle Steering Mode.........................................................3-70
3.4.6 Towing...........................................................................................................3-71
3.4.6.1 General Towing Regulations.................................................................3-71
3.4.6.2 Towing with a Defective Drive Motor And/Or Shift Transimission ........3-71
3.4.6.3 Towing with a Intact Drive Motor............................................................3-71
3.5 Crane Operates in Worksite....................................................................................3-72
3.5.1 General . .......................................................................................................3-72
3.5.1.1 Selecting the Location..........................................................................3-72
3.5.1.2 Converting from Driving Mode to Crane Operation..............................3-72
3.5.1.3 Moving the Support Pads from Transport Position to Operating Position...
......................................................................................................................... 3-74
3.5.1.4 Moving the Support Pads from Operating Position to Transport Position...
.......................................................................................................................... 3-74
3.5.1.5 Support Pads........................................................................................3-74
3.5.1.6 Converting from Crane Operation to Driving Mode..............................3-76
3.5.2 Support Control Unit.......................................................................................3-78
3.5.2.1 Extending the Sliding Beams with Support Control Unit.......................3-80
3.5.2.2 Supporting Manually.............................................................................3-82
3.5.2.3 Retracting Support Cylinders with Support Control Unit.......................3-86
3.5.2.4 Retracting Sliding Beams with Support Control Unit............................3-87
3.5.3 Before Leaving Worksite..............................................................................3-88
4 Crane Superstructure Operation

4.1 Operating and Control Instruments...........................................................................4-2
4.2 Superstructure Control System ..............................................................................4-14
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4.2.1 General...........................................................................................................4-14
4.2.2 Superstructure Control System Startup..........................................................4-16
4.2.3 “Superstructure Operating” Program..............................................................4-19
4.2.3.1 Warning Information Display.................................................................4-21
4.2.3.2 Crane Operating Condition Display......................................................4-22
4.2.4 Boom Length Combination Selecting Program.............................................4-25
4.2.4.1 Telescopic Boom Telescoping Program................................................4-26
4.2.4.2 Manual / Automatic Switchover Program.............................................4-29
4.2.5 Operating Condition Setting Program Interface.............................................4-30
4.2.6 Support Operating Program..........................................................................4-31
4.2.7 Help Program................................................................................................4-35
4.2.7.1 Engine condition test program..............................................................4-36
4.2.7.2 LMBTest program................................................................................4-37
4.2.7.3 Lmi Information Display.......................................................................4-41
4.2.8 Io Port Inquiry Program................................................................................4-42
4.2.8.1 Main Controller Di/O............................................................................4-43
4.2.8.2 Auxiliary Controller Di/O......................................................................4-43
4.2.8.3 Analogue Quantity Input......................................................................4-44
4.2.8.4 Can Communication Condition Test Program.....................................4-44
4.2.9 Manufacturer parameters setting...................................................................4-45
4.3 Crane Startup......................................................................................................... 4-46
4.3.1 Checks Before Starting up.............................................................................4-46
4.3.1.1 Checking the Fuel Level.......................................................................4-46
4.3.1.2 Checking the Coolant Level..................................................................4-47
4.3.1.3 Checking the Central Lubrication System............................................4-47
4.3.1.4 Checking General Condition of Crane..................................................4-48
4.3.2 Crane Operator’s Cab Workplace.................................................................4-48
4.3.2.1 Adjusting Crane Operator’s Seat..........................................................4-48
4.3.2.2 Footboard.............................................................................................4-50
4.3.2.3 Turning Air-conditioner/Ventilation on...................................................4-50
4.3.2.4 Tilting Crane Cab..................................................................................4-52
4.3.2.5 Operating the Windshield Wiper/Windshield Washing System............4-54
4.3.2.6 Checking the Signal Horn.....................................................................4-54
4.3.3 Staring Superstructure Engine.......................................................................4-56
4.3.3.1 Startig Superstructure Engine..............................................................4-56
4.3.3.2 Checking the Instruments After Starting the Engine . ..........................4-58
4.3.3.3 Engine Monitoring.................................................................................4-60
4.3.3.4 Turning the Superstructure Engine off . ...............................................4-64
4.3.3.5 Turning the Superstructure Engine off in the event of Danger.............4-64
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4.3.4 Superstructure Control System After Engine Start.........................................4-66

4.3.4.1 Waiting for the Runup Phase................................................................4-66
4.3.4.2 Selecting the New Configuration and Hoist Rope Reeving..................4-66
4.4 Safety Equipment...................................................................................................4-68
4.4.1 General...........................................................................................................4-68
4.4.2 Spirit Levels....................................................................................................4-68
4.4.2.1 Spirit Levels on Chassis........................................................................4-68
4.4.2.2 Spirit Levels on Superstructure.............................................................4-68
4.4.3 Torque Control system...................................................................................4-70
4.4.3.1 Overload Protection...............................................................................4-70
4.4.3.2 Support Program...................................................................................4-70
4.4.3.3 Control Parameters Program.................................................................4-70
4.4.4 Wind Warning System ..................................................................................4-72
4.4.5 Hoist Limit Switch “Hoist Top”........................................................................4-72
4.4.6 Limit Switch Winch Reeled off.......................................................................4-73
4.4.7 Emergency off Switch....................................................................................4-74
4.4.8 Control Release.............................................................................................4-74
4.4.9 Bypassing .....................................................................................................4-76
4.4.9.1 Bypassing”Luffing up if Overload Occurs”�� 4-76
4.5 Superstructure........................................................................................................4-78
4.5.1 General . ........................................................................................................4-78
4.5.1.1 Locking the Superstructure .................................................................4-78
4.5.1.2 Locking the Engine Control..................................................................4-80
4.5.1.3 “Power Plus” Rapid Gear......................................................................4-82
4.5.2 Superstructure Control System......................................................................4-82
4.5.3 Luffing............................................................................................................4-82
4.5.3.1 Preselect the Maximum Luffing Speed of Telescopic Boom . ...............4-82
4.5.4 Lifting / Lowering ...........................................................................................4-84
4.5.4.1 Lifting/Lowering the Winch 1(Main Winch)............................................4-84
4.5.4.2 Lifting/Lowering the Winch 1(Auxiliary Winch)......................................4-84
4.5.5 Turning the Crane Superstructure..................................................................4-86
4.5.5.1 Preselect Rotation Speed......................................................................4-87
4.5.5.2 Slewing Gear Generally........................................................................4-88
4.5.6 Telescoping ..................................................................................................4-92
4.5.6.1 General . ...............................................................................................4-92
4.5.6.2 Automatic Telescoping..........................................................................4-98
4.6 Rope Reeving........................................................................................................4-102
4.6.1 General . .....................................................................................................4-102
4.6.1.1 Wire Cables and Cable end Connection.............................................4-102
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4.6.2 Reeving the Hook Block in and out.............................................................4-102

4.6.2.1 Reeving in .......................................................................................4-102
4.6.2.2 Lowering the Hook Block.....................................................................4-106
4.6.3 Attaching and Remove Load Hook ..............................................................4-108
4.6.3.1 Assembly............................................................................................4-108
4.6.3.2 Removing .......................................................................................4-110
4.6.4 Reeving Charts............................................................................................4-112
4.6.4.1 Reeving T Operation...........................................................................4-112
4.6.4.2 Reeving TK Operation .......................................................................4-116
4.6.4.3 Counterweight....................................................................................4-117
5 Equipment
5.1 Safety Technical Guidelines......................................................................................5-2
5.1.1 Checking the Retaining Elements....................................................................5-2
5.1.2 Checking the Ropes ........................................................................................5-2
5.1.2.1 Attaching New Hoist Rope.......................................................................5-3
5.1.3 Checks Before Supporting the Crane.....................................................................5-4
5.1.4 Checks Before Crane Operation......................................................................5-5
5.1.5 Transporting Components................................................................................5-6
5.1.5.1 Transporting Lattice Components............................................................5-6
5.1.6 Weights . ..........................................................................................................5-7
5.1.7 Assembly / Dismantling....................................................................................5-7
5.1.7.1 General . .................................................................................................5-7
5.1.7.2 Assembly/Disassembly of the Jib............................................................5-9
5.1.7.3 Assembling/Dismantling the Hydraulic Lines.........................................5-12
5.1.8 Setting-up and Taking-down...........................................................................5-14
5.1.9 Checking the Preconditions............................................................................5-14
5.2 Folding Jib – TK.......................................................................................................5-16
5.2.1 General . ........................................................................................................5-16
5.2.1.1 Folding Jib Variations ...........................................................................5-16
5.2.1.2 Fastening Points”Folding Jib Complete”................................................5-18
5.2.2 Assembly of the Folding Jib . .........................................................................5-20
5.2.2.1 General . ...............................................................................................5-20
5.2.2.2 Reeving out the Hoist Rope on the Telescopic Boom Head..................5-22
5.2.2.3 Important Check Before Swinging out the Hydraulic Folding Jibs.........5-24
5.2.2.4 Assembly of the Single Folding Jib Carried on the Crane.....................5-25
5.2.2.5 Assembly of the Dual Folding Jib Carried on the Crane........................5-30
5.2.2.6 Assembly of the 3-Piece Folding Jib......................................................5-36
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5.2.2.7 Assembly of the 4-Piece Folding Jib......................................................5-40

5.2.2.8 Installing Separaely Transported Folding Jib on the Crane...................5-44
5.2.3 Reeving in the Hoist Rope . ...........................................................................5-48
5.2.3.1 Swinging the Rope Guide Pulley into Operating Position......................5-48
5.2.3.2 Reeving in the Hoist Rope.....................................................................5-48
5.2.4 Electrical Connections ...................................................................................5-49
5.2.4.1 General . ...............................................................................................5-49
5.2.4.2 Electrical Connections on Telescopic Boom..........................................5-49
5.2.4.3 Electrical Connections on Folding Jib ..................................................5-49
5.2.4.4 Function Check......................................................................................5-50
5.2.5 Erection (with Folding Jib) .............................................................................5-52
5.2.5.1 Preparatory Work .................................................................................5-52
5.2.5.2 Erection Procedure . .............................................................................5-53
5.2.6 Adjusting the Folding Jib angle of the Hydraulic Folding Jib..........................5-54
5.2.6.1 Angle Display for Folding Jib.................................................................5-54
5.2.6.2 Luffing with “Hydraulic Angle Adjustment”.............................................5-56
5.2.6.3 Telescoping . .......................................................................................5-56
5.2.7 Reeving out the Hoist Rope .........................................................................5-58
5.2.7.1 Pinning/Unpinning the Rope Retaining Pins..........................................5-58
5.2.7.2 Swinging the Rope Guide Pullry into Transport Position.......................5-58
5.2.8 Removing the Folding Jib ..............................................................................5-60
5.2.8.1 General . ...............................................................................................5-60
5.2.8.2 Preparatory Work Before Swinging in the Hydraulic Folding Jibs.........5-62
5.2.8.3 Removing the Single Folding Jib Carried on the Crane, Part 1.............5-64
5.2.8.4 Removing the Single Folding Jib Carried on the Crane, Part 2.............5-66
5.2.8.5 Removing the Dual Folding Jib Carried on the Crane...........................5-68
5.2.8.6 Disassembly of the 3-Piece Folding Jib.................................................5-74
5.2.8.7 Disassembly of the 4-Piece Folding Jib.................................................5-76
5.2.8.8 Disassembly Separaely Transported Folding Jib on the Crane.............5-82
5.3 Winch 2 ..................................................................................................................5-84
5.3.1 General...........................................................................................................5-84
5.3.2 Assembly........................................................................................................5-84
5.3.3 Assemble Winch 2..........................................................................................5-84
5.3.4 Connect Supply Lines.....................................................................................5-86
5.3.5 Dismantling.....................................................................................................5-86
5.3.6 Disconnecting the Supply Lines.....................................................................5-86
5.3.7 Dismantling the Winch 2.................................................................................5-87
5.4 Boom Nose..............................................................................................................5-88
5.4.1 General...........................................................................................................5-88
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SAC2200
5.4.2 Aassembly .....................................................................................................5-88

5.4.2.1 Move Boom Nose to Operation Position...............................................5-88
5.4.2.2 Reeving the Hoisting Cable ..................................................................5-90
5.4.2.3 Hoisting Limit Switch ............................................................................5-90
5.4.2.4 Single Hook Operation..........................................................................5-90
5.4.2.5 Dual Hook Operation ............................................................................5-90
5.4.2.6 Function Check......................................................................................5-90
5.4.3 Dismantling . ..................................................................................................5-92
5.4.3.1 Swivel Boom Nose to Transporting Position..........................................5-92
5.5 Telescopic Boom Extension....................................................................................5-92
5.5.1 General . .......................................................................................................5-92
5.5.1.1 Attachment Points..................................................................................5-92
5.5.2 Assembly ......................................................................................................5-94
5.5.2.1 Assembly Process ................................................................................5-94
5.5.3 Create Electrical and Hydraulic Connections.................................................5-96
5.5.3.1 Create Hydraulic Connection.................................................................5-96
5.5.3.2 Electrical Connections...........................................................................5-96
5.5.3.3 Test........................................................................................................5-96
5.5.4 Dismantling . ..................................................................................................5-97
5.5.4.1 Disassembly Procedure.........................................................................5-98
6 Additional Equipment
6.1 Heater / Engine Preheating.......................................................................................6-2
6.1.1 Heating the driver’s cab . .................................................................................6-2
6.1.1.1 Temperature Adjustment System.............................................................6-2
6.1.2 Engine preheating ..........................................................................................6-2
6.1.3 Heating the console . .....................................................................................6-4
6.1.3.1 Air-conditioning System in Console.........................................................6-4
6.1.4 Engine preheating ...........................................................................................6-4
7 Maintenance and Service

7.1 General . ..................................................................................................................7-2
7.1.1 Sany Customer Service for You........................................................................7-3
7.1.2 Cleaning And Care of the Crane.......................................................................7-5
7.1.2.1 Instructions for Sound Damping (Soundproofing)...................................7-5
7.1.2.2 Care Instructions for the Driver’s Cab And the Crane Cab......................7-6
7.1.3 Taking the Crane out of Service for Job Interruption........................................7-6
7.1.4 Maintenance Guidelines..................................................................................7-7
XI
Table of Contents
SAC2200
7.2 Crane Chassis...........................................................................................................7-8

7.2.1 Crane Chassis Maintenance And Inspection Plan............................................7-8
7.3 Crane Superstructure..............................................................................................7-16
7.3.1 Crane Superstructure Maintenance And Inspection Plan...............................7-16
7.4 Crane Chassis Maintenance Guidelines................................................................7-23
7.4.1 Driving Motor .................................................................................................7-23
7.4.1.1 Engine Oil .............................................................................................7-24
7.4.1.2 Engine Coolant .....................................................................................7-24
7.4.1.3 Air Filter ................................................................................................7-24
7.4.1.4 Turbocharger.........................................................................................7-26
7.4.1.5 Fuel Preliminary Filter............................................................................7-32
7.4.2 Automated Shift Transmission........................................................................7-34
7.4.2.1 Checking the Oil Level at Automatic Transmission................................7-34
7.4.2.2 Replacing the Oil of Automatic Transmission Unit.................................7-36
7.4.2.3 Changing the Fine Filter........................................................................7-36
7.4.3 Transfer Gearbox .........................................................................................7-38
7.4.3.1 Checking the Oil Level .........................................................................7-38
7.4.3.2 Changing the Oil....................................................................................7-40
7.4.4 Hydraulic System ..........................................................................................7-42
7.4.4.1 Hydraulic Tank ......................................................................................7-42
7.4.4.2 Diaphram Reserviors of Axle Suspension/Axle Locking System...........7-48
7.4.4.3 Hydraulic Hoses................................................................................... 7-52
7.4.5 Compressed Air And Brake System Air Dryer............................................... 7-58
7.4.5.1 Replacing the Granular Cartridge..........................................................7-58
7.4.6 Tires / Wheels . .............................................................................................7-58
7.4.6.1 Checking the Tires.................................................................................7-58
7.4.6.2 Inflating the Tires ..................................................................................7-60
7.4.6.3 Safety And Maintenance Instructions for Disk Wheels..........................7-62
7.4.6.4 Changing the Wheel..............................................................................7-64
7.4.7 Axles ..............................................................................................................7-66
7.4.7.1 Axle Mounts �� 7-66
7.4.7.2 Wheel Hubs...........................................................................................7-68
7.4.8 Axle Alignment ..............................................................................................7-70
7.4.8.1 Checking the Axle Alignment.................................................................7-70
7.4.9 Electrical System - Lighting............................................................................7-70
7.4.9.1 Battery Maintenance ............................................................................7-71
7.4.9.2 Mixing Battery Acid ...............................................................................7-72
7.4.9.3 Removal And Recharging......................................................................7-73
XII
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SAC2200
7.5 Superstructure Maintenance Guidelines.................................................................7-75

7.5.1 Crane Engine ................................................................................................7-75
7.5.1.1 Engine Oil .............................................................................................7-76
7.5.1.2 Engine Coolant .....................................................................................7-78
7.5.1.3 Air Filter.................................................................................................7-78
7.5.2 Hydraulic System ..........................................................................................7-80
7.5.2.1 Hydraulic Tank ......................................................................................7-80
7.5.2.2 Pressure Filter in Crane Hydraulics . ....................................................7-82
7.5.2.3 Diaphram Reservoirs . ..........................................................................7-84
7.5.2.4 Hydraulic Hoses ...................................................................................7-85
7.5.2.5 Troubleshooting on Hydraulic System...................................................7-88
7.5.3 Central Lubricating System ...........................................................................7-93
7.5.3.1 Components of the System ..................................................................7-94
7.5.3.2 Setting the Lubrication And Interval Times ...........................................7-94
7.5.3.3 Function Check ....................................................................................7-96
7.5.3.4 Cycle Control.........................................................................................7-96
7.5.3.5 Intervention in the Automatic Lubrication (Intermediate Lubrication).....7-98
7.5.3.6 Filling Grease Container........................................................................7-98
7.5.3.7 Venting the Central Lubrication System...............................................7-98
7.5.3.8 Filling the Grease Lines . ...................................................................7-100
7.5.3.9 Central Lubricating System, Troubleshooting......................................7-101
7.5.4 Slewing Ring Connection ............................................................................7-102
7.5.4.1 Greasing the Slewing Ring..................................................................7-102
7.5.4.2 Tilting Free Play of Roller Slewing Ring..............................................7-102
7.5.5 Winches . .....................................................................................................7-104
7.5.5.1 Overflow Container . ...........................................................................7-104
7.5.5.2 Hoist Gear Transmission ....................................................................7-104
7.5.6 Slewing Gear Transmission . .......................................................................7-106
7.5.6.1 Changing the Oil . ...............................................................................7-106
7.5.7 Electrical System - Lighting..........................................................................7-106
7.5.8 Telescopic Boomg .......................................................................................7-108
7.5.8.1 Greasing the Telescopic Boom............................................................7-108
7.6 Lubrication Chart And Filling Quantity...................................................................7-112
7.6.1 Crane Chassis.............................................................................................7-112
7.6.2 Crane Superstructure..................................................................................7-116
7.7 Oil And Grease Filling . .........................................................................................7-118
XIII
Table of Contents
SAC2200
8 Crane Inspections
8.1 Periodic Inspection....................................................................................................8-2
8.1.1 Steel Bearing Structures Inspection ................................................................8-5
8.1.1.1 Repair Welds...........................................................................................8-7
8.1.1.2 Inspection of the Disk Wheels (Rims)...................................................8-14
8.1.2 Inspecting the Hoist And Luffing Winches .....................................................8-15
8.1.2.1 Inspections ...........................................................................................8-16
8.1.2.2 Requirements for Monitoring the Winches............................................8-18
8.1.3 Inspection of the Load Hooks ........................................................................8-26
8.1.3.1 Inspection And Monitoring Procedure....................................................8-27
8.1.4 Inspection of the Rope Feed Mechanics in the Telescopic Boom.................8-28
8.1.4.1 Inspection of the Pre-tension on the Luffing Ropes .............................8-28
8.1.4.2 The Rope Discard Time.........................................................................8-28
8.1.5 Testing the Operation of the Inner and Outer Interlocking Systems of the
Telescopic Boom.....................................................................................................8-28
8.1.6 Testing the Interlocking System or Limit Switches on the Jib Stops and the
Boom A Frames.......................................................................................................8-29
8.1.7 Testing the Nitrogen Storage Tank for Specified Gas Pressure, Particularly for
Job Stops and Suspension StorageTanks (Comply with Specifications).................8-29
8.1.8 Inspecting the Cable Pulleys..........................................................................8-29
8.1.8.1 Inspect the entire cable pulley assemblies for damage and cracks once a
year.................................................................................................................... 8-29
8.1.8.2 Also check for wear on the rope groove...............................................8-29
8.1.9 Testing Overload Protection Operation...........................................................8-30
8.1.9.1 Position the longest booms at minimum and maximum radius: Check the
load indicator, using the hook block as a test load............................................8-30
8.1.9.2 Measure the indicated radius for the longest boom at its minimum radius
and at a boom angle of 45°...............................................................................8-30
8.1.10 Testing the Roller Slewing Ring....................................................................8-30
8.1.10.1 Tilting Free Play Measurement...........................................................8-30
8.1.11 Inspecting the Mounting of the Load Bearing Equipment.............................8-31
8.1.11.1 Slewing ring connection mounting bolts are pre-stressed at the factory,
so that no loosening of the bolted connections will occur during normal crane
operation............................................................................................................8-31
8.1.12 Inspecting the Oil And Fuel Reservoirs........................................................8-32
8.1.13 Inspection of the Auxiliary Reeving Winch, Towing Winch And Spare Wheel
Winch.......................................................................................................................8-32
8.2 Inspection of Crane Wire Ropes ............................................................................8-43
8.2.1 Take-down Time for Broken Rope..................................................................8-46
XIV
Table of Contents
SAC2200
8.2.1.1 Anti-twist Rope.......................................................................................8-46

8.2.2 Inspection ......................................................................................................8-47
8.2.3 Take-down Time.............................................................................................8-48
8.3 Inspection on Crane Rope.......................................................................................8-51
8.3.1 Rope Storage ................................................................................................8-51
8.3.1.1 Reeving.................................................................................................8-52
8.3.2 Maintenance...................................................................................................8-53
8.3.2.1 Increase and Cancellation ofd Non-twisting Rope Torque.....................8-53
8.4 Inspection ..............................................................................................................8-56
8.4.1 Adjust Rope Torque........................................................................................8-56
8.5 Inspection on Air Brake System..............................................................................8-60
8.5.1 Visual Inspection............................................................................................8-61
8.5.2 Function And Performance Test ....................................................................8-61
8.5.2.1 Function Test.........................................................................................8-61
8.5.2.2 Performance Test Interval . ...................................................................8-62
8.5.2.3 Inspection of the Wheel Brake...............................................................8-63
9. General Notes
9.1 Application Regulation for the Overload Protection Devices of Crane with Telescopic
Boom...............................................................................................................................9-2
9.1.1 Inspection Procedures......................................................................................9-2
9.1.2 Exercise Care When Conducting Maintenance And Repairs...........................9-4
9.1.3 Important Servicing...........................................................................................9-5
9.1.4 Maintenance Notes for Replacement Parts......................................................9-5
9.1.5 Recommendations for Travel Operation...........................................................9-6
9.1.6 Disposal............................................................................................................9-6
9.1.7 Wheel Changes................................................................................................9-7
9.1.8 Tire Changes....................................................................................................9-8
XV
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SAC2200
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XVI
Introduction
SAC2200
Introduction
0 Introduction
0.1 Overview...................................................................................................................0-2
0.2 Your Documentation Package.................................................................................... 0-4
0. 3 Your Sany Machine..................................................................................................... 0-8
0.4 Contact Information.................................................................................................. 0-14
0-1
Introduction
SAC2200
0 INTRODUCTION
0.1 Overview
●SANY built All Terrain Cranes offer high-

quality performance and five star-grade after-
sales service.
●SANY built All Terrain Cranes are widely

used throughout the woldwide industry for
various applications.
●SANY is a leading manufacturer of

construction equipment worldwide.
This operator ’s manual provides safety,

operation, maintenance, troubleshooting and
technical specifications. In order to properly
use your equipment, it is important to read
this manual carefully before beginning any
operations.
Items addressed in this manual are designed

to help you:
•Understand the structure and performance of

the All Terrain Crane.
• Reduce improper operation and point out

possible hazardous situations.
• Increase equipment efficiency during

operation.
• Prolong the service life of equipment.
• Reduce maintenance costs.
0-2
Introduction
SAC2200
Always keep this manual nearby and have

all personnel involved with any job-related
procedures read it periodically.
If you sell the machine, be sure to give this

manual to the next owner.
Continuing improvements in the design of this

machine can lead to changes in detail which
may not be covered in this manual. Always
consult your SANY distributor for the latest
available information on this machine or if
there are any questions regarding information
in this manual.
0-3
Introduction
SAC2200
0.2 Your Documentation Package
The documentation for this machine includes

the following items:
• Safety, Operation & Maintenance Manual

(SOMM) —This manual is in the operator cab
seat pocket.
• Parts Book —This publication consists of

parts lists and matching drawings for ordering
spare parts as-needed. If it was not already
shipped with your machine, the parts book for
this machine is available directly from SANY.
• Load Charts —These sheets graphically

present load calculations, allowable wind
speed, work equipment lifting height/operating
range, and load limitations and covered in
the Safety, Operation & Maintenance Manual
(SOMM).
0-4
Introduction
SAC2200
0.2.1 Recommendations on using the

documentation
• This documentation applies only to this

machine and should not be used with any other
machines.
• To ensure that the documentation is always

complete and up to date:
• Keep all pages inside its binder (if shipped

loose leaf).
• Insert SANY replacement pages immediately

into the appropriate book and destroy old
versions of those pages.
0.2.2 Documentation storage
Always keep the operator manual and load

charts with the machine in the operator cab.
The parts book is best left shelved indoors and

should always be available to maintenance
and service personnel as needed.
0-5
Introduction
SAC2200
0.2.3 Operation manual organization
The operator’s manual is designed for the use

and maintenance of this machine. Each section
of this manual provides information o n e m u s t
be familiar with before operating this machine.
Keep this manual with the machine for any one
to reference at all times. Replace it immediately
if it is damaged or lost. Due to improvement
and updating of products, some information
may differ from your machine. If you have any
questions about the machine, contact a SANY
distributor before operating or repairing the
machine.
1. Introduction
This section provides an overview of what is
covered in the rest of this manual, including
machine labeling information and SANY
contact information.
2. Safety
This section covers basic safety information
relating to this equipment. Make sure you fully
understand all the precautions described
in this manual and the safety labels on the
machine before operating or maintaining this
machine. Failure to do so may result in serious
injury or death.
3. Operation
This section provides some basic operating
procedures for this All Terrain Crane. Study and
become familiar with all operating procedures
before performing any job functions with the
machine.
0-6
Introduction
SAC2200
4. Maintenance
This section provides all general maintenance
and repair procedures.Detailed rebuild /
replacement / repair information is covered in
a separate shop manual. Study and become
familiar with all repair and maintenance
procedures before performing any repair or
maintenance operations.
5. Accessories and miscellanous

This section includes description of indication
plate, main parts and components, list of
wearing parts and spare parts, attached tools
and accessories, along with instruction on
railway transportation.
0-7
Introduction
SAC2200
0. 3 Your Sany Machine
0.3.1 Breaking in a new machine
Your machine has been thoroughly adjusted

a n d t e s t e d b e f o r e s h i p m e n t . H o w e v e r,
i n i t i a l o p e r at i o n o f t h e m a c hi n e u n d er
severe conditions can adversely affect the
performance of the machine and shorten the
machine life. Therefore, SANY recommends
that you allow a break-in period of 100
operating hours before full scale operation.
During the break-in period:
• Let the machine warm up prior to any

operation.
• Avoid operating with severe loads and at high

speeds.
• Avoid sudden starts, fast movements and

stops.
• Always let the machine cool down at the end of

use before shutting down.
0-8
Introduction
SAC2200
0.3.2 Directional reference of the

machine
All views are taken from the operator’s seat

and facing forward as indicated by the arrow in
the illustration.
Right
Rear
Superstructure operator cab
Slewing mechanism
0-9
Introduction
SAC2200
0.3.3 Machine information
The serial numbers and model numbers on

the components are the only numbers that
your SANY distributor will need when ordering
Product
replacement parts or for requiring assistance. date
Record this information in this manual for plate
future reference. Below are the locations of
the data plates.
1. Product identification plate
1) Product data plate
On the right side of the chassis panel behind

operator cab.
VIN:
Product Type:
全路面起重机
All Terrain Crane
Engine Model:
Rated Power:
Max. Rated Lifting Capacity/Working Radius:
Date of Production:
No.
0-10
Introduction
SAC2200
1) Chassis data plate
It is located between 1st and 2nd axles on the

Chassis
right side of frame. date
plate
VIN:
Product Type:
全路面起重机底盘
All Terrain Crane Chassis
Engine Model:
Rated Power:
Date of Production:
No.
0-11
Introduction
SAC2200
2. Engine identification plate

On the side of engine.
Model:
Power (kw):
Number:
information:
Additional
3. Swing motor data plates

On top of swing motors. (Rexroth shown)
Make:
Model:
ID Number:
0-12
Introduction
SAC2200
4. Winch motor data plates

Each winch (W1 and W2) has its own data
plate.
Model:
ID Number: W1
ID Number: W2
5. Hydraulic pump data plate

On the side of pump.
Model:
ID Number:
0-13
Introduction
SAC2200
0.3.4 Table for serial number and

distributor info
This location is for you to record information relating to your machine. It is advised that you keep
this manual with your machine at all times for reference.
Machine Serial No.
Engine Serial No.
Distributor Name:
Address:
Phone Numbers:
0.4 Contact Information

Thank you for purchasing a SANY machine.
In the event that you should need to contact
us for any reason, you can reach us as
follows:
Our address:
SANY Industry Town, Changsha Jinzhou
Development Zone, Hunan, China 410600
Phone: 0086-21-58592902
Fax: 0086-21-58596210
E-mail: sanyservice@sany.com.cn
Service hotline: 0086-21-58592902
Complaint hotline: 0086-21-58590631
0-14
Description of Crane
SAC2200
1 Description of Crane
1.1 Terminology............................................................................................................... 1-2
1.2 Product Description................................................................................................... 1-6
1.3 Technical Data......................................................................................................... 1-11

1-1
SAC2200
1 DESCRIPTION OF CRANE
1.1 Terminology
1.1.1Crane chassis
1——5-axle chassis
2——Tyres- (single tyre for axle 1-5)
3——Drive motor
4——Cab
5——Sliding beams with support rams
6——Support pads
1.1.2 Crane superstructure
10——Crane motor
11——Crane cab
12——Counterweight
13——Luffing cylinders
14——Winch 1
—— For work condition of T, TK and TVK
15——Winch 2
——Double hook for work condition of TK and
TVK
1.1.3 Telescopic boom (T)
20——Articulated piece
21——Telescopic part 2
1-2
SAC2200
1-3
SAC2200
1-4
SAC2200
1.1.4 Additional boom
(1) Folding jib, type TK*

31 Adapter
32 Articulated piece
33 Folding jib
34 Intermediate piece
(2) Folding jib with extension (TVK)*

31 Adapter
33 Folding jib
35 Extension
(3) Hydraulic adjustable folding jib with

extension (TNZK)*
31 Adapter
33 Folding jib
40 Adjusting cylinder
(4) Hydraulic adjustable folding jib with

extension (TVNZK)*
31 Adapter
33 Folding jib
35 Extension
40 Adjusting cylinder
1-5
SAC2200
1.2 Product Description
1.2.1 Crane chassis
(1) Frame
In-house manufactured, weight-optimised,
distortion-resistant box structure made from
high-strength, close-grained structural steel.
(2) Supports
4-point support, fully hydraulically extendable
horizontally and vertically.
Automatic support leveling.
Electronic slope indicator.
(3) Motor
8-cylinder diesel, manufactured by BENZ,
model OM502LA, water-cooled.
Performance: 390 KW at 1800 rpm
Maximum torque: 2400 Nm at 1300 rpm
Fuel tank: 500 l
(4)Transmission
ZF 12-speed transmission system with
automatic switching system AS-TRONIC.
ZF intarder attached directly to the
transmission.
Two-stage transfer gearbox, with lockable
distributor differential.
(5) Axles
All 5 axles are welded and made from high-
strength, close-grained structural steel.
All axles with steering.
Axles 2, 4 and 5 are planetary axles with
differential locks.
(6) Suspension
All axles with "Level-matic suspension" hydro-
pneumatic suspension and hydraulically
lockable.
1-6
SAC2200
(7) Tires
10 tyres.
Tyre size: 16.00 R 25
(8) Steering
ZF servocom power steering gear, dual circuit
system with hydraulic servo mechanism and
auxiliary stand-by pump, powered from the
axle.
The axles 3, 4 and 5 are steered electro-
hydraulically, depending on the speed, and
from 30 km/hr.; the third and fourth axle are
affixed to straight forward travel.
From 60 km/hr., the fifth axle is affixed for
straight forward travel.
(9) Brakes
Service brake: all-wheel power-assisted
compressed air brake, dual-circuit system
All axles are equipped with disk brakes.
Handbrake: spring-loaded brake acting on the
wheels of the second to fifth axle
Retarder: engine brake as exhaust flap
retention strap brake with auxiliary braking
system.
(10) Driver's cab

Spacious cab made of steel, corrosion-
r e si s ta n t th r o u g h ca ta p h o r e ti c E - c o a t ,
elastomerically suspended and hydraulically
damped.
Sound and heat insulating interior panelling
according to EC-guideline, safety glass,
operating and control instruments, luxury
equipment.
(11) Electrical system

Modern data bus technology, 24 Volt DC, 2
batteries, each with 170 Ah.
1-7
SAC2200
(1) Slewing table

In-house manufactured, weight-optimised and
distortion-resistant welded structure made
from high-strength, close-grained structural
steel. A 3-row roller slewing ring is used as
the connecting element to the crane chassis,
providing unlimited rotation.
(2) Crane engine

6-cylinder diesel, manufactured by BENZ,
model OM906LA, water-cooled.
Performance: 170 KW at 2200 rpm
Maximum torque: 810 Nm at 1200-1600rpm
Fuel tank: 200 l
(3) Crane drive

Diesel hydraulic with 3 axial piston adjustment
pumps with servo control and power control, 1
dual gear pump.
Hydraulic power system in a compact design
is flanged directly onto the Diesel engine,
complete drive assembly encased for noise
reduction.
(4) Controls
Electronic control system from HIRSCHMANN-
system (PLC control). Two 4–way manual
control levers, self-centering. Infinitely variable
control of all crane movements by adjusting
the hydraulic pumps, additional speed control
when adjusting the diesel engine RPM.
(5) Hoist gear

Axial piston adjusting motor. A winch with
built-in planetary gear and spring-loaded stop
brake. The hoist gear is powered in a closed
oil circuit.
(6) Luffing gear

1 differential cylinder with safety check valves.
(7) Slewing gear

Axial piston fixed displacement motor,
planetary gear, spring-loaded stop brake.
1-8
SAC2200
(8) Crane driver's cab

Steel construction, fully galvanized, powder-
coated, with safety glass, operating and
control elements, luxury equipment.
Cab can be tilted backwards.
(9) Safety equipment

HIRSCHMANN overload system.
(10) Counterweight
78 t
(11) Telescopic boom

Dent and distortion-resistant design made from
high-strength, close-grained structural steel
with oval boom section, 1 articulated piece and
5 telescopic sections. All telescopic sections
are hydraulically extendable independently of
each other.
Boom length: 13.5m to 62m
(12) Jib
Folding jib
12.2m to 36m long, can be attached below 0°
to 40° in relation to telescopic boom.
Telescopic boom extension
7 m long lattice component, of which 7 m are
a higher coupling point for the folding jib.
(13) Winch 2
For dual hook operation or during operations
with folding jib if main hoist rope is to remain
reeved.
(14) Electrical system

Modern CAN data bus technology, 24 Volt DC,
2 batteries, each with 120 Ah.
1-9
SAC2200
1.2.3 Additional equipment
(1) Tyres
10 tyres
Tire size: 16.00R25
(2) Hydraulic luffing jib

Jib hydraulic luffing cylinder can be adjusted
below 0° to 40°.
(3) Lifting equipment

145t, 75t, 35t and 12t
(4) Support pad

4 thick pads.
Pad size: 2m×2m×100m
1-10
SAC2200
1.3 Technical Data
(1) Dimension
Refer to external dimension drawing.
4000
2040
17
12
2551
2990
5549 3496
3500
8500
5800
2996
R1 R1
R1 20 11
25 44 55
87 R9
66
1
R5563
5220 3825
1-11
SAC2200
(2)Tyres
Tire pressure when
Tire pressure when driving
Tyre size Wheel weight (KG) “driving with the equipment
on public roads (BAR)
in place”(BAR)
16.00R25 340 9 10
(3) Axle loads

- Crane in driving position
- For driving condition, refer to Chapter 3.4
Axle 1 2 3 4 5 Total weight
t 12 12 12 12 12 60
(4)Lifting equipment
Load(t) Pulleys Strands Self weight (kg)
145 7 14 1704
75 3 7 1106
35 1 3 823.7
12 - 1 503.2
1-12
SAC2200
(5)Support forces
Max.support strength per support
Front Rear
(KN)
With nominal load 1180 1350
(6)Workplace-related emission value

Stationary noise LpAeq ( db (A))
Sound pressure level at nominal RPM
Left ear Right ear
Driver’s cab, driver’s side 74 74
Driver’s cab, passenger side 74
Operator’s cab 74 74
(7)Speeds
Driving speeds
Gear 1 2 3 4 5 6 7 8 9 10
Speed 5.5 6.8 8.9 11.3 14.5 18.4 24.1 31.4 40.3 51.5
Gear 1 12 R1 R2 Max. gradiient
Speed 65.5 83 5.9 7.5 ＞ 55%
1-13
SAC2200
Crane speeds
Rope diameter(mm)/rope
Drives Infinitely variable
length(m)
Hoist gear 1 0-130m/min for single strand 24/280

Hoist gear 2 0-130m/min for single strand 24/280
Slewing gear 0-1.8s rpm/min
Luffing gear 90s to 82°boom position
Telescoping 500s from 13.5m to 62m
(8) Rope diameter

24mm
(9) Lifting heights

(See pages ahead)
1-14
SAC2200
Telescopic boom
96m
92
20 40 88
HK22m
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
2.5m
24
18m 2
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80m
1-15
SAC2200
Telescopic boom with folding jib (TK12.2m)
88m
84
40 80
20
m
76
HK12.2
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
2.5m
24
18m 2
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80m
1-16
SAC2200
Telescopic boom with folding jib (TK22m)
96m
92
20 40 88
HK22m
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
2.5m
24
18m 2
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80m
1-17
SAC2200
100m
96
20 40
HK29m
92
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88m
1-18
SAC2200
108m
104
20
40
HK36m
100
96
92
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84m
1-19
SAC2200
Telescopic boom with folding jib (TK12.2m)
92m
88
20 40
84
.2m
V H K 12
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
2.5m
24
18m 2
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80m
1-20
SAC2200
Telescopic boom with folding jib and extension

(TVK19.2m)
100m
96
20 40 92
.2m
VHK19
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80m
1-21
SAC2200

(TVK22m)
100m
96
20 40
m
VHK22
92
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84m 88m
1-22
SAC2200

(TVK26.2m)
108m
104
40 100
20
.2m
96
VHK26
92
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84m
1-23
SAC2200

(TVK29m)
112m
108
104
40
20
100
m
VHK29
96
92
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88m
1-24
SAC2200

(TVK36m)
116m
112
20 40 108
m
VHK36
104
100
96
92
88
84
80
76
72
68
62m
64
58.5m
60
54m
56
49.5m
52
45m
48
44
40.5m
40
36m
36
31.5m
32
27m
28
.5m
24
18m 22
20
13.5m
16
12
0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88m
1-25
SAC2200
E
G
PA
K
AN
BL
1-26
Safety
SAC2200
Safety
2. Safety
Foreword......................................................................................................................... 2-2
2.1 Traffic Regulations................................................................................................... 2-10
2.2 Crane Break-in Specifications................................................................................. 2-11
2.3 Planning Crane Operation....................................................................................... 2-13
2.4 Safety-Technical Regulation.................................................................................... 2-14
2.5 Warning Signs......................................................................................................... 2-65
2.6 Operation of Crane Superstructure......................................................................... 2-66
2.7 Taking on a load...................................................................................................... 2-71
2.8 Crane Operation..................................................................................................... 2-74
2.9 Equipment............................................................................................................... 2-79
2.10 Inspection of Cranes........................................................................................... 2-107
2.11 General Notes...................................................................................................... 2-182
2-1
Safety
SAC2200
FOREWORD
General
This crane has been built according to the
present level of technology and recognized
safety technical regulations. Despite that,
dangers to body and life for the user and/or
third persons or damage to the crane and /or
other material assets can occur.
This crane may only be used in flawless
technical condition and according to its
mission as well as with constant awareness
of safety and dangers. Any problems, which
could affect safety must be fixed immediately.
Modifications on the crane may only be made
with written approval by SANY Mobile Cranes
Co., Ltd..
Warning notes
The following terms that are used in these
operating instructions DANGER, WARNING,
CAUTION and ATTENTION are intended to
point out certain important rules of conduct to
all persons who work with the crane.
2-2
Safety
SAC2200
Warning signs Signal word Explanation
Designates a dangerous situation

DANGER which will lead to death or serious
DANGER injury if it is not prevented.
Designates a dangerous situation,

WARNING which can lead to death or serious
injury if it is not prevented.
WARNING

CAUTION which can lead to slight or medium-
grade injury if it is not prevented.
CAUTION

ATTENTION which can lead to property damage
if it is not prevented.
ATTENTION
2-3
Safety
SAC2200
Further notes
Operating instructions
2-4
Safety
SAC2200

Risk of fatal accidents if crane is not
operated correctly!
Incorrect operation of the crane can result
in death or serious injury!
Only authorized and trained expert
personnel are permitted to work on the
crane!
The operating instructions and on-site

regulations and specifications (such as
accident prevention regulations) must be
followed.
Using these operating instructions:

- avoids problems due to improper operation
Observing these operating instructions:

- increases reliability in use
- extends the service life of your crane
- reduces repair costs and downtime
Always keep these operating instructions
handy in the driver's or crane cab.
The operating instructions belong with the
crane!
Only operate the crane if you are well
familiarized with the equipment, and always
follow these operating instructions.
Note!
• If you have received additional
information from us relating to the crane,
such as technical information bulletins,
instructions and / or supplements to
the operating instructions, then this
information must also be observed and
kept with the operating instructions.
If there is anything in the operating

instructions or the individual chapters that
you do not understand, please contact us
before starting the relevant work.
2-5
Safety
SAC2200
The information and illustrations contained

in these operating instructions may
not be copied or distributed, nor used
for competitive purposes. All rights are
expressly reserved in accordance with
copyright laws.
All accident prevention guidelines,

operating instructions, etc. are based on
destined use of the crane.
Destined use
The destined use of the crane consists solely
in vertical lifting and lowering of free and non-
adhered loads, whose weight and center of
gravity are known.
To do so, a hook or hook block approved by

SANY must be reeved on the hoist rope and
it may only be operated within the permissible
crane configurations.
Driving with the crane, with or without

an attached load is only permissible if
a corresponding driving or load chart is
available. The crane configurations intended
for it and the safety conditions must be
observed according to the corresponding
operating instructions.
Any other use or any other exceeding

utilization is not destined use.
Part of destined use is also adherence of

required safety regulations, conditions,
preconditions, crane configurations and
working steps as noted in the crane
documentation (operating instructions, load
chart, job planer).
The manufacturer is not liable for damages,

which are caused by non-destined use or
improper use of the crane. Any associated risk
it is carried solely by the owner, the operator
and the user of the crane.
2-6
Safety
SAC2200
Non-destined use
Non -destined use is:
- Working outside the permissible crane
configurations according to the load chart
- Working outside the permissible projection
radii and slewing ranges according to the load
chart
- Selecting load values, which do not
correspond to the actual crane configuration
- Selecting LMB-Codes, which do not match
the actual crane configuration
- Working with bypassed load moment limiter
or bypassed hoist limit switch
- Increasing the projection radius of the lifted
load after a LMB shut off, for example by
diagonally pulling the load
- Using the support pressure display as a
safety function against tipping over
- Using equipment or attachment parts which
are not approved for the crane
- Using the crane at sports and recreational
events, especially for 'Bungee' jumps
- Driving on a public road in non-permissible
driving condition (axle load, dimension)
- Driving with the equipment in place in a non-
permissible driving condition
- Pushing, pulling or lifting loads with the
leveling regulation, the sliding beams or the
support cylinders
- Pushing, pulling or lifting loads by actuating
the slewing gear, the luffing gear or the
telescoping gear
- Ripping stuck objects loose with the crane
- Utilizing the crane for a longer period of time
for material handling tasks
- Releasing the crane suddenly (grapple or
dumping operation)
- Putting the crane into service when the
weight of the load, which is suspended load
on the crane, is changed, for example by filling
a container suspended on the load hook
2-7
Safety
SAC2200
The crane may not be used for:

- attaching a stuck load for which the weight
and center of gravity are not known and which
has been released first, for example with a
cutting torch
- letting persons drive along outside the
driver's cab
- transporting personnel in the crane cab while
driving
- transporting personnel with the lifting
equipment and on the load
- transporting personnel with containers
(cherry pickers), if no written approval of the
corresponding job safety board has been
issued
- transporting loads on the chassis
- two hook operation without auxili a r y
equipment
- extended material handling operation
The operating instructions must be read and

used by all persons who are involved in use,
operation, assembly and maintenance of the
crane.
Safety equipment
Special attention must be paid to the
safety equipment built into the crane. The
functionality of the safety equipment must be
monitored at all times. The crane must not be
operated if the safety equipment is not working
or not working correctly.
Note!
Your motto must always be
Safety first!
The crane has been built in accordance
with the applicable crane operation and
driving regulations and has been approved
by the relevant authorities.
2-8
Safety
SAC2200
Attachment and spare parts
DANGER
Danger to life if original attachment parts
are not used!
If the crane is operated with attachment
parts, which are not original, then the crane
can fail and cause fatal accidents!
Crane components can be damaged!
• Operate the crane only with original
attachment parts!
• Crane operation with attachment parts,
which do not belong to the crane is
prohibited!
DANGER
The crane permit and the manufacturer's
warranty will become void!
If originally installed parts are modified,
manipulated or replaced (e.g. removal of
parts, installation of non-original parts),
both the crane permit as well as the
manufacturer's warranty will become void.
• Do not modify original parts!
• Do not remove original parts!
• Always use SANY original spare parts!
Definition of directional data

Forward driving means driving with the driver’s
cab on the front.
Reverse driving means driving with the tail
lights of the chassis on the front.
Front, rear, right, left on the crane refer to the
condition, that the driver’s cab and the boom
point in the same direction. Front is always in
direction of the driver’s cab.
Front, rear, right, left in the driver’s cab refer to
the crane chassis. The driver’s cab is always
in the front.
Front, rear, right, left in the crane operator’s
cab refer to the superstructure. Front is always
in direction of the boom.
Customer request
Customer-specific equipment is marked with *.
2-9
Safety
SAC2200
2. SAFETY
2.1 Traffic Regulations
The crane is approved for road travel when

used in accordance with regional traffic
regulations.
The crane must be made to comply with the
relevant local traffic regulations, before it
is driven on public streets, roads and other
places.
The weights, axle loads and dimensions
specified in the permits must be maintained
and shall not be exceeded by additionally
loading the crane.
The technically feasible axle loads may be
different from those permitted by local road
traffic regulations.
Axle loads greater than 12 t are not permitted
for street traffic in China.
All consequences for driving on

roads with an axle load that exceeds 12 t rest
with the crane operator.
Danger!
Exceeding the axle load and total weight
increases the risk of accident!
Any increase in axle load and total weight
reduces braking performance in direct
proportion to the excess weight.
Brake lining wear is greater and risk of
brake overheating in higher. This condition
exceeds the specifications of the steering
mechanism, operating and parking brakes
and retarder!
It shortens the life of all components
subjected to the increased axle load; e.g.
brakes, tires, rims and axles, as well as
the entire drive, suspension and steering
assemblies.
! Do not exceed the specified axle load or
total weight under any circumstances!
2-10
Safety
SAC2200
A hook block may only be transported at the

front if:
- this is permitted by the current driving
condition of the crane
- it has been reeved at least four times
- and lashed using the eye provided on the
front towing coupling
Danger!
Risk of accident if driver's field of vision is
blocked!
! Do not allow the hook block to impair the
driver's field of vision when driving the
crane on public roads!
If a boom nose is attached, it must be moved

from the operating position to the transport
position to prevent field of vision impairment
and must be secured in this position using
bolts and safety springs.
National traffic regulations

Be sure to comply with all valid national traffic
regulations when driving the crane! The cab
may not be occupied by passengers while
driving the crane.
2.2 Crane Break-in Specifications
Caution!
Risk of damaging while driving the crane.
! It is absolutely essential to break-in the
crane!
Do observe the following specifications:

Continuously monitor temperature and oil
pressure indicators while driving!
Stop immediately if there are any fault
indications!
Perform the following maintenance after the
first 50 km and 100 km:
- Do not over-torque the wheel nuts (maximum
permissible torque = 600 Nm). Make sure that
wheel nuts are tight.
2-11
Safety
SAC2200
- Check engine water and oil levels.

- Check automatic or manual transmission and
load transmission oil levels.
- Visually inspect engine, gearbox and axles
for any leakage or loose components.
- Check that drive shaft is properly seated.
- Check that there are no other loose carriage
components.
- Visually inspect tire condition and inflation.
Breaking in the brake linings

To achieve optimum braking performance,
all new brake linings must be broken in by
activating the brakes.
Danger!
Risk of accident!
The risk of accident increases when new
brake linings are subjected to one or more
braking operations over extended periods
of time or if the vehicle is forced to a stop
by hard braking from maximum speed
several times.
! Hard braking and continuous braking are not

permitted!
Activate the brakes by pumping them at low to
medium speed.
Hard braking is not permitted.In general,
the break-in distance depends on the type
of vehicle, but a minimum of 500 km is
recommended.
During this phase, the maximum brake drum
or brake disk temperature may not exceed 200
°C.
The temperature rise resulting from each
individual braking action should not exceed
15% of maximum.
2-12
Safety
SAC2200
2.3 Planning Crane Operation
In addition to a perfectly working crane and a

well-trained crew, crane operation planning is
an important principle of safe crane operation.
Danger!
Missing information increases the risk of
accidents!
Crane operation may not be possible or
improvisation can result if a crane operator
does not have all the required data.
! A crane operator must have exact data
before starting any work!
The crane operator must obtain or receive

the necessary information in a timely fashion
before driving to the work site. In particular:
- type of crane operation
- work site evironment;
- work site (travel distance);
- route;
- height and width clearance measurements;
- electrical transmission lines (including
voltages);
- space restrictions at the work site;
- movement restrictions caused by buildings;
- weight and dimensions of the load(s) to be
hoisted;
- required hoisting height and boom projection;
- ground bearing capacity at the work site.
Based on the above information, the crane
operator must assemble the equipment
required to operate the crane:
- hook block / load hook
- Jib
- separate lifting accessories
- counterweight
- underlay materials for support pads
2-13
Safety
SAC2200
2.4 Safety-Technical Regulation
2.4.1 Requirements of the crane

operator
The crane operator's primary responsibility is

to use and operate the crane in a manner that
is safe for both himself and others.
The following important safety guidelines will
help you achieve this. Many crane accidents
are caused by incorrect crane operation.
Danger!
Danger due to incorrect crane operation!
! In the interest of both yourself and others,
make sure you understand how your crane
operates and familiarize yourself with all
the risks associated with the work to be
done.
The main operating errors, which are made

again and again while operating or driving a
crane, are as follows:
— Not paying careful attention while working,
for example:
— slewing too quickly
— quick braking of the load
— diagonal pulling
— loose cable formations;
— overloading
— driving too fast with a load, or setting up
and loading on an uneven surface
—attaching the load incorrectly
unsuitable operation; especially diagonal
pulling, breaking away stuck loads
problems when driving on a road without
a load, for example overload of engine or
transmission
crashing into bridges, roofs or high voltage
wiring due to insufficient vertical clearance
inadequate support; support base, support
under the support pads
incorrect assembly or disassembly of booms.
2-14
Safety
SAC2200
Many crane damages are caused by improper

maintenance:
— insufficient oil, grease or antifreeze
— contamination
— broken cable wires, defective tires, worn
parts
— emergency limit switches or load torque
limiter (LMB) not operating properly
— brake and clutch failure
— hydraulic defects; for example cracked
hoses
— loose bolts
Personal protective devices
Danger!
Increased danger of accidents!
If protective devices are not worn, the
crane operator or the auxiliary personnel
can be killed or severely injured!
The crane operator and auxiliary personnel
are obligated to carry personal protective
devices along and to wear them!
Use personal protective devices according
to relevant standards!
Personal protective devices include the

following equipment:
— Hard hat
— Protective gloves
— Catch belt to prevent falling
— Safety shoes
— Warning apparel
Danger!
High risk of accident!

Even personal protection equipment does
not provide 100% protection!
A helmet can protect against small falling
objects, but not against falling loads.
Personnel can nonetheless be killed or
seriously injured!
•Always remain aware of your surroundings
and behave in a safe manner!
2-15
Safety
SAC2200
Obligations of the crane operator

1) Before starting to work, the crane operator
must check the brake function and the
emergency shut off devices. He must monitor
the condition of the crane for obvious defects.
On wireless controlled cranes, he must check
the assignment of control unit and crane.
2) The crane operator must cease crane

operation in case of defects, which would
endanger the safety.
3) The crane operator must report all defects

on the crane to the appropriate supervisor,
also to his replacement in case of crane
change. For mobile cranes, which are set up
and taken down at their corresponding jobsite,
he must enter any defects in the crane log
book.
4) The crane operator must make sure that:

• all control devices are set to neutral or idle
position before release of the energy supply to
the drive components,
• the control devices are set to neutral or idle
position and the energy supply is shut off
before leaving the control platform,
• when taking down the control unit for wireless
control, it is secured to prevent unauthorized
operation.
5) The crane operator must ensure that

cranes subjected to wind are not operated
past the limits which were set by the crane
manufacturer, and that the boom is taken
down at least when the critical wind speeds for
the crane are reached and at the end of the
work.
2-16
Safety
SAC2200
6) The crane operator must monitor the load

at all crane movements or the load tackle
devices when moving the crane without a load,
if they could cause a dangerous situation. If
observation is not possible, then the crane
operator may move the crane only with the aid
of a guide.
7) The crane operator must give warning signs

when necessary.
8) The crane operator may not move loads

over personnel.
9) Any loads attached by hand may only be

moved by the crane operator after he received
a clear sign from the person who attached
the load, the guide or any other responsible
party which was assigned to that task by
the contractor. If signals must be used to
communicate with the crane operator, then
they must be agreed upon before use between
the responsible party and the crane operator.
If the crane operator determines that the loads
are not properly attached, then he may not
move them.
10) As long as a load is suspended on the

crane, the crane operator must keep the control
devices within reach. This does not apply for
towing of vehicles with towing cranes.
11) The crane operator may not run up to end

positions operationally, if they are limited by
the emergency limit switches.
12) After a load moment limiter was triggered,

the crane operator may not take on an
overload by pulling in / raising the boom.
13) The crane operator may not bypass the

overload protection to increase the hoisting
power of the crane.
2-17
Safety
SAC2200
2.4.2 Selecting an operating site
Danger
It is very important to support the crane
only on ground with sufficient load bearing
capacity!
It is important to choose an appropriate location
for crane operation in order to minimize safety
risks.
When selecting the placement location of the

crane, observe the following:
1) Select the placement location in such a
way that crane movements can be carried
out without collision, and that the outrigger
supports can be extended to the support base
stipulated in the load charts.
Make sure that no personnel is injured or
killed!
Always keep a safety distance of 0.5 m. If this
is not possible, secure the danger zone.
2) Support the crane correctly and support the

support pads according to the load bearing
capacity of the ground on the placement
location.
3) Keep a safety distance to basements or

similar.
4) Keep a safety distance to slopes or

embankments or similar.
5) Keep the radius to a minimum. Never utilize

the crane 100%.
6) Select the correct boom length to the load

case.
7) Diagonal pull is not permitted!
2-18
Safety
SAC2200
2-19
Safety
SAC2200
2.4.3 Maintenance work on the crane

superstructure or boom
Risk of falling!
During maintenance work, personnel must
be secured with appropriate antifall guards
to prevent them from falling. If this is not
observed, maintenance personnel could
fall and suffer life-threatening injuries.
• All maintenance work above a height of 2 m

must normally be carried out using suitable
aids (lifting platforms, scaffolding, ladders,
auxiliary crane etc.)! The height above which
maintenance work must be carried out with
aids depends on national regulations. The
national regulations must be adhered to!
• If work cannot be carried out using these
aids or from the ground, the maintenance
personnel must protect themselves from falling
with personal protection equipment (such as
be safety belts)!
• Only step on such aids with clean shoes!
• Keep aids clean and free of snow and ice!
2-20
Safety
SAC2200
2.4.4 Obligations of the crane operator
1.) Before starting to work, the crane operator

must check the brake function and the
emergency shut off devices. He must monitor
the condition of the crane for obvious defects.
On wireless controlled cranes, he must check
the assignment of control unit and crane.
2.) The crane operator must cease crane

operation in case of defects, which would
endanger the safety.
3.) The crane operator must report all defects

on the crane to the appropriate supervisor,
also to his replacement in case of crane
change. For mobile cranes, which are set up
and taken down at their corresponding jobsite,
he must enter any defects in the crane log
book.
4.) The crane operator must make sure that:

•all control devices are set to neutral or idle
position before release of the energy supply to
the drive components,
•the control devices are set to neutral or idle
position and the energy supply is shut off
before leaving the control platform,
•when taking down the control unit for wireless
control, it is secured to prevent unauthorized
operation.
5.) The crane operator must ensure that

cranes subjected to wind are not operated
past the limits which were set by the crane
manufacturer, and that the boom is taken
down at least when the critical wind speeds for
the crane are reached and at the end of the
work.
2-21
Safety
SAC2200
6.) The crane operator must monitor the load

at all crane movements or the load tackle
devices when moving the crane without a load,
if they could cause a dangerous situation. If
observation is not possible, then the crane
operator may move the crane only with the aid
of a guide.
7.) The crane operator must give warning

signs when necessary.
8.) The crane operator may not move loads

over personnel.
9.) Any loads attached by hand may only be

moved by the crane operator after he received
a clear sign from the person who attached
the load, the guide or any other responsible
party which was assigned to that task by
the contractor. If signals must be used to
communicate with the crane operator, then
they must be agreed upon before use between
the responsible party and the crane operator.
If the crane operator determines that the loads
are not properly attached, then he may not
move them.
10.) As long as a load is suspended on the

crane, the crane operator must keep the control
devices within reach. This does not apply for
towing of vehicles with towing cranes.
11.) The crane operator may not run up to end

positions operationally, if they are limited by
the emergency limit switches.
12.) After a load moment limiter was triggered,

the crane operator may not take on an
overload by pulling in / raising the boom.
13.) The crane operator may not bypass the

overload protection to increase the hoisting
power of the crane.
2-22
Safety
SAC2200
2-23
Safety
SAC2200
2.4.5 Selecting the location
It is very important to choose an appropriate

location for crane operation in order to
minimize safety risks.

Risk of accidents due to ground with
insufficient load bearing capacity!
If the crane is supported on ground with
insufficient load bearing capacity, then it
can topple over and kill personnel!
• Only support or drive the crane on ground
with the required load-bearing capacity!
• Act responsibly when planning and
selecting the crane location and route. If
necessary, consult an authorized inspector.
• Note the following points!
When selecting the location for the crane,

observe the following:
1.) Select the placement location in such a
way that crane movements can be carried
out without collision, and that the outrigger
supports can be extended to the support base
stipulated in the load charts.
Make sure that no personnel is injured or
killed!
Always keep a safety distance of 0.5 m. If this
is not possible, secure the danger zone.
2.) Support the crane correctly and support
the support pads according to the load bearing
capacity of the ground on the placement
location.
3.) Keep a safety distance to basements or
similar.
4.) Keep a safety distance to slopes or
embankments or similar.
5.) Keep the radius to a minimum. Never
utilize the crane 100%.
6.) Select the correct boom length to the load
case.
7.) Diagonal pull is not permitted!
8.) Select the correct reeving of the hoist rope
to the load case.
9.) Bear in mind the weight and the wind
exposure surface of the load.
2-24
Safety
SAC2200
2-25
Safety
SAC2200
10.) Select tackle according to the weight of

the load, the type of attachment and the incline
angle.
11.) Keep sufficient distance to electrical
overhead wiring.
2.4.6 Slopes and ditches

The crane may not be set up too close to
slopes or ditches. Depending on the type of
ground, ensure an adequate safety clearance
A and safety clearance B as well as a
corresponding load entry angle α and slope
angle β.

DANGER
Crane can topple over!
The edge of the slope or excavation can
break in if safety distance A or safety
distance B is too small.
If the edge of the slope or excavation
breaks in, the crane can topple over and
kill personnel!
• An authorized and trained specialist
should perform calculations to verify the
load bearing capacity of the ground!
• Safety distance A and safety distance B
should be calculated by an authorized and
trained specialist!
• Always maintain the calculated safety
distance A and safety distance B!
• Support the sides of the slope or ditch!
Abbreviation Term
A Distance to bottom of excavation
B Distance to excavation
T Depth of excavation
α Load entry angle
β Slope angle
2-26
Safety
SAC2200
≥
α
2-27
Safety
SAC2200
Notice!
! Without calculated proof of safe
placement, the slope angles of β given in
the chart may not be exceeded!
Ground Slope angle

for non-cohesive and soft cohesive ground β=45°
for stiff or semi-solid cohesive ground β=60°
for rock β=80°
Calculation safety distance A:

Soil type required load entry angle α Formula
soft ground α≤30° A=2×T
solid ground α≤45° A=1×T
2-28
Safety
SAC2200
≥
α
2-29
Safety
SAC2200
2.4.7 Permissible ground pressure
When the crane is supported, the support

cylinders transmit significant forces to the
ground. In certain cases, a single support
cylinder has to transmit almost the entire
weight of the crane, plus the load weight, to
the ground.
The ground must be able to safely absorb this
pressure every time. If the support pad area
is inadequate, then it must be supported from
below according to the load bearing capacity
of the ground.
The required support area can be calculated
from the load bearing capacity of the ground
and the crane support force.
Notice!
! Consider that the support force, due to
the counterweight, can be higher without a
load than with a load.
Caution!
The crane may tip if incorrectly supported
from below!
Only strong materials may be used for the
support pad bases; for example properly
dimensioned wooden timbers.
In order to ensure that pressure is evenly
distributed over the base surface, the
support pads must be positioned in the
center of the support base.
2-30
Safety
SAC2200
Permissible ground pressure
Soil type N/cm2

1 Organic ground: peat, sludge, muck 0
2 Uncompacted fill: construction debris 0 ～ 10
3 Non-cohesive ground: sand, gravel, rocks and mix 20
Cohesive soil:
a) clayed silt, mixed with topsoil
12
b) silt, consisting of poor clay and coarse clay
13
c) plastic clay, consisting of potter’s clay and fill
stiff
9
semi-solid
4 14
solid
20
d) mixed granular ground, clay to sand, gravel and
rocky areas
15
stiff
22
semi-solid
33
solid
Rock in evenly solid condition:
5 a) brittle, with traces of decomposition 150
b) not brittle 450
2-31
Safety
SAC2200
If there is any doubt about the

load bearing capacity of the ground at the
placement site, soil tests should be carried
out, for example with a penetrometer.
Example: Calculation of specific support pressure

Maximum support force according to chapter 1.03: 720 kN 720000N
Surface of square support pad with 550 mm side length according to
3025cm2
chapter 1.03: 302500 mm2
80 % as carrying surface of support pad: 302500 mm2 x 0.8 = 242000

2420cm2
mm2
720000N/3600cm2
Specific support pressure = Support force / surface support pad
=297.52N/cm2
Specific support pressure: 298N/cm2
2-32
Safety
SAC2200
The value of the specific support pressure is

far above the permissible ground pressure for
all types of granular soil. If this crane is utilized
on bedrock, type of ground gravel, permissible
ground pressure 20 N/cm2 , then the support
surface must be increased.
Example: Calculation of required support surface

Maximum support force according to chapter 1.03: 720 kN 720000N
2
Permissible ground pressure: 20 N/mm 20N/cm2
Required support surface = Support force / permissible ground

720000N/20N/cm2 =36000cm2
pressure
Required support surface: 36000cm2=3.6m2
The surface of the support for each support

pad must be at least 3.6 m2 .
Note!
• The corresponding support forces can be
determined with the crane job planer.
2-33
Safety
SAC2200
2.4.8 Supporting
It is absolutely essential that the crane be

supported exactly in accordance with the load
charts to ensure safe operation.
The match of the sliding beams placement
surfaces must be observed to ensure proper
force transfer between the sliding beams.
The crane may only be supported in these
extension conditions.
Danger!
Risk of toppling the crane!
Intermediate positions of the specified
support widths may not be carried out,
because the force transfer is only possible
via the side placement surfaces and in
intermediate positions, due to the lack of
placement surfaces, an incorrect force
transmission can occur on the upper
chord.
! Pin the sliding beams to prevent
subsequent movement of the placement
surfaces.
! The pins must be completely inserted and
secured!
All 4 sliding beams and support cylinders must
be extended according to the data in the load
chart, also those on the counterweight side.
If only the load side sliding beams are
extended, the crane can tip over when turning
or setting down the load.
Danger!
Incorrectly extending the sliding beams
increases the risk of tipping the crane!
1.The load suspended on the hook causes

tension and deformation of the hoist rope and
telescopic boom, the same applies to lattice
jibs and guy ropes. If the load is dropped from
the tackle cables or if the tackle or hoist rope
breaks in this situation, a sudden relief occurs.
The boom snaps back quickly. This can cause
the crane to topple over.
2-34
Safety
SAC2200
2-35
Safety
SAC2200
2. Despite previous assumption, it might

become necessary to swing the load to the
opposite side. This can cause the crane to
topple over.
3. When turning from the vehicle longitudinal
direction, the crane can topple over due to the
boom or counterweight momentum.
4. It is imperative that all 4 sliding beams and
support cylinders be extended according to
the data in the load chart!
Aligning the crane
In order to safely operate the crane, it is very
important to level it and install a proper base
for the support pads.
Danger!
The crane may topple if it leans!
If the crane is positioned at an incline, and
if the boom is turned towards the slope,
then the radius is increased as a result. It
is possible that the slewing gear can no
longer hold the crane superstructure and,
in extreme cases, the crane can topple
over.
Be sure to align the crane horizontally!
Example: At a boom length of 50 m, uneven
adjustment of the crane by only 5° will cause
an boom radius of 10 m to be increased by a =
4 m.
Checking safety measures
The crane is correctly supported:
- The placement location has been selected
in such a way that the crane can be operated
with the least possible radius.
- The load bearing capacity of the ground is
adequate.
- There is sufficient distance to ditches and
slopes.
- All four sliding beams and support cylinders
have been extended according to the support
base given in the load chart.
- The sliding beams are secured with pins to
prevent them from moving.
- The support pads are secured.
- The crane is aligned horizontally.
2-36
Safety
SAC2200
2-37
Safety
SAC2200
- The axles are relieved, which means the tires

do not touch the ground.
- It has been ensured that there are no live
electrical wires within the working range of the
crane.
- There are no obstacles which will hinder
required crane movements.
- The axle suspension is locked.
2.4.9 Crane operation with a load

Before beginning any work, the crane operator
must be convinced that the crane is in safe
operating condition. All safety systems, such
as load moment limiter, hoist limit switches,
brakes, etc., are in good working order.
- The load moment limiter must be adjusted
according to the current crane configuration.
- Crane loads may never exceed those
specified in the load charts.
- The loads given in the load chart may not be
exceeded.
- The crane operator must know the weight,
the center of gravity and the dimensions of the
load before operating the crane.
- Load carriers, lifting equipment and tackle
must be in accordance with specified
requirements.
- It must be observed, that the weight of the
hook block and the weight of the tackle must
be subtracted from the load given in the load
chart.
Example:
Maximum permissible load
30,000kg 30,000 kg
according to chart
Weight of the hook block 370 kg -370 kg
Weight of the slinging rope 40 kg -40 kg
Actual useful load of the crane Total = 29,590 kg
In this case, the load to be lifted may not exceed 29,590kg.
2-38
Safety
SAC2200
2.4.9.1 Counterweight
The counterweight required depends on

the weight of the load to be lifted and the boom
radius required to do the work. The deciding
factor for the selection of the counterweight is
the data in the corresponding load chart.
Danger!
Risk of tipping the crane!
It is imperative that the counterweight is
installed according to the load chart!
2.4.9.2 Hoist Gear, Hoist Rope
The lifting capability of the crane is a function

of the power rating of the hoist gear and the
hoist rope reeving possibilities. When working
with a single strand, the crane can only lift as
much of a load as the hoist gear is able to pull.
If the load to be lifted is heavier than the hoist
gear is capable of lifting, the hoist rope must
be configured using block and tackle principles
by appropriate reeving between the pulley
head and the hook block.
When reeving, carefully observe the load chart
specifications and the operating instructions.
Danger!
Risk of accident caused by cable breakage
or damage to the hoist gear box or crane
engine!
2-39
Safety
SAC2200
2.4.9.3 Crane Operation
Danger!
Danger of accidents if the following points
are not observed!
It is imperative to comply with the following
instructions.
Danger exists if:

The load torque limiter is not set to the actual
configuration status of the crane, and as a
result, cannot fulfill its function as a safety
device.
The load torque limiter is defective or put out

of operation.
The sliding arms of the hydraulic supports are

not extended to the points specified in the load
chart.
The support pads are not supported with

stable base material sufficiently large for the
soil conditions.
If the load is pulled at an angle.
It is particularly dangerous when pulling to the

side since the telescopic boom has a lower
torque resistance to the side.
The load may not be pulled at an angle.
An excessive load is attached to the hook

during dismantling work, which then hangs
freely on the crane when it is detached.
If loads which have become stuck are pulled

free with the hook block.
Even if the weight of the load which is stuck is

no greater than the permissible lifting load, the
crane may topple over backwards if the load
is suddenly freed since the tension created in
the boom can cause it to jerk back violently.
2-40
Safety
SAC2200
Work is carried out in strong winds. Refer to

the data given in the load chart.
The crane is not aligned horizontally and the

load is slewed toward the slope.
The hook load begins swinging because the

crane operator has not properly controlled the
movements.
The loads and radii contained in the load

charts are exceeded.
When working in the vicinity of power cables,

these are not isolated by electricity engineers
or if the hazardous area is not covered of fenced
off.
If it is not possible to take such measures, a

sufficient safety clearance must be maintained:
Minimum distance
Rated voltage
[m] [ft]
<1 kV(1000 V) 1 3
1k V - 110 kV 3 9
110 kV - 220 kV 4 13
220 kV - 380 kV 5 16
If rated voltage is unknown 5 16
Warning!
If, despite all precautions having been
taken, a flashover occurs, carry out the
following procedure:
-Keep calm!
-Do not leave the crane cab.
-Warn those around the crane not to move
and not to touch the crane.
-Move the crane away from the danger
area.
2-41
Safety
SAC2200
2.4.10 Grounding the crane
Danger!
Danger of fatal injury due to electrical
shock!
There is a risk of electrical shock, if the
crane is not properly grounded.
Properly ground the crane!
The crane must be grounded before operation:
- near transmitters (radio and TV transmitters,
radio stations, etc. )
- near high frequency switching stations
- in case of severe possibility of thunderstorms
or potential thunderstorms
The crane can become electrostatically
charged especially if the crane is equipped
with synthetic support pads or if the support
pads are placed on insulating materials (such
as wooden planks).
Danger!
shock!
Prevent the crane from electrostatic
charge!
To prevent the crane from electrostatic charge,
the following is required:
- an electrically conductive grounding rod,
approx. 2 m long, which is inserted into the
ground
- an electrically conductive cable with a
diameter of at least 16 mm2
- ground connection on the crane, or a screw
clamp, as is used for welding work
2-42
Safety
SAC2200
The following applies:

- always use a cross grounding rod as
grounding rod
- the grounding resistance must be less than
0.5 Ohm
- the connection between the crane and the
ground must always be a proper electrically
conductive connection
Connect one end of the grounding cable with a
diameter of at least 16 mm2 with the grounding
rod,which is inserted into the ground.
Insert the grounding rod at least 1.5 m into the
ground.
Moisten the soil around the metal rod for better
conductivity.
Notice!
The grounding resistance depends on the
make up of the ground material and on the
active contact surfaces of the grounding
rod.
Connect the other end of the grounding
cable with a diameter of at least 16 mm 2
with the grounding connection on the
crane, see chapter 3.01.
Notice!
The connection between the crane and
the ground must always be a proper
electrically conductive connection.
If there is a possibility to connect
a foundation or band ground with
correspondingly smaller grounding
resistance, then this grounding method
should always be preferred.
Danger!
shock!
Make sure that the connection between
the crane and the ground is a proper
electrically conductive connection.
2-43
Safety
SAC2200
Grounding the load
Danger!
shock!
load is not properly grounded.
Properly ground the load
The load must be grounded before operation:
- near transmitters (radio and TV transmitters,
radio stations, etc. )
- near high frequency switching stations
- in case of severe possibility of thunderstorms
or potential thunderstorms
The load can become electrostatically
charged, even if the crane is grounded. This
applies in particular if a hook block with pulleys
made of synthetic material and non-conductive
fastening equipment (for example plastic or
manila ropes) are used.
Danger!
shock!
load is not properly grounded.
Prevent the load from electrostatic charge!
The connection between the load and the
ground must always be a proper electrically
conductive connection.
To p r e v e n t t h e l o a d f r o m b e c o m i n g
electrostatically charged, the following is
required:
- an electrically conductive grounding rod,
approx. 2 m long, which is inserted into the
ground
- an electrically conductive cable with a
diameter of at least 16 mm2
- an electrically conductive metal rod with
insulated handle to touch the load
Connect one end of the grounding cable with a
diameter of at least 16 mm2 with the grounding
rod, which is inserted into the ground
Insert the grounding rod at least 1.5 m into the
ground
Moisten the soil around the metal rod for better
conductivity
2-44
Safety
SAC2200
Notice!
The grounding resistance depends on the
make up of the ground material and on the
active contact surfaces of the grounding
rod.
Connect the other end of the grounding
cable with a diameter of at least 16 mm 2
with the metal rod with insulated handle.
Danger!
shock!
The metal rod may only be held on the
insulated handle!
Hold the metal rods on the insulated
handle.
Touch the load with the metal rod before
touching it with the hands.
In weather conditions, which can include
lightning:
- Stop work on the crane immediately.
- Always place down the load.
- If possible, telescope the boom in and bring
it into a safe condition.
- Turn the crane engine off.
Danger!
Danger of accidents due to lightning
strikes!
Make sure that there are no persons near
the immediate area of the crane!
Welding work on the load
Notice!
The load must also be grounded.
In case of welding work on the load, the
screw clamp of the welding unit must
be attached on the welding piece to
avoid current flow via hoist rope, crane
superstructure pr crane chassis.
2-45
Safety
SAC2200
Caution!
Danger of damage to the heater control
units!
Disconnect the negtive and positive cables
from the batteries and connect the positive
cables to the vahicle ground.
2-46
Safety
SAC2200
2.4.11 Safety instructions for external

power supply (230 V AC)
A potential hazard exists when supplying a

crane with external power from a low voltage
distribution system (230 V AC).
In particular, the following conditions pose
an electrical hazard: touching a crane with
open grounds(caused by the mechanical
stress on flexible supply cables or the service
connection), loose terminal connections,
high wire or contact resistance, mixed up
conductors, defective or missing protective
equipment (fault interrupters) in combination
with a body contact on the crane.
DANGER
Danger of fatal injury if the body conducts
current!
Water and/or defective devices can cause
hazardous stray voltages when touched.
Subject to lethal currents.
•The external supply cable must be in good
working order!
Make sure that the external flexible supply line

is in good working order.
Where applicable, we recommend the use of
an isolation transformer.
DANGER
Risk of electric shock!
•To check the protective measures and
to decide if the crane can be supplied
with power form the general distribution
network, always use a qualified electricians
with the appropriate measuring equipment
in accordance with VDE.
2-47
Safety
SAC2200
2.4.12 Endangering air traffic
When working with crane, heights are reached

which could endanger air traffic. This applies
especially to areas near airports.

DANGER
Endangering air traffic!
If no protective measures are taken, this
can result in endangerment to air traffic!
• Get the approval from agency responsible
for air traffic!
• Install the airplane warning light on the
boom head and turn it on!
2-48
Safety
SAC2200
2.4.13 Joint lifting of a load by

numerous cranes
If a load is to be lifted by means of several

cranes, the procedure must be previously
determined by means of the contractor or his
representatives, and must be carried out in
the presence of a supervisor nominated by the
contractor.
Proceed with particular care in the following
cases:
- The part to be lifted has an uneven structure
or the centre of gravity is unknown. Eventually,
only use 75% of the permissible load!
- Dynamic influences are to be taken into
account when the load is freed.
- The cranes have differing load-bearing
capacities
Note!
•In th e even t of di ffe ring loa d-b e a r i n g
capacities of the cranes, attach the loads in
such a way as each crane is only loaded with
its own permissible load-bearing capacity.

DANGER
High risk of accident during dual-lifting!
When lifting or lowering the load, the
individual cranes can be overloaded and
topple over!
Personnel can be killed or seriously
injured!
• Only load the individual cranes with their
individually permissible load capacities!
• Diagonal pull is not permitted!
2-49
Safety
SAC2200
2.4.14 Working in the vicinity of

transmitters
Strong electromagnetic fields are likely to be

present if the construction site is close to a
transmitter.
These electromagnetic fields can pose direct
or indirect danger to persons or objects, for
example:
- Effect on human organs due to temperature
increase.
- Danger of burns or inflammation due to
temperature increase.
- Spark or electric arc formation.
Danger!
Risk due to electromagnetic fields!
Before operating a crane in the vicinity of
transmitters, be sure to consult with SANY!
Also consult a high frequency specialist!
High frequency (HF) radiation from a

transmitter demands supplementary work
safety procedures and UVV regulation for
crane operators:
Every crane must be “totally” grounded. Check

visually or with a simple tester to ensure that
ladder, cab and cable pulleys are grounded.
All personnel working on the crane or with
large metal objects must protect themselves
from burns by wearing non-conductive
synthetic gloves and suitable clothing while
working.
There is no need to panic if you feel your hand

warm up. Always work under the assumption
that the respective workpiece, structural steel
member or support is “hot”.
2-50
Safety
SAC2200
2-51
Safety
SAC2200
The temperature of objects affected by high

frequency radiation depends on their “size”.
Cranes, carriers and coverings, for example,
are “hotter”.
Contact with other crane loads is not permitted

when operating the crane (arcing). Since
defects caused by burns considerably reduce
cable carrying capacity, any such occurrences
must be reported immediately to the
machinery supervisor so that the cables can
be inspected.
An insulator 1 is required at all times between

the crane load hook and tackle. It is strictly
prohibited to remove this insulator 1.
Do not touch the cables above the insulator 1.

Loads that are attached to the crane may
not be touched by any unprotected parts of
the body after the load has been lifted or set
down.
Do not work with a bare upper torso or in short

pants, this is prohibited.
To minimize absorption of high-frequency

radiation, larger loads should be transported
horizontally if possible.
Loads must be grounded, or additional

insulation used (rubber material between
the object and gloves) when manual work is
required.
Use a suitable measuring instrument to check

the “temperature” of the object. If, for example
500 V can be measured on a tool at a distance
of 1 cm to - 2 cm, then the tool may not be
touched with bare hands.
2-52
Safety
SAC2200
2-53
Safety
SAC2200
The greater the distance, the higher is the

voltage on the object: at a distance of 10 cm,
the voltage is approx. 600 V, at a distance of
30 cm, the voltage is approx.2000 V.
To avoid secondary accidents, use a safety

belt when working on structures that are high
off the ground.
Handling explosive matter (such as refuelling)

may only be done at least 6 m away from the
place where sparks could form due to handling
of larger metal parts. Use only conductive
rubber hoses to refuel.
A ny accidents and unexpected eve n t s

must immediately be reported to the local
construction supervisor and the safety
engineer.
Endangering air traffic
When working with crane, heights are reached

which could endanger air traffic. This applies
especially to areas near airports.
Danger!
Endangering air traffic!
If no protective measures are taken, this can

result in endangerment to air traffic!
Get the approval from agency responsible for

air traffic !
Install the airplane warning light on the boom

head and turn it on !
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2.4.15 Hand signals for guidance
For all crane movements, the crane operator

must always keep the load, as well as the
crane hook or loading equipment when the
crane is not loaded, in his field of vision.
Danger!
Danger of accident due to suspended
loads!
Constantly keep loads in sight !
Do not remain under a suspended load !
If this is not possible, the crane operator may
only operate the crane if he is signed by an
assigned guide.
The operator may be guided by hand signals
or a two-way radio. It is absolutely essential
that there be no misunderstandings.
Caution!
Danger of accident caused by
misunderstood hand signals !
Hand signals must be mutually agreed
upon and clearly executed !
We recommend using the hand signals
described on the previous page.
In any case, national regulations must be
observed when abroad.
Hand signal explanation:
1 = Luff up boom
2 = Luff down boom
3 = Lift load slowly
4 = Lower load slowly
5 = Luff up boom slowly
6 = Luff down boom slowly
7 = Luff up boom and hold load steady
8 = Luff down boom and hold load steady
9 = Telescope out boom
10 = Telescope in boom
11 = Luff up boom and lower load
12 = Luff down boom and lift load
13 = Lift load
14 = Lower load
15 = Turn load in this direction
16 = Shut down all systems
17 = Stop!
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2.4.16 Consideration of wind conditions
It is imperative to observe the permissible

wind speed data given in the load charts:
- for the equipped crane
- for crane operation.
If the wind speed is larger than the maximum
permissible wind speed, then crane operation
must cease. The boom and the attachments
must be taken down.
The crane operator must check with the
a pp ro p ri ate w ea th e r b u rea u a bo u t t h e
expected wind speeds, at:
the start of crane operation
interruption of crane operation
when resuming crane operation
Danger !
Crane can topple over !
If the crane is operated at wind speeds
which are larger than the maximum
permissible wind speeds according to the
load charts, then it can topple over and kill
personnel !
If wind speeds are expected which are
larger than the maximum permissible wind
speeds for the equipped crane, then the
attachments and the boom must be taken
down !
If wind speeds are expected which are
larger than the maximum permissible
winds speeds for the crane operation, then
it is prohibited to lift a load !
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Wind force Wind speed

Effect of the wind in the inland
Beaufort Description [m/s] [km/h]
0 Calm 0-0.2 1 No wind, smoke rises straight up
Wind direction is shown only by observing the

1 Slight air (draft) 0.3-1.5 1-5
trail of smoke, not by the wind sock
Wind can be felt on the face, the leaves rustle,

2 Light breeze 1.6-3.3 6-11
wind sock moves slightly
Leaves and thin twigs move, wind extends a

3 Gentle breeze 3.4-5.4 12-19
small breeze flag
Moderate Swirls up dust and loose paper, moves twigs

4 5.5-7.9 20-28
breeze and thin branches
Small deciduous trees begin to sway, foam

5 Fresh breeze 8-10.7 29-38
forms at sea
Thicker branches move; telephone lines begin to

6 Strong breeze 10.8-13.8 39-49
whistle, umbrellas are difficult to use
7 Stiff wind 13.9-17.1 50-61 Entire trees swaying; difficult to walk into wind
8 Gale force wind 17.2-20.7 62-74 Breaks twigs off trees, walking becomes difficult
Minor damage to property (chimney tops and
9 Gale 20.8-24.4 75-88
roofing tile are blown off)
Trees are uprooted, significant damage to

10 Severe gale 24.5-28.4 89-102
property
11 Violent storm 28.5-32.6 103-117 Extensive, widespread storm damage
12 Hurricane 32.7-36.9 118-133 Major destruction
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2.4.17 Interruption of crane work
Interruption of crane work

If the crane operator leaves the equipped
crane during crane operation, then it must
be ensured that no danger to crane or
surrounding area can occur in case of an
unforeseen event.
Danger!
Risk of fatal injury!
Situations may occur which could
cause the crane to become unsafe if left
unsupervised.
This could cause the crane to topple over,
resulting in major personal injury and
property damage.
Always keep the crane under full control !
Incidents which could occur (for example):

- The ground giving way due to severe rain
- Melting ice under the supports
- Bad weather, storms, thunderstorms
- Landslides
- Wash outs
- Support cylinder failure
- Luffing cylinder failure
- Vandalism
Make sure that the following prerequisites are
met:
- There is no load on the hook
- The crane poses no traffic obstacle
Notice!
If crane work must be interrupted if the
crane is equipped, then it must be ensured
that measures are initiated in time by
trained, qualified personnel, to bring
the crane into a safe condition in case
something happens.
Danger!
Risk of accident!
If it is not possible to maintain full control
over a rigged crane, the machinery and
boom must be taken down.
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3
2
4 4
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Taking up crane operation again
Upon resumption of crane operation, the

crane operator is required to check the
state of the crane and its safety systems.
Danger!
Risk of accident!
If the crane operator leaves the cab, even
for a short time, the operating mode setting
must be checked and reset, if necessary,
before resuming crane operation.
Check operating mode settings and reset,
if necessary.
Ending crane operation

Before the crane operator may leave the
crane, the following prerequisites must be met:
Remove the load on the crane hook or place it
on the ground.
Telescope the telescopic boom all the way in
and place the boom down.
Turn the heater off.
Apply the parking brake on the crane chassis.
Turn the engine off and pull the ignition key.
Bring the control lever (master switch) to
0-position.
Secure the mobile crane to prevent
unauthorized use. Close all control platforms
with a lock, if they are not used at the time or if
they are not occupied.
Secure the mobile crane to prevent it from
rolling off. See paragraph “Parking the
vehicle”.
Parking the vehicle
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21
20 20 20 20
A B
20 20 20
A B
22 22
Outside of Outside of
front outrigger rear outrigger
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Danger!
Danger of accidents if the vehicle rolls
away!
If the following points are not observed by
the crane operator, personnel can be killed.
It is prohibited to park the vehicle at a
slope or an incline of more than 18%.
The parking brake must always be applied
when parking the vehicle.
The ground where the vehicle is parked
must be of sufficient load carrying capacity
and level, so that the wedges will not slip
away under load or be pushed into the soil.
Make sure that the following prerequisites are

met:
- the vehicle is standing on level ground of
sufficient load carrying capacity
- the parking brake is applied
Under the following conditions, the vehicle
must be secured against rolling away by using
the specified number of wheel chocks or
wedges - in addition to the parking brake:
- The vehicle is being parked on an uphill or
downhill slope.
- The vehicle is being parked and not guarded.
- The vehicle is defective, especially if the
brake system is defective.
Danger!
Vehicle rolling uncontrollably away!
The vehicle may roll away uncontrollably
if all the specified chocks are not placed
directly behind the wheels. This may result
in fatal injuries.
All wedges must be placed in such a way
that they act against the downdrift force!
Place all stipulated wedges tightly directly
under the wheel !
Place all stipulated wedges tightly so that
they have an immediate braking action and
keep the vehicle in parking position!
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2.5 Warning Signs
Notice!
Warning signs are safety signs, which warn
of a risk or danger.
For that reason, all warning signs on
the crane must be complete and always
legible.
Warning signs on the crane
The following warning signs are installed on

the crane:
1. Climbing forbidden
2. Caution for scald
3. Caution for falling substance
4. Oiling
20. Keeping away
21. Centering swing table
22. Outrigger over limit
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2.6 Operation of Crane

Superstructure
2.6.1 Technical safety instructions for

working with loads
Please see Chapter 1.04, “Technical safety

notes”.
DANGER
Risk of accident!
For steep boom positions, for which no
loads are specified in the load charts
there is a risk of the crane superstructure
toppling when slewing “backwards”, i.e.
towards the counterweight side! There is
a particular danger if the support basis
has been reduced and supported with the
sliding beams retracted!
• Always comply with the boom projection
radii specified in the load charts!
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DANGER
Risk of accident from cracks in the rope!
• Always comply with the reeving numbers
specified in the load chart for maximum
loads!

DANGER
Risk of accident!
• Call in an additional observer if the lowest
windings position of a winch drum has
been reached!
• The job of the additional observer is to
ensure that there are always at least three
windings on the winch drum!
Always comply with the maximum load

specified in the load chart.
Initiate all crane movements carefully and
also use the brakes carefully during crane
movements.
That way you can avoid a swinging or
pendulum motion in the suspended load.
Reeve the hook block to the maximum extent
required to lift the load. Bigger hook blocks
must not be reeved.
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2.6.2 Checking before starting to work

with the crane
Before starting work with the crane, the crane

operator must carry out a further inspection to
satisfy himself about the crane's operational
safety:
- Check that the crane is properly supported
and level.
- Check that all values in the load chart that
apply to the current equipment configuration
have been entered and met.
- Ensure that there are no people or objects in
the crane danger zone.
DANGER
Danger of accidents when slewing the
crane from persons or objects in the
danger zone.
This applies particularly in narrow building
site situations, in the rear boom projection
radius of the counterweight and towards
the chassis!
• Give a short warning signal (hooter)
before starting a crane movement!
• Ensure before starting any slewing
movement that there are no people or
objects in the danger zone!
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2.6.2.1 Visual check for damage
DANGER
Risk of accident!
• In the event of deficiencies that threaten
operational safety, stop crane operations
immediately!
The following deficiencies threaten the crane's

operational safety:
- Damage to load-bearing parts of the crane
design, such as booms, supports etc.
- Failure of the hoist gear brake and
consequent slipping of the load
- Functional failures in the crane control
system
- Functional failures in the control and warning
lights
- Damage to the hoist ropes
- Functional failures in the safety devices
- Leakage in the crane hydraulics
Inform the appropriate supervisor about the
deficiencies on the crane and also inform your
relief when crane operators are changed.
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2.6.2.2 Telescopic boom distortion because

of sunshine on one side
A temperature difference occurs between

the side facing the sun and the side facing
away from the sun in cranes with telescopic
booms. This causes telescopic boom side
distortion, which can reduce the load-bearing
capacity of the telescopic boom. For example,
a temperature difference between the two
boom sides of 30 °C and a boom length of 60
m results in a length difference caused by the
temperature difference between the two sides
of the telescopic boom of approximately 22
mm. Particularly with narrow boom parts, this
causes the profiles to bend sideways!
If the maximum load is being fully utilized,

particularly when a telescopic boom extension
such as a lattice jib, luffing lattice jib or folding
jib is being used, the equipment must be
visually inspected before picking up the load in
order to ensure that the boom is not showing
signs of side deformation because the sun
shining on one side.
DANGER
Risk of accident because of component
overloading!
If the telescopic boom has become
distorted because of one-sided sunlight,
this can cause component overloading and
therefore accidents!
• Turn crane so that both sides of the boom

are brought to about the same temperature,
therefore preventing side deformation!
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2.7 Taking on a load
The crane must always be operated in such

a way that its load-bearing parts are not
destroyed and its stability is ensured.
2.7.1 Lifting the load

DANGER
Danger of crushing for people in the load

zone!
• Exercise extreme caution when lifting a
load!

DANGER
Risk of toppling crane!

If an attempt to lift a load above the
hoist gear causes the LICCON overload
protection to switch off, then the load must
not be lifted by raising the boom head. This
leads to overloading and toppling of the
crane!
• Do not lift the load by raising the boom
head from the ground!
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Note!
When using an auxiliary winch* (installation
or reeving winch), observe the following:
• Only use the auxiliary winch (installation
or reeving winch) for installation and not to
lift loads!
• Lifting of loads with the auxiliary winch is
prohibited!
If the rope is manually attached to the load to

be raised by an assistant:
- Make sure that the assistant's hands are not
crushed between the load and the rope by the
tautly pulled ropes.
- Make sure that the assistant's body parts
(hands, legs etc.) are not crushed by a
pendulum movement of the load during lifting.
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2.7.2 Diagonal pulling

DANGER
Diagonal pulling can destroy the crane or
cause it to topple over!
• The hook block must always be attached
vertically over the center of gravity of the
load to be lifted!
• Diagonal pulling is not permitted!
The crane is designed only to lift loads

vertically. During diagonal pulling, regardless
of whether this is done in the same direction
as the boom or diagonally, horizontal forces
are generated in addition to the vertical ones,
for which the boom is not designed.
2.7.3 Breaking away fixed loads

DANGER
Ripping stuck loads free can destroy the
crane or cause it to topple over!
• Ripping stuck loads free is prohibited!
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2.8 Crane Operation
The maximum load-bearing capacity is not just

limited by stability, but in many cases a load-
bearing component breaks when the crane
is overloaded before the crane topples over.
Particularly components that are susceptible to
buckling such as the telescopic boom may fail
suddenly without showing signs of distortion
beforehand if the crane is overloaded.
2.8.1 General
A swaying load must always be kept under

control. A fundamental requirement for this
is the safe and delicate control of the crane's
functions.

DANGER
Risk of accident due to swaying loads!

A swaying load can damage the crane and
cause it to topple!
•All crane movements must be executed
slowly and delicately!
•Initiate all crane movements slowly!
•Apply the brakes slowly in all crane
movements!
•Crane operation with swaying loads is
prohibited!
CAUTION
Risk of damage to the rope pulleys!
• Remove hook blocks, boom, folding jibs,
auxiliary booms and boom noses in such a
way that the rope pulleys do not lie on the
ground!
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2.8.2 Guiding the load
The use of guide ropes is recommended

to help the crane operator to manage the
load more precisely and to prevent the load
from swaying. This will prevent undesirable
movements of the load and consequent
damage.
2.8.3 Carrying people
The crane is not designed to carry people.
DANGER
Risk of accident!
• Never carry people on the load or on
tackle!
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2.8.4 Danger of crushing
DANGER
Risk of accident!
Extreme care is needed when lowering
a load! Danger of crushing people in the
immediate area of the load being lowered!
• Standing under swaying loads is strictly
prohibited!
2.8.5 Working in the vicinity of

electricity transmission lines

DANGER
Risk of accident!
Failure to observe the following notes can
lead to damage!
• Note the following points carefully!
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If there are electricity transmission lines in the

immediate vicinity of the building site, these
must be switched off by qualified electricians.
If this is not possible, the danger area must
be covered over or cordoned off. If even these
measures cannot be carried out, the following
safety distances must be maintained:
Rated voltage Minimum distance

1kV 1m
1kV—110kV 3m
110kV—220kV 4m
220kV—380kV 5m
with unknown power supply voltage 5m
If the crane becomes electrified despite having

taken all necessary precautions, proceed as
follows:
- Remain calm!
- Stay inside the crane driver's cab!
- Warn anyone who is outside and advise
them to remain stationary and not to touch the
crane!
- Move the crane away from the danger zone!
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2.8.6 Ram work or pulling sheet piles
Vibration can be transmitted to the supporting

steel structure of the crane during ram work or
when pulling sheet piles with the crane. This
vibration can cause premature fatigue of the
material and therefore cracks in the supporting
steel structure.

DANGER

Important instructions when carrying out
ram work or pulling sheet piles!
If the crane is used for ram work or pulling
sheet piles the following instructions must
be followed.
Failure to follow the instructions can result
in damage to the crane.
• The ramming equipment must not
introduce vibration into the boom!
• When pulling sheet piles the maximum
lifting power of the crane is limited as per
the load chart!
Restricting the maximum lifting power
via the crane overload protection only is
forbidden!The lifting force restriction can
be achieved by suspending a crane scale
between the load hook and the pulling
equipment.
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2.9 Equipment
2.9.1 Checking the retaining elements
Retaining elements are used to secure the

pins in the folding jibs and lattice components.
The spring force of the retaining elements may
significantly reduce if they are mechanically
damaged or distorted. Do not re-use retaining
elements if there is insufficient spring force.
The pins must be secured with correctly
functioning retaining elements.

DANGER
Risk of accident if retaining element does
not provide enough spring force!
It cannot be guaranteed that the pin is
correctly secured if the retaining element
does not provide sufficient spring force.
• Use retaining elements with sufficient
spring force!
2.9.2 Checking the ropes
The ropes must be checked by an expert

before assembly and checks must be
performed at regular intervals in order to
detect possible damage or wear and tear at an
early stage. See chapter 4.04.
The ropes must be removed immediately if
any of the following damage is detected:
- Breakage of a strand
- Wire breaks
- Broken wire nests
- Reduction in the rope diameter by more than
10% of the nominal size
- Rope deformation
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2.9.3 Attaching a new hoist rope
In order to guarantee safety and operating

characteristics only use original Liebherr
replacement parts.
Worn rope pulleys must be removed and
replaced before fitting a new hoist rope. If
this is not done the new hoist rope will be
damaged.
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2.9.4 Inspection procedures
Note!
• If the crane operator leaves the cab,
even for a short time, the operating
mode settings must be checked and
reset if necessary before resuming crane
operation.
Perform the following checks before operating

the crane:
- Check whether the axle suspension is
locked.
- Check whether the support pads are secured
in their operating position.
- Check whether the ground provides
adequate load-bearing capacity.
- Check whether there is sufficient safety
clearance to slopes and excavations.
- Check whether there are any live cables
within the operating range of the crane.
- Ensure that the work can be carried out with
minimum boom projection.
- Check that there are no obstacles which
might hinder required crane movement.
- Check whether pins have been fitted to
secure the sliding beams against sliding.
- Check whether the crane is supported.
- Check whether the crane is level.
- Check that the tires are not in contact with
the ground.
- Check that the overload protection has been
adjusted as per the information in the load
chart.
- Check if the bypass key button and the
assembly key button are turned off.
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- Check the shut off of the overload protection

by running against the operating position on
“top” and “bottom”.
by running against the hoist limit switch.
- Check the easy movement and function of
the wind speed sensor.
- Check the shut off of the limit switches -
lattice jib “lowest position”.
- Check the shut off of the limit switches – flap
in position lattice jib “steepest position”.
- Check the easy movement of the pendulum
for the mechanical relapse retainer over the
total swing range of the pendulum.

DANGER
If the control measures are not carried out
before crane operation, then the crane can
topple over or be damaged!
Personnel can be killed or injured!
• Crane operation with safety devices

which are not functioning correctly is strictly
prohibited!
• Start crane operation only after all safety
devices have been checked and are
functioning correctly!
• Start crane operation only if the overload
protection has been set according to the data
in the load chart!
• Start crane operation only if the crane is
properly supported and horizontally aligned!
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2.9.5 Dangerous conditions without

shut off
2.9.5.1 Block position of relapse cylinders

when setting down a load

DANGER
Damage to boom or relapse cylinder!
If the block position of the relapse
cylinders is triggered by the boom or the
derrick with attached, freely suspended
load, then there is a danger of damaging
the boom or the relapse cylinders when
setting down the load onto the ground! By
setting down the load, the crane is relieved,
which causes the boom system to move to
the rear.
There is no shut off of the hoist gear down
function!
• Actuate the opposite direction of
movement which caused the block position
and eliminate the block position!
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2.9.6 Transporting components
Ensure that any components transported

by support vehicle are secured correctly. If
necessary, transport these components on
supports or using a special transport device.
2.9.6.1 Transporting lattice components
If the lattice components are pushed inside

each other for transportation purposes, they
must each be secured with 2 chains.
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2.9.7 Pneumatic springs for assembly

support of components
Pneumatic springs are installed on various

components to simplify the installation of these
components.
DANGER
Danger of crushing!
Defective pneumatic springs no longer
provide the supporting properties on the
movable components!
Due to falling components, personnel can
be killed or severely injured!
• Do not use components with defective

pneumatic springs! Replace defective
pneumatic springs!
• Always check pneumatic springs for external
damage before actuating the corresponding
components!
• It is strictly prohibited for personnel or objects
to remain within the movement range of the
components, which are supported by the
pneumatic spring!
• It is prohibited for personnel or objects to
remain within the danger zone of the moveable
components!
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2.9.8 Weights
Note!
Do note:
• The weight of each component is
specified in the corresponding chapter or
stated on the plate fitted to the component!
• Contact the customer service department
of SANY if the component weight is not
stated on the plate or in the operating
instructions.
• If components are pushed into one
another (for example intermediate pieces)
or folded together (for example the folding
jib), then the total weight is given by the
sum of the individual components.
• Use auxiliary crane with sufficient load
carrying capacity.
2.9.9 Reduction of load carrying

capacity with placed guy posts
Note!
• The reduction of the load carrying
capacity depends on the boom angle and
the boom length. The longer the main
boom and the wider the boom is inclined to
the horizontal, the larger is the reduction of
load carrying capacity.
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2.9.10 Bypassing the overload

protection

DANGER
Increased accident risk when bypassing
the overload protection!
Proper use of the crane is ensured by
means of the construction of the overload
protection system and observance of
the information in the crane’s operating
instructions.
All sensibly foreseeable erroneous
operations of the crane have been taken
into consideration.
Impermissible crane operation with
bypassed overload protection – with the
aim of increasing the maximum load-
bearing capacity of the crane above the
rated value in the load chart, or to extend
the designated working range of the
crane – does not constitute a sensibly
foreseeable erroneous operation, rather,
deliberate improper use with high risk of
accident!
The possible risks and consequences of
such deliberate improper use are detailed
in the operating instructions.
Such deliberate improper use can neither
be prevented by means of the constructive
design, nor by means of information in the
operating instructions!
• Only operate the bypass key button in
accordance with the operating instructions!
• All other usage of the bypass key button
other than as described in the operating
instructions is impermissible!
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2.9.10.1 Bypassing overload protection
If the maximum permissible load torque is

exceeded, the overload protection switches
off all crane movements that increase load
torque. The switch-off can be bypassed by
means of the bypass key button. The overload
protection displays remain functional.

DANGER

If overload protection is bypassed, there is
no further protection against overloading
the crane!
In the event of deliberate improper use, the
crane could collapse, the boom can break
off or the crane can topple over!
Personnel can be killed!
This could result in serious damage!
• It is only permitted to bypass the
overload protection during assembly or in
emergencies!
• The bypass key button may only be
actuated by persons who are aware of the
effects of their acts regarding the bypass
of the overload safety!
• Bypassing the overload protection
requires the presence of the crane
supervisor and must be performed with
utmost caution!
• Crane operation with bypassed overload
protection is strictly prohibited!
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2.9.10.2 Bypass of hoist-top switch-off
If the hook block contacts the hoist limit switch

weight during its upward movement, the hoist
limit switch is triggered. The crane movements
“Spool up winches”, “Luff boom down” and
“Telescope telescopic boom out” are switched
off. The switch-off can be bypassed by means
of the bypass key button.

DANGER

When bypassing the hoist top shut-off,
there is a risk that the hook block may
be pulled against the pulley head when
continuing to lift or luffing down the boom.
This may damage the pulleys and cause
the loads to fall!
• Only bypass the hoist top shut-off in the
presence of a crane supervisor and with
the help of a “guide”. The guide must be
in direct contact with the crane operator
and must continually monitor the distance
between the hook block and the boom
head.
• Carry out all crane movements with
maximum care and minimum speed.
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2.9.11 Assembly / dismantling

DANGER
Risk of fatal injury due to incorrect
assembly or disassembly!
The assembly/disassembly of components
should never be performed by untrained
personnel. Incorrect assembly/disassembly
can result in death or severe injury!
• Assembly and disassembly should
only be carried out by authorized trained
experts!
Note!
• For assembly / disassembly of individual
components, also refer to the chapters
relating to those components!
• Only use the auxiliary winch (installation
or reeving winch) for installation and not to
lift loads!
• Lifting of loads with the auxiliary winch is
prohibited!
Normal assembly / disassembly procedures
require all separately transported
components to be transported close to the
ground using appropriate auxiliary cranes
and fastening equipment. They should be
safely (correctly) connected to the crane.
Suspended loads such as counterweights,
lattice components or auxiliary booms
must be placed on the ground or on a
frame or other suitable load bearing device
before being approached by installation
personnel.
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DANGER
Danger of impact and crushing!
There is a risk of impact and crushing
when standing in the vicinity of swinging
suspended loads.
• During assembly/disassembly nobody
should be in the dangerous area around
or even underneath the suspended load
before the load has been secured!
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DANGER
Danger of falling!
D u r i n g a s s e m b l y a n d d i s a s s e m b l y,
personnel must be secured with
appropriate antifall guards to prevent
them from falling. If this is not observed,
personnel could fall and suffer life-
threatening injuries.
• All assembly work from a height of 2
m must generally be carried out using
suitable aids (lifting platforms, scaffolding,
ladders, auxiliary crane, etc.)! The height
above which assembly/disassembly work
must be carried out with aids depends
on national regulations. The national
regulations must be adhered to!
• Work which cannot be performed on
the ground or using such aids requires
that installation personnel use suitable
personal protection equipment (such as
safety belts) to protect against falling !
A description of the fastening points for
personal protection equipment is given in
chapter 2.06.
• Any antifall guards (railings) fitted to the
crane superstructure must be brought and
secured into their correct position prior to
assembly/dismantling. See chapter 1.06.
• Only step on maintenance aids and
guards with clean shoes!
• Keep aids and antifall guards clean and
free from snow and ice!
• It is prohibited to walk on the telescopic
or auxiliary booms!
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2.9.11.1 Assembly/disassembly of the

booms
Lattice components which are not in contact

with the ground during assembly / disassembly
must be supported by appropriate and stable
materials. Adjust the height of the body so
that the lattice components are not in contact
with the ground. Pay particular attention if the
lattice components are equipped with rope
pulleys. Otherwise the rope pulleys could be
damaged.
During dismantling it must be ensured that the
auxiliary crane lifts its load vertically. The crane
operator must ensure that the load bearing
capacity of the auxiliary crane is sufficient to
safely raise the dismantled component at the
given radius. When attaching the auxiliary crane
it must be ensured that the hook of the auxiliary
crane is above the center of gravity of the
dismantled component and the fastening ropes
are attached to the load.
DANGER
Angular pulling can destroy the crane or
cause it to topple over.
The hook block must always be attached
load to be lifted!
Diagonal pulling is not permitted!
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DANGER
Danger of accident at assembly/disassembly
of booms!
The dismantling of unsecured or
unsupported booms may result in fatal injury
or mutilation.
• Never unpin the pins under unsecured or
unsupported booms!
• Never unpin the connecting pins on
unsecured or unsupported booms!
• Do not stand under the booms or within
the complete danger zone during the
pinning and unpinning procedure of the
booms!
• Secure the pins in the bearing points and
the supports!
• Do not lean the ladder against the
component being disassembled!
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DANGER
Danger of accidents if the pins are twisted!
The pins can be twisted by diagonal pull or
if the hoisting force of the auxiliary crane
is too high or too low.
Distorted parts can suddenly detach
themselves when the pins are unpinned.
This represents a fatal injury risk to
installation personnel.
• When the pins are unpinned, the “hoisting
force” of the auxiliary crane must be
adapted to the “weight” of the parts being
lifted!
• Do not remove stiff pins by force!
• Remedy the cause of the distortion!
Note!
Instructions for pinning and unpinning:
• Unpin or pin both pins at the same
horizontal level, i.e. left and right!
• Pin the lower pins from inside to outside
and unpin from outside to inside!
• Pin and unpin horizontally-mounted
double-cone pins from outside to inside!
• Pin and unpin vertically-mounted double-
cone pins from top to bottom!
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2.9.11.2 Assembly of lattice components

for cranes with telescopic booms
1. Assembly of lattice components for guyed

auxiliary boom with an auxiliary crane
The illustrations serve as examples. The
illustrations may differ depending on the crane.
DANGER
Risk of fatal injury when assembling

auxiliary booms!
If the pins are not pinned in the given
order, lattice components may suddenly
flap or even fall down. This can result in
life-threatening injuries to personnel.
• Pins must be pinned in the order
specified!
• Pin and secure pins at both sides ( level
A) at point 1, illustration 1.
B) at point 2, illustration 2.
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A A
B B
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2. Dismantling of lattice components for guyed

auxiliary boom with an auxiliary crane
DANGER
Risk of fatal injury when dismantling auxiliary

booms!
If the pins are not unpinned in the given order,
lattice components may suddenly flap or even
fall down. This can result in life-threatening
injuries to personnel.
•Pins must be unpinned in the order specified!
• Unsecure and unpin pins at both sides (level
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3. Fitting of lattice components on self-

supporting auxiliary booms without using an
auxiliary crane
DANGER
Risk of fatal injury when dismantling

auxiliary booms!
If the pins are not unpinned in the given
•Pins must be unpinned in the order
specified!
The assembly / dismantling of lattice

components on cranes with hydraulic angle
adjustment and self-supporting auxiliary boom
may be performed using the crane itself.
Proceed as follows:
• Fit the lattice components to the required
length.
• Pin and secure pins at both sides (level A) at
point 1, illustration 1.
• Luff auxiliary boom up until the pins can be
pinned at point 2, illustration 2.
• Pin and secure pins at both sides (level B) at
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4. Dismantling of lattice components on self-

supporting auxiliary booms without using an
auxiliary crane
DANGER
Risk of fatal injury when dismantling

auxiliary booms!
• Pins must be unpinned in the order
specified!
The assembly / dismantling of lattice

components on cranes with hydraulic angle
adjustment and self-supporting auxiliary boom
may be performed using the crane itself.
Proceed as follows:
• Luff the auxiliary boom down until the head
piece is lightly touching the ground, illustration
2.
• Luff the auxiliary boom down until the lattice
component to be dismantled is completely
touching the ground, illustration 3.
• Completely dismantle the auxiliary boom.
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2.9.11.3 Bypassing during assembly and

dismantling
Note!
• The assembly key button is only installed
on certain cranes.
DANGER
High risk of injury when operating crane

with assembly key button enabled!
Operating the assembly key button
bypasses the hoist limit switch and the
overload protection!
In the event of deliberate improper use, the
crane could collapse, the boom can break
off or the crane can topple over!
Personnel can be killed!
This could result in serious damage!
• Only operate the assembly key button when

performing assembly and disassembly tasks!
• All other usage of the assembly key button
other than as described in the operating
instructions is impermissible!
• The assembly key button may only be
operated by persons, who are aware of the
consequences of a bypass!
• Operating the crane with the assembly key
button enabled is strictly forbidden!
• The assembly key button must be removed
immediately and handed to an authorized
person after carrying out any assembly and
disassembly work!
- The LICCON overload protection is inactive.
- Acoustic signal stops.
-The red beacon in the crane cab extinguishes.
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2.9.11.4 Assembling/dismantling the

hydraulic lines
When hydraulic lines are connected and

disconnected using quick-release couplings,
please ensure that the coupling procedure is
being performed correctly.

DANGER
Risk of accident due to loss of pressure or

leakage!
Incorrectly coupled or self-loosening
quick-release couplings (particularly return
lines) can result in serious injury from
component failure!
• Check that the quick-release couplings have

been properly connected before using the
crane.
• Depressurise hydraulic system before
connecting and disconnecting. Turn off engine
and wait for short time.
• Assemble coupling components (sleeve and
connector) and screw together using hand-
tightened nut.
• Tighten hydraulic coupling by hand. Rotate
hand-tightened nut until it reaches a tangible,
fixed stop position.
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2.9.12 Setting-up and taking-down
Ensure that the following prerequisites are

met:
- The crane is properly supported.
- The crane is level.
- The counterweight has been attached to the
turntable in accordance with the load chart.
- The telescopic boom is fully telescoped in.
- The boom has been attached in accordance
with the load chart specifications and the
manufacturer's operating manual.
- All limit switches have been correctly fitted
and are fully operational.
- All pinned connections have been secured.
- The hoist rope has been correctly placed in
the rope pulleys and prevented from jumping
out using rope retaining pins.
- No persons are present in the danger zone.
- There are no loose parts on the telescopic or
auxiliary booms.
- In winter, the telescopic boom, boom and
associated components (limit switches, cable
drums, flashing beacon, wind speed gauge
etc.) must be kept free of ice and snow.

DANGER
Danger of fatal injury!

• Incorrectly fitted or faulty limit switches
and falling parts (pins, spring-loaded safety
pins, ice etc.) can cause injury!
2.9.12.1 Checking the preconditions
• Check whether all preconditions have been

met.
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2.10 Inspection of Cranes
2.10.1 Periodic Inspection on Crane
2.10.1.1 General
This crane was tested at the manufacturer's

facilities prior to shipment in accordance with
the latest ISO, FEM and DIN Standards and
BGV D6 (BGG 905).
The safety level achieved during initial
commissioning may not be attainable during
operation.
Examples of the root cause of such deviations
include; e.g., wear and tear, corrosion,
effects of forced operations, changes in the
environment and changes to the mode of
operation.
The operator is responsible for taking the
necessary steps to ensure that the level of
safety is maintained.
The crane operator is therefore obliged to
have the crane inspected by an expert, at
intervals varying to the operational conditions
but at least once per year, from the first day of
vehicle registration.
The crane must be inspected by an authorized
inspector every four years after it has been
licensed. After its twelfth year of operation,
the crane must be inspected annually by an
authorized inspector.
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ATTENTION
There is a risk of weakening the supporting

components when major changes or
repairs are made to the crane!
• In such cases, the operator must have
the crane inspected by an expert before
putting it back into service.
Respective local regulations also apply.
Expert: is a person whose technical training

and experience means that he has adequate
knowledge in the field of inspecting technical
equipment. He is adequately familiar with
the relevant national work safety regulations,
accident prevention regulations, and standards
that he is able to evaluate the operational
safety of the equipment (for example cranes).
Responsible employees from specialist
workshops and customer service engineers
may be considered as experts.
ATTENTION
• Experts are not authorized inspectors!
Authorized inspector: is a person whose

technical training and experience means
that he has explicit knowledge in the field
of inspecting technical equipment. He is
adequately familiar with the relevant national
work safety regulations, accident prevention
regulations, and standards that he is able
to evaluate the operational safety of the
equipment (for example cranes). He is to test
the technical equipment and is able to certify
the equipment as safe. Authorized inspectors
are typically qualified engineers.
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ATTENTION
• Authorized inspectors are legally

recognized experts who have received
special training!
Periodic inspections are principally a visual

inspection, where the authorized inspector /
expert appraises the condition of the crane
and its components.
The purpose of the inspections is to avoid
accidents by detecting deficiencies in a timely
fashion. Any deficiencies determined by the
inspectors must be documented, corrected,
and subsequently reinspected.
A number of important examples of items that
are particularly important during the periodic
crane inspections are listed in the following.
We wish to advise that the two different types
of inspectors take sole responsibility for the
inspections that they carry out. This chapter
does not necessarily cover the entire scope of
the inspections.
A checklist for periodic inspections
recommended for SANY vehicles and crawler
cranes is included in the appendix to assist the
inspectors.
If the inspector has any questions they should
be directed to SANY technical department.

DANGER
Risk of accident!
• Adhere to the following inspection
guidelines and intervals.
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2.10.1.2 Inspecting load-bearing steel

structures

DANGER

The load-bearing steel structures have to
be checked by an authorized inspector at
least once a year.
If this is not the case, they could fail and
cause fatal injury or seriously damage the
crane!
• Load-bearing steel structures must be

checked by an authorized inspector at least
once a year!
• Shorten the inspection intervals if the crane
is subjected to above-average duty cycles,
for example when handling large material
quantities or frequently erecting long boom
systems.
• If the crane was subjected to excessive
operating loads; e.g., due to an unusual
impact, the load-bearing steel structures must
be inspected immediately!
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Steel bearing components such as telescopic

booms, turntables, chassis, support equipment
(e.g., sliding beams or movable stanchions)
must be carefully inspected, at the very
least during the annual recommended crane
inspections. Even though weld joints are not
normally situated at maximum load locations,
it is nevertheless important that they be
inspected with particular care during the
periodic inspections.
We would like to point out that the steel
framework of mobile cranes is designed for
a limited number of stress work cycles. This
determines the design life of the steel support
structures. The life is not determined solely by
the number of stress cycles. It also depends
on the loads applied during operation (duty
cycle).
SANY cranes are designed for assembly
operation and can only perform a limited
number of stress cycles. They are designed
for special movement characteristics. For
example: continuous deployment of drive
forces, occasional operation and load
conditions according to DIN 15018:1984 Part
3 or EN 13000:2004.
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Example of a duty cycle according to the

grouping for SANY Mobile Cranes:
ATTENTION
• The life of SANY mobile cranes can

drastically reduce, for example when
used in magnet, grab or material handling
applications.
Therefore, the load-bearing steel components

and the weld joints require thorough appraisal
by the authorized inspector during the
specified periodic inspections.
If damage (e.g., cracks) are apparent in any
part of the steel structure, the total extent of
the damage must be determined by qualified
specialists using appropriate material test
methods; e.g., magnetic crack detection,
ultrasound or x-rays. The specialists should
then advise whether or not the damaged area
can be repaired by welding or other means.
The following diagrams are samples of the
load-bearing weld designs. The welds or steel
structural zones that require inspection may
be present more than once and in various
forms. The joints or zones must be inspected
all around at the locations identified by arrows.
LI: Load proportion in relation to maximum
load [%]
ATTENTION NI: Stress cycles in relation to maximum load
[%]
• The scope and extent of all inspections
remain the sole responsibility of the
inspectors.
• The scope of the checks and the test
results must be traceably documented.
This documentation forms part of the crane
records and should be safely stored during
the entire service life of the crane.
• The following diagrams are provided to
assist the inspector. The diagrams are only
examples and are not necessarily 100%
complete!
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1. Repair welds
If defects such as cracks or permanent
deformation are detected on load-bearing
steel components, they should be immediately
reported to SANY Customer Service
Department.
Furthermore, the defect must immediately
be appraised by an authorized inspector in
accordance with standard welding practice
rules. The inspector must immediately
ascertain whether or not the crane can
continue to be operated safely until the time of
the repair.
The following items apply to the repair weld:

- Repair welds may only be carried out by the
following persons or companies:
- SANY personnel, or third-party personnel
c o n t r a c t e d b y S A N Y, w i t h a p p r o p r i a t e
qualifications according to EN 287-1 for the
subject material (W 03) and welding method.
- Companies whose suitability is verified
according to DIN 18800, Part 7, DIN 15018,
and DIN 4132 with an endorsement for
cranes, crane runways and the following high
and ultra-high-tensile fine-grained construction
steel:
S690QL1 W.No.1.8988 plates
S690QL W.No.1.8928 plates
S700MC W.No.1.8974 plates
S960MC W.No.— plates
S770QL W.No.1.8938 pipe
S890QL1 W.No.1.8925 pipe
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Experience in repairing mobile and crawler

cranes using the appropriate materials and
application of welding methods in accordance
with MAGM (135), especially manual arc
welding E (111), are absolutely essential.
- Repair instructions that identify the basic
material, along with the required welding
accessories and supplementary materials,
must be requested from SANY before starting
the repair. The required non-destructive tests
must be carried out and documented.
- The repair weld must be carried out in
accordance with the latest revision of SANY's
internal welding guideline, ISR B 010!
- The repaired structural component must
subsequently be subjected to a load test.
- The required test loads and boom
configurations shall be obtained from SANY
Customer Service! Successful test results
shall be documented in the crane inspection
log!
- We also refer to observing the accident
prevention regulations “Principles for testing
cranes by authorized inspectors or experts in
accordance with UVV Cranes BGV D6 and
BGG 905”!
DANGER
Danger of serious personnel injury and
equipment damage!
Comply absolutely with all
recommendations, particularly welding
specifications!
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2.10.2 Inspecting the rims
The rim is one of the most important safety

relevant components on the vehicle.
The rim construction is a welded steel design
and must be tested in accordance with
paragraph 1, “Inspecting load-bearing steel
structures”.
In addition, rim must be inspected for cracks

on both the outsides and the insides, at
the very least during the annually specified
crane inspection. We recommend using the
dye check method. Immediately replace any
rims that show evidence of cracks or crack
formation.
The operator is to inspect the rims, regardless

of the actual duty cycle they were exposed to
after maximum 40000 km.
In particular, the rims should be inspected

for cracks that are developing in the basic
material, as well as at the locations indicated
by the arrows.
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2.10.3 Inspecting the hoist and luffing

winches
The hoist and luffing winches are designed

using integrated planetary gears. The
transmissions are sized for long life and the
drive shafts and gearwheels are rated for
endurance.
Even though the hoist and luffing winches
are designed for long life, an external visual
inspection in not adequate, since their life can
be significantly affected by bad maintenance
(insufficient oil), using oil that does not meet
specification requirements, defective seals,
improper operation or overloading.
The inspection must therefore be carried out
by an expert in accordance with the following
requirements.
2.10.3.1 Inspections
Inspection intervals
1000 hours of operation, minimum once per
year
Inspecting oil level

Check the oil level using the dipstick. For
hoist and luffing winches without a dipstick,
we recommend that the oil is drained and the
amount compared to the specified oil quantity.
Evaluating oil color

Assume that the oil has been overheated if it
is black and/or a burnt oil smell is detected.
Change the oil.
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Checking for foreign substances

This inspection should be carried out by
a qualified laboratory. The used oil shall
be dribbled onto the specified woven filter
medium. Visual inspection using a magnifying
glass may reveal coarse particles.
If particles are detected, all the oil's properties
must be examined by a qualified laboratory.
Evaluation of foreign substances found in the

oil
A qualified laboratory shall be used to assess
the oil.
The maximum permissible quantity of foreign
material measured by weight is 0.15% of
total oil weight. Maximum permissible foreign
particle size from fine abrasion is 0.25
microns.
If above values are exceeded, the
transmission must be dismantled to determine
the root cause of the excessive abrasion.
Damaged components shall be replaced and
the transmission refilled with fresh oil.
NOTICE!
Danger of property damage!
• Repairs may only be carried out by
specialists with appropriate equipment
knowledge.
Visual inspection
The transmissions shall be checked for
leakage, since loss of oil, in addition to
polluting the environment, can lead to
transmission failure.
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Inspecting the transmission brakes

Check the brakes each time the transmissions
are inspected.
In order to do so, proceed as follows:
- Hook on and lift a load just above the ground
which creates the maximum rope tension at
the uppermost reel position.
- Remove the plug from the brake lifting
magnet.
This means the brake remains closed when
activated.
- Operate the winch in the lowering direction.
ATTENTION
• The brake may not slip through, in other

words, the winch may not turn. If the brake
slips though, SANY customer service
department is to be informed.
• Only re-start crane operations after
checking and release by SANY customer
services!
ATTENTION
Danger of property damage!

• Only qualified personnel with specialized
knowledge shall be used to assess
transmissions and brakes.
Documenting the completed inspection and

tests
The results of the annual inspections and
maintenance work, including the steps taken,
shall be documented by the competent or
authorized inspector, including attachments
from the inspection labs and qualified service
companies if any.
This documentation shall be filed in the crane
inspection log under the heading "Periodic
inspections".
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2.10.3.2 Requirements for monitoring the

winches
Design life
The designer of your crane used a theoretical
total operating time when designing and sizing
the winches. This resulted in the design life of
the equipment.
Your crane winches are classified according to
ISO 4301/1 as follows:
Winches Classification
Power train group: M3
Duty cycle: L1
Duty cycle factor Km: 0.125
Design life D: 3200h
Note!
• The “design life” is not equal to the real
(true) life of a winch!
The actual life of the winch is affected by many

additional outside factors; for example:
- Overloads caused by unapproved use of the
crane
- Inadequate maintenance: Oil is not changed
in a timely manner
- Improper operation:
•Extreme acceleration or braking of the load
•Load falling onto the cables
- Improper maintenance:
•Using the wrong type of oil
•Too much or too little oil
•Contamination during oil changes
• Assembly errors during repair and
maintenance
- Undetected leakage
- Incorrectly set safety devices
- Hidden damage from accidents
- Extreme environmental conditions:
•Extreme temperatures
•Corrosive atmosphere
•Dust and dirt
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Actual usage component of the design life

The crane operator is obligated to carry out an
inspection of the crane at least once a year.
At this time, the actual usage component of

the design life shall be calculated. If necessary,
the crane operator shall subcontract this work
to an authorized inspector.
The actual operating conditions (duty

cycle) and the winch operating hours at
each inspection interval are required to
determine the proportion of the design life
that has actually been used. The operator
is responsible for maintaining the crane
inspection log documentation.
Determining the operating conditions (duty

cycle)
The crane’s duty cycle is split into groups,

please refer to ISO 4301/1.
One of the following duty cycles shall be

selected and recorded in the crane inspection
log for the respective inspection interval
based on knowledge of the actual operating
conditions. A more precise determination of
the duty cycle is permissible.
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Duty cycle class light L1

Definition:
Power train or parts thereof are subjected to
maximum loading in exceptional cases, but
normally only operate at very light loads. Graph:
Operating time components:

10% of the time at maximum load (dead load
and 1/1 working load)
40% of the time with dead load and 1/3
working load
50% of the time only with dead load
Duty cycle factor:

Km=0.125
Note!
• Duty cycle L1 with duty cycle factor Km
= 0.125 is normally applied to cranes used
for assembly operations.
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Duty cycle class medium L2

Definition:
Power train or parts thereof are subjected to
maximum loading relatively often, but normally
only operate at light load. Graph:

1/6 of the time at maximum load (dead load
1/6 of the time with dead load and 2/3 working
load
1/6 of the time with dead load and 1/3 working
load
Duty cycle factor:

Km=0.25
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Duty cycle class heavy L3 Graph:

Definition:
Power train or parts thereof are frequently
subjected to maximum loading and normally
operate at medium load.

Duty cycle factor:

Km=0.5
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Duty cycle class very heavy L4 Graph:

Definition:
Power train or parts thereof are regularly
subjected to near maximum load.

Duty cycle factor:

Km=1
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Determining the effective operating hours Ti

The effective operating hours calculated
using the following method shall be entered
into crane inspection log for the respective
inspection interval.
There are four different scenarios:
1.) Operating hour meter installed on every
winch
If an operating hour meter is installed on every
winch, the effective operating hours Ti can be
read directly during each inspection.
2.) Operating hour meter installed for the

overall crane drive
The winch proportion of the total
superstructure operating hours must be
estimated.
For cranes used in assembly operations, the
operating time for the hoist winches can be
estimated at 20% of the total operating hours
of the superstructure.
3.) One operating hour meter is used for both

the crane engine and the crane drive
The winch proportion of the total crane
operating hours must be estimated.
For cranes used in assembly operations, the
operating time for the superstructure can be
estimated at 60% of the total operating hours
of the crane. If the hoist winch proportion
is estimated at 20% of the superstructure
operating hours (see previous item), then in
relation to the total operating hours of the
crane: 12%.
4.) No operating hour meter installed

In this case the operator must estimate and
document the actual operating hours of the
winch. The approximate percentages stated
above normally apply to main hoist winches.
For auxiliary hoist winches or luffing winches,
the proportion of the total operating hours can
be significantly less and should therefore be
estimated by the operator.
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Determining the actual usage proportion of the

design life
For an inspection interval i (maximum 1
year), the actually used proportion Si of the
theoretical design life is derived from the
formula:
Abbreviation Explanation
Si Used proportion of the theoretical design life
Duty cycle factor that was used to select the winch ratings. This
Km
factor is given in the operating manual.
Duty cycle factor for inspection interval according to Chapter

Kmi
“Determining the operating conditions”
Effective operating hours for inspection interval i according to

Ti
Section “Determining the effective operating hours Ti ”
The actually used hours proportion is

subtracted from the remaining design life D i
after each inspection interval (see example).
If the remaining design life is not long enough

to cover the next projected operating period, a
general overhaul of the winch is required.
If the design life D has been reached (see

chapter on “Design life”), the winch may only be
operated after conducting a general overhaul.
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A general overhaul of the winch is required not

later than 10 years after commissioning.
The general overhaul shall be arranged

by the operator and carried out by the
manufacturer or the manufacturer's authorized
representatives and must be documented in
the inspection log. After the general overhaul,
the manufacturer or the manufacturer's
authorized representative will define a new
design life D.
If the design life has not been reached after

10 years, continued operation of the winch
without a general overhaul is acceptable,
provided that the crane's authorized inspector
has confirmed the accuracy of the actual
usage calculation by signing the crane
inspection log at each authorized inspection
interval.
In such a case, the crane authorized inspector

must thoroughly inspect the winch. This
comprises at least:
- External visual inspection (leakage, damage,
deformation).
- Oil inspection, particularly looking for metal
residues.
- Load test at minimum and maximum cable
tension, at maximum speed in both cases. At
least one layer shall be spooled. Pay particular
attention to any unusual noises during the load
test.
The crane's authorized inspector must confirm

this inspection in the crane inspection log and
must make a statement regarding suitability
of the winch for continued operation. The next
inspection shall take place at the end of the
12th operating year, and thereafter annually.
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Example:
According to the manufacturer's operating
manual, a mobile crane with a separate
operating hour meter for the crane engine and
the crane drives classified as follows:
- Power train group: M3
- Duty cycle: light L1
- Duty cycle factor: Km = 0.125
- Design life: D = 3200 h
Actual usage proportion S of the design life
is calculated using the individual inspection
intervals as follows:
First inspection (first year)

The crane was used for assembly work during
the elapsed year:
Duty cycle L1, in other words Km1 = 0.125.
The superstructure operating hour meter
indicates 800 hours. The winch operated
about 20% of the time; i.e. T1 = 160 h.
The actual usage proportion S of the design

life at the time of the first inspection is
therefore:
0.125
S1 = × 160h = 160h
0.125
Remaining design life:

D1 = 3200 h – 160 h = 3040 h
The above values shall be recorded in the
crane inspection log.
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Second inspection (second year)

The crane was used at a harbor for unloading
work:
indicates 2000 hours; i.e., during this period:
2000 h – 800 h = 1200 h (800 h were used
during the first year of operation)
The winch operated about 40% of the time; i.e.
T2 = 480 h.
The actual usage proportion S2 of the design

life at the time of the second inspection is
therefore:
0.5
S2 = × 480h = 1920h
0.125

D2 = 3040 h – 1920 h = 1120 h
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Third inspection (third year)

The crane was used for assembly work and
occasionally at a harbour for unloading work:
3000 h – 2000 h = 1000 h (2000 h were used
during the first two years of operation)
The winch operated about 30% of the time; i.e.
T3 = 300 h.
life at the time of the third inspection is
therefore:
0.25
S3 = × 300h = 600h
0.125

D3 = 1120 h – 600 h = 520 h
Table for determining the theoretical remaining

design life
Table 1 includes an example.
The remaining theoretical design life is to be
documented in table 2.
2-135
Chart to determine the remaining theoretical service life of winch No. 1 (Main hoist winch)
2-136
Crane type: SAC2200 Si=Used part of theoretical service life since last inspection
Safety
Fabrication No.: Di=Remaining theoretical service life

SAC2200
Put in service: Di-1=Remaining theoretical service life after previous inspection

Serial number of winch according to data tag: Km=Factor of load collective, which was taken for calculation of
Last general overhaul performed on: ......... winch.
Configuration data of winch This factor is to be taken from the Operating Manual
(See Operating Manual): Kmi=Factor of load collective in inspection interval i
Drive gear group: M3 Ti=Effective operating hours in inspection interval i
Load collective: Q1(L1) (*) In the following pages, carry over the last line from the
Factor of load collective Km: 0.125 previous page.
Theoretical service life D: 3200hrs
Date Operating Used

Operating part
of hours Operating
Inspection conditions Factor Operating of Remaining
Initial of Operating hours
Interval since of Total crane Hours theoretical theoretical Name Name
Service super- hours of
No. last load operating of service life service of of
structure of winch since Signature Remarks Signature
(max. Inspection collective hours Super- D: life inspector expert
Data since winch last
annually) (load Kmi (h) structure Di=Di-1-Si
of last (h) inspection
collective) (h) (h)
inspection inspection (Ti)
(h) (h)
(*)0 0 0 3200
160(20% of
1 L1 0.125 800 800 160 3040
800)
480(40% of
2 L3 0.5 2000 1200 1920 1120
1200)
300(30% of
3 L2 0.25 3000 1000 600 520
1000)
4
CAUTION: Perform general overhaul at least once every 10 years. In case of deviation, see guidelines in this chapter.
General overhaul last performed on:
Chart to determine the remaining theoretical service life of winch No. .......(Main hoist winch)
Crane type: SAC2200 Si=Used part of theoretical service life since last inspection
Fabrication No.: ............. Di=Remaining theoretical service life
Put in service: ............. Di-1=Remaining theoretical service life after previous inspection
Serial number of winch according to data tag: ............. Km=Factor of load collective, which was taken for calculation of
Last general overhaul performed on: .............. winch.
Configuration data of winch This factor is to be taken from the Operating Manual
(See Operating Manual): ............. Kmi=Factor of load collective in inspection interval i
Drive gear group: M Ti=Effective operating hours in inspection interval i
Load collective: Q...(L...) (*) In the following pages, carry over the last line from the
Factor of load collective Km: ............. previous page.
Theoretical service life D: .............
Date Operating Used

Operating part
of hours Operating
Inspection conditions Factor Operating of Remaining
Initial of Operating hours
Interval since of Total crane Hours theoretical theoretical Name Name
Service super- hours of
No. last load operating of service life service of of
structure of winch since Signature Remarks Signature
(max. Inspection collective hours Super- D: life inspector expert
Data since winch last
annually) (load Kmi (h) structure Di=Di-1-Si
of last (h) inspection
collective) (h) (h)
inspection inspection (Ti)
(h) (h)
(*)
CAUTION: Perform general overhaul at least once every 10 years. In case of deviation, see guidelines in this chapter.
General overhaul last performed on:
2-137
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2-138
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2.10.4 Inspecting the load hooks
The load hooks must be inspected annually by

an expert.
expert must be documented, corrected, and
subsequently reinspected.
2.10.4.1 Inspection and monitoring

procedure
1. Deformation
The hook should be inspected for distortion as
required, but at least once a year; e.g., at the
hook jaw. The original dimensions, (y) or (y1)
and (y2), are given on the load hook itself.
Measure between the punch marks.
DANGER
Risk of accident!
Hook jaw distortion may not exceed 10% of
the original dimensions (y) or (y1) and (y2).
• Do not use a load hook that exhibits
greater distortion.
• Advise the SANY Customer Service
Department.
2 .Corrosion
DANGER
Risk of accidents caused by thread
corrosion/wear and tear!
• Stop using the load hook.
• Advise the SANY Customer Service
Department.
Unscrew the nut from the hook shank
so that the threads can be inspected for
corrosion and wear and tear.
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2.10.5 Inspection of the rope feed

mechanics in the telescopic boom
Inspection of the pre-tension on the luffing

ropes.
The rope discard time is as per DIN 15020 or
ISO 4309.
2.10.6 Inspecting the operation of the

inner and outer interlocking systems of
the telescopic boom
For cranes with a pneumatic interlocking

system: Pin pattern, wear and tear and safety
interlocking.
2.10.7 Inspecting the safety switching

on the relapse supports
Inspecting the interlocking system or limit

switches on the relapse supports and the
boom A-frames.
2.10.8 Inspecting the nitrogen storage

tank
Inspect the nitrogen storage tank for specified

gas pressure, particularly for relapse supports
and suspension storage tanks (comply with
specifications).
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2.10.9 Inspecting the rope pulleys
DANGER
Risk of accident when damaged or
cracked!
• Replace rope pulley as soon as possible.
Inspect the entire rope pulley assemblies for

damage and cracks once a year.
If rope pulleys are subjected to any impacts
(e .g ., w i th b u i l d i n gs) or a re o th e r w i s e
overloaded, they must be immediately visually
inspected for damage or cracks.
Also check for wear on the rope groove.
Replace the pulley if the bottom of the rope
groove has been worn down more than 1/4 of
the rope diameter.
2.10.10 Testing overload protection

operation
Position the longest boom at minimum and

maximum radius: Check the load indicator,
using the hook block as a test load.
The indicator reading shall not deviate more
than 10% off the true load value at these two
extreme positions.
Measure the indicated radius for the longest
boom at its minimum radius and at a boom
angle of 45°. The indicator reading shall not
deviate more than 10% off the measured
projection.
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2.10.11 Inspecting the mounting of the

load bearing equipment
Check that the mounting bolts for the roller

slewing ring, winches, slewing gears and
trailer coupling are properly seated.
Slewing ring connection mounting bolts

are pre-stressed at the factory, so that no
loosening of the bolted connections will occur
during normal crane operation.
However, the bolted connection may become

overloaded and the bolts may be permanently
stretched if the crane is overloaded or if a fixed
load is pulled free. It is therefore important to
check these bolts for proper seating during the
annual crane inspection or after an overload
has occurred.
Completely remove loose bolts, plus the two
adjacent ones, and immediately check for
damage. Inspect the bolts, particularly for
cracks or permanent distortion. If a bolt has
been stretched by more than 0.2% (related to
its original length) or if cracks or other damage
are detected, then the damaged bolts must be
replaced. If the bolts have been stretched or
there is other damage, then also replace the
adjacent bolts.
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2.10.12 Inspecting the oil and fuel

reservoirs
Oil and fuel reservoirs shall be inspected at

least once a year and checked all around for
leakage during the periodic inspections every
four years.
Repairs shall only be carried out by trained
and knowledge able specialists.
Improper repairs; e.g., welding, hard or soft
soldering is not permitted, particularly if the
SANY Customer Service Department has not
been consulted!
2.10.13 Inspection of the auxiliary

reeving winch, towing winch and spare
wheel winch
Determine the design life of the auxiliary

reeving, towing and spare wheel winches from
their respective original manufacturer.
2.10.14 Appendix
The following is a checklist to assist the

inspector during the periodic inspections of
SANY cranes.
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2.10.14.1 Inspection recommendations for

periodic inspections of SANY cranes
Company: Inspector:
Crane manufacturer: SANY Crane type:
Serial number: Stock number:
Construction year: Date:
Inspector's signature for No. 1 to 20:
1. Inspection category: Crane document

Component inspected A B C D E Comments
Crane inspection log
Operating and installation instructions
Crane register
Load chart manual
Operation planner
2. Inspection category: Signs / labeling

Factory nameplate
Loading information
Operating specifications label
Prohibition and command signs
Other safety labels
3. Inspection category: Vehicle 1

Frame 2
Supports 3
Axles
Wheels
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3. Inspection category: Vehicle 1

Tires
Bearings
Transmission
Drive shaft
Leaf springs / springs
Shock absorbers
Steering
Brakes
Hydraulic suspension
4. Inspection category: Chassis 1

Enclosures
Treads
Counterweight holders
Suspension equipment
Ladders
Hook block mounting2
Boom support2
5. Inspection category: Chassis - driver cab 1

Doors
Windows / glazing
Windscreen wiper
Mirror
Seat
Heating
Ventilation
Soundproofing
Tachograph
First-aid box
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5. Inspection category: Chassis - driver cab 1

Replacement lamps
Hazard warning triangle
Safety vest
6. Inspection category: Chassis - drive 1

Combustion engine
Exhaust system
Fuel tank
Filters
Soundproofing
Engine mounting
Oil levels
Fuel lines
7. Inspection category: Chassis - hydraulics 1

Oil reservoirs
Filters
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure limiting valves
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8. Inspection category: Chassis - compressed air system 1

Compressor
Filters
Air tanks
Valves
8. Inspection category: Chassis - compressed air system 1

Lines
Hoses
Cylinder
9. Inspection category: Chassis - electrical system 1

Motors
Generators
Battery
Switch
Lines
Fuses
Resistors
Lighting
Brake lights
Indicator lights
Tail lights
Working lights
Signaling systems
Control lights
Battery switch
Limit switches: Transmission, steering, engine
Supporting pressure indicator
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10. Inspection category: Chassis - control systems 1

Engine control
Transmission
Couplings
Circuits
Brakes
Steering
Monitoring indicators
Engine braking performance
10. Inspection category: Chassis - control systems

2
Support controls
Axle suspension
Crane leveling
Rear axle steering
11. Inspection category: Superstructure

Frame
Enclosures
Treads
Bearings
Counterweights
Relapse retainer
Slewing ring connection: Tilting free play
Slewing ring connection: Mounting bolts
Slewing ring connection: Gearing
Slewing gear: Mounting bolts
Slewing gear: Gearing
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12. Inspection category: Superstructure - crane operator‘s cab

Doors
Windows / glazing
Windscreen wiper
Mirror
Seat
Heating
Ventilation
Soundproofing
Operating and control joysticks
Gear shifting
Safety: Crushing / shear locations
13. Inspection category: Superstructure - hand-hold and protection systems

Grab handles and treads To the cab and to the power train
Enclosures
Covers
Hatches
14. Inspection category: Superstructure - engine

Combustion engine
Exhaust system
Fuel tank
Filters
Soundproofing
Engine mounting
Fuel lines
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15. Inspection category: Superstructure - hydraulic system

Oil reservoirs
Filters
Pumps
Motors
Valves
Lines
Hoses
Cylinder
Pressure limiting valves
Lowering brake valves
Brake controls: Hoist gear
Brake controls: Slewing gear
16. Inspection category: Superstructure - electrical system

Motors
Generators
Batteries
Switch
Lines
Fuses
Resistors
Lighting
17. Inspection category: Superstructure - control systems

Engine control
Transmission
Flexible couplings
Circuits
2-150
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18. Inspection category: Superstructure - rope drives

Winch 1
Winch 2
Winch 3
Winch 4
Rope pulleys
Rope end connection
Rope for winch 1
Rope for winch 2
Rope for winch 3
Rope for winch 4
Stay ropes
19. Inspection category: Superstructure - load hook

Pulleys
Pulley guard
Axle support
Load hook
Load hook mounting
Hook safety device
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20. Inspection category: Superstructure - safety and switching systems

Hoist emergency limit switch I
Hoist emergency limit switch II
Lowering emergency limit switch I
Lowering emergency limit switch II
Boom emergency limit switch I
Boom emergency limit switch II
Luffing jib: Boom limit switch I
Luffing jib: Boom limit switch II
Load torque limiter
Angle indicator: Boom
Angle indicator: Luffing jib
Angle indicator: Slewing gear
Safety devices: Controls
Operating range limiter
Pressure sensors
Speed sensor
Wind sensor
Sliding beam monitoring
Support pressure indicator
Slope indicator
Length indicator: Projection, boom length
Emergency stop
Engine stop
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21. Inspection category: Boom

Weld joints
Rope pulleys
Luffing cylinder
Telescoping cylinder
Boom extension ropes
Boom retraction ropes
Boom bearings
Boom pinning
Guy posts
Relapse cylinders
Inspection criteria:
A= present / complete
B= condition / maintenance
C= function
D= repair / replace
E= reinspection required
Assessment:
satisfactory=x
unsatisfactory=-
not required=0
Comments:
1
Inspection of the crane carrier vehicle road
worthiness is also fulfilled if it has already
been certified
by the road traffic department certification
authority. For cranes that are not certified for
use on public roads, an expert or authorized
inspector must conduct the required tests to
validate the vehicle‘s road worthiness.
2
These inspections must be carried out by a
authorized inspector even if it has passed the
road traffic department test and is certified.
3
Inspection of the winches with respect to the
actually used proportion of their design life.
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2.10.15 Inspection on wire rope
2.10.15.1 Introduction
DANGER
Danger of fatal injury due to defective

crane ropes!
• Do observe the following criteria.
The rope should be considered to be a

wearing part of a crane that must be replaced
if checking shows that its strength has reduced
to such an extent that continued use thereof
may be dangerous. Regular checking of the
rope is required in order to safely carry loads
using correctly deployed equipment, meaning
that the rope must be stop being used at an
appropriate point in time.
The take-down criteria with regard to rope
breaks, wear, corrosion and deformation
can be applied immediately under all usage
conditions. The different factors are dealt
with in ISO 4309, which is intended to serve
as a guideline to competent experts who are
involved in maintaining and testing cranes.
The criteria that are dealt with are intended
to provide appropriate safety for transporting
loads with cranes until the rope is taken down.
2.10.15.2 Wire rope
1. Condition before installing

The rope is usually replaced with a rope that
is of the same type as the original. If the spare
part is of another type, the user must ensure
that the rope characteristics are at least as
good as those of the rope that was taken
down.
Before installing a new wire rope the grooves
of the rope drums and pulleys must be
checked in order to ensure that they can
accommodate the spare part correctly (see
section entitled “Checking”).
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2. Installing
When the rope is removed from the spool
or unwound from a reel, it must be ensured
that the rope is not twisted, otherwise loops,
reverse bends or kinks may occur.
If the rope is looped over any part of the
system when it is not under strain, these areas
must be protected accordingly.
Before starting to use the rope on the system
the user must ensure that all components
that are functionally associated with the rope
have been set up in such a way that they will
operate correctly. The crane should be used
for lifting at approximately 10% of the normal
load in order to stabilize the rope.
3. Maintenance
The ropes are maintained depending on the
type of crane, the deployment thereof, the
environment and the type of rope that is used.
Unless other instructions from the crane or
rope manufacturer apply, wherever possible
the rope should be cleaned and lubricated with
grease or oil, particularly in areas in which the
rope is subjected to bending when it runs over
pulleys.
The lubricant that is used must be suitable for
steel ropes.
Lack of maintenance will reduce the service
life of the rope, particularly if the crane is used
in a corrosive environment and if re-lubricating
is not possible because of the nature of the
respective deployment of the crane.
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4 Checking
4.1 Frequency
Daily checking
If possible, all visible parts of the ropes must
be checked for general wear and deformation
on every working day. Special attention must
be made to the rope end connections. Any
suspected changes in the condition of the rope
must be reported and the rope checked by a
trained expert in accordance with the section
entitled “Points to check on the rope”.
In the event that the lower rope lays on the
drum are used infrequently or not at all,
periodically unwind and rewind the entire drum
at the appropriate tension. A rope is most cost-
effective when the entire length is used. An
appropriate rope length should therefore be
used when operating the crane over longer
periods.
Note!
• If a rope is replaced, then it must be
pretensioned and placed with a pretension
of 10% of the maximum rope pull.
Special checking as described in section

“Points to check on the rope”
The rope must be checked after any events
that may have led to damage to the rope and /
or the rope ends and whenever the rope starts
to be used again after being taken down and
then re-installed.
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4.2 Checking the spooling behavior of the rope

on the cable drum
To avoid spooling errors and connected rope
damage, it is necessary to check the spooling
behavior daily. As a precaution, the rope
should be spooled off and on again regularly.
Possible spooling errors:

—— Cutting into the lower rope layers 1
—— Loop formation in the lower rope layers 2
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4.3 Points to check on the rope

General
Although the entire length of the rope must be
checked, particular attention must be paid to
checking the following areas:
— at the rope end points at both sides, for
both moving and fixed ropes
— the part of the rope that runs through the
block or over rope pulleys; particular attention
must be paid to parts of the rope that are on
rope pulleys when under load (see appendix 1)
in systems that carry out repeated movements
— parts of the rope that run over a
compensation pulley
— all parts of the rope that can be subjected
to wear caused by external elements (e.g.
protruding hatch surrounds)
— all parts of the rope that are subjected to
the effects of heat
— on the contact positions of the ropes when
spooling up
— check the inside of the rope for corrosion
and material fatigue
The results of the checking must be entered in

the system checking log (for typical example
see section entitled “Rope checking log” and
appendix 2).
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Checking the rope in the uphill pitch zones of

the rope coil for flat sections
In the cross area of the coiled up rope
layers, the rope is under more strain and can
therefore be flattened. To void flat sections,
the rope can be shortened on the rope drum
fixed point.
If the wires in the outer braids are flattened to
no more than maximum half the wire diameter:
—— Shorten the rope by a length of 1/3 of the
rope drum circumference and reset.
DANGER
Rope breakage!
If the following measures are not observed,
the rope can break, the load can fall down
and fatally injure personnel!
• Take the rope down when the take down

criteria is reached, as described in section
“Take down criteria”!
• Take the rope down when the wires in the
outer braids are flattened by more than half
the wire diameter!
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Rope suspension and connection systems -

except loops
The rope must be examined at the exits of
the rope suspension and connection system,
since this area is particularly susceptible to
initial signs of material fatigue (wire breaks)
and corrosion. The rope suspension and
connection systems must also be examined
for signs of deformation or wear.
Rope suspension and connection systems

with pressure sleeves must undergo the same
checking, and the sleeve must be checked
for cracks in the sleeve material and possible
slippage of the rope in the sleeve.
Detachable rope suspension systems (cotters,

rope clamps) must be checked for wire breaks
inside and beneath the mount or fastening; it
must also be examined whether the cotters
and screwed-on rope clamps are firmly
connected to the rope. This check should
also ensure that the requirements of the rope
suspension and connection systems standards
and procedural guidelines are complied with.
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5. Take-down criteria
The safe use of the rope is assessed in
accordance with the following criteria:
1) Number of wire breaks
2) Broken wire nests
3) Wire break increase rate
4) Strand breaks
5) Rope diameter reduction, including the
reduction caused by damage to the rope core
6) External and internal wear
7) External and internal corrosion
8) Deformation
9) Damage caused by the effects of heat or
arc welders
These individual factors must be taken into

consideration in accordance with the relevant
criteria during all examinations. However, rope
quality deterioration frequently results from a
combination of the individual factors, meaning
that a worsening effect occurs that can be
detected by an expert and that influences the
decision as to whether the rope has reached
its rope removal limit and whether it can
continue to be used.
The checker must investigate whether the
deterioration has been caused by a fault in
the system; if this is the case remedial action
should be recommended before fitting a new
error.
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5.1 Number of wire breaks

The number of wire breaks must be
determined by visually inspecting the entire
length of the rope. If a wire break is found,
sections that are 30 × d (d = nominal rope
diameter) in length are marked at both sides
of this point. These sections must examined
extremely carefully. All wire breaks are now
carefully counted in each section. Please
compare the number if visible wire breaks with
appendix 4.
If the number of visible wire breaks is less than
the number specified in the table, the area
in which the most broken wires are found is
marked to a length of 6 × d. Count the number
of visible wire breaks again and compare the
result with appendix 4. If the number of visible
wire breaks is less than the number specified
in the table, the rope does not have to be
taken down yet.
Note!
Defining the interval until the next check
• The interval until the next check is set
depending on the number of visible wire
breaks.
5.2 Broken wire nests

If the wire breaks are extremely close together
and form wire nests, the rope must be taken
down. If the frequency of such wire breaks
occurs over a rope length of less than 6d or is
concentrated on one strand, taking the rope
down is recommended, even if the number of
wire breaks is less than the maximum number
specified in the tables.
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5.3 Wire break increase rate

For applications in which the main reason for
damage to the rope is material fatigue, the
first wire breaks will not occur until a certain
time has elapsed, but the number of wire
breaks will increase rapidly at ever-decreasing
intervals.
Careful checking and logging of the
increased number of wire breaks over time is
recommended in these cases.
5.4 Strand breaks

If an entire strand breaks, the rope must be
taken down.
5.5 Reduction in rope diameter caused by

damage to core rope
The rope diameter can be reduced as a result
to damage to the core because of:
1) Internal wear and notching
2) Internal wear because of friction between
individual strands and wires in the rope,
particularly if it is subjected to bending
3) Steel core breakage
4) Break in internal layers of multi-strand ropes
If the rope diameter (average of two diameter
measurements) is reduced by 3% of the
nominal diameter (rotation resistant ropes) or
10% of the nominal diameter of other ropes
due to these factors, the ropes must be taken
down, even if no wire breaks are visible.
Note!
Diameter of new ropes
• New ropes can have an actual diameter
that is greater than the nominal diameter,
meaning that proportionally greater wear is
possible.
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5.6 External wear

Abrasion of outer wires of outer rope strands
as a result of rubbing contact under pressure
with the grooves in the rope reels and drums.
This condition is particularly evident in moving
ropes in the areas in which they come into
contact with rope pulleys when the load
is being moved and braked, and manifest
themselves as flattened surfaces on the outer
wires. Wear is increased by lack of or incorrect
lubrication and the effect of dust.
Wear reduces the breaking strain of steel

ropes because the cross section of the steel
is reduced. The rope must be taken down if
the actual rope diameter has reduced by 7%
or more because of outer wear, even if no wire
breaks are visible.
2-164
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5.7 External and internal corrosion

Corrosion is a particular problem in maritime
climates and atmospheres that are polluted by
industrial emissions, reducing breaking strain
and accelerating material fatigue because
of the reduction in the rope material cross
section, leading to irregular surfaces that are
the starting point for stress cracks.
1) External corrosion
Corrosion of the outer rope wires can be
determined by visual inspection
2) Internal corrosion
This condition is more difficult to detect than
external corrosion.
Note!
Internal corrosion
• If there are any signs of internal corrosion
the rope must be checked by a competent
expert.
DANGER
Occurrence of internal corrosion!
• If the suspicion of extreme internal
corrosion is confirmed, the rope must be
taken down immediately.
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5.8 Rope deformation

A visible change to the rope structure is
referred to as “rope deformation” and can
cause a change at the deformation point that
results in irregular rope tension.
A distinction is made between the following
important types of rope deformation on the
basis of the rope appearance (see following
sections):
1) Corkscrew-like deformation
2) Basket formation
3) Strands protruding from the rope
4) Wire loop formation
5) Flattening
6) Reverse bends or knots
7) Kinks
Corkscrew-like deformation (see Appendix 3,

table 1)
If there is any corkscrew-like deformation
the rope must be taken down if the following
condition is met:
d = nominal diameter of rope

d1= rope sheath diameter Corkscrew-like deformation
Length of rope must be less than 25d.
Basket formation(see appendix 3, table 2)

If there are kinks in the rope it must be
replaced immediately.
Strands protruding from the rope(see appendix

3, table 3)
The rope it must be replaced immediately if
this kind of deformation occurs.
2-166
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Wire loop formation (see appendix 3, tables 4

and 5)
In this case, certain wires or groups of wires
protrude from the rope at the side facing
the rope pulley in the form of loops - this is
normally the result of sudden strain. If serious
deformation occurs the rope must be taken
down.
Flattening (see appendix 3, tables 8 and 9)

Flattening is the result of mechanical damage;
if it is pronounced the rope must be replaced.
Reverse bends or knots (see appendix 3,

tables 6 and 7)
If the rope has any reverse loops or knots it
must be taken down immediately.
Kinks (see appendix 3, table 10)

Kinks are angled deformations in the rope
caused by external influences. If there
are kinks in the rope it must be replaced
immediately.
5.9 Damage caused by the effects of heat or

arc welders
Steel ropes that have been subjected to
extremely high temperatures, which can be
detected externally because of the colouring
that it causes, must be taken down.
2-167
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2.10.15.3 Operating behavior of steel ropes
Exact logging of information by the checker

can be useful for predicting the behavior of
a certain type of steel rope on a crane. This
information is useful for planning and adapting
maintenance instructions and controlling the
stocking of spare ropes. The use of such
a prediction system should not cause the
examinations to be less strict or the rope
usage time to be extended beyond the criteria
that are specified in the previous sections of
this guideline for the monitoring and taking
down of crane ropes.
2.10.15.4 Condition of equipment that is

functionally associated with the rope
Note!
Rope radius
• The radius must not be smaller than the
actual diameter of the rope.
Rope drums and pulleys must be checked

at regular intervals in order to ensure that all
these components rotate correctly in their
bearings. Stiff or blocked rope pulleys wear
rapidly and unevenly and cause serious rope
abrasion. Ineffective compensation pulleys
can lead to irregular rope tension. The radius
at the bottom of the rope grooves of all rope
pulleys and the drum must be suitable for the
nominal diameter of the rope. If the radius has
become too big or too small the rope groove
must be reworked or the rope pulley replaced.
2-168
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2.10.15.5 Rope checking log
The user must produce a log for each of the

regular checks in which all rope checking
information is recorded. Typical example of a
log - see appendix 2.
2.10.15.6 Rope storage and marking
Clean, dry rope storage facilities must be

provided in order to prevent damage to ropes
that are not in use; it must also be ensured that
the ropes can be clearly and unambiguously
assigned to their checking logs.
2.10.15.7 Wire ropes and rope end

connections
DANGER
Risk of accident!
• Correct choice and use of rope and
rope end connections are decisive
preconditions for proper and accident-free
crane operation.
The wire ropes and rope end connections

selected in accordance with their usage. It
must be determined whether a non-twisting or
twisting rope is required. The type of rope that
is selected then determines the type of rope
end connections that are used.
2-169
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1. Non-twisting ropes and their rope end

connections
Non-twisting ropes are special ropes that
produce extremely little torque and twisting at
the rope end connection when they are under
strain.
Because of this rope characteristic, these
ropes are used as hoist ropes.
Typical non-twisting wire rope structures are

ropes with 15 to 18 outer strands. Non-twisting
ropes are symbolically depicted with 15 outer
strands (circles) (see table 1).
Non-twisting ropes can be optionally used with
the following rope end connections:
—— Rope end connection rotating in the form
of a PFEIFER link with swivel or spin stabilizer
/ swivel
—— Rope end connection non-rotating in the
form of a PFEIFER link without swivel or cotter
If possible, preference should be given to
the use of a rotating rope end connection to
reduce torsional stress with non-twisting ropes
(see table 2).
DANGER
equipment damage!
• Never use rotating rope end connections
with twisting ropes!
Note!
Usage warning!
• The usage warning on the rotating
PFEIFER link with swivel indicates that this
rope end connection may not be used for
twisting ropes (see table 3)!
2-170
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2. Twisting ropes and their rope end

connections
Twisting ropes generate high torque levels at
the rope end connection when they are under
strain. For this reason, the rope ends must be
protected from twisting using an appropriate
rope end connection to prevent the rope from
unscrewing under strain!
Because of this rope characteristic, these
ropes are used as adjusting ropes, retracting
ropes or control ropes.
Typical twisting wire rope structures are ropes

with 8 to 10 outer strands. Twisting ropes are
symbolically depicted with 8 outer strands
(circles) (see table 4).
Twisting ropes can only be used with the
following rope end connections:
—— Rope end connection non-rotating in
the form of a PFEIFER link without swivel or
cotter.
Connecting the rope to the fixed point of the
winch drum also constitutes a non-rotating
rope end connection
DANGER
equipment damage!
• Never use twisting ropes with a rotating
rope end connection!
• Never install a twist compensator / swivel!
Note!
Usage warning!
• The usage warning on PFEIFER links
without swivel and cotter indicates that this
rope end connection may not be used for
twisting ropes in combination with a twist
compensator/swivel (see table 5)!
2-171
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2.10.15.8 Twisting caused by stretching in

non-twisting ropes and remedying thereof
DANGER
Damage to the cable!
• Do proceed with extreme caution when
performing the following actions.
• Do follow the following instructions to the
letter.
1) The number of strands should be the

number at which the hook block twists the
most.
2) Extend boom head fully and lower the

block.
3) Load hook block with at least approx. 10-

15% of nominal tension per strand.
• The following actions must be performed by
an assistant before lifting the load:
• Rotate twisted hook block to straight position
by hand (strands are no longer touching).
• Then rotate hook block by an additional 360°
by hand (strands touch each other).
4) When lifting the load, hold the hook block in

the specified twisted position until the load lifts
from the ground.
Caution: When the hook block comes under
strain, it will attempt to rotate back to a straight
position. Now release the hook block.
5) In the next step, raise the load to a height

of approximately 15 m below the maximum
height. The boom remains out all the way.
6)Then lower the load and put it down.

Now there is much less hook block twisting,
possibly even no twisting at all.
7) Repeat this procedure if necessary.
2-172
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Fig. 1
A- Hook block B- Cable pulley C- Rope drum
2-173
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2.10.15.9 Appendix 1
Diagram of possible defects with reference to

different issues that must be considered during
checking:
1) Check rope end connection at rope drum
2) Examine for incorrect spooling up, which

causes deformation (crushing) and wear,
which can have serious consequences at rope
crossing points
3) Examine for wire breaks
4) Examine for corrosion
5) Look for deformation as a result of block

loading
6) Inspect parts of rope that run over rope

pulleys for wire breaks and wear
• Rope suspension and connection systems:
• Check for wire breaks and corrosion
• Also inspect parts of rope that run on or next
to compensating pulleys
7) Look for deformation
8) Check rope diameter
9) Carefully check length of rope that runs

through the lower block, particularly the part
that rests on the rope pulley under strain
10) Check for wire breaks and surface wear
11) Check for corrosion
2-174
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Machine:
Data sheet for ropes
Application:
Construction: Date fitted:

Direction of rope lay: RH / LH 1) Date discarded:
Type of lay: Ordinary / Langs 1 )
Nominal diameter:
Tensile grade:
Minimum breaking load:
Quality: ungalvanized / galvanized 1)
Working load:
Type of core:
Steel/natural or synthetic textile/mixed
1)
Preformation:
Diameter measured:
Length of rope:
Under a load of:
Type of termination:
Reduction of Damage
Abrasion of Overall
Visible broken wires Corrosion rope and
Outer wires assessment
diameter deformation
Positions
measured
Number Numbe Degree of Degree of

Degree of
in length in length deterioration Deterioration % Nature
Deterioration 2)
of 6d of 30d 2) 2)
Date: Signature:
Rope supplier: Number of working hours:

Other observations: Reasons for discard:
1) Delete as applirope
2) In these columns, describe the latter as:
slight, medium, high, very high, discard.
2-175
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2-176
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2.10.15.10 Appendix 2
Note!
Depiction of deformation
The deformation is that is depicted is
exaggerated in order to show it more
clearly
• The ropes that are shown would have had
to be taken down long before they reached
this stage.
Typical examples of damage that can occur to

wire ropes:
— Picture 1:
Corkscrew-like deformation: deformation
where rope is in the form of a spiral along its
longitudinal axis.
The rope must be taken down if the
deformation exceeds the value that is
mentioned in chapter “Take-down criteria”,
section entitled “Corkscrew-like deformation”.
— Picture 2:
Basket formation on a multi-strand rope.
Reason for immediate rope take-down.
— Picture 3:
Steel core rope exit, generally in combination
with basket formation in the immediate vicinity.
— Picture 4:
Only one strand is affected by loop formation,
although the examination of a longer section
of rope shows that the deformation is visible at
regular intervals; normally deformation along
the length of an impact.
2-177
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— Picture 5:
Serious worsening of the previous problem
(see picture 4) (typical of hoist rope in a ram
system).
— Picture 6:
A serious reverse bend or knot
Note the destroyed lay that leads to the exit of
the fibre layer.
— Picture 7:
A wire rope that has been kinked during
installation but started to be used anyway
and now suffers from localised wear and
substandard rope tension.
Reason for rope take-down.
— Picture 8:
Crushing as a result of local mechanical
damage causing imbalance beneath the
strands, resulting in wire breaks.
— Picture 9:
Crushing of a multi-strand rope caused by
incorrect spooling up on the rope drum.
Note increase in length of outer strands of lay.
Here too, imbalance would occur under strain.
— Picture 10:
Example of serious kinking
2-178
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2.10.15.11 Appendix 3
Guideline for number of wire breaks in
accordance with ISO 4309 for power train
classification groups M1, M2, M3 and M4
1. Wire ropes
Hoist ropes, assembly ropes, guy ropes,
control ropes
Number of visible broken wires requiring rope removal, over a length of

Rope diameter
6 x rope diameter 30 x rope diameter
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1. General
Always check the entire length of the guy
posts before installing. Including the concealed
bearing surfaces and holes.
2. Checking by an expert
The guy posts must be checked at least once
per annum by an expert (in accordance with
VBG 9, VBG 9a). The guy posts must also
be checked by an expert more frequently in
accordance with the usage conditions and
operational situation if necessary .
The checking frequency generally depends on
the usage conditions and should be increased
in line with the amount of use of the equipment
if necessary The checks must be documented.
DANGER
Risk of accident in case of guy post failure!
•If the following damage is found, the guy
posts must no longer be used and must be
replaced immediately!
2-180
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2.1 Cracks and notches

The guy posts must be carefully inspected for
cracks and notches. If cracks are found the
guy posts must be replaced. In case of doubt
the relevant areas must be carefully examined
using magnetic crack detection, for example.
Repairs are not permitted.
2.2 Stretching
Check for guy post stretching by measuring
the guy posts. The guy posts must not stretch
by more than 0.2%, e.g. 14 mm with 7000 mm
guy posts.
2.3 Wear
Check holes, bolts and bolt retainers for signs
of wear.
2.4 Damaged paintwork

Check guy post paintwork at regular intervals
(signs of corrosion). Make good damaged
paintwork. The guy posts must not be stored
in aggressive media such as salt water.
2.5 Distortion
If the guy posts become distorted (e.g. bent)
they must be replaced.
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2.11 General Notes
2.11.1 Daily checking
The following checks are to be carried out

daily and before each start-up:
- Check that all oil and fuel lines are leak-free
and dry.
- Check that the injection pump, fuel and oil
filters are leak-free.
- Check that the hydraulic units, fan drive
hydraulic motors and their supply lines are
leak-free.
- Check that the exhaust system and exhaust
flange are leak-free.
- Check whether the exhaust flap retention flap
is free.
The return springs that open the exhaust

flaps must function properly, because seized,
and therefore closed exhaust flaps during
engine operation will result in considerable
overheating.
- Inspect electrical wiring and ensure that there
is sufficient clearance to hot exhaust system
piping and that it is properly fastened and that
there is no insulation damage.
- Inspect the soundproofing mats for soiling
from solutions and large quantities of oil or
fuel, as well as other damage.
Immediately remove any soundproofing mats

that are excessively damaged or soiled and
replace them with new ones.
Observe care instructions in the maintenance
chapter regarding sound damping when
cleaning the engine or gearbox room.
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2.11.2 Repair and maintenance tasks
Note!
• Repair and maintenance tasks are to be
carried out carefully!
Ta k e p a r t i c u l a r p r e c a u t i o n s r e g a r d i n g
cleanliness when replacing diesel and oil
filters. Remove any diesel fuel or oil that has
leaked. Perform a test run on the systems
to ensure that there are no leaks. The diesel
engine V-room must be inspected regularly,
and any oil or diesel fuel must be cleaned up,
particularly after repairs and servicing. Any
fuel that has collected in V-room can spread
throughout the engine room while the crane is
traveling on the road and can ignite if it comes
into contact with hot surfaces.
We stress that all electrical wiring must be

installed according to the regulations and
must be properly fastened. Immediately
repair any wiring insulation that exhibits
signs of chafing or brittleness as a result of
operational activities. Any wiring that is not
in perfect condition is to be immediately and
professionally replaced.
We would like to particularly emphasize that

over time fuel and oil lines can become brittle
or porous as they age. Any hoses that appear
to be excessively porous should be replaced
immediately see crane maintenance chapter.
2-183
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2.11.3 Important servicing
The following service tasks are to be carried

out regularly:
- Grease drive shafts with SANY special
grease
- Regularly check that the drive shaft bolts are
properly seated
- Check gearbox and engine oil levels regularly
Add oil as required during normal operation.
If oil consumption or loss is unusually high,
determine the cause and correct.
2.11.4 Maintenance notes for

replacement parts
The following is to be considered when

replacing drive components such as engine,
gearbox or axles:
- Before re-starting, be sure to refill with the
correct type of oil to the centre of the min. -
max. markings
Refer to the nameplate and operating
materials and lubricants to determine the oil
type
- Conduct initial maintenance according to
chapter “Maintenance intervals”; thereafter,
maintain in accordance with the specified
maintenance intervals.
- Maintain break-in instructions, see chapter
1.02
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2.11.5 Instructions for travel operation
NOTICE!
Engine damage!
If the permissible engine speed in
exceeded, the engine can be seriously
damaged!
• Do not exceed the permissible engine
rpm!
2.11.6 Disposal of service fluids and

lubricants
Note!
Engine, gearbox and hydraulic oils, grease,
fuels!
• These substances may not be disposed of
in the ground, waterways, drains, sewers or
groundwater!
• Comply with the regulations specified by
local authorities before disposing of any of
these items or substances!
Note!
Radiator fluids for diesel engines and
heating systems!
• Undiluted antifreeze / corrosion protection
substances must be treated as hazardous
waste!
• Follow the regulations of the local authorities
when disposing of used cooling fluids (mixture
of antifreeze/corrosion protection solution and
tap water)!
2-185
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2.11.7 Tires
2.11.7.1 Wheel checks
DANGER
If the clamp collar 2 is not properly
installed, it can be violently ejected when
the tire is inflated causing death!
• If the clamp collar 2 is not correctly
seated, please obtain the assistance of an
authorized trained specialist!
• Do not make any alteration to the tire
pressure!
• Visually check the side ring and clamp
collar 2 for correct positioning!
DANGER
• In the event of insufficient profile or
damage to the tires, exchange tires for new
ones!
• Maintain correct tire pressure! See
chapter 1.03.
• If the tire pressure has sunk below 3
bar, the tire may only be pumped up by
qualified and trained personnel!
• Replace damaged rims 1 with new ones
immediately!
• Check depth of tread.
• Check tires for damage.
• Check tire inflation pressure.
• Check wheel disks 1 for damage.
2-186
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2.11.7.2 Tire changes
Note!
• Tires may only be changed by authorized
and trained specialist personnel!
•This applies both to dismounting and
mounting of the tire on the wheel disk 1!
2.11.7.3 Wheel changes
1. In event of tire failure
Note!
The following is to be considered in the
event of tire failure!
• Pay attention to road traffic when stopping!

• The steering wheel could judder. Hold on to
the steering wheel tightly with both hands!
• Select the flattest possible surface for
undertaking a wheel change! Select the site
in such a way as the road traffic is obstructed
as little as possible and you will not be
endangered when changing the wheel!
• Secure the vehicle and the breakdown site!
•“Free-standing” crane operation is absolutely
prohibited!
2-187
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WARNING
Toppling wheel!
The wheel can topple over when changing
the wheel and seriously injure personnel!
• Secure the wheel against toppling!

• Only operate the support when no wheels
are leaned against a sliding beam or support
cylinder!
• Step away quickly if a wheel threatens to
topple!
• Exchange wheels with the help of a second
person if possible!
• Engage parking brake.
• Lock the axle suspension.
• Loosen wheel nuts on faulty wheel.
DANGER
•Select a support base where the mobile
crane cannot topple over!
•Support mobile crane insofar as the
wheels can be changed.
Wheels that are on their side are extremely

difficult to lift up. For this reason, do not put
the wheels down when changing a wheel.
•Lift spare wheel using the crane, put down
next to defective wheel and prevent from
rolling away or toppling over.
•Unscrew wheel nuts and remove defective
wheel.
2-188
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DANGER
Defective spare wheel!
• Before mounting, visually inspect the rim
1, the side ring, the clamp collar 2 and the
tire! Never mount a defective spare wheel!
• Only mount wheels that are approved for
the vehicle!
• Mount spare wheel.
Note!
• The tightening torque for the wheel nuts
is 600 Nm.
• Re-fit wheel nuts and tighten crossways
to 600 Nm.
•After the first 50 and the first 100 traveled
kilometers:
• Ensure that wheel nuts are tight, re-
tighten if necessary.
2. Changing the wheels with each other

Crane vehicle tires are subjected to differing
loads during operation.
Tire rotation is recommended to ensure that all

the vehicle's tire wear uniformly. Tires should
be rotated as soon as uneven wear patterns
are detected. We recommend intervals in
the range of 5000 km and 10000 km. Tires
should be rotated in a crosswise pattern (see
following diagrams). The location should also
be selected so that tires that are evenly worn
are installed in locations where the wear
pattern is uneven.
This process has a positive impact on driving

comfort and tire life.
2-189
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2-190
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2-191
Safety
SAC2200
2-192
Crane Chassis Operation
SAC2200

3 Crane Chassis Operation
3.1 Chassis Control Devices and Instruments................................................................ 3-2
3.2 Before Setting off..................................................................................................... 3-16
3.3 Axle Sprung /Axle Locking System.......................................................................... 3-26
3.4 Crane Driving Operation.......................................................................................... 3-34
3.5 Crane Operates in Worksite.................................................................................... 3-72
3-1
SAC2200
3.CRANE CHASSIS
OPERATION
3.1 Chassis Control Devices and

Instruments
3.1.1 General operating instruments
1 Pedal -Service brake

2 Pedal -Engine control
3 Control handle -Control lever on gear box
4 Handle -Parking brake
5 Control handle -Control lever on intarder
6 Switch, button -Switch: switch between right / left outside
mirror
-Button: electric mirror adjustment
7 Instrument -Display suspension pressure (left front)
8 Instrument -Display suspension pressure (right front)
9 Instrument -Display suspension pressure (left rear)
10 Instrument -Display suspension pressure (right rear)
11 Steering wheel
12 Left-hand steering column switch -Switch from low beam to high beam
-Operate headlamp flasher
-Turn signal activation (left / right)
13 Right-hand steering columns witch -Activate windshield wiper system
-Activate windshield wiper (0, instrument, I, II)
-Activate signal horn
14 Handle -Pneumatic steering wheel angle and height
adjustment
15 Handle -Activate front safety cover
16 Cigarette lighter
17 Rotary switch -Select pendant height
-Raise / descend pendant height
18 Handle -Adjust horizontal setting
19 Button -Adjust seat cushion depth
20 Button -Adjust seat cushion depth
21 Button -Adjust backrest setting
22 Button -Adjust backrest upper section
3-2
SAC2200
3 4 5 6
2 7
8
9
10
12 11 13
22
14
21
15
20
18 19
16 17
12
13
3-3
SAC2200
23 Keyboard
24 Tachograph -Speedometer
-Odometer
25 Gear display -Display “N/D/R”
-Gear display
-Fault code
26 Bar chart -Current brake pressure with operated brake
circuit I,II[bar] 0 - 10
27 Bar chart -Current brake pressure with gear box power
[bar],0 - 10
28 LED display -Transport condition
-Vehicle fault code
-Marked interface for steering system
-Marked interface for suspension system
29 Air-conditioner panel
30 Rotary switch -Activate 3 air-conditioners
31 Radio
32 Main control cabinet -Install controller consolidatedly
33 Vehicle master switch -EPEC2024
34 Engine switch -ADM2
35 Engine preheating switch
36 Intarder switch
37 Gear box switch
38 Diagnostics -Connection to engine diagnostics
-Engine parameters setting
-Engine condition monitoring
39 Built-in socket -24V
40 Channel
41 Terminal row -Activate circuit connection
42 Auxiliary keyboard -Control lights
-The function control on the button lights up:
function has been selected and performed
43 Keyboard -The function control on the button lights up:
function has been selected and performed
-The function control on the button flashes:
function has been selected but not performed
3-4
SAC2200
24 100-115 25 31
30
23 29
27 28 26
35 34 33
38
36
39
40 37
41
32
3-5
SAC2200
Note: To ensure safety and assist steering, the

axle suspension / axle locking system can only
be activated through “2-handed button”
44 Driver’s cab cabinet box

45 Switch -Left power window
46 Switch -Right power window
47 Switch -Right power window
48 Loudspeaker
49 Seat belt
50 Switch
51 Switch
52 Button
53 Switch
12 13
50 51 52
53
3-6
SAC2200
116-135
44
47
42
48
49
45
43
46
136-165
3-7
SAC2200
3.1.2 Indicator on main instrument

panel
100 Control light -Steering left

101 Control light -Battery charging
102 Warning light -Lubricating oil pressure
103 Warning light -Water temperature
104 Warning light -Low atmosphere pressure
105 Control light -Operation of intarder
106 Control light -Reverse
107 Warning light -I# ABS
108 Warning light -II# ABS
109 Control light -Engine preheating
110 Control light -Rear fog light
111 Control light -High beam
112 Warning light -Door unlocked
113 Warning light -Coolant level
114 Control light -Parking brake
115 Warning light -Steering right
3.1.3 Auxiliary control panel
116 Warning light -Engine (stop needed)

117 Warning light -Lubricating oil level
118 Warning light -Main steering (steering pump)
119 Control light -Distributor case in neutral”N”
120 Warning light -Engine (check needed)
121 Warning light -Gearbox
122 Warning light -Auxiliary steering (auxiliary steering pump)
123 Control light -Distributor case at low gear
124 Rocker switch -Distributor case in neutral “N”
125 Rocker switch -Switch from high to low gear of distributor
case
126 Rocker switch -I# ABS check
127 Rocker switch -II# ABS check
128 Rocker switch -Rear fog light
129 Rocker switch -Switch from electric to gas horn
130 Rocker switch -Air-conditioner switch
131 Rocker switch -Creeper switch
132 Rocker switch -Distributor case differential lock + axle 1
133 Rocker switch -Inter-wheel differential lock between axle 1
and 2
134 Rocker switch -Inter-wheel differential lock between axle 4
and 5 +inter-axle differential lock of axle 4
135 Rocker switch -Heating switch for rear-view mirror
3-8
SAC2200
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115
116 117 118 119
120 121 122 123 124 125 126 127
128 129 130 131 132 133 134 135
3-9
SAC2200
3.1.4 Side control panel
136 2-handed switch -Traveling mode

Function check: (136-141)
Flashes: fail to select current mode
Lights up: select current mode
Does not light up: current mode has been
selected
137 2-handed switch -All wheel steering mode
138 2-handed switch -Crab traveling mode
139 2-handed switch -No-deviation steering mode
140 2-handed switch -Independent rear axle steering mode
141 2-handed switch -Rear axle locking mode
142 2-handed switch -Independent rear axle steering left
143 2-handed switch -Independent rear axle steering right
144 Switch -2-handed switch
145 Free
146 Switch -Left front suspension point selected
147 Switch -Right front suspension point selected
148 2-handed switch -Suspendedly lift
Function check:
Flashes: conducting lift
Lights up: complete lift
Does not light up: no operation of lift
149 Switch -Lift axle 3
150 2-handed switch -Suspension system spot automatically
Function check:
Flashes: conducting spotting
Lights up: complete spotting
151 Switch -Lift the whole machine
152 Switch -Rotary warning light switch
153 Switch -Intarder power switch
154 Switch -Superstructure control switch
155 Free
156 Switch -Left rear suspension point selected
157 Switch -Right rear suspension point selected
158 2-handed switch -Suspension descends
Function check:
Flashes: conducting descend
Lights up: complete descend
Does not light up: no operation of descend
159 2-handed switch -Release / lock suspension system
Function check:
Lights up: suspension system locked
Does not light up: suspended
3-10
SAC2200
160 Switch -Manual operation mode of suspension

system
161 2-handed switch -Switch between mode of 3 / 4
162 Switch -Outrigger illuminating lamp
163 Switch -Outrigger power
164 Switch -Chassis power switch
165 Free
136 137 138 139 140 141 142 143 144 145
146 147 148 149 150 151 152 153 154 155
156 157 158 159 160 161 162 163 164 165
3-11
SAC2200
3.1.5 Support control unit
3.1.5.1 Right support control unit
250 Button -Retract left rear vertical support cylinder

251 Button -Extend left rear vertical support cylinder
252 Button -Retract left front vertical support cylinder
253 Button -Extend left front vertical support cylinder
254 Button -Extend right rear horizontal support box

255 Button -Retract right rear horizontal support box
256 Button -Extend right front horizontal support box
257 Button -Retract right front horizontal support box
258 Button -Retract right rear vertical support cylinder

259 Button -Extend right rear vertical support cylinder
260 Button -Retract right front vertical support cylinder
261 Button -Extend right front vertical support cylinder
262 Display -Left rear support force

263 Display -Left front support force
264 Display -Right rear support force
265 Display -Right front support force
266 Free
267 Display -Vertical support extension position
268 Display -Inclination angle
269 Button -Support control unit release
Note:
Before the support cylinders or the sliding
beam can be moved, the support control
unit release 269 must first be operated.
270 Free
271 Button -Retract all support cylinders and align
horizontally
272 Button -Extend all support cylinders and align
horizontally
273 Button -Engine off
274 Button -Engine on
275 Button -Reduce engine Rpm
276 Button -Increase engine Rpm
277 LED -Illuminates with support control unit release
3-12
SAC2200
267 269 277273 268 275
250 252
251 253
262 263
258 260
259 261
264 265
254 255 271 274 276 256 257

272
267 269 277 273 268 275
290 288
291 289
295 294
282 280
283 281
293 292
284 285 271 274276 286 287

272
3-13
SAC2200
3.1.5.2 Left support control unit
266 Free
267 Display -Vertical support extension position
268 Display -Inclination angle
269 Button -Support control unit release
Note:
Before the support cylinders or the sliding
beams can be moved, the support control
unit release 269 must first be operated.
270 Free
271 Button -Retract all support cylinders and align
horizontally
272 Button -Extend all support cylinders and align
horizontally
273 Button -Engine off
274 Button -Engine on
275 Button -Reduce engine Rpm
276 Button -Increase engine Rpm
277 LED -Illuminates with support control unit release
280 Button -Retract left rear vertical support cylinder

281 Button -Extend left rear vertical support cylinder
282 Button -Retract left front vertical support cylinder
283 Button -Extend left front vertical support cylinder
284 Button -Extend left front horizontal support box

285 Button -Retract left front horizontal support box
286 Button -Extend left rear horizontal support box
287 Button -Retract left rear horizontal support box
288 Button -Retract right rear vertical support cylinder

289 Button -Extend right rear vertical support cylinder
290 Button -Retract right front vertical support cylinder
291 Button -Extend right front vertical support cylinder
292 Display -Left rear support force

293 Display -Left front support force
294 Display -Right rear support force
295 Display -Right front support force
3-14
SAC2200
267 269 277273 268 275
250 252
251 253
262 263
258 260
259 261
264 265
254 255 271 274 276 256 257

272
267 269 277 273 268 275
290 288
291 289
295 294
282 280
283 281
293 292
284 285 271 274276 286 287

272
3-15
SAC2200
3.2 Before Setting Off
3.2.1 General checks before setting off

Various checks must be performed before
setting off.
Note:For a detailed description of

the tasks listed below, refer to chapter 7.4.
3.2.1.1 Checking oil level and filters
Check oil level in the vehicle engine

Check oil levels in automatic transmission and
transfer gearbox
Check oil level in hydraulic reservoir for
steering, support and axle suspension
Check filter on hydraulic oil reservoir
3.2.1.2 Checking the fuel level
Check fuel reserve at fuel gauge in driver cab.
Notice: if the fuel tank has been

run dry, always deaerate the whole fuel
system.
3.2.1.3 Checking the coolant level
Fill coolant equalizing reservoir up to overflow

on filler neck.
Danger: danger of injury due to

scalding of the skin.Engine must be cold
when performing coolant level check!
3-16
SAC2200
3.2.1.4 Checking the tires (spare wheel

included)
Danger: check tires for damage at

regular intervals also check depth of tread
and air pressure.Risk of accident if
incorrect tires are used!
Depth of tire tread must not be less than the

legally prescribed minimum
Check depth of tire tread.
Check that tires are correctly mounted on the
rim.
Note: never exceed the max.

permitted inflation pressure.
Danger:the retaining ring must be

correctly mounted on to the rim when
checking tire pressures and after a tire has
been fitted.If the sealing ring is not
correctly fitted, call in trained specialists.
Tires must be checked before setting off.
See Chapter 7.4 on Chassis Maintenance.
3-17
SAC2200
3.2.1.5 Checking the crane general

transport condition
Notice:for transportation on public

highways the maximum crane axle load of
12 t must be adhered to as described in
Chapter 3.4.
To be in a suitable condition for transportation,
all loose parts on the mobile crane must be
fastened and secured.
-While driving, the wind gauge must not be

mounted on the telescopic boom.
-Point crane superstructure in direction of travel
and mechanically lock to prevent twisting.
-The telescopic boom must be fully telescoped
in and set down on the boom support.
-Retract and secure the footboard beside the
crane cab.
-Close windows and door 4 of crane operator's
cab.
-Secure the assembly ladder under the front
bumper.
-Individually secure the four sliding beams
of the hydraulic supports using pins 1/1a to
prevent them from unintentionally extending.
Secure the four pins 2 in the respective
transportation retainers.
-Secure 2 folding ladders on the crane
-Lock the switch boxes 6 for the left and right
support control units.
-Secure all locks on tool boxes, cabinet doors
and panels.
-Set rotary switch 3 to “driving mode”.

-Select steering program “Road driving”.
-Set the axle suspension / axle locking system
to “sprung” suspension level for road driving,
see chapter 3.3.
-Move the four support pads to the
transportation position and secure using
pins 5 to prevent them from unintentionally
extending.
3-18
SAC2200
3-19
SAC2200
3.2.1.6 Checking the lighting
Ensure that the battery master switch and the

ignition are switched on.
Danger: danger of accident if

lighting is defective!
3-20
SAC2200
3.2.2 Driver's cab
3.2.2.1 Adjusting the driver’s seat
The driver seat has pneumatic suspension 10

and can be adjusted to suit any driver height
or size.
- Lock the horizontal suspension 1
- Adjust horizontal setting 2
- Adjust seat cushion depth 3
- Adjust backrest setting 4
- Adjust backrest upper section 5
3-21
SAC2200
3.2.2.2 Adjusting the mirror
Clean outside mirrors before setting off and

adjust to suit driver's field of view. Operate
switch 6 on side control panel.
Result:
You can switch between the left and right
outside mirrors.
– Mirror is adjusted.
3.2.2.3 Adjusting the steering wheel
The steering wheel is adjusted pneumatically.

Adjust handle 14.
Result:
– The angle and height of the steering wheel
are adjusted.
Danger: do not adjust or readjust

steering wheel, driver’s seat and mirror
while traveling.
3.2.2.4 Turning heater / ventilation on
The cab can be heated or ventilated to the

desired temperature.
To adjust the heating or ventilation, use rotary
switch on the air-conditioner control panel.
3.2.2.5 Putting on seat belt (49)
Danger: if the seatbelt is not worn

during travel operation, the driver or the
passenger can be fatally injured in case of
an accident or total braking action.
3-22
SAC2200
49
14
3-23
SAC2200
3.2.2.6 Checking main controls
For some checks, the ignition also has to be

switched on.
(1) Checking with the ignition switched off
-Hazard warning system: press button 13 with
function control and check.
-Rotating beacons: press button 152 with
-Parking lights: press button 51 with function
control and check.
(2) Checking with the ignition switched on
(Ignition switch on the position of “I”)
-Driving light: press button 12 with function
control, check control light 111.
-Fog lamps* (only with driving light or parking
light switched on): press button 50 with
-Rear fog lamps* (only with driving light or
parking light switched on): press button 128
with function control and check control light
110.
-Windshield wiper / washer system: check
steering column switch 13 with windshield
washer system reservoir.
-Horn: press horn button (52) in the center of
steering wheel with function control and check.
-Flashlight: operate switch (12) with function
control and check, check control light 100 and
115.

Danger: abnormal parts should be
well repaired before setting off.
3-24
SAC2200
128
100 110 111 115
50 51 52
152
12 13
3-25
SAC2200
3.3 Axle Sprung / Axle Locking

System
3.3.1 Description
The axles are hydro-pneumatically sprung

via maintenance-free hydraulic cylinders,
the height can be adjusted and they can be
hydraulically locked. Depending on the driving
condition the axles can be interconnected via
axle pressure compensation.
3.3.1.1 Axle sprung
See illustration 1 for more information.

Used for driving on roads. All axles are
sprung. Spring travel +150 mm/-150 mm. In
order to improve fording capability the entire
chassis can be raised by 150 mm. In order to
reduce height to clear low obstacles the entire
chassis can be lowered by 150 mm. On a
slope the entire chassis can be tilted +/- 9° to
the side. The side stability of the vehicle when
cornering is safeguarded by the hydraulic axle
suspension.
3.3.1.2 Axle locked

For supporting the crane. All axles are locked.
Used for “driving with equipment in place”
on level ground. All axles are locked. Axle
pressure compensation occurs between axles
1 + 2 and 3 - 5.
3-26
SAC2200
3-27
SAC2200
144
146 147 148 149 150 151
156 157 158 159 160 161
3-28
SAC2200
3.3.2 Axle sprung / axle locking system
Danger: risk of injury when

operating axle suspension/axle locking
system!Ensure that no persons are present
in the crane danger zone!
3.3.2.1 Road driving / off-road driving
For transit journeys on roads, motorways and

for off-road driving, switch button 159 off.
Result:
-The function control on button 159 does not
light up.
- All axles are sprung in this position.
- The level of the crane can be controlled.
3.3.2.2 Level control
Level control can be manual or automatic.
Warning:do not perform level

control unless the vehicle is stationary!
Perform level control on a level and load-
bearing surface.Never raise or lower the
vehicle fully when driving on an uneven
road surface.
Ensure that the following preconditions are
met:
-the vehicle is on a level surface
-the engine is running
-the axle suspension is sprung
-the transmission is in neutral “N”
(1) Automatic level control

The crane is automatically moved to a level
position (driving height for road driving) by
the level switches attached to the suspension
cylinders.
-Press button 144 and button 150
-The function control on the button 150, 146,
147, 156 and 157 flashes
-The function controls for manual level control
(buttons 150, 146 147, 156 and 157) light up
3-29
SAC2200
(2) Manual level control
Caution: the level position is

adjusted manually by pressing button 160
for manual level control.
While the automatic level control is
switched on by shutting off button 160.
Warning: performing manual level

control on public highways is only
permitted in order to adapt the crane to
special situations such as lowering the
crane to reduce the height in order to drive
under a bridge.
Level control must only be performed in

special situations and with the vehicle
stationary!
Raising vehicle
Raising left front vehicle
- Press and hold down button 146, control light
lights up;
- Press button 148 + 2-handed switch 144;
Control light on button 146 flashes, left front
vehicle is raised;
- Release button 148 or 2-handed switch 144,
raising stops.
Raising right front vehicle

lights up;
- Control light on button 147 flashes, right front
vehicle is raised;
- Release button 148 or 2-handed switch 144,
raising stops.
3-30
SAC2200
Raising left rear vehicle

-Press and hold down 156, control light lights
up;
-Press button 148 + 2-handed switch 144;
-Control light 156 on button 156 flashes, left
rear vehicle is raised;
-Release button 148 or 2-handed switch 144,
raising stops.
Raising right rear vehicle

Press and hold down button 157, control light
lights up;
-Press button 148 + 2-handed switch 144
-Control light on button 157 flashes, right rear
vehicle is raised;
raising stops.
Lowering vehicle
Left front vehicle lowers
-Press and hold down button 146, control light
lights up;
–Control light on button 146 flashes, left front
vehicle is lowered;
-Release button 158 or 2-handed switch,
lowering stops.
Right front vehicle lowers
-Press and hold down button 147, control light
lights up;
-Control light on button 147 flashes, right front
vehicle is lowered;
lowering stops.
3-31
SAC2200
Left rear vehicle lowers

lights up;
- Control light on button 156 flashes, left rear
vehicle is lowered;
- Release button 158 or 2-handed switch,
lowering stops.
Right rear vehicle lowers

lights up;
- Control light on button 157 flashes, right rear
vehicle is raised;
- Release button 158 or 2-handed switch,
lowering stops.
Raising entire vehicle

- Press and hold down button 146, button 147,
button 156 and button 157, control light lights
up;
- Press button 148 + 2-handed button 144;
- Control lights on button 146, 147,156 and
157 flash, the vehicle is fully raised.
- Release button 148 or 2-handed button 144,
raising stops.
Lowering entire vehicle

- Press and hold down button 146, button 147,
button 156 and button 157, control light lights
up;
- Press button 158 + 2-handed button 144;
- Control lights on button 146, 147, 156, 157
flash, the vehicle is fully lowered;
- Release button 158 or 2-handed button 144,
lowering stops.
3-32
SAC2200
3.3.3 Axle locking system
3.3.3.1 General
All axles are to be locked in the following

circumstances:
- Supporting the crane
- Driving with the equipment in place
3.3.3.2 Switching on axle locking
Ensure that the surface on which the vehicle is

parked is level and has adequate load-bearing
capacity.
Caution: axle will be automatically

locked once engine restarts up after engine
stop.
The hydro-pneumatic suspension on all
axles is locked
Press and hold down button 159 + 2-handed

button 144 till the control light on button 159
lights up.
3.3.3.3 Supporting the crane
A detailed description of how to support the crane

can be found in chapter 3.5.
3-33
SAC2200
3.4 Crane Driving Operation
3.4.1 Crane driving conditions
Before the crane can be driven on public

roads, the telescopic boom must be fully
telescoped in.
Caution: always observe national

regulations when driving on public
highways.
3.4.1.1 Axle loads up to 12 t

met:
the telescopic boom is fully telescoped in and
correctly positioned
-the hoist rope is hung up and tightened on the
front towing coupling
-the axle suspension system has been set to
“sprung”
-the vehicle overall weight is less than 60t.
3.4.1.2 Axle loads above 12 t
Danger: increased danger of

accidents!
The brake stopping distance is greater due
to the greater overall weight!
Brake lining wear is greater and risk of
brake overheating is higher.
The steering system, service brake,
parking brake and retarder no longer meet
the regulations!
The service life of all components affected
by the increased axle load such as: brakes,
tires, wheel rims, axles and all drive,
suspension and steering components is
reduced.
3-34
SAC2200
109 114 101 102 104 118 122 121
P 0 I
II
53
UP-C
164 154
3-35
SAC2200
3.4.2 Starting and stopping the engine
3.4.2.1 Starting the engine

met:
- the battery master switch 164 has been
turned on
- the transmission is in neutral “N”
- the rotary switch 154 is set to chassis
operation
With coolant temperature above 20 °C or with
engine at operating temperature
Turn the ignition starter switch 53 to position “I”.
- The control light 109 flashes.
- The charge control light 101 illuminates.
- The engine is ready to start.
Turn the ignition starter switch 53 to position “II”
and start the engine.
Troubleshooting: if the engine
does not start after a maximum of 3
seconds?
Wait for 1 minute. The starter can be
operated three times for 3 seconds per
attempt with a pause in between of one
minute respectively.
3.4.2.2 Checking the instruments after

starting the engine
The following control lights must extinguish

when the engine is running:
- Check the engine oil pressure 102 control
light.
Caution: if the engine oil pressure
control light 102 stay illuminated, turn off
the engine immediately for there is a
danger of engine damage.
- Check the preheat control light 109.
- Check charge control light 101.
- Check the gear box control light 121.
- Check the steering circuit I control light 118.
- The steering circuit II control light 122 only
extinguishes at a speed of approx. 10 km/h.
- Check the low pressure control light 104.
3-36
SAC2200
3.4.2.3 Turning off the engine

met:
- the transmission is in neutral “N”
- the rotary switch 154 is set to chassis
operation
Caution: turn off the engine
immediately in the following event:
- dropping or sharply fluctuating oil pressure;
- reduced performance and RPM without a
change in engine control ;
- the appearance of large amounts of
smokeincreasing coolant temperatures or
suddenly occurring abnormal engine noises.
- Turn the ignition starter switch 53 back to the
stop.
114 104
3-37
SAC2200
3.4.3 Driving
3.4.3.1 Changing the idling speed
The idle speed is set through the diagnostics

from BENZ; contact a service engineer if there
should be some change.
3.4.3.2 Parking brake
1. Applying
Danger: if the manual lever 4 is

not correctly engaged when the parking
brake is applied, then the vehicle can roll
off uncontrollably and fatally injur e
personnel.
Pull the hand lever 4 back until it locks into
place.
Result:
- The parking brake is locked on.
- The control light 114 lights up.
2. Releasing
Danger: when the parking brake is

released, the crane can immediately start
moving. This may result in fatal injuries.
Pull back the hand lever 4 hand lever as
far as the stop in the lever's longitudinal
direction and push forward.
Result:
- Parking brake is released.
- The control light 114 turns off.
3.4.3.3 Service brake
Depress the pedal 1 slowly
Danger:carry out a test braking

procedure immediately before starting to
drive.
3-38
SAC2200
114 104
0 B 1 2 3 4 5
153
3-39
SAC2200
3.4.3.4 Intarder
The retarder consists of the engine brake, the

hydraulic intarder.
Conditions of use
Warning: utmost care should be

taken when operating the intarder!
Switch through the individual stages one
by one while constantly observing the
vehicle handling characteristics.
Caution: the intarder can only be

operated with the engine turned on. If the
intarder is being operated it is not possible
to accelerate.
Sensible use of the intarder with
anticipating driving methods reduces wear
on the service brake and thereby reduces
operating costs.
On long descending gradients

On long descending gradients, select a
switching stage that leaves further switching
stages available for any other adjusting
braking procedures which may be required.
Danger: if there is not sufficient

braking effect, brake the vehicle using the
service brake and change down.
3-40
SAC2200
114 104
0 B 1 2 3 4 5
153
3-41
SAC2200
On snow, ice and dirty road surfaces

Careful use of the intarder will ensure safe
and sure deceleration even under bad road
surface conditions.
Danger: in the event that the

wheels lock when operating the intarder,
select a lower switching stage!
Operating
Before conducting gear shift on intarder, it is
a must to press down steering column switch
153.The intarder is operated using the control
rod 5 on 7-stage steering column switch,
which is composed of gear B and 1-5 switch
settings.
- In switch position B, the intarder can regulate
brake force on long descending gradients
- In switch settings 1 to 5 the intarder, the
engine brake and the eddy current brake* are
active.
- In switch setting 0; shut off intarder.
Danger: overheating of intarder!

As soon as the vehicle is stationary or no
more deceleration is required, switch off
the intarder.
3-42
SAC2200
114 104
0 B 1 2 3 4 5
153
3-43
SAC2200
3.4.3.5 Automated shift transmission
1. General
There is no clutch pedal equipped on the
automatic transmission. It is suggested to
tread on engine control on the plain road
before traveling on descending gradient till
the clutch has been shut off. Release manual
brake 4 immediately. Engine control can be
increased as required.
The automated shift transmission can be
driven in automatic or in manual mode. The
transmission has 12 forward gears and 2
reverse gears. The current gear positions will
be indicated on the display 25.
Danger: crane will move once

brake handle is released. Therefore, foot
brake will be applied to decelerate vehicle
or drive vehicle forwards through engine
control.
2. Switching between automatic and

manual mode
Automatic mode is activated automatically
when the ignition is switched on. In the neutral
“N” and reverse “R” drive ranges, manual
mode is always activated.
- Push transmission control rod 3 rightwards
under automatic mode: manual mode to
automatic mode
- Push transmission control rod 3 leftwards
under manual mode: automatic mode to
manual mode
3-44
SAC2200
25
60
3-45
SAC2200
3. Selecting the direction

Reverse direction “R”
Turn rotary switch 60 to position “R”, “R” is
display on display 25.
Neutral position “N”

Turn rotary switch 60 to position “N”, “N” is
display on display 25.
This setting is used to start the engine and for
idling mode.
Neutral position is also to be used when
the vehicle is not manned and the engine is
running.
CAUTION: in the event that the

driver is required to leave the crane while
the engine is running, ensure that the
parking brake is locked on correctly and
that the wheels are chocked.
Forward direction “D”
Turn rotary switch 60 to position “D”
This drive range is selected for general driving
in a forward direction. Vehicle is stationary
when it is shifted from reverse to forward.
4. Automatic mode
In automatic mode, the driver operates only
the engine control or the brake. Gear shifts
are carried out automatically by the system
depending on driving conditions and usage
mode. Depending on the preset driving Gear box display 25
direction, the transmission automatically
selects a starting gear.
CAUTION: apply foot brake when

switching from neutral “N” into a drive
range.
NOTE: automatic mode only operate under

the traveling condition of “D”. System will
automatically shift to manual mode when Automatic mode Current gear
other traveling condition is applied.
3-46
SAC2200
5. Manual mode
In manual mode the gears are selected by the
driver using the steering column switch 3.
CAUTION: apply the foot brake

when switching from neutral “N” into a
drive range. Gear box display 25
Changing up: push handle lever 3 upwards

- ”+”represents vehicle changes up one gear
- ”+ +”represents gears are changed up
cyclically
Changing down: pull handle lever 3 backwards

- ”-”represents vehicle changes down one gear
- ”- -”represents gears are changed down
cyclically
Manual mode Current gear
3-47
SAC2200
6. Warning information display
(1) Self-test for gear box defects (ignition

turned on)
(2) Loss of pressure
(3) System defects

Traveling limited
(4) System defects

Engine stops immediately
3-48
SAC2200
(5) Clutch check

Clutch is not in place
(6) Clutch warning

Clutch overloaded
(7) High-temperature warning
3-49
SAC2200
3.4.3.6 Transfer case operation
There equips high / low / neutral 3 gears on

transfer case.
Gear switching is only possible when vehicle
is stationary.
High gear is applied in normal traveling.
Low gear is applied when there is need to
increase drive shaft torque.
Vehicle should be kept stationary when neutral
gear is applied.
Press neutral gear switch 124, control light 119
lights up, vehicle transfer case is at neutral
gear.
Press switchover switch 125 between high and
low gear, control light 123 lights up, vehicle
transfer case is at low gear.
3.4.3.7 Creeper gear
CAUTION:creeper gear can

provide maximum drive force when vehicle
is traveling on bad roads. Gear switch
should be conducted when vehicle is
stationary.
Press creeper switch 131, control light lights

up, vehicle is under creeper condition.
3-50
SAC2200
124 125 131

123 119
3-51
SAC2200
3.4.3.8 Important control instruments while

driving
1. Steering circuit II (warning light 122)

At a driving speed of approximately 10 km/
h the warning light 122 for hydraulic steering
circuit II goes off.
WARNING: if warning light does

not extinguish and steering circuit II is not
operative. The crane should be immediately
brought to a standstill and rectify the cause
of the defect.
2. Engine oil pressure (warning light 102)
WARNING: if engine oil pressure

warning light alarms during traveling,
vehicle should be shut off. In case of low
or missing oil pressure, there is no engine
lubrication. This results in engine damage.
3. Low pressure (warning light 104)
WARNING: the crane should be

immediately brought to a standstill and
rectify the cause of the defect once these
warning lights light up for the no-operation
of brake system or gear box clutch.
4. Coolant temperature
WARNING: stop the crane and

shut off engine immediately once warning
light lights up during traveling. Excessive
coolant temperature can result in engine
damage.
5. Gear oil temperature
WARNING: stop the crane and

shut off engine immediately once warning
light lights up during traveling.
3-52
SAC2200
102 103 104 121 122
3-53
SAC2200
3.4.3.9 Finishing driving operations
1. Stopping
Brake the crane until it comes to a standstill.
The selected drive range can remain switched
on.
Use the service or parking brake to ensure
that the crane does not roll away.
CAUTION: for longer stops (more

than 1 minute), shift the transmission into
neutral “N”. This will reduce clutch wear
and increase the service life of the clutch.
2. Interrupting a driving operation when the

engine is running
Shift the transmission into neutral “N” before
leaving driver’s seat.
Close the parking brake 4, the control light 114
lights up.
3. Stopping the vehicle when the engine is

running (parking)
Shift the transmission into neutral “N”.
Close the parking brake 4, the control light 201
lights up.
CAUTION:if the crane has been

operated at full engine output or in the
event that the coolant temperature is above
95 °C, allow the engine to run without load
at idling speed for 1-2 minutes.
If special functions (parking light, rotating

beacons, hazard warning lights, auxiliary
heating*) are switched on, switch off special
functions.
Switch off the ignition and pull out the ignition
key.
Switch off the battery master switch 164.
Lock the driver's cab.
Secure the vehicle with chocks against
uncontrolled rolling away.
3-54
SAC2200
114
164
3-55
SAC2200
3.4.4 Differential locks
This vehicle is equipped with differential locks

for driving off-road, on tracks and in winery
conditions.
The differential locks may only be added when
the vehicle is stationary and in the following
sequence:
- Longitudinal differential lock in transfer
gearbox + axle 1 is added
- Longitudinal differential lock axle 4 +
transversal differential lock axle 4 + axle 5 is
added
- Transversal differential lock axle 1 + axle 2 is
added
CAUTION: longitudinal differential

lock axle 4 + transversal differential lock
axle 4 + axle 5 is added.
Transversal differential lock axle 1 + axle 2
is added.

WARNING: danger of damage to
driving axles!
Only add differential locks and off when the

vehicle is stationary!
Never add differential locks when the driving
wheels are turning!
Drive carefully, do not start jerkily, do not drive
at full engine control!
Only drive on straight routes and do not
attempt to corner!
Only drive on difficult terrain (e.g. sand, slush,
loose or slippery subsoil etc.) with differential
locks!
3-56
SAC2200
132 133 134
144
3-57
SAC2200
3.4.4.1 Turning the differential locks off
Differential lock can increase grip when

crane travels on solid subsoil by reducing the
traveling speed of each gear.

met:
- The vehicle is stationary
- The transmission is in neutral “N”
gearbox + axle 1
- Press button 132 and button 144.

lock in transfer gearbox + axle 1 is added
only when control light on button 132 lights
up.
3.4.4.2 Addition Of Longitudinal Differential

Lock Axle 4 + Transversal Differential Lock
Axle 4 + Axle 5

met:
- The transmission is in neutral position “N”
- Longitudinal differential lock in transfer gear
box + axle 1 is added.
Additional of longitudinal differential lock axle

4 + transversal differential lock axle 4 + axle 5
- Press button 134 + 144
-Longitudinal differential lock axle 4 +
transversal differential lock axle 4 + axle 5 is
added.

lock axle 4 + transversal differential lock
axle 4 + axle 5 is added only when control
light on button 134 lights up.
3-58
SAC2200
132 133 134
144
3-59
SAC2200
3.4.4.3 Addition of transversal differential

lock axle 1 + axle 2

met:
- The transmission is in neutral position “N”
gearbox + axle 1 is added
Addition of transversal differential lock axle 1 +

axle 2
- Press button 133 + 144
- Transversal differential lock axle 1 + axle 2 is
added
CAUTION: transversal differential

lock axle 1 + axle 2 is added.
WARNING: immediately shut off

those additional differential locks once
there is no need (if terrain gets solid or
rough). Drive axle along with drive train will
be seriously damaged if vehicle travels on
difficult terrain with additional differential
lock.
3-60
SAC2200
132 133 134
144
3-61
SAC2200
3.4.5 Steering
There are 6 operating modes for steering the

crane:
Road driving, illustration 1
All-wheel steering, illustration 2
Crab steering, illustration 3
Reduced swing-out rate, illustration 4
Independent steering, illustration 5
Locked rear axle steering, illustration 6
CAUTION: only drive in “Road

driving” operating mode on public roads.
3.4.5.1 General
DANGER: danger of crushing!

Ensure no-one is between the wheels when
the engine is started and a gear is selected.
- Any shift between different operating modes

is checked each time by the system. Shift will
not be realized if a shift is not permitted.
- Shift between different operating modes
should be done when vehicle is stationary, and
the wheel on each axle is traveling linearly
(the steering angle of the wheels is beyond the
set error range).
- When the power supply is switched on, the
operating mode last selected is activated.
- From a temperature of -20 °C before driving
off, operate steering several times so that the
fluid in the steering cylinders becomes warm.
3-62
SAC2200
3-63
SAC2200
1. Function controls
There are function controls equipped on the
function-selecting switch 136-141.
- Function control on the button illuminates.
Operating mode is activated.
- Function control on button does not
illuminate.
Operating mode is not activated.
- Function control on the button is flashing
quickly.
Operating mode has been selected, but has
not yet been accepted by the control system.
CAUTION: when function controls

flash, the reason for the failure in mode
selection are:
Defect in steering system, refer to failure
code;
No steering axle is traveling linearly,
readjust steering condition.
3-64
SAC2200
136 137 138 139 140 141 142 143 144
3-65
SAC2200
3.4.5.2 Changing between operating modes
1. Direct selection
Select the desired operating mode using the
button 144 and the operating mode button.
Turn the steering wheel until the wheels on
the front axles go through the 0° position. The
wheels of the rear axle will be automatically
positioned.
When the desired operating mode has been
achieved the control light on the operating
mode button will remain continuously
illuminated.
2. Indirect selection
Select the independent steering mode using
the button 114 and the independent steering
mode button 140.
When the independent steering mode
has been activated the control light on the
independent steering mode button will remain
continuously illuminated.
Turn auxiliary steering axle left by pressing
button 144 and independent axle steering left
button 142;
Turn auxiliary steering axle right by pressing
button 144 and independent axle steering right
button 143;
Adjust the steering angle for auxiliary steering
axle as requested.
3-66
SAC2200
136 137 138 139 140 141 142 143 144
3-67
SAC2200
3.4.5.3 Road driving
The “Road driving” operating mode is the

default setting. In this mode, the rear steering
axles are steered depending on the steering of
the front axles. The steering angle reduces as
the vehicle accelerates.
Press button 136 and button 144.
136 144
3.4.5.4 All-wheel steering
In the “All-wheel steering” operating mode, the

vehicle attains as small a turn as possible.
The maximum driving speed is limited to 20
km/h.
137 144
3-68
SAC2200
3.4.5.5 Crab steering
In the “Crab steering” operating mode, the

rear steering axles are steered in the same
direction as the front axles. The maximum
driving speed is limited to 20 km/h.
138 144
3.4.5.6 Reduced swing-out rate
In the “Reduced swing-out rate” operating

mode, the rear steering axles are locked
dependent on the front axles so that the swing-
out rate of the vehicle rear-end is reduced to a
minimum. This operating mode would typically
be selected when driving away from the edge
of a house. The maximum driving speed is
limited to 20 km/h.
139 144
3-69
SAC2200
3.4.5.7 Independent steering
In the “Independent steering” operating

mode, the rear steering axles are steered
independent of the steering effort of the front
axles using the key 142 and the key 143. The
maximum driving speed is limited to 20 km/h.
142 143
140 144
3.4.5.8 Locked rear axle steering mode
In the “locked rear steering” operating mode,

the steering axle is locked in the centering
position with no steering.
Press button 141 and button 144
141 144
3-70
SAC2200
3.4.6 Towing
3.4.6.1 General towing regulations
DA N G E R ： t h e fo l l o w i n g t o w i n g
regulations must be adhered to:
Release the parking brake when towing, or the
brake system will be damaged.
When towing, the speed must always remain below
20 km/h.
Use the tow coupling to tow the vehicle.
Only tow with a tow bar.
Turn on the hazard warning system and the driving
light.
3.4.6.2 Towing with a defective drive motor

and / or shift transmission
If the driving motor cannot be star ted, a

compressed air supply must be established from
the towing vehicle to the mobile crane. A hose
coupling is attached at the front under the bumper
to supply compressed air to the mobile crane to be
towed. Use a hose pipe to connect this attachment
for the external supply with the towing vehicle.
DANGER：the supply pressure of the

compressed air brake system of the mobile crane
to be towed must be at least 6 bar.
With the engine turned off the vehicle can only be
steered from a speed of 5 km/h - 10 km/h.
Switch the gear box to neutral “N”.
3.4.6.3 Towing with an intact drive motor
1. Towing with damage to the transfer gearbox

Disconnect the drive shafts from the transfer
gearbox to the driving axles at the driving
axles and tie up.
Allow the engine to run at idling speed, switch
the gear box to neutral “N”.
2. Towing with damage to the driving axles
For example: damage happens to axle 3
Disengage the drive shaft between normal
axle 2 and axle 3, and fasten it.
Withdraw the damaged half shaft.
3-71
SAC2200
CAUTION: only authorized and

specially trained personnel can carry out
towing arrangements in case of damage to
the driving axles.
3.5 Crane Operates in Worksite
3.5.1 General
3.5.1.1Selecting the location
Select crane operating location where the

supports can be extended to provide the
support specified in the load charts and the
crane can be levelled.
3.5.1.2 Convert from driving mode to crane

operation

met:
- the crane is on a level and load-bearing
surface
- the parking brake is applied
- the manual transmission is in neutral position
“N”
- the engine is running
1. Locking the axle suspension

The axle suspension must be locked before
the crane is supported.
Press button 159 and button 144, function
control on suspension / locking button
illuminates, .axle suspension is locked.
2. Converting to crane operation

met:
- the engine is turned off
- the ignition is turned off
- the axle suspension is locked
Turn the button 154 to the symbol “Crane
operation”, the crane has been switched to
superstructure operation.
3-72
SAC2200
159 144 154
3-73
SAC2200
3.5.1.3 Moving the support pads from

transport position to operating position
- Withdraw socket pin 1

- Pull support pad outwards using handle
until socket pin 2 meets ball head of support
cylinder
- Insert socket pin 1 into the original hole
3.5.1.4 Moving the support pads from

operating position to transport position
- Withdraw socket pin 4

- Use handle to slide support pad until it meets
ball head of support cylinder
- Insert socket pin 4 into the original hole
3.5.1.5 Support pads
Take suitable wood, steel plates or concrete

slabs of a suitable size as support pads.
3-74
SAC2200
2 1 3 4
3-75
SAC2200
3.5.1.6 Converting from crane operation to

driving mode

met:
- the boom is fully telescoped in
- the boom is locked at the position of traveling
- the crane vertical cylinder is fully telescoped
in
- the wheels are in contact with the ground
- the axle suspension is unlocked
- the gearbox is in neutral position "N"
1. Switching the axle locking off
DANGER: if the axle block is

turned off without the wheels being in
contact with the ground, then the axle
suspension can be damaged if the axles
drop down.
Do not switch axle locking off until all wheels
are in contact with the ground.
- Retract support cylinders until all wheels are
in contact with the ground.
- Press button 159 and button 159, the
function control on the button 159 goes out,
the axle suspension is active.
- Retract the support cylinders and the sliding
beams all the way.
2. Converting to driving mode

met:
- the ignition is turned off
Turn the switch 154 to the right to the symbol
“Driving mode”, the crane is switched to
driving mode.
3-76
SAC2200
159 144 154
3-77
SAC2200
3.5.2 Support control unit
The crane may be supported by support

control units on the chassis as well as from the
cab of the crane.
An support control unit (switch box) with
buttons is attached to both sides of the vehicle
for operating the support.
- Turn the ignition on.
- Press support control unit release 269.
Result:
- All buttons and the green LED 277 “Support
control unit release” illuminate.
- The support control unit is activated.
- The release goes off if no other key is
pressed for 60 s or if the support control unit
release 269 is pressed again.
- Deactivation of the support control unit is
indicated by the button flashing and the green
LED 277 going off.
The engine can be started using the button

274 or turned off using the button 273.
The engine RPM can be varied during the
supporting procedure using the button 276
and the button 275.
DANGER: the crane operator must

set the overload protection in accordance
with the load chart for the respective
support width.
The support cylinders must be on a base in
accordance with specifications.
3-78
SAC2200
254, 286 256 ,284
3-79
SAC2200
3.5.2.1 Extending the sliding beams with

support control unit
CAUTION: the sliding beams on

the left side of the vehicle can only be
operated using the support control unit
attached at this side.
The sliding beams on the right side of the
vehicle can only be operated using the
support control unit attached at this side.
- Remove retaining pins 1 from the sliding

beams.
- Open the control box on the left, right support
units.
DANGER:the operator must

monitor the extension and retraction of the
sliding beams.
Make sure that there are no persons or
objects within the danger zone when
extending or retracting the sliding beams.
- Extend sliding beams to the support basis
specified in the load chart:
- Left support control unit: Press button 254
and button 256.
- Right support control unit: Press button 284
and button 286.
- Use retaining pin to pin the 4 sliding beams.
DANGER:the sliding beams must

be pinned to prevent movement of the
bearing surfaces after positioning!
- Pin all retaining pins into A and B and lock.
- Do not support in intermediate positions!
CAUTION: for safety, the engine

control in the driver’s cab should be shut
off when support control unit starts to
operate. Engine adjustment will operate
through after the support leveling power
has been turned off.
3-80
SAC2200
DANGER：ensure that there are no

persons or objects present in the danger zone
when the support cylinders are being extended and
retracted.
Raise the crane until the wheels are no longer
touching the ground.
Do not extend the support cylinders all the way
during crane operation (up to stop position)! If
support cylinder has been moved out all the way,
retract again by at least 10 mm.
DANGER：ensure that there are no

persons or objects present in the danger zone
when the support cylinders are being extended and
retracted.
3-81
SAC2200
3.5.2.2 Supporting Manually
Extend individual support cylinders evenly by

pressing the relevant buttons and support the
crane.
Left support control unit: Press button 251,
button 253, button 259 and button 261.
Right support control unit: Press button 281,
1. Aligning the crane horizontally

Extend and retract individual support cylinders
until the innermost light emitting diode (LED)
lights up.The maximum permitted deviation
from the horizontal position is 0.5 % (0.3°)!
DANGER: if the crane is n o t

aligned horizontally, it may tip over and
cause fatal injury!
2. Supporting automatically
Press button 272, all support cylinders are
extended until the crane is levelled.
DANGER: when the automatic

support is operated the crane is levelled
automatically. Ensure that the alignment is
within the permitted tolerance and that all
four support pads are touching the ground.
3-82
SAC2200
269 277 2732 75
274 276
269 277 273 275
274 276
3-83
SAC2200
3. Checking supports
DANGER: in order to minimize the

accident risk the extending distances and
the following safety regulations must be
adhered to.
Always extend all 4 sliding support beams, i.e.

also on the side opposite the load.
- The load suspended on the hook causes

tension and deformation of the hoist rope and
telescopic boom (also applies to jib and stay
ropes, if used). If the load is dropped or a stay
rope or hoist rope breaks in this situation, the
crane is suddenly unloaded. The boom snaps
back. If only the sliding beams at the load side
are extended the crane could tip over.
- Another situation may occur when it becomes
necessary to slew the load to the opposite
side. If only the sliding beams on the load side
are extended the crane could tip over.
- When rotating out of the longitudinal vehicle
direction, the boom or counterweight force
could tip over the crane unless all four sliding
beams are extended.
3-84
SAC2200
251 253
259 261
272
291 289
283 281
272
3-85
SAC2200
3.5.2.3 Retracting support cylinders with

- Open the left or right support control boxes

on undercarriage.
- Start the engine.
- Evenly retract the support cylinders by
pressing the relevant buttons until the wheels
are touching the ground.
- Left support control unit: Press button 250,
- Right support control unit: Press button 280,
or
- Press button 271 until all wheels are in
contact with the ground.
- Press button 130 and button 143 and switch
off axle locking.
WARNING: if the axle block is

turned off without the wheels being in
contact with the ground, then the axle
suspension can be damaged if the axles
drop down.
- Retract all four support cylinders all the way.
DANGER: ensure that there are no

persons or objects in the danger zone.
3-86
SAC2200
3.5.2.4 Retracting sliding beams with

CAUTION: the sliding beams on

the left side of the vehicle can only be
operated using the left support control
unit.
The sliding beams on the right side of the
vehicle can only be operated using the
right support control unit.
- Unpin retaining pin A.

- The sliding beams at the left side of the
vehicle are retracted individually and locked by
4 socket pins.Left support control unit: Press
button 255 and button 257.
- Right support control unit: Press button 285
and button 287.
DANGER:only operate the sliding

beams that you can see.
Ensure that there are no persons or objects
in the danger zone.
- Keep engine running at idle speed.

- Shut off engine.
290 ,250 252, 288
282 ,258 260, 280
255 ,287 271 257 ,285
3-87
SAC2200
3.5.3 Before leaving the work site

Perform the following checks before leaving
the work site:
- Check that the axle suspension is switched
on.
- Check whether the support cylinders are fully
retracted.
- Check whether the support pads are in
transport position and have been secured.
Check whether the sliding beams have been
fully retracted and pinned.
- Check whether the retaining pins have been
secured in their holders.
- Check whether the chocks are in their
holders.
- Check whether the control boxes for left,
right control units are closed.
- Check whether the steering of independent
rear axle is relocked (axle 3 is well locked).
- Check whether the telescopic boom has
been retracted and placed on the boom
support.
- Check whether the turntable panels are
locked.
- Check whether the cover on turntable is
closed.
Check whether the doors and windows of the
crane cab are closed.
- Check whether the folding ladder and cab
have been correctly secured.
- Check whether the spare wheel has been
properly secured.
- Check whether the hoist rope has been hung
up and fixed on the front towing coupling.
- Check whether all the counterweights have
been fastened as specified in chapter 3, 4.
3-88
SAC2200
DANGER: locking mechanisms,

spring-loaded safety pins and retaining
pins must be fitted and secured to prevent
them from becoming loose during the
journey and causing damage.
CAUTION: after a longer period of

time on the construction site, all the checks
described in Chapter 3.2 must be carried
out before starting to drive.
3-89
SAC2200
E
G
PA
K
AN
BL
3-90
Crane Superstructure Operation
SAC2200

4 Crane Superstructure Operation
4.1 Operating and Control Instruments........................................................................... 4-2
4.2 Superstructure Control System .............................................................................. 4-14
4.3 Crane Startup.......................................................................................................... 4-46
4.4 Safety Equipment................................................................................................... 4-68
4.5 Superstructure........................................................................................................ 4-78
4.6 Rope Reeving........................................................................................................ 4-102
4-1
SAC2200
4 CRANE SUPERSTRUCTURE
OPERATION
4.1 Operating and Control

Instruments
300 Superstructure control panel

301 Console electric control cabinet
302 Engine control pedal
303 Slewing brake
304 Receiver - Windshield washer fluid
305 Wiper - Ceiling wiper
306 Seat - Adjustable
306-1 Handle - Adjust horizontal setting
306-2 Rotary switch - Adjust air spring height
306-3 Button - Adjust seat front section height
306-4 Button - Adjust seat rear section height
306-5 Button - Adjust backrest angle
307 Armrest control box
4-2
SAC2200
305
300
301
302
303
304
306
307
306-5
306-4
306 -3
306 -1 306 -2
4-3
SAC2200
308 Display - Control and operation display

309 Instrument - Tachograph
310 Instrument - Fuel gauge
311 Instrument - Lubricating oil pressure gauge
312 Instrument - Water temperature gauge
313 Button - Emergency off switch
314 Key switch - Superstructure key switch
315-319 Free
320 Control light - Charge display
321 Control light - Preheat engine
322 Warning light - Engine failure (check needed)
323 Warning light - Engine stop (stop needed)
324 Warning light - Low coolant level
325 Warning light - Water temperature
326 Warning light - Lubricating oil pressure
327 Control light - Boom pin / cylinder pin operation position
328 Rocker switch - I / II pump check
(Position I: I pump check; Position 0: I & II
operate; Position II: II pump check)
329-330 Free
331 Rocker switch - Superstructure power switch
332 Rocker switch - Manually operated boom pin / cylinder pin
(Position I: withdraw boom pin; Position 0: no
operation; Position II: withdraw cylinder pin)
333 Rocker switch - Emergency operation switch

(Position I: obverse operation; Position 0: no
operation; Position II: reverse operation)
334 Rocker switch - Retract counterweight cylinder

(Position I: retract cylinder; Position 0: no
operation; Position II; extend cylinder)
335 Rocker switch - Insert / withdraw slewing pin

(Position I: withdraw pin; Position 0: no
operation; Position II: insert pin)
336 Rocker switch - Working light switch

337 Rocker switch - Boom illuminating switch
338 Rocker switch - Rotating warning light
339 Rocker switch - Instrument light
340 Rocker switch - Ceiling wiper switch
341 Rocker switch - Wiper spraying switch
342 Rocker switch - Front wiper switch
343 Rocker switch - Bypassing switch
344-350 Free
4-4
SAC2200
309
308
310
311
312
313
314
4-5
SAC2200
351 Controller - Engine ADM2

352 Controller - Activate engine preheat
353 Terminal row - Console connection
354 Relay - Activate relay
355 Terminal row - Fuse terminal
356 Channel
357-359 Free
4-6
SAC2200
354
351
355
352 356
353
4-7
SAC2200
360 Handle - Left side control handle assembly

361 Handle - Right side control handle assembly
362 Control panel - Console air-conditioner control panel
362-1 Switch - Turn on / off air-conditioner
362-2 Rotary switch - Adjust air-conditioner temperature
362-3 Rotary switch - Adjust air-conditioner fan
363 Air-conditioner
4-8
SAC2200
360 361
362
363
362-1
362-2
362-3
4-9
SAC2200
364 Rocker switch - Switch between telescoping operation/winch

2 reeling operation
Position 0: telescoping operation
Position I: winch 2 reeling operation
365 Rocker switch - Adjust cab angle

Position I: cab up; Position 0: no operation;
Position II: cab down
366 Rocker switch - Cab footswitch extends / retracts

Position I: extending; Position 0: no operation;
Position II: retracting
367 Rocker switch - Slewing brake

368 Rocker switch - Boom / jib luffing operation
Position 0: boom luffing;
Position I: jib luffing
369 Rocker switch - The bypass may only be carried out if the
overload has been caused by luffing down at
freely suspended load and the crane operator
is absolutely certain that he can leave the
overload range by luffing up.
370 Rocker switch - Turn acoustic warning off

371-375 Plate
376-379 Free
4-10
SAC2200
364 365 366 367 368 369 370 371
372 373 374 375
4-11
SAC2200
380 Button - Free slewing

381 Button - Horn
382 Button - Operating key
- Operation as displayed on the identification
board 386 can only function by pressing such
key
383 Button - Engine rated speed
384 Button - Rapid gear
385 Button - Operating key
Operation as displayed on the identification
board 393 can only function by pressing such
key
386 Identification board - Display left handle function and operation

387 Identifier - Turntable rotates anticlockwise
388 Identifier - Turntable rotates clockwise
389 Identifier - Winch 2 hook down
390 Identifier - Winch 2 hook up
391 Identifier - Extend boom
392 Identifier - Retract boom
393 Identification board - Display right handle function and operation
394 Identifier - Luff boom up
395 Identifier - Luff boom down
396 Identifier - Luff jib up
397 Identifier - Luff jib down
398 Identifier - Winch 1 hook down
399 Identifier - Winch 1 hook up
4-12
SAC2200
382 /385
380 381 383 384
360 361
398
389 391
386 393
387 395
390 392 388

394 396 399 397
4-13
SAC2200
4.2 Superstructure Control

System
CAUTION !
The monitor illustrations in this chapter are
only examples. The numerical values in the
individual icons and tables do not necessarily
match exactly to the crane. Furthermore
many of the illustrations show the maximum
configuration. In normal crane operations, an
identical display will not appear on the monitor.
4.2.1 General
The superstructure control system is a

computer system for controlling and monitoring
mobile cranes. In addition to the Load torque
limiter = LMI there are a number of application
programs that can be used for controlling and
monitoring the crane movements:
1 “Superstructure control system start-up”
program
2 “Superstructure operating” program
3 “Boom length combination selecting”
program
4 “Engine monitoring” program
5 “Support” program
6 “Operating condition setting” program
7 “Telescoping” program
8 “Manual switchover” program
9 “Virtual wall setting” program
10 “Harness communication monitoring”
program
11 “Time setting” program

Load torque limiter (LMI)
Load torque limiter is implemented in
microprocessor of superstructure. The
superstructure operating system works on the
principle of comparing the actual load with the
maximum permissible load.
4-14
SAC2200
Actual load
The current load is recorded by acquiring
variable values.The load on the crane is jointly
set by the load torque and the boom torque.
This exerts a force in the boom luffing cylinder
that is measured by a pressure gauge.
The boom torque is calculated from data from
the angle sensors (boom angle), the length
sensors(boom length) and from crane data
(boom weights) for the set operating mode.
The boom projection radius is calculated with
data from the angle sensors (boom angle),
the length sensors (boom length) and from
geometry data for the set operating mode.
This also takes into account the bending of the
boom under its own weight, and the weight of
the load.
The actual load is calculated from the total
load, the boom torque and the boom projection
radius.
Maximum load according to load chart and

reeving
Crane data such as load charts, boom weights
and geometry data are stored in the main
memory of the load torque limiter system.”The
“maximum load according to the load
chart and the reeving type” is continuously
calculated from the load charts for the current
configuration, the reeving type and the
calculated load.
The actual load and the “maximum load
according to the load chart and reeving” are
compared. When these approach the specified
limits, there is a advance warning. If this limit
is exceeded, the overload stop is triggered,
and any crane movements that are raising the
load torque are switched off.
Connection between components of chassis
and superstructure is done through CAN.
4-15
SAC2200
4.2.2 Superstructure control system

start-up
After switching on, the superstructure control

system performs a self-test.
First, the connections from the microprocessor
to the monitor are checked. If no errors are
found during the system test, the monitor
shows this image:
1——Operating condition setting
1.1——Operating condition setting: 0: no
setting 1: T 2: TK 3: TVK
1.2——Extension with no boom: activate the
TK operating condition, and then select the
extension length (with no boom) through Key
1.2, as shown in the following figure. The
operating condition of TVK is set accordingly.
2——Jib angle setting: 0: 0° 1:20° 2:40° 3:45°,
and the selected value will be framed with
green light band.
3 ——Support condi ti ons setti ng: th e 3
support conditions can only be activated
under the operating condition of T, namely,
0: full-extending, 1:half-extending and 2:full-
retracting. The support is fixed at full-extending
state under the operating conditions of TK and
TVK. The selected value will be framed with
green light band.
4——Magnification: the magnification can be
selected from 1~16, and the selected value
will be framed with green light band.
5 —— C o u n t e r w e i g h t : t h e r e a r e 6
counterweights for selection, and the selected
value will be framed with green light band.
6——Confirmation: the operating program
interface can be steeped into through the
confirmation button.
4-16
SAC2200
4-17
SAC2200
4-18
SAC2200
4.2.3 “Superstructure operating”

program
Main components of superstructure operation

display
A——Condition and warning information
display
B——Crane operating condition display
C——Function procedure display
The function keys on superstructure operating
display contain different meaning and function
in different procedures. See below for each
procedure.
4-19
SAC2200
“Superstructure operating” program

Superstructure operating control display will
step into subprogram interface once started
up. Crane leveling condition, hoisting capacity,
support span, wind speed, winch, slewing,
boom / jib luffing angle are all included in such
interface. Function subprogram icon match
exactly to function keys.
NOTICE!
Subprogram interfaces like hoisting
setting, support operation, virtual wall and
hoisting performance table can be stepped
into through function keys on main
operation interface.
CAUTION!
For illustrations in this chapter are only
examples, the actual parameters dominate.
4-20
SAC2200
4.2.3.1 Warning information display
1——Hoisting height limit caution

2——Lowering height limit caution
3——Support force caution
4——Operating condition precaution: LMI is in
danger.
5——Engine caution
6——Operating stop caution: remedy failure
once LMI fails.
7——Engine stop caution
8——Virtual wall caution
9——CAN communication failure caution
4-21
SAC2200
4.2.3.2 Crane operating condition display
Operating condition information
1——Hoisting torque percentage: green-

normal operation; yellow-torque percentage
above 90% but below 100%; red-overload.
2——Operating condition code is made up of
8-digit organization number, with operating
condition of jib, counterweight, boom pin, etc
included. Refer to the chapter on “Operating
setting program” for detailed information.
3——High/low gear display
4——Non-free slide state
5——Left control lever
6——Right control lever
7——Jib length display
8——Radius display
9——Operating height display
10——Horizontal obliquity display
11——Support force and support span display
12——Current time display
13——Jib pitching angle display
14——Current wind speed and permitted
maximum speed display
15——Slewing angle and slewing speed
display
16——Operating condition display of main
winch
17——Operating condition display of auxiliary
winch
18——Hook magnification and maximum
hoisting capacity display
19——Hook capacity and percentage thereof
display
20——Counterweight display
4-22
SAC2200
2 12
3
4
5 13
7 14
8 15
9 16
17
18
10
19
11
20
4-23
SAC2200
Function program selecting
1——Back to operating condition setting

program
2——“Boom telescopic combination selecting”
program covers 44 different kinds of telescopic
combination conditions in such program, which
enables operator to select corresponding
hoisting operation.
3——Operating speed limit for superstructure
4——Support operating program. Support
operating can be carried out through
superstructure display after the completion
of support leveling, limiting parameters at the
same time.
5——Help program
6——IO port inquiry program
7——Manufacturer parameters setting
8——Turn acoustic warning off
4-24
SAC2200
4.2.4 Boom length combination

selecting program
1——Boom length combination table covers

44 kinds of boom length combination.
2——Boom length combination selected
indication. The selected combination will be
framed with red light band.
3——On switchover buttons for boom length
combination selecting program there are 3
buttons represent moving upwards, leftwards,
rightwards and downwards respectively.
4——Confirmation interface for boom length
combination can be stepped into through
the confirmation button for boom length
combination selecting program after the
completion of program selection.
5——Cancel the boom length combination
that has been selected.
4 5
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SAC2200
4.2.4.1 Telescopic boom telescoping

program
1——Hoisting state display

2——Telescopic proximity switch monitor
3——Telescopic boom display
4——Telescoping condition display
5——Manual/automatic condition display
6——Back to operating program interface
2 3
5 6
4-26
SAC2200
2.1——Proximity switch for cylinder pin/boom

pin display.
Green proximity switch signal represents
effective monitoring, while no color signal
represents ineffective monitoring. All proximity
switches are set accordingly.
2.2——Proximity switch display for telescopic
boom.
Effective signal can be monitored when
telescopic cylinder head moves to the
corresponding area at the end part, and
proximity switch turns green. On the contrary,
switch will display no color if no effective signal
is monitored.
2 . 3 —— P r o x i m i t y s w i t c h d i s p l a y f o r
overextended boom.
Proximity switch turns green when telescopic
cylinder has been overextended.
2.1
2.2 2.3
4-27
SAC2200
4.1——Telescopic cylinder telescoping length

monitor functions to display the extend length
of telescopic cylinder under current operation.
4.2——Telescopic boom telescoping condition
display
4 . 3 —— Te l e s c o p i c b o o m c o m b i n a t i o n
monitor functions to display the extend length
percentage value for each telescopic boom
section (2~6)under current operation.
4. 1
4. 2
4. 3
3.1——Telescopic boom luffing angle

3.2——Telescopic boom operating radius 3.1
3.2
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SAC2200
4.2.4.2 Manual / automatic switchover

program
1——Current selected mode display

2——Automatic button
3——Manual button
4 —— C o m p l e t e s e l e c t i o n a n d j u m p t o
telescoping program
5——Cancel the selection
2 3 4 5
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SAC2200
4.2.5 Operating condition setting

program interface
The right lower corner of set item will be

covered with green cursor when superstructure
operating speed is under set. Such setting can
be done through speed value selecting button
subsequently.
1——Limit display for maximum slewing speed

2——Limit display for maximum winch 1
speed
3——Limit display for maximum telescoping
speed of telescopic cylinder
4——Limit display for maximum luffing speed
5——Limit display for maximum winch 2
speed
6 —— S p e e d v a l u e s e l e c t i n g b u t t o n ：
0%,10%,20%,50%,75% and 100%
7——Switchover button for set items, the
selected item will be covered with green cursor
8——Operating program interface can be
stepped into through the confirmation button
for selected items.
8—Jump to “main operating program” interface
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SAC2200
4.2.6 Support operating program
1——Crane operating radius and angle

display
2——Wire magnification and maximum
permitted hoisting capacity display
3——Crane hoisting capacity and percentage
thereof display
4——Crane horizontal obliquity display
5——Support operating condition display, see
following chapter for detailed information
6——Support operating function program
combination
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SAC2200
Support operating function program

combination
6.1——Operate support lamp
6.2——Activate support operating activation
button
6.3——Jump to “support operating setting”
program
6.4——Start engine
6.5——Extend all supports synchronically
6.6——Retract all supports synchronically
6.7——Accelerate
6.8——Decelerate
6.9——Engine stop button
6.10——Back to operating program interface
Support operating condition display

5.1——Retract vertical support
5.2——Extend vertical support
5.3——Extend horizontal support
5.4——Retract horizontal support
5. 35 .4
5. 1
5. 2
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SAC2200
Support operating condition display
1——Support force warning setting

2——Function program set button
3——Data increase radius: as shown above,
once “10” is selected, it will be marked with
green circle and the set data will increase or
decrease at a radius of 10. Similarly, the data
will increase or decrease at a radius of 1 once
“1” has been selected.
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SAC2200
1.1——Maximum support force setting during

operation
1.2——Minimum support force setting during
operation
interface
1. 1
1. 2
2.1——Set data increase

2.2——Set data decrease
2.3——8 data selected indication, the selected
ones will be framed with green cursor.
2.4——Support condition display interface
can be stepped into through the confirmation
button
2.5——Cancel operation
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SAC2200
4.2.7 Help Program
1——Engine condition test program

2——LMI inquiry program
3——LMI information inquiry program
1 3
4-35
SAC2200
4.2.7.1Engine condition test program
1——Superstructure engine lubricating oil

pressure display
2 —— S u p e r s t r u c t u r e e n g i n e c o o l a n t
temperature display
3——Superstructure battery energy content
display
4——Superstructure engine torque display
5——Superstructure engine torque percentage
display
6——Superstructure oil tank level display
7——Chassis engine lubricating oil pressure
display
8——Chassis engine coolant temperature
display
9——Chassis battery energy content display
4-36
SAC2200
4.2.7.2 LMBTest program
1——Boom performance table

2——Jib performance table
3——Operating condition inquiry
4-37
SAC2200
Boom performance table inquiry program

1——Radius display
2——Boom length display
3——Load capacity display for different radiuses
and boom length combinations
4——Telescoping percentage and magnification
display for each boom section
5——Page turning button
6——Function selection button set
Jib performance table inquiry program
Jib performance table inquiry program goes

accordingly to the one of boom.
2
1
4-38
SAC2200
Operating condition setting program interface
1——Operating radius setting

2——Operating height setting
3——Load capacity setting
4——Jib length setting
5——Minimum counterweight selected indication
6——Shortest support selected indication
7——Shortest boom selected indication
8——Step into the operating condition inquiry
interface
9——Back to crane performance table interface
4-39
SAC2200
Operating condition inquiry program
4-40
SAC2200
4.2.7.3 LMI information display
4-41
SAC2200
4.2.8 IO port inquiry program
1—Superstructure engine speed and hoist

state display
2—Telescopic proximity switch monitor
3—Telescopic boom display
4—Telescoping condition display
5—Manual / automatic condition display
6—Function subprogram button
4-42
SAC2200
4.2.8.1 Main controller DI/O
4.2.8.2 Auxiliary controller DI/O
4-43
SAC2200
4.2.8.3 Analogue quantity input
4.2.8.4 Can communication condition test

program
4-44
SAC2200
4.2.9 Manufacturer parameters setting
4-45
SAC2200
4.3 Crane Startup
4.3.1 Checks before starting up

Various checks must be performed before
starting up.
CAUTION: refer to chapter 7.5 on

“superstructure maintenance instruction”
for detailed information.
4.3.1.1 Checking the fuel level
On the monitor, the amount in the tank is given

in the form of a numerical display in percent
[%].
WARNING: do not run the fuel tank dry.

If the fuel tank has been run dry, always
deaerate the whole fuel system.
4-46
SAC2200
4.3.1.2 Checking the coolant level
Fill coolant expansion tank up to overflow on

filler neck.
DANGER: coolant temperature

should be lower than 50° when performing
level check and fill. Danger of injury due to
scalding of the skin!
4.3.1.3 Checking central lubrication system
The grease container must be kept filled with

grease as specified in the lubrication chart.
NOTICE: see chapter 7.5.
4-47
SAC2200
4.3.1.4 Checking general condition of crane
Before starting up engine, ensure the following

prerequisites are met:
- Check that the crane is properly supported
on a level load-bearing surface, and has been
set up horizontally.
- Check that the toothed ring of the slewing
ring connection is clean and greased.
- Check the air supply to the oil cooler and
water cooler.
- Check that the side covers are closed and
locked.
- Ensure that there are no people or objects in
the crane danger zone.
- Make sure that the cable / rope drums and
the limit switches are free of snow and ice.
- Make sure that there are no loose parts on
the superstructure or boom.
DANGER: before raising the

boom, check that there are no loose parts
on the boom and/or the jib, such as pins,
safety springs or ice. Risk of accident from
falling parts!
4.3.2 Crane operator's cab workplace
4.3.2.1 Adjusting crane operator's seat
The crane operator's seat can be adjusted to

suit different body sizes.
Adjust operator’s seat

- Using the lever 306-1, adjust angle of seat.
- Using the lever 306-2, adjust height of seat.
- Using the lever 306-3, adjust the inclination
of seat front section.
of seat rear section.
of backrest.
4-48
SAC2200
306 -5
306 -4
306 -3
306 -1 306 -2
4-49
SAC2200
4.3.2.2 Footboard
The footboard beside the console can be

moved towards the door, which enables the
crane operator to enter and leave the crane,
and the crane cab footboard can be extended
or retracted.
DANGER: with the completion of

operation, retract the footboard again and
secure it in the end position.
The extending / retracting of footboard
can be realized by the arrow direction
illustrated on the button 366.
4.3.2.3 Turning air conditioner / ventilation

on
The cab can be heated or ventilated to the

desired temperature.
The operating controls for heater / ventilation
are on the rail box.
- Turn the air-conditioner on with the switch
362-1
- Turn the air-conditioner off with the switch
362-1
- Control temperature with the variable switch
362-2
- Move variable switch 362-3 to fresh air
4-50
SAC2200
366
362-1
362-2
362-3
4-51
SAC2200
4.3.2.4 Tilting crane cab
To give the crane operator a better field of

view, the cab can be tilted upwards.
DANGER: if the cab is tilted

upwards, it is forbidden to stand on the
footboard.
Set the crane to horizontal with the
completion of crane operation.
-Press and hold down button 365 till the

desired field of view is reached.
CAUTION: if the cab is tilted and

the counterweight has been lowered on to
the chassis, do not turn the superstructure
towards the rear.
4-52
SAC2200
365
4-53
SAC2200
4.3.2.5 Operating the windshield wiper /

windshield washing system
1. Operating the windshield wiper

Activate the windshield wiper on the front
window with switch 342, and the one on the
roof window with switch 340.
2. Operating the windshield washing system

The windshield wipers on the front and roof
windows can be assisted by a windshield
washing system.
CAUTION: before the start of the

cold season, fill the container for the
windshield washing fluid with standard
antifreeze mix.
Activate the windshield wiper on the front

window and the windshield washing system
with the button 341.
4.3.2.6 Checking the signal horn
Before starting work, check that the signal

horn is functioning.
CAUTION: only use the signal

horn in dangerous situations, to maintain
its warning effect.
4-54
SAC2200
340 341 342
4-55
SAC2200
4.3.3 Starting superstructure engine

met:
- the battery master switches are on
- the transmission is in neutral position “N”
- the switch 154 is set to superstructure
operation
4.3.3.1 Starting superstructure engine
- Turn ignition switch to position “I”, engine

is ready to start.
- Turn ignition switch to position “II”, engine is
started.
CAUTION: if engine is not started
310s later, wait for 1 minute, and the starter
can be operated three times for 310
seconds per attempt with a pause in
between of one minute each time.
1. Starting the superstructure engine with
flame starting device
- The engine is equipped with a flame starting
device to improve the cold start process.
- The preheating operation is activated
automatically with the startup of ignition switch
at a temperature lower or equal to － 20°C.
- The flame starting system can not be started
at a temperature above － 20°C
-Turn ignition switch 314 to position “I”.
- Engine can be started after 5-35s’ operation
of preheating system.
- The flame starting is switched off
automatically, if:
Engine is not started up within the wait for run-
up phase.
Engine is started up after the phase for
preheating operation has been reached.
CAUTION: battery functioning

capacity in the cold season.
The starting capacity of the battery is
considerably reduced in cold weather: for
example, at a temperature of 10 °C, the
battery is at only 66% of its normal capacity
once the engine has been turned off, store
batteries in a heated room, if possible.
4-56
SAC2200
154
UP-C
314
4-57
SAC2200
4.3.3.2 Checking the instruments after

starting the engine
1. Crane operation
As soon as a stable voltage is present with
the engine running, the crane controls are
automatically switched on. A self-test of the
microprocessor system follows, and after a
few seconds the configuration state screen
appears on the monitor 308.
2. Checking the instruments

The numerical display for engine oil pressure
(3 or 7) should not flash.
The following icons should be checked when
engine is running:
- Coolant temperature (1 or 4).
- Battery voltage (5).
CAUTION: chassis engine monitor

icon appear only after the startup of
engine.
WARNING: shut off engine for

defect detection once engine oil pressure
is too low. The engine could be damaged
as a result of insufficient oil pressure.
Shut off engine immediately once coolant
temperature is too high.The engine could
be damaged as a result of over high
coolant temperature.
Never allow engine to run with full load
before the normal operating temperature
has been reached. Do not cut off
battery control lever during operation,
otherwise,engine will uncontrolledly stop.
4-58
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4-59
SAC2200
4.3.3.3 Engine monitoring
1. General
Starting program
Automatic mode:
-Check if there is need to.
or
-Check when lights for superstructure
precaution or warning lights illuminate.
4-60
SAC2200
2. General view
Precaution
Relevant icons are automatically displayed as
precaution once defects occur after engine
startup.
“Warning” signs (4.1)
“Warning” signs are automatically displayed
once WARNING event occurs in engine
monitoring.
“Stop” signs (4.2)

“Stop” signs are displayed automatically once
STOP event occurs in engine monitoring.
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SAC2200
Advance warning Warning (5.2) Stop (6.2)
Engine oil pressure (display value)

missing
×
Erroneous engine oil pressure (display
×
value) ×
Engine oil pressure warning active
Coolant temperature (display value)

missing
Coolant temperature(display value) ×
missing × ×
Coolant temperature warning active ×
Coolant level warning active
Battery voltage (display value missing

×
Erroneous battery voltage (display
×
value)
×
Battery voltage ≤16V or ≥36V
Fuel reserve (display value) missing

Erroneous fuel reserve (display value) ×
Fuel reserve (display value) ≤5% ×
Fuel reserve (display value) ≤1% ×
×
Fuel reserve (display value) = 0 ×
4-62
SAC2200
4-63
SAC2200
4.3.3.4 Turning the superstructure engine

off
- Turn ignition starter switch 314 back to the

stop
- Pull out ignition starter switch 320 and store
in a safe place
CAUTION: if the crane has been

operated at full engine output, or with very
high coolant temperatures (above 95°C) let
the engine run without load for 1-2 minutes
at idling speed.
4.3.3.5 Turning the superstructure engine

off in the event of danger
- Press the emergency-off switch 313 to shut

off engine immediately in the event of danger.
- Press the emergency-off switch 313, the
crane will be turned off immediately.
WARNING:only use the

emergency off-switch 313 in case of
serious emergency. Use of the emergency
off-switch 313 in normal situations is
forbidden!
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SAC2200
309
308
310
311
312
313
314
4-65
SAC2200

after engine start
4.3.4.1 Waiting for the run-up phase
After being switched on, the superstructure

control system runs up and carries out a self-
test.
The configuration screen appears on the
monitor if run-up is done successfully.
CAUTION: normally, the most

recently set configuration state and reeving
number will be displayed. If there has been
a loss of data in the storage device (cold
start), the first valid configuration state
appears in the configuration screen. The
reeving number is set to “0”.
4.3.4.2 Selecting the new configuration and

hoist rope reeving
CAUTION: check whether the

correct short code and the correct reeving
number have been selected on the
operating screen.
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4.4 Safety Equipment
4.4.1 General
Every time the crane is operated,

the crane operator is required to satisfy
himself about the functionality of the safety
systems.
DANGER: operating the crane with

defective warning and safety systems can
lead to life-threatening accidents!
4.4.2 Spirit levels

To ensure the working safety of the crane, it
must be properly supported on a level load-
bearing surface, and be set up horizontally.
CAUTION: the maximum permitted

deviation from the horizontal position of
the crane is ± 0.5% (± 0.3°).
DANGER: if the crane is n o t

aligned horizontally, it may tip over.
4.4.2.1 Spirit levels on chassis
A support control unit with buttons is attached

to each side of the vehicle for operating the
support, together with an electronic slope
display.
4.4.2.2 Spirit levels on the superstructure
The horizontal alignment of the crane is

displayed in the crane control system both
graphically and numerically.
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SAC2200
4.4.3 Torque control system

The torque control system is a system for
controlling and monitoring mobile cranes.
As well as overload protection there are a
number of application programs that can be
used for controlling and monitoring the crane's
movements, see chapter 4.2.
4.4.3.1 Overload protection

The electronic overload protection switches
off all crane movements that increase the
load torque if the permissible load torque is
exceeded. Only crane movements that reduce
load torque can be made.
WA R N I N G : t h e p r e s e n c e o f
overload protection does not relieve the
crane operator of his duty of care and
attention. Before lifting a load, determine
its approximate weight and centre of
gravity, and with the help of the load chart,
decide whether the crane is in a position to
carry out this job.
DANGER: the overload protection

is a safety mechanism. It must not be used
operationally as a way of switching off
crane movements of any kind.The overload
protection must be adjusted before using
the crane to the current set up condition, in
accordance with the load chart. Only that
way can it fulfil its protective task.
The crane operator must meet his duty of
care and attention, despite the overload
protection.
The overload protection cannot cover all
possible operational conditions.
4.4.3.2 Support program
See chapter 4.2 on control system for support

program introduction.
4.4.3.3 Control parameters program
See chapter 4.2 on control system for control

parameters program introduction.
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4-71
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4.4.4 Wind warning system

The wind warning is displayed through torque
control system operation chart.
If the actual wind speed value exceeds the
displayed maximum value, the “Wind warning”
begins to flash.
DANGER: if crane movements has

not been switched off when actual wind
speed value exceeds the displayed
maximum value. Stop crane operation and
lower the boom immediately.
WARNING: the wind indicator

should be well mounted and connected
(operate normally) under the operation of
sub arm, otherwise, failure in overload
protection system will be displayed.
4.4.5 Hoist limit switch “Hoist top”

The hoist limit switch is intended to prevent
the hook block from colliding with the boom
head. Before every use of the crane, the hoist
limit switch functionality must be checked by
moving the switch weight with the book block.
On activating the hoist limit switch, the crane
movements “Lift”, “Luff down” and “Telescope
out” are switched off.
DANGER: during crane operation,

bypass the hoist limit switch only with the
key switch if a guide is monitoring the
distance between the hook block and the
boom head.
The guide must be in direct contact with
the crane operator.
Carry out any hoist movement with utmost
caution and at minimum speed.
In emergency situations, only an authorized
person may bypass the hoist limit switch.
Do not use the hoist limit switch as an
operational shut off function, otherwise,
the crane may topple over or be destroyed.
4-72
SAC2200
4.4.6 Limit switch winch reeled off

The cam-type limit switch installed in the winch
switches “Winch reel off” off if there are only 3
rope winds remaining on the winch.
DANGER: if the following notes

are not observed, the rope attachment may
be torn out and the load may topple. The
cam-type limit switch must switch off when
there are 3 rope winds remaining on the
winch!
If the hoist rope is spooled up during
assembly, please ensure that the rope
end remains in front of the winch and is
not spooled up over the winch. If the rope
end is pulled over the winch by another
rotation, the cam-type limit switch must be
re-set!
4-73
SAC2200
4.4.7 Emergency off switch

If the EMERGENCY OFF switch 313 is
operated, the motor and the electrical crane
control are switched off. Every movement
carried out can be immediately stopped.
DANGER:only use the EMERGENCY OFF

switch in the event of a clear emergency!
The use of the EMERGENCY OFF switch
for normal operation is not permitted!
4.4.8 Control release

Switches (382 / 385) on the control lever
should be pressed when superstructure is
under operation.
CAUTION: this safety equipment

prevents unintended crane movements by
accidentally touching the master switch
when getting in or out of the cab.
4-74
SAC2200
382/ 385
313
4-75
SAC2200
4.4.9 Bypassing
4.4.9.1Bypassing “Luff up if overload

occurs”
If overloading occurs the “Luffing up” crane

movement is disabled, although this is a
load torque-reducing crane movement with a
suspended load.
Crane operation can be carried out freely
when button 369 is held down and control rod
is turned to “luffing up”.
DANGER: never lift a load by

luffing up the boom if, when trying to lift
the load, the hoist gear would be switched
off by the load torque limiter, otherwise,
the crane may topple over.
Only bypass within the limit range if the
overload protection with a freely hanging
load does not report an overload.
4-76
SAC2200
F1 F2 F3 F4 F5 F6 F7 F8
369
4-77
SAC2200
4.5 Superstructure
4.5.1General

met:
- crane is supported and level in accordance
with the information in the load chart
- the operator's cab is at the operating
position
- the ladder in operator's cab is at the
operating position
- the folding boom (if solely attched) is turned
to the position of "telescoping boom operating"
- the counterweight is attached and secured
in accordance with the information in the load
chart
- the crane engine is running
- the hook block is correctly reeved as shown
in reeving plan
- all safety devices have been adjusted as per
the information in the load chart
- there are no persons or objects in the danger
zone
WARNING: in order to protect the

crane and reduce the danger of accidents
always use the master switch slowly and
sensitively.
4.5.1.1 Locking the superstructure
During crane operation only lock mechanically

“towards the back” or as in chapter 4.09,
mechanically lock the superstructure to the
chassis.
- the symbol that locking mechanism of the

superstructure is locked appears by pressing
button 335.
4-78
SAC2200
F1 F2 F3 F4 F5 F6 F7 F8
335
380 381 383 384
382 385
360 361
4-79
SAC2200
4.5.1.2 Locking the engine control
Locking engine RPM frees the crane operator

if he needs to work for a length of time with
constant RPM. The engine control can be
locked in any position.
1. Engine RPM
- Tread on engine control to reach required
RPM.
- Press button 383 on lever 361 to lock the
engine control.
2. Releasing the engine RPM

- Press button 383 again to release engine
RPM.
4.5.1.3 “Power Plus” rapid gear
The “power plus” rapid gear (an operation

mode characterizes with the confluence of
double pumps) can be realized through button
384.
1. Switching on “Power Plus” rapid gear

- Using button 384 to switch on “power plus”
rapid gear
DANGER: do not turn on rapid

gear in the event of one to three strand
reeving or if the crane is loaded to more
than 50% of its maximum permitted load
carrying capacity for the respective boom
radius.
2. Switching off “Power Plus” rapid gear

- Press button 384 again to shut off “power
plus”rapid gear and switch over to the
compound operation mode of single pump.
4-80
SAC2200
F1 F2 F3 F4 F5 F6 F7 F8
380 381 383 384
382 385
360 361
4-81
SAC2200
The following prerequisite should be met:

- Crane is running.
- Superstructure control system runs up after a
self-test. The configuration screen appears on
monitor if no fault is found out.
4.5.3 Luffing
Boom luffing:
Boom luffing is activated when button 368 is
set to the position “I”
Turning control lever 361 to icon 396 = boom
luffing up
Turning control lever 361 to icon 397 = boom
luffing down
Jib luffing
Jib luffing is activated when button 368 is set
to the position “II”
Turning control lever 361 to icon 394 = jib
luffing up
Turning control lever 361 to icon 395 = jib
luffing down
CAUTION: the speed of the crane

movement “Luffing” is controlled by the
control lever 361 and by the pedal 301 of
the engine control.
4.5.3.1 Preselect the maximum luffing

speed of telescopic boom
In the “Control Parameter program”, it is

possible to preselect the maximum luffing
speed of the telescopic boom.
WARNING: the maximum luffing

speed of the telescopic boom can not be
modified after the startup of crane.
4-82
SAC2200
302 301
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
364 368
4-83
SAC2200
4.5.4 Lifting / lowering
WARNING: do not allow slack

cable to build up when spooling up and/or
reeling off the hoisting rope.
4.5.4.1 Lifting / lowering the winch 1 (main

winch)
Turning control lever 361 to icon 398 = winch

1 hook up
1 hook down
CAUTION:adjust winch speed

through control lever 361 and engine
adjusting pedal 301.
4.5.4.2 Lifting / lowering the winch 2

(auxiliary winch)
Winch 2 is activated when button 364 is set to

the position “II”
2 hook down
2 hook up
CAUTION:adjust winch speed

through control lever 360 and engine
adjusting pedal 301.
4-84
SAC2200
302 301
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
364 368
4-85
SAC2200
4.5.5 Turning the crane superstructure
Ensure that the superstructure is unpinned

before initiating the turning movement.
- Press button 335 to unpin the superstructure.
DANGER: ensure that there are no

obstacles in the crane slewing area and no
persons in the danger zone. Operator
should give a short warning signal (horn)
before starting a crane movement;
otherwise, fatal injury may occur.
Lean lever(360)towards icon(387)=slewing

table turns left
Lean lever(360)towards icon(389)=slewing
table turns right
CAUTION: crane speed can be

adjusted by deflecting control lever 360,
engine adjusting pedal 301 / brake pedal
302.
DANGER: when slewing with a

load, initiate the turning movement very
carefully, and apply the brakes. Load
shakes if startup or slow movement is
done unevenly, which may cause broken
boom and tipping over of crane.
4-86
SAC2200
4.5.5.1 Preselect rotation speed
The load chart manual gives the maximum

rotation speeds in percentages.
WARNING: the maximum rotation

speed depends on the boom length and the
operation mode, and must under no
circumstances be exceeded.
WARNING: the maximum rotation

speed can not be modified after the startup
of crane.
The basic principle is that with a longer
boom and a heavier load, the crane should
be operated at lower speed.
302 301
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
335
4-87
SAC2200
4.5.5.2 Slewing gear generally
The operation of slewing gear is realizes

through parking brake. It means that the
braking effect starts as soon as control lever
360 is moved towards the neutral position
while released as soon as it is moved away
from the neutral position.
C A U TION : t he pa r k ing br a k e
operates automatically, if:
- Engine is shut off,
- Open parking brake through button 367
- Parking brake can be shut off through
button 367.
- Pedal 302 can be taken as slewing
retarder.
CAUTION: the parking brake can

not be switched off in these situations:
- Slewing gear switched off by the sliding
beam monitoring.
- There exists limitation from worksite.
1. Switching slewing gear to freewheel

Slewing gear is switched to freewheel and
the boom can be positioned over the load
more easily through button 381. Do not rotate
control lever 360 during this operation.
DANGER:if superstructure slews

unintentionally to the side (for example
because of wind), following steps should
be taken:
- Do not release foot switch 381.

- Crane will stop abruptly if button 381 is
released and destruction to crane will be
caused by shaking load from this operation.
- Move lever 360 in slewing direction and
then release button 381. Brake the slewing
movements by slowly resetting lever 360.
4-88
SAC2200
302 301
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
367
4-89
SAC2200
2. Applying slewing gear brake

Crane is equipped with extra pedal 302 to
brake slewing gear. When turning against
the wind in strong sidewinds and a long
boom system, the superstructure moves in
the opposite direction because of leakage in
the hydraulic motor. Such condition can be
solved by operating slewing gear brake 302
and move lever 360 to the desired slewing
direction, or slowly releasing the slewing gear
brake 302 until the superstructure turns in the
desired slewing direction.
The slewing gear brake must only be used at

minimal slewing speeds, in other words with
lever almost at the neutral position. It can only
be applied in the following conditions:
1. Driving in strong sidewinds

Operate slewing gear brake 302 and move
lever 360 to the desired slewing direction.
Slowly release the slewing gear brake 302
until the superstructure turns in the desired
slewing direction.
2. Stopping the slewing movement in strong

sidewinds
Decelerate the crane with lever 360 at minimal
rotation speed.
Apply slewing gear brake 302 carefully, until
the crane has come to a stop at the desired
position.
CAUTION: slewing gear brake can

not be used as extra slewing brake;
otherwise, slewing brake, slewing gear and
slewing support may all be damaged.
DANGER: if foot brake is applied

with lever at neutral position to decelerate
crane, the crane may be damaged by
overload from this operation.
4-90
SAC2200
302 301
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
367
4-91
SAC2200
4.5.6 Telescoping
4.5.6.1 General
1. Cranes with two winches
CAUTION:for cranes with two

winches, the switch 364 must be at position
“telescoping”.
Move lever 360 towards icon 391 = telescopic

boom is telescoped out
Move lever 360 towards icon 392 = telescopic
boom is telescoped in
CAUTION:speed of crane
movement is controlled by the deflection of
lever 360 and by the pedal 301 of the
engine control.
4-92
SAC2200
302 301
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
364 368
4-93
SAC2200
2. Telescopic boom control system
The automatic telescopic boom control system

consists of:
- the dual action telescoping cylinder
- the hydraulically operated gripper pinning
- the hydraulically operated boom pins
- the electrically controlled sensor system
In the telescoping screen the crane operator

can see, in dynamic graphics, the pinning
state of the telescopic boom, the position of
the individual telescopes in relation to each
other, and the boom status of the telescoping
cylinder.
With the automatic telescoping procedure,

the crane operator can easily telescope
the telescoping boom, as he does not
have to concern himself with the pinning or
unpinning of the telescoping cylinder or the
telescope. The telescoping control system
therefore makes possible very straightforward
telescoping; only the desired telescoping
targets need to be entered into the system.
The telescoping control system decides the

sequence in which the individual telescopes
will be moved in order to achieve the desired
end state. After setting the desired telescoping
targets, all telescoping movements, as well
as locking and unlocking, are carried out fully
automatically.
The following procedures are carried out by

the system:
- locking and unlocking of the telescoping
cylinders
- pinning and unpinning of the telescopes
- sequence of events for the telescopes to be
telescoped, in order to achieve the desired
end state
This automatic process will however only be

carried out as long as the lever is operated.
4-94
SAC2200
The lever determines the direction and the

speed of the telescoping movement. In this
way the crane operator has continuous control
over the crane.
The direction of the cylinder movement is set

by the superstructure control system.
Lock left cylinder pin Lock right cylinder pin Lock boom pin 3
2 Unlock left cylinder pin Unlock right cylinder pin Unlock boom pin
Lock pin postion

Boom state Section 2 Section 3 Section 4 Section 5 Section 6 Overextend
Cylinder length
4
Cylinder length percentage for current section
Boom extend
5 mode
Target telescoping percentage
Actual telescoping percentage
Manual
6 AUTO
F1 F2 F3 F4 F5 F6 F7 F8
380 381 383 384
382 385
360 361
389 391 398
386 393
387 395
390 392
388 394 396 399 397
4-95
SAC2200
3. Telescoping
The superstructure control system displays the
direction in which the next telescoping must
be done, and the lever must also be pressed
to correspond to this direction setting.
CAUTION:there is no direct
connection between the direction of
movement of lever and cylinder when
telescopic cylinder is running.
As illustrated in instruction program, it is

possible to move to a telescope target
automatically without an operating screen. It is
therefore also not essential to keep watching
the monitor all the time.
If the direction needs to be changed by the

master switch, the telescopic boom remains
stationary if the current direction is to be
maintained. This also means that the master
switch must be moved in the other direction.
If there is no further movement in the other
direction, this means that the telescope target
has been reached.
CAUTION:the telescoping
operation can be done manually or
automatically.
4-96
SAC2200
Unlock left cylinder pin Unlock right cylinder pin Unlock boom pin
Lock pin postion

Cylinder length
Boom extend Target telescoping percentage

mode
Manual
AUTO
F1 F2 F3 F4 F5 F6 F7 F8
380 381 383 384
382 38
360 36
389 391
390 392
388 394 396 399 397
4-97
SAC2200
4.5.6.2 AUTOMATIC TELESCOPING
Confirm with currently selected boom

combination.
1. Selecting the telescoping target

- Target selection via the boom combination.
CAUTION: a change in the

telescoping target is only possible if the
lever is at neutral.
4-98
SAC2200
4-99
SAC2200
3. Telescoping to the selected target

If the desired telescoping target is set, then
the direction in which the lever 360 must be
deflected is displayed on the operating screen
and on the telescoping screen.
Up arrow appearing in the automatic icon =

telescopic boom is telescoped out
Down arrow appearing in the automatic icon =
telescopic boom is telescoped in
CAUTION:if the master switch is

moved against the specified direction, the
telescope remains stationary. The default
direction remains visible as a possible
error criterion.
If the set telescoping target has been reached,

then the telescopic boom remains stationary,
regardless of any movements of the lever,
and the markings on the set telescoping
target begin to flash. The target has thus been
reached.
4. Aborting telescoping
Telescoping can be aborted at any time.
The pins, the telescoping cylinders and the
telescopes remain where they were, in the
last state they were in when the lever was still
being pressed.
It is also possible to proceed manually by
switching over to manual operation.
If desired, a new telescoping target can be set
and telescoped to automatically.
4-100
SAC2200
Unlock left cylinder pin Unlock right cylinder pin Unlock boom pin
Lock pin postion

Cylinder length
Boom extend Target telescoping percentage

mode
Manual
AUTO
F1 F2 F3 F4 F5 F6 F7 F8
380 381 383 384
382 38
360 36
389 391
390 392
388 394 396 399 397
4-101
SAC2200
4.6 Rope Reeving
4.6.1 General
4.6.1.1Wire cables and cable end

connections
The type of cable that is selected then

determines the type of cable end connections
that are used, refer to chapter 8.4.
DANGER!
Correct choice and use of the wire cable
and the cable end connections are a
decisive prerequisite for proper and
accident-free crane operation.
4.6.2 Reeving the hook block in and out
4.6.2.1 Reeving in

met:
- the crane is properly supported and aligned
horizontally.
- an assistant to guide the hoisting cable is
present.
1. Assembly
-Place required hook block under the boom
head of the telescopic boom.
-At the hook block 15 remove the safety
springs 14 of both cable securing tubes and
pull out both cable securing tubes.
-At the boom head remove the safety springs
at cable securing tube 12 and at cable
securing tube 13 and pull out both cable
securing tubes.
-The assistant guides the hoisting cable over
the telescopic boom to the boom head and at
the same time the crane driver uses the winch.
-Lay the hoisting cable over the upper cable
pulley and as specified in the reeving plan
for the corresponding loading table, reeve
between the boom head and the hook block.
-Insert the cable securing tube again and
secure with safety springs.
4-102
SAC2200
1 2 2
3 6
4
5
6
6
12
11
13
7
4
14
8
10 15
7 9
4-103
SAC2200
DANGER!
Complete the assembly operations in a
stable area.
Risk of accidents from improper operation
of the crane function and danger of
slipping on the telescopic boom!
2. Attaching hoisting cable, figure 1, 2, 3

- Remove safety spring 2 on the cable block 1,
pull out pin 3;
- Bolt cable lock 1, depending on reeving,
either at the boom head or at the hook block
and secure with safety springs;
- Pull out cable securing pin 4 on cable block
1;
- Attach the rope end with press nipple 6
in the cable lock 1 and pull the rope firmly
“downwards” (in direction of arrow), until the
press nipple is on the cone 5;
- Reassemble the cable securing pin 4 onto
cable block 1.
3. Attaching hoisting limit switch weight

-Detach hoisting limit switch weight by opening
the pin 10 on hoisting limit switch;
-Loosen and unscrew cap nut 9;
-Dismount the hoisting limit switch weight 7;
-Lock rope with hoisting weight and
reassemble bolt and cap nut 9;
-Screw pin 10 and connect hoisting limit
sensors with hoisting weight 7 through chain
8.
CAUTION!
In the event of multiple hoisting cable
reeving, the hoisting limit switch weight 7
must always be laid around the “stationary
rope strand”, in other words around the
rope strand that leads directly to the cable
block.
4-104
SAC2200
4. Performing visual check

Have the following items checked after the rope
has been reeved in.
whether all the pins are secured firmly.
whether the hoisting limit switch weight is attached
to the “stationary strand”.
Check and/or enter the reeving number into the
configuration program.
DANGER！
Incorrect reeving or incorrect entry can lead to
accidents.
4-105
SAC2200
4.6.2.2 Lowering the hook block
-Lower the hook block and set it on the

ground.
WARNING!
Make sure the hook block is safely
positioned.
Danger of injury from the hook block
toppling over while reeving out!
1. Unhooking the hoisting cable

-Unhook the rope securing pin 4 on cable
block 1 and release press nipple 6;
-Push the hoisting cable upwards; detach the
rope nipple 6;
-Slowly reeve the hoisting cable in.
DANGER!
Ensure that there are no people around
hook block and do not allow slack cable to
build up.
- Attach the hoisting cable onto the front tail

connector and tighten it slightly or reeve the
hoisting cable onto the spool.
CAUTION!
Hoisting cable (without locker) should be
reeved completely onto the winch if has not
been attached to the front tail connector.
WARNING!
Reeve the hoisting cable onto the spool
until 2m is left.
Do not pull the hoisting cable end from
underneath the winch.
4-106
SAC2200
1 2 2
3 6
4
5
6
6
12
11
13
7
4
14
8
10 15
7 9
4-107
SAC2200
4.6.3 Attaching and remove load hook
4.6.3.1 Assembly
-Place load hook 16 under the boom head of

the telescopic boom;
-At the boom head remove the safety springs
at cable securing tube 12 and at cable
securing tube 13 and pull out both cable
securing tubes;
-Place hoisting cable over the upper cable
pulley 11;
-The assistant guides the hoisting cable over
the telescopic boom to the boom head and at
the same time the crane driver uses the winch;
-Plug in the cable securing tube 12 and the
cable securing tube 13 and secure with safety
springs;
-Bolt cable lock 1 in the load hook and secure
with safety springs.
DANGER!
Complete the assembly operations in a
stable area!
Risk of accidents from improper operation
of the crane function and danger of
slipping on the telescopic boom!
1. Hooking in the hoisting cable, figure 7

-Pull out the cable securing pin 4 on the cable
block 1;
-Insert hoisting cable into the hoisting ring 17
on the hoisting limit switch;
-Attach the rope end with press nipple 6 in
the cable lock and pull the rope firmly in the
direction of the arrow, until the press nipple
contacts the cone 5.
-Install the cable securing pin 4 onto the cable
block 1.
2. Performing visual check

Have the following items checked after the
rope has been reeved in.
whether all the pins are secured firmly.
Check and/or enter the reeving number into
the configuration program.
4-108
SAC2200
12
11
13
17
1
16
16
5 4 6
2 3 5
6 2 6
4-109
SAC2200
DANGER!
Incorrect reeving or incorrect entry can
lead to accidents.
4.6.3.2 Removing
Place load hook 26 on the ground.
1. Removing hoisting cable, figure 5

-Unhook the rope securing pin 4 and release
press nipple 6;
-Push the hoisting cable upwards (in the
direction of arrow); detach the rope nipple 6;
-Slowly reeve the hoisting cable in.
DANGER!
Ensure that there are no people around
hook block and do not allow slack cable to
build up.
-Attach the hoisting cable onto the front tail

connector and tighten it slightly to avoid the
free sliding of telescopic boom.
CAUTION!
Hoisting cable (without locker) should be
reeved completely onto the winch if has not
been attached to the front tail connector.
WARNING!
Reeve the hoisting cable onto the spool
until 2m is left.
Do not pull the hoisting cable end from
underneath the winch.
4-110
SAC2200
12
11
13
17
1
16
16
5 4 6
2 3 5
6 2 6
4-111
SAC2200
4.6.4 Reeving charts
4.6.4.1 Reeving T operation
1. Pulley hook block / load hook
Reeving Cable fixed position

1 time at the hook block or at cable fixed position load hook
2 times at the boom head
3 times at the hook block
4-112
SAC2200
2. 3 pulley hook block

7 times at the boom block
4-113
SAC2200

9 times at the boom block
10 times at the side of the boom head
4-114
SAC2200
Reeving Cable fixed point

4-115
SAC2200

4.6.4.2 Reeving TK operation

1. Single pulley or load hook

1 time at the hook block or at the load hook
4-116
SAC2200
4.6.4.3 Counterweight
1. General
The counterweight distribution must be
performed as described in chapter 3.4 prior
to driving on public roads. The counterweight
plates are marked with their own weights.
DANGER!
Risk of accidents from toppling of the
crane!
Attach counterweight in accordance with
the information in the load table; otherwise,
the crane may be damaged or topple over.
2
2
2
1
5
7
5
6
4 4
4-117
SAC2200
(1) Counterweight combinations
CAUTION:risk of accidents from

toppling of the crane!
Counterweight combinations specified in
the following tables must be applied!
The crane may topple, if another
counterweight combination is used than
specified in the tables.
Counterweight (t) Combination Individual weight (t)

0 - -
12 Counterweight plate 1 12
Counterweight plate 1 12
22
42
44
Additional ballast 4 12
Additional ballast 4 12
4-118
SAC2200
(2) Checking counterweight plates
DANGER!
Accident hazard due to damaged
counterweight plates!
If damaged counterweight plates
are loaded, the stable seating of the
counterweight plates can no longer be
guaranteed.
Replace damaged counterweight plates!

A visual check for damages and foreign matter
must be performed prior to the assembly
and/or the disassembly of the counterweight
plates.
When depositing the counterweight plate

1 on the centering cone 8 and stacking the
counterweight plates, no foreign matter may
be located between the counterweight plates.
2. Assembly
(1) General
met:
- the crane is properly supported and aligned
horizontally
- the transport vehicle with the counterweight
plates is directly near the supported crane
- the ballast cylinders are completely retracted
DANGER!
Accident hazard due toppling crane!
A toppling hazard exists when swivelling
the crane at steep boom positions, for
which no load capacities are listed in the
load capacity tables! There is a particular
risk if the support basis has been reduced
or supported with the sliding beams
retracted.
The specifications in the load capacity
tables must be adhered to!
4-119
SAC2200
(2)Stacking counterweight plates on the

vehicle
Start engine.
Set the overload protection according to the
load capacity table and the counterweight
assembled to the revolving platform.
DANGER!
crane!
Prior to the boom being lifted from the
transporting surface, the crane must be
supported according to the load capacity
table and the overload protection must be
set according to the valid load capacity
table. The boom lengths and projections
specified in the load capacity table may
not be exceeded during loading! If this is
not observed, an accident risk of the crane
toppling exists!
Comply with the load chart specifications!
The counterweight plate 1, as load bearing

plate for the other counterweight plates, must
always be deposited first on the deposit frame
8.
Attach counterweight plate 1 to cables and
deposit on the centering cones of the storage
frame 8 using a crane.
Deposit the required counterweight plates on
the counterweight plate 1.
DANGER!
crane!
If the additional ballast 4 “is attached only
on the right” or “only on the left,” the crane
may topple.
The additional ballast 4 must always be
attached in pairs on the right and on the
left!
Attach the additional ballast 4 on the right
and on the left.
4-120
SAC2200
2
2
2
1
5
7
5
6
4 4
4-121
SAC2200
(3) Picking up counterweight plates

Turn crane superstructure until the small
indicator 7 on the rotary table is even with the
marked screw, 5 fig. 2.
Result:
The ballast cylinders are now located next to
the retraction openings of the counterweight
plate 1.
Press switch 369.

Result:
The crane superstructure is locked with the
crane chassis.
Press button 370 until an acoustical signal

sounds.
Result:
The ballast cylinders are completed extended
when the acoustic signal sounds.
Press switch 369.

Result:
The crane superstructure is unlocked.
Carefully turn the crane superstructure to the

right until the large indicator 6 with the marked
screw 5 is even, fig. 1.
Result:
The ballast cylinders are now retracted in the
mountings of the counterweight plate 1.
Press switch 369.

Result:
crane chassis.
4-122
SAC2200
2
2
2
1
5
7
5
6
4 4
4-123
SAC2200
DANGER!
No movement (lift/lower counterweight)
may be operated until the crane
superstructure is locked!
Push button 370 upward until an acoustic

signal sounds.
Result:
The ballast cylinders are completed retracted
Press switch 369.

Result:
Depositing the counterweight on the crane

chassis and turning the crane superstructure
may be omitted in this case; the remaining
operation sequences remain the same.
4-124
SAC2200
3. Disassembling the counterweight plates

(1) General
met:
the crane is properly supported and aligned
horizontally
the transport vehicle is located directly
near the supported crane to assume the
counterweight plates
DANGER!
Accident hazard due to toppling of crane!
A toppling hazard exists when swivelling
the crane at steep boom positions, for
which no load capacities are listed in the
load capacity tables! There is a particular
risk if the support basis has been reduced
or supported with the sliding beams
retracted.
The specifications in the load capacity
tables must be adhered to!
(2) Removing counterweight plates

Turn crane superstructure until the large
indicator 6 on the rotary table is even with the
marked screw 5, fig. 1.
WARNING!
The superstructure must be locked with the
crane chassis, so that the counterweight is
fixed on the centering cone 8 and may then
be deposited.
Lock the crane superstructure with the
crane chassis.
4-125
SAC2200
Press switch 369.

Result:
crane chassis.
Press button 370 until an acoustical signal

sounds.
Result:
The ballast cylinders are completed extended
Press switch 369.

Result:
Turn the crane superstructure to the left until

the small indicator 7 on the rotary table is even
with the marked screw 5, fig. 2.
Result:
The ballast cylinders are now located next to
the retraction openings of the counterweight
plate 1.
Press switch 369.

Result:
crane chassis.
Push button 370 upward until an acoustic

signal sounds.
Result:
The ballast cylinders are completed retracted
Press switch 369.

Result:
4-126
SAC2200
2
2
2
1
5
7
5
6
4 4
4-127
SAC2200
(3) Lifting the counterweight plates individually

from the vehicle frame with the crane
Set the overload protection according to
the load capacity table and the loaded
counterweight.
DANGER!
crane!
The boom lengths and projections
specified in the load capacity table may
not be exceeded! If this is not observed, an
accident risk of the crane toppling exists!
Absolutely observe the boom lengths and
projections listed in the load capacity
table!
Individually attach counterweight plates to

the cables and deposit these with the crane
to the transporting vehicle.
(4) Driving with counterweight plates deposited

on the vehicle frame
The axle loads are increased with the
deposited counterweights.
DANGER!
Exceeding the axle load and total weight
increases the risk of accidents!
If the axle loads and the overall vehicle
weight are incorrectly increased due to
non-observance, the braking capacity
is also reduced in the same ratio of the
weight excess! The steering system,
service brake, parking brake and retarder
no longer meet the EC-guidelines!
Do not exceed the specified axle load or
total weight under any circumstances!
4-128
SAC2200
2
2
2
1
5
7
5
6
4 4
4-129
SAC2200
E
G
PA
K
AN
BL
4-130
Equipment
SAC2200
Equipment
5 Equipment
5.1 Safety Technical Guidelines...................................................................................... 5-2
5.2 Folding Jib – TK....................................................................................................... 5-16
5.3 Winch 2 .................................................................................................................. 5-84
5.4 Boom Nose.............................................................................................................. 5-88
5.5 Telescopic Boom Extension..................................................................................... 5-92
5-1
Equipment
SAC2200
5. EQUIPMENT
5.1 Safety Technical Guidelines
5.1.1 Checking the retaining elements
Retaining elements are used to secure the

pins in the folding jibs and lattice components.
The spring force of the retaining elements may
significantly reduce if they are mechanically
damaged or distorted. Do not re-use retaining
elements if there is insufficient spring force.
The pins must be secured with correctly
functioning retaining elements.
DANGER!
Risk of accident if retaining element does
not provide enough spring force!
It cannot be guaranteed that the pin is
correctly secured if the retaining element
does not provide sufficient spring force.
Use retaining elements with sufficient
spring force!
5.1.2 Checking the ropes
The ropes must be checked by an expert

before assembly and checks must be
performed at regular intervals in order to
detect possible damage or wear and tear at an
early stage. See chapter 8.4. The ropes must
be removed immediately if any of the following
damage is detected:
- Breakage of a strand
- Wire breaks
- Broken wire nests
- Reduction in the rope diameter by more than
10% of the nominal size
- Rope deformation
5-2
Equipment
SAC2200
5.1.2.1 Attaching a new hoist rope
In order to guarantee safety and operating

characteristics only use the replacement parts
of the same type.
Worn rope pulleys must be removed and
replaced before fitting a new hoist rope. If
this is not done the new hoist rope will be
damaged.
Cam-type limit switch

The cam-type limit switch is calibrated in the
factory to switch off when only 3 hoist rope
windings are left on the winch.
DANGER!
If the following instructions are not
observed, the hoist rope end attachment
may be torn out causing the load to topple.
- The cam-type limit switch must be readjusted

if a new hoist rope is used!
- The cam-type limit switch must be adjusted
to switch off when only 3 hoist rope windings
remain on the winch!
- If the hoist rope is spooled up during
assembly, the hoist rope end must remain in
front of the winch. It should not be pulled over
the winch; otherwise the cam-type limit switch
must be readjusted!
5-3
Equipment
SAC2200
5.1.3 Checks before supporting the

crane
Perform the following checks before

supporting the crane:
- Check whether the axle suspension is
locked.
- Check whether the ground provides
adequate load-bearing capacity.
-Check whether the support pads are secured
in their operating position.
- Check whether there is sufficient safety
clearance to slopes and excavations.
- Check whether there are any live cables
within the operating range of the crane.
- Ensure that the work can be carried out with
minimum boom projection.
- Check that there are no obstacles which
might hinder required crane movement.
5-4
Equipment
SAC2200
5.1.4 Checks before crane operation
CAUTION!
If the crane operator leaves the cab, even
for a short time, the operating mode
settings must be
checked and reset if necessary before
resuming crane operation.
Perform the following checks before operating

the crane:
- Check whether pins have been fitted to
secure the sliding beams against sliding.
- Check whether the crane is supported and
level.
- Check that the tires are not in contact with
the ground.
- Check that the overload protection has been
adjusted as per the information in the load
chart.
- Check if the bypass key button on the
monitor and the assembly key button are
turned off.
-Check the shut off of the overload protection
by running against the operating position
on“top” and “bottom”.
by running against the hoist limit switch.
lattice jib “steepest position”.
lattice jib “lowest position”.
- Check whether the cable has been correctly
installed in pulley groove and secured with
rope retaining pin.
- Check whether there are loose parts on
telescopic boom and jib.
5-5
Equipment
SAC2200
DANGER!
If the control measures are not carried out
before crane operation, then the crane can
topple over or be damaged!Personnel can
be killed or injured!
- Crane operation with safety devices

which are not functioning correctly is strictly
prohibited!
- Start crane operation only after all safety
devices have been checked and are
functioning correctly!
- Start crane operation only if the crane is
properly supported and horizontally aligned!
5.1.5 Transporting components

Ensure that any components transported
by support vehicle are secured correctly. If
necessary, transport these components on
supports or using a special transport device.
5.1.5.1 Transporting lattice components
If the lattice components are pushed inside

each other for transportation purposes, they
must each be secured with 2 chains.
5-6
Equipment
SAC2200
5.1.6 Weights
CAUTION!
- The weight of each component is
specified in the corresponding chapter or
stated on the plate fitted to the component!
- If components are pushed into one
another (for example intermediate pieces)
or folded together (for example the folding
jib), then the total weight is given by the
sum of the individual components.
- Use auxiliary crane with sufficient load
carrying capacity.
5.1.7 Assembly / dismantling
5.1.7.1 General
DANGER!
Risk of fatal injury due to incorrect
assembly or disassembly!
Assembly and disassembly should only be
carried out by authorized trained experts!
CAUTION!
- For assembly/disassembly of individual
components, also refer to the chapters
relating to those components!
- Lifting of loads with the auxiliary winch is
prohibited!
-Normal assembly/disassembly procedures
require all separately transported
components to be transported close to the
ground using appropriate auxiliary cranes
and fastening equipment. They should be
safely (correctly) connected to the crane.
- Suspended loads such as counterweights,
lattice components or jibs must be placed
on the ground or on a frame or other
suitable load bearing device before being
approached by installation personnel.
5-7
Equipment
SAC2200
DANGER!
There is a risk of impact and crushing
when standing in the vicinity of swinging
suspended loads.
During assembly / disassembly nobody
should be in the dangerous area around
or even underneath the suspended load
before the load has been secured!
DANGER!
appropriate anti-fall guards to prevent
- All assembly work from a height of 2 m

must generally be carried out using suitable
auxiliary crane, etc.)! The height above which
assembly/dismantling work must be carried
out with aids depends on national regulations.
The national regulations must be adhered to!
- Work which cannot be performed on the
ground or using such aids requires that
installation personnel use suitable personal
protection equipment (such as safety belts)
to protect against falling! A description of
the fastening points for personal protection
equipment is given in chapter 2.6.
- Any anti-fall guards (railings) fitted to the
crane superstructure must be brought and
secured into their correct position prior to
assembly/dismantling. See chapter 2.6.
It is prohibited to walk on the telescopic or jib!
5-8
Equipment
SAC2200
5.1.7.2 Assembly / disassembly of the jib
During dismantling it must be ensured that

the auxiliary crane lifts its load vertically.
The crane operator must ensure that the
load bearing capacity of the auxiliary crane
is sufficient to safely raise the dismantled
component at the given radius.
When attaching the auxiliary crane it must be
ensured that the hook of the auxiliary crane is
above the center of gravity of the dismantled
component and the fastening ropes are
attached to the load.
DANGER!
Risk of toppling crane!
Angular pulling can destroy the crane or
cause it to topple over.
The hook block must always be attached
load to be lifted!
DANGER!
Risk of accident when assembling/
dismantling the jib!
Disassembling unsecured or non-
supported jibs are result in death or severe
injury!
Never unpin the pins under unsecured or
unsupported jibs!
- Never unpin the connecting pins under

unsecured or unsupported jibs!
- Do not stand beneath an jib or in its vicinity
when the jib is being pinned or unpinned!
- Safely secure the pins in the bearing points
as well as receptacles!
- Do not lean the ladder against the component
being disassembled!
5-9
Equipment
SAC2200
DANGER!
Distorted parts can suddenly detach
themselves when the pins are unpinned.
This represents a fatal injury risk to
installation personnel.
- When the pins are unpinned, the “hoisting

force” of the auxiliary crane must be adapted
to the “weight” of the parts being lifted!
- Do not remove stiff pins by force!
- Remedy the cause of the distortion!
CAUTION!
Instructions for pinning and unpinning:
- Unpin or pin both pins at the same
horizontal level, i.e. left and right!
- Pin the lower pins from inside to outside
and unpin from outside to inside!
- Pin and unpin horizontally-mounted
double-cone pins from outside to inside!
- Pin and unpin vertically-mounted double-
cone pins from top to bottom!
1. Assembly of lattice components for guyed

jib with an auxiliary crane
DANGER!
If the pins are not pinned in the given
Pins must be pinned in the order specified!
- Pin and secure pins at both sides (level A) at

- Pin and secure pins at both sides (level B) at

- Pin and secure pins at both sides (level A) at

- Pin and secure pins at both sides (level B) at

5-10
Equipment
SAC2200
1
1
A A
B B
5-11
Equipment
SAC2200
2. Dismantling of lattice components for guyed

jib with an auxiliary crane
DANGER!
Pins must be unpinned in the order specified:
- Unsecure and unpin pins at both sides ( level




5.1.7.3 Assembling/dismantling the

hydraulic lines
When hydraulic lines are connected and

disconnected using quick-release couplings,
please ensure that the coupling procedure is
being performed correctly.
DANGER!
Incorrectly coupled or self-loosening
quick-release couplings (particularly return
lines) can result in serious injury from
component failure!
Check that the quick-release couplings
have been properly connected before using
the crane.
5-12
Equipment
SAC2200
A A
1
B B
1
5-13
Equipment
SAC2200
- Depressurize hydraulic system before

connecting and disconnecting. Turn off engine
and wait for short time (approximately 5min).
- Assemble coupling components (sleeve and
connector) and screw together using hand-
tightened nut.
- Tighten hydraulic coupling by hand. Rotate
hand-tightened nut until it reaches a tangible,
fixed stop position.
- Carry out connecting and disconnecting with
hand but not tools to avoid damage.
5.1.8 Setting-up and taking-down

met:
- The crane is properly supported and level.
- The telescopic boom is fully telescoped in.
- The jib has been attached in accordance with
the load chart specifications and operating
instructions.
- All limit switches have been correctly fitted
and are fully operational.
- All pinned connections have been secured.
- The hoist rope has been correctly placed in
out using rope retaining pins.
- There are no loose parts on the telescopic or
jibs.
In winter:
The telescopic boom, jib and associated
components (limit switches, cable drums,
flashing beacon, wind speed gauge etc.) must
be kept free of ice and snow.
5.1.9 Checking the preconditions
Check whether all preconditions have been

met.
5-14
Equipment
SAC2200
5-15
Equipment
SAC2200
5.2 Folding Jib – TK
5.2.1 General
This crane may be equipped with a hydraulic

or mechanical folding jib. The folding jib
with “a mechanical angle adjustment” may
be assembled as a straight 0 ° extension or
below an angle of 20 ° or 40 ° to the telescopic
boom. The folding jib is folded onto the
telescopic boom and mechanically secured for
on road travel.
DANGER!
Danger of accident when moving with
folding jib!
Make sure that the folding jib is properly
secured before moving the crane on public
roads.
5.2.1.1 Folding jib variations
The following folding jib variations are

possible:
1. Single folding jib, see illustration 1
Position Description Length

1 Adapter 1.7m
2 Reduction piece 7.355m
6 Articulated piece 3.55m
Length of single folding jib 12.2m
2. Dual folding jib, see illustration 2

1 Adapter 1.7m
3 Head piece 9.395m
Length of dual folding jib 22m
5-16
Equipment
SAC2200
3. 3-piece folding jib, see illustration 3

1 Adapter 1.7m
3 Head piece 9.395m
4 Folding jib extension 7m
Length of 3-piece folding jib 29m
4. 4-piece folding jib, see illustration 4

1 Adapter 1.7m
3 Head piece 9.395m
Length of 4-piece folding jib 36m
5-17
Equipment
SAC2200
5.2.1.2 Fastening points “folding jib

complete”
1. General
Various fastening eyes are installed on
the folding jib for the different methods of
transporting it. The transportation methods
vary in terms of single or dual folding jib.
DANGER!
Life-threatening situations can arise if
the folding jib is improperly or incorrectly
fastened.
Please ensure that the folding jib is
attached in accordance with the fastening
points as shown on the signs!
CAUTION!
For the dual folding jib with “mechanical”
or “hydraulic angle adjustment”, lifting
equipment with a length of 2 m must be
used.
2 . Single folding jib, see illustration 5

As illustrated in fig 5, the weight is 1823kg.
3. Dual folding jib, see illustration 6

As illustrated in fig 6, the weight is 2422kg.
4. Boom extension (folding jib extension)

As illustrated in fig 7, the boom extension
weight is 628.5kg; the folding jib extension
weight is 569.5kg.
5-18
Equipment
SAC2200
5-19
Equipment
SAC2200
5.2.2 Assembly of the folding jib
For easy operation, the swing cylinder 10

can be folded up and locked with chain, if
necessary.
5.2.2.1 General
DANGER!
Danger of fatal injuries due to falling
folding jib!
As a result of improperly mounted,
damaged or non-existing catch bar 40 on
the telescopic boom articulated piece, the
folding jib – due to an assembly error – can
fall down and cause fatal injuries.
- Before folding jib assembly, make sure that

the catch bar 40 is properly mounted on the
telescopic boom articulated piece and that it is
not damaged.
- The catch bar 40 is a mechanical safety
device. For that reason, it is prohibited to
change the catch bar 40 in any way.
- It is prohibited for anyone to remain in the
swing range as well as the folding range of the
folding jib!
- The folding jib must be secured with an
auxiliary rope during the swing process!
5-20
Equipment
SAC2200
DANGER!
Danger of falling!

assembly/disassembly work must be carried
- If work cannot be carried out using these aids
or from the ground, the assembly personnel
must be protected from falling using suitable
means (such as safety belts)!
Do not walk on the telescopic boom or

folding jib!

met:
- the crane is properly supported and
horizontally aligned
- the counterweight has been attached to the
turntable according to the load chart
- the telescopic boom is fully telescoped in
- the folding jib has been secured on the
telescopic boom articulated piece for transport
- the telescopic boom has been luffed down to
the rear or the side in the 0° position
DANGER!
Danger of accident if the folding jib swings
out by itself when it is unpinned!
If the telescopic boom is not in the 0° position,

there is a danger of accidents if the folding jib
swings out by itself when it is unpinned.
Move the telescopic boom to 0° position.
5-21
Equipment
SAC2200
5.2.2.2 Reeving out the hoist rope on the

telescopic boom head
In order to speed up the subsequent reeving in

of the hoist rope after assembly of the folding
jib, set down the hook block at a distance from
the crane.
- Telescope the telescopic boom out to the
corresponding length (based on the folding jib
length).
- Set the hook block down on the ground.
- Detach the hoist rope at the rope fixed point.
- For safety reasons, remove the hoist limit
switch weight and the chain.
CAUTION!
When operating the folding jib, the hoist
limit switch must be pulled mechanically
and the control rope must be attached
to the telescopic boom head with a snap
hook.
The telescopic boom may remain reeved if
the hoist rope of winch 2 is used for folding
jib operation.
- Remove the rope retaining tube at the pulley

head and the end pulley.
- Fully telescope the telescopic boom in again.
5-22
Equipment
SAC2200
40
10
5-23
Equipment
SAC2200
5.2.2.3 Important check before swinging

out the hydraulic folding jibs
DANGER!
Danger of fatal injury if the folding jib folds
down by itself!
Prior to swinging out the folding jib, check
whether a pressure of 60 bar is shown
on the pressure gauge 44. If the pressure
on the pressure gauge 44 is too low, fatal
accidents can occur if the folding jib folds
down by itself!
5-24
Equipment
SAC2200
5.2.2.4 Assembly of the single folding jib

carried on the crane
The head piece 3, which is not required,

remains pinned to the telescopic boom during
single folding jib operation.
DANGER!
Danger of fatal injuries if head piece falls
down!
During operation with the single folding jib,
the head piece 3 may not be unpinned from
the telescopic boom. Otherwise, there is a
danger of accidents if the head piece 3 falls
down.
5-25
Equipment
SAC2200
1. Assembly procedure, part 1

- Release and unpin the spring-loaded pin 8.
- Swing the folding jib support 18 out until the
spring-loaded pin 8 reengages.
- Uncouple the hydraulic line at point E.
- Attach the auxiliary rope 17 at point C.
- Release and unpin the pins 23.
- Pull the nylon rope 13 and loosen the lock
between the head piece 3 and the reduction
piece 2.
- Start the crane engine.
- Press button 451 and swing out the folding
jib with swing cylinder until it can be pinned at
point A.
- Insert the pins 9 at the top and at the bottom
at point A and secure.
DANGER!
Special retaining clips must be used to
secure the pins 9.
The use of spring-loaded pins or safety
springs on the pins 9 is not permitted.
The folding jib may only be unlocked at
point D, when the pins 9 are pinned and
secured at the top and bottom at point A.
- Swing the safety bracket 14 with assembly

rod 11 to the side.
- Press lever 15 with the assembly rod 11
upward and latch into the link.
- Press button 451 and swing the folding jib
with swing cylinder all the way out.
- Unlock the swing cylinder 10 with assembly
rod 11.
- Swing the reduction piece 2 with the auxiliary
rope 12 by 180° until it can be pinned on the
top and at the bottom at the point B.
DANGER!
It is prohibited for anyone to remain in the
swing range as well as the folding range of
the folding jib!
The folding jib could fall down due to an
assembly error.
5-26
Equipment
SAC2200
B A
9 14
15
14
1
16
D
43
45
44
10
11
18
12
40
13
3 18
451
C
17
450
23
5-27
Equipment
SAC2200
2. Assembly procedure, part 2
DANGER!
springs is prohibited on pin 20 and pin 21!
To secure the pin 20 and the pin 21, use the
special retaining clips.
- Pin and secure pin 20 at bottom at point B.
NOTICE: in order to be able to pin at the

top on point B, the hydraulic/mechanical
assembly aid 22 must be used.
- Release pin 24 and unpin from bore 23.

- Pin and secure the assembly aid 22 to the
towing bracket with pin 24.
- Close the knob 26.
- Extend the hydraulic cylinder of the assembly
aid by operating the manual pump until the
bore on the eye of the folding jib is aligned
with that on the telescopic boom.
- Pin and secure the pin 21 on top on point B.
5-28
Equipment
SAC2200
22
19
24 26
25
20 21
5-29
Equipment
SAC2200
5.2.2.5 Assembly of the dual folding jib

1. Reduction piece assembly, part 1

- Swing the folding jib support 18 out until the
spring-loaded pin 8 reengages.
- Uncouple the hydraulic line at point E.
- Release and unpin pins 23.
piece 2.
- Press button 451 and swing out the folding
jib with swing cylinder until it can be pinned at
point A.
- Insert the pins 9 at the top and at the bottom
at point A and secure.
DANGER!
Special retaining clips must be used to
secure the pins 9.
springs on the pins 9 is not permitted.
The folding jib may only be unlocked at
point D, when the pins 9 are pinned and
secured at the top and bottom at point A.
- Swing the safety bracket 14 with assembly

rod 11 to the side.
- Press lever 15 with the assembly rod 11
upward and latch into the link.
with swing cylinder all the way out.
- Unlock the swing cylinder 10 with assembly
rod 11.
- Swing the reduction piece 2 with the auxiliary
rope 12 by 180° until it can be pinned on the
top and at the bottom at the point B.
DANGER!
the folding jib!
The folding jib could fall down due to an
assembly error.
5-30
Equipment
SAC2200
B A
9 14
15
14
1
16
D
43
45
44
10
11
18
12
40
13
3 18
451
C
17
450
23
5-31
Equipment
SAC2200
2. Reduction piece assembly, part 2
DANGER!
springs is prohibited on pin 20 and pin 21!
To secure the pin 20 and the pin 21, use the
- Pin and secure pin 20 at bottom at point B.
NOTICE: in order to be able to pin at the

top on point B, the hydraulic/mechanical
assembly aid 22 must be used.
- Release pin 24 and unpin from bore 23.

- Pin and secure the assembly aid 22 to the
towing bracket with pin 24.
- Close the knob 26.
-Extend the hydraulic cylinder of the assembly
aid by operating the manual pump until the
bore on the eye of the folding jib is aligned
with that on the telescopic boom.
- Pin and secure the pin 21 on top on point B.
5-32
Equipment
SAC2200
27
7
F
13
3 3
17
22
19
26
24
20 21
25
B
5-33
Equipment
SAC2200
3. Assembly of head piece

- Remove auxiliary rope 12 at point C and
attach on head piece 3.
piece 2.
CAUTION!
In order to prevent the folding jib from
swinging out by itself, the head piece 3
should be held with the auxiliary rope!
- Swing the head piece 3 forward by 180° until

it can be pinned at point C.
DANGER!
swing range as well as the folding range
of the folding jib! The folding jib could fall
down due to an assembly error.
- Pin and secure pins 27 at top and bottom

using safety clips.
- Remove auxiliary rope.
5-34
Equipment
SAC2200
27
7
F
13
3 3
17
22
19
26
24
20 21
25
B
5-35
Equipment
SAC2200
5.2.2.6 Assembly of the 3-piece folding jib
The 3-piece folding jib is a folding jib which

has been extended with a folding jib extension.

met:
the folding jib is attached on the telescopic
boom or on the telescopic boom extension
an auxiliary crane with sufficient load carrying
capacity is available
DANGER!
If the following conditions are not met,
personnel may be fatally injured during the
assembly/disassembly.
- When knocking out the pins, no one may
remain under the folding jib!
- Pin and unpin the pins in the specified
sequence!
- Attach the reduction piece 2 with the head

piece 3 on the auxiliary crane and tighten
cable slightly.
- Release and unpin the pins 50 on both sides
- Release the pins 51 on both sides and unpin
from the outside to the inside.
- Place the reduction piece 2 with the head
piece 3 down.
- Attach the folding jib extension to the
auxiliary crane and insert into the fork heads
on the articulated piece 6.
- Pin the folding jib extension 4 with the
articulated piece 6:
Pin the pins 50 on both sides from the outside
to the inside and secure.
5-36
Equipment
SAC2200
2
2
55 55
54 54
52 53 52 53
5
5
50 51 50 51
6 6
5-37
Equipment
SAC2200
- Attach the reduction piece 2 on the auxiliary

crane and insert into the fork heads on the
folding jib extension 4.
- Pin the reduction piece 2 with the folding jib
extension 4:
DANGER!
Distorted parts can suddenly fly off when the

pins are unpinned.
to the“weight” of the parts being lifted!
5-38
Equipment
SAC2200
2
2
55 55
54 54
52 53 52 53
5
5
50 51 50 51
6 6
5-39
Equipment
SAC2200
5.2.2.7 Assembly of the 4-piece folding jib
The 4-piece folding jib is a folding jib, which

has been extended with two folding jib
extensions.
met:
- the folding jib is attached on the telescopic
boom or on the telescopic boom extension
- an auxiliary crane with sufficient load carrying
capacity is available
DANGER!
- When knocking out the pins, no one may
- Pin and unpin the pins in the specified
sequence!

piece 3 on the auxiliary crane and tighten
cable slightly.
- Release the pins 51 on both sides and unpin
from the outside to the inside.
piece 3 down.
- Attach the 1st folding jib extension 4 to the
on the articulated piece 6.
- Pin the 1st folding jib extension 4 with the
articulated piece 6:
5-40
Equipment
SAC2200
2
2
55 55
54 54
52 53 52 53
5
5
50 51 50 51
6 6
5-41
Equipment
SAC2200
- Attach the 2nd reduction piece 5 to the

on the 1st folding jib extension 4.
- Pin the 2nd folding jib extension 5 with the
1st folding jib extension 4:
- Attach the reduction piece 2 to the auxiliary

crane and insert into the fork heads on the 2nd
folding jib extension 5.
- Pin the reduction piece 2 to the auxiliary
crane with the 2nd folding jib extension 5:
DANGER!
Distorted parts can suddenly fly off when the

pins are unpinned.
to the“weight” of the parts being lifted!
5-42
Equipment
SAC2200
2
2
55 55
54 54
52 53 52 53
5
5
50 51 50 51
6 6
5-43
Equipment
SAC2200
5.2.2.8 Installing separately transported

folding jib on the crane
1. Installing separately transported folding jib

for crane operating position
- Attach the auxiliary crane to corresponding
fastening points on folding jib.
- Lift the folding jib with the auxiliary crane and
guide it into pin points on the telescopic boom.
- Pin the folding jib to telescopic boom:
Pin and secure pin 9 on top and on the bottom
at point A.
Pin and secure pins 20 on the top and bottom
at point B.
DANGER!
To secure the pins 9 and pins 20 use the
The use of spring-loaded safety pins or
safety springs is prohibited on pins 9 and
pins 20.
2. Installing separately transported folding jib
for transport position

An auxiliary crane must be available for the
installation of the separate folding jib.
met:
- the telescopic boom is in travel direction in 0°
position
5-44
Equipment
SAC2200
20 21
5-45
Equipment
SAC2200
DANGER!
Danger of accident from involuntary
swinging out of the folding jib when
removing the tackle!
If the telescopic boom is not in 0° position,
a risk of accident exists due to involuntary
swinging out of the folding jib when the
tackle is removed.

- Lift the folding jib with the auxiliary crane and
guide it into pin points on the telescopic boom
head.
- Pin and secure pin 9 on top and on the
bottom at point A.
- Swing the jib by 180° until it can be pinned
on the top and at the bottom.
- Connect the corresponding points at the jib
with the ones at the boom
- Remove auxiliary crane
DANGER!
Carry out auxiliary crane movements only
with utmost care and the least possible
acceleration.
Carry out auxiliary crane movements only
with utmost care and the least possible
acceleration.
DANGER!
Danger of fatal injuries due to falling
folding jib!
Due to improperly pinned folding jib on the
telescopic boom, life threatening or even
fatal injuries can occur.Before removing
the auxiliary crane, make sure that the
folding jib is pinned and secured on point
A on top and bottom.
5-46
Equipment
SAC2200
9
1
5-47
Equipment
SAC2200
5.2.3 Reeving in the hoist rope
DANGER!
When stepping on the folding jib, for
example to reeve the hoist rope in or out,
there is a risk of slipping and falling from
the folding jib.
5.2.3.1 Swinging the rope guide pulley into

operating position

- Swing the cable guide pulley 29 into
operating position.
- Pin the rope guide pulley 29 in operating
position: Pin and secure pin 30.
5.2.3.2 Reeving in the hoist rope
- Release and unpin the rope retaining pin 28

and rope retaining pin 31.
For operation with dual folding jib, 3-piece
folding jib or 4-piece folding jib: Release and
unpin the rope retaining pins 34.
- Place hoist rope over the rope guide pulley
29 and over the end pulley 32 or over the end
pulley 35.
- Pin the rope retaining pin in again and secure
with linch pins.
- Reeve in the load hook or hoist rope.
- Attach hoist limit switch weight.
CAUTION!
If the rope retaining pin 31 is inserted
during operation with the dual folding jib,
the 3-piece folding jib or the 4-piece folding
jib, then the slack hoist rope may scrape
against the rope retaining pin 31 and be
damaged.
5-48
Equipment
SAC2200
5.2.4 Electrical connections
5.2.4.1 General
NOTICE!
The electrical connections must be covered
after the operation in “single hook mode”
or “dual hook mode” is completed.
5.2.4.2 Electrical connections on telescopic

boom
- Insert the cable plug with resistance into the

socket;
- In single hook operation, insert the hoist limit
switch into “hoist limit switch 1” socket; while
the socket with resistance is inserted into “hoist
limit switch 2” socket;
- In two hook operation, insert the two hoist
limit switches into “hoist limit switch 1” socket
and “hoist limit switch 2” socket separately;
- Insert wind speed sensor into “wind speed
sensor” socket.
5.2.4.3 Electrical connections on folding jib
- The cable plug on folding jib is inserted into

socket on the telescopic boom;
- In single hook operation: the 2 sockets with
resistance are inserted into “hoist limit switch
1” socket and “hoist limit switch 2” socket
separately; the hoist limit switch on folding jib
is inserted into the “hoist limit switch” socket
on telescopic boom terminal box;
- In two hook operation: the hoist limit switch
on telescopic boom is inserted into “hoist limit
switch 1” socket, the cable plug with resistance
is inserted into “hoist limit switch 2” socket and
the hoist limit switch on folding jib is inserted
into “hoist limit switch” socket telescopic boom
terminal box.
- Insert the cable plug on aircraft warning lamp
(-X460) into socket (-X460Y)
- Insert the cable plug on wind speed sensor
(-X 556W) into socket (-X556)
5-49
Equipment
SAC2200
5.2.4.4 Function check

met:
- the electrical connections have been
established
- the control system is running
- the drive rod on limit switch has been well
lubricated
1. Wind speed sensors

Check the function and movement of wind
speed sensor through symbol element “wind
speed”.
WARNING!
Check the function of the wind speed
sensor after every installation.
2. Hoist limit switches

Manually actuate all active hoist limit switches.
Result:
- The corresponding symbol element “Hoist
top” appears on the monitor.
- The winch turns off.
5-50
Equipment
SAC2200
5-51
Equipment
SAC2200
5.2.5 Erection (with folding jib)
5.2.5.1 Preparatory work

met:
- the folding jib has been installed according to
the load chart and the operating manual
- all limit switches are correctly installed and
fully functioning
- all pin connections have been secured
- the hoist rope has been correctly placed in
out with the rope retaining pins
- there are no loose parts on the telescopic
boom and the folding jib
- the telescopic boom, the folding jib and its
components (such as: limit switch, airplane
warning light, wind speed sensor) must be free
of snow and ice in winter
DANGER!
Incorrectly installed or non-functioning
limits switches as well as falling
components (such as: pins, spring-loaded
pins, ice) can cause accidents!
5-52
Equipment
SAC2200
5.2.5.2 Erection procedure
- Set the overload protection according to the

required set up condition and confirm.
- Luff the telescopic boom with installed folding
jib up until the release is issued by the system.
- Telescope the telescopic boom out to values
specified in the load chart.
DANGER!
Luffing the telescopic boom with installed
folding jib up can only be carried out when
the release is issued by the system.
The loads listed in the load chart may not
be exceeded or fallen below, even if there
is no load on the hook! If this regulation is
not observed, the crane can topple over.
5-53
Equipment
SAC2200
5.2.6 Adjusting the folding jib angle of

the hydraulic folding jib
The adjustment range of the folding jib is

between 0 ° and 40 ° to the telescopic boom.
DANGER!
The crane can topple over if the maximum
load carrying capacity of the crane is
exceeded.
The data in the load charts must be strictly
adhered to!
The load charts for the hydraulically adjustable
folding jib are only valid for angles 0 °, 20 °
and 40 °!
For the adjustment angles between the
nominal angles of 0°, 20° and 40°, the
maximum load carrying capacity will be
determined by the control system shown on
the monitor.
met:
- the hydraulic connections have been
established
- the electrical connections have been
established
- the engine is running
- operating mode has been set
5.2.6.1 Angle display for folding jib
The relative angle between the telescopic

boom pulley head and the folding jib will be
shown on the monitor.
5-54
Equipment
SAC2200
5-55
Equipment
SAC2200
5.2.6.2 Luffing with “hydraulic angle

adjustment”

met:
the switch 430 is set to position right “luff
folding jib”
If the folding jib is to be luffed down:
Move the master switch 420 to the right in
direction X+.
If the folding jib is to be luffed up:
Move the master switch 420 to the left in
direction X-.
5.2.6.3 Telescoping
Ensure that the following prerequisite is met:

the folding jib is at a nominal angle of 0° or 20°
or 40°
Telescope the telescopic boom as described

in Chapter 4.5.
5-56
Equipment
SAC2200
5-57
Equipment
SAC2200
5.2.7 Reeving out the hoist rope
DANGER!
When stepping on the folding jib, for
example to reeve the hoist rope in or out,
there is a risk of slipping and falling from
the folding jib.

met:
- the hook block / load hook has been placed
on the ground
- the hoist rope is detached to the rope fixed
point
- the hoist limit switch weight and the chain
have been removed
5.2.7.1 Pinning/unpinning the rope

retaining pins
- Release and unpin the rope retaining pin 28

and rope retaining pin 31.
- For operation with dual folding jib, 3-piece
folding jib or 4-piece folding jib: Release and
unpin rope retaining pin 34.
- Spool up the hoist rope.
- Repin the rope retaining pin 28, rope
retaining pin 31 and rope retaining pin 34 and
secure with linch pins.
5.2.7.2 Swinging the rope guide pulley into

transport position

- Swing the rope guide pulley into transport
position.
- Pin the rope guide pulley in transport
position: Pin and secure pin 30.
5-58
Equipment
SAC2200
34
35
34
32
31
29
28
30
5-59
Equipment
SAC2200
5.2.8 Removing the folding jib
5.2.8.1 General
DANGER!
The folding jib can fall down due to a
disassembly error.
- Standing under the folding jib during the

swing operation is prohibited!
- It is prohibited for anyone to remain in the
swing range as well as the folding range of the
folding jib!
- The folding jib must be secured with an
auxiliary rope during the swing process!
DANGER!

assembly/disassembly work must be carried
- If work cannot be carried out using these aids
or from the ground, the assembly personnel
must be protected from falling using suitable
means (such as safety belts)!
5-60
Equipment
SAC2200
45
44
5-61
Equipment
SAC2200
Do not walk on the telescopic boom or

folding jib!

met:
- the folding jib is in 0° position
- the electrical/hydraulic connections on the
folding jib have been released
- the rope guide pulley has been folded from
the operating position to the transport position
- the telescopic boom has been luffed down to
the rear or the side in the 0° position
DANGER!
If the telescopic boom is not in the 0°
position, there is a danger of accidents if
the folding jib swings out by itself when it
is unpinned.
5.2.8.2 Preparatory work before swinging

in the hydraulic folding jibs
Before swinging the hydraulic folding jib in,

the folding jib must be fully luffed up and
held on block for approximately 15 seconds.
This causes the hydraulic reservoir to fill: the
pressure gauge 44 must then show 200 to 250
bar.
5-62
Equipment
SAC2200
45
44
5-63
Equipment
SAC2200
5.2.8.3 Removing the single folding jib

carried on the crane, part 1
- Disengage the lever 16 with the assembly

rod from the link 14 and pull downward.
- Swing out the folding jib support 9 until the
spring-loaded pin 8 engages again.
- Close the knob 26 on the manual pump 25.
aid 22 by actuating the manual pump 25 until
the pin 21 can be unpinned.
- Open the knob 26 on the manual pump 25.
- Unpin the pins 24 and insert into bore 19 and
secure.
- Release the pin 20 on the bottom and unpin.
DANGER!
In order to prevent the folding jib from
swinging out by itself, hold the folding jib
with the auxiliary rope when removing the
pin.
Ensure there is no person or object within
the danger zone of crane.
Standing under the folding jib during swing
operation is prohibited.
5-64
Equipment
SAC2200
17
C
14 15
14 16
18
43
8
22
19
26
24
20 21
25
5-65
Equipment
SAC2200
5.2.8.4 Removing the single folding jib

carried on the crane, part 2
- Swing the folding jib back until the swing

cylinder 10 is locked to the folding jib.
- Press button 450 and swing in the folding
jib with the swing cylinder until the lock 43
engages audibly.
- Carry out visual check.
- Secure the manual lever 15 with the safety
bracket 14.
- Release the pin 7 at point A, unpin and insert
into transport retainer.
- Empty the overflow tank on the hydraulic
cylinder.
DANGER!
Do not pull out pin 7 before lock 43 has
been well locked or before the manual lever
15 has been well secured with the safety
bracket 14.
5-66
Equipment
SAC2200
B A
9
14
15
14
1 16
D
43
E
45
44
11
18 10
12
13
40
8
3
2 18
451
C
17
23
450
5-67
Equipment
SAC2200
5.2.8.5 Removing the dual folding jib

1. Disassembly of the head piece 3

- Attach the auxiliary rope 17 on the head
piece.
- Release and unpin the pin 27.
- Swing out the head piece 3.
DANGER!
The pins 23 must remain pinned.
When removing the pin, the folding jib
may swing out unintentionally. In order to
prevent the folding jib from swinging out
by itself: Do not lean the ladder against the
folding jib.
Ensure there is no person or object within
the danger zone of crane.
Standing under the folding jib during swing
operation is prohibited.
- Ensure the head piece 3 and the reduction

piece 2 are properly locked together.
DANGER!
Insert safety spring 7 on point F.Prevent
the lock between the head piece 3 and
the articulated piece 2 from opening
inadvertently.
- Carry out visual check

- Remove the auxiliary rope 17 from the head
piece 3 and attach on point C.
- Disengage the lever 16 with the assembly
rod from the link 13 and pull downward.
- Swing out the extension of the folding jib
support 18 until the spring-loaded pin 8
engages again.
5-68
Equipment
SAC2200
23
27
C
43
14 15
18
16
8
7
3
13 3
2
2
22
19 17
24
26
25
20 21
5-69
Equipment
SAC2200
2. Reduction piece 2 removal, part 1

In order to remove the pin at the top of the
point B, the hydraulic/mechanical assembly
aid 22 must be used.
- Close the knob 26 on the manual pump 25.
aid 22 by actuating the manual pump 25 until
the pin 21 can be unpinned.
- Release and unpin the pin 21 on top.
- Open the knob 26 on the manual pump 25
and the hydraulic cylinder of the assembly aid
22 returns to the starting position.
- Unpin the pins 24 and insert into bore 19 and
secure.
- Release the pin 21 on the bottom and unpin.
CAUTION!
When removing the pin 20, the folding jib
may swing out unintentionally. In order to
prevent the folding jib from swinging out
by itself:
Hold the folding jib with the auxiliary rope!
Do not lean the ladder against the folding
jib!
5-70
Equipment
SAC2200
23
27
C
43
14 15
18
16
8
7
3
13 3
2
2
22
19 17
24
26
25
20 21
5-71
Equipment
SAC2200
3. Reduction piece 2 removal, part 2
DANGER!
disassembly error.
Standing under the folding jib during the
swing operation is prohibited!
the folding jib!
- Swing the folding jib back until the swing

cylinder 10 is locked to the folding jib.
- Press button 450 and swing in the folding
jib with the swing cylinder until the lock 43
engages audibly.
- Carry out visual check.
- Secure the manual lever 16 with the safety
bracket 15.
- Release the pin 9 at point A, unpin and insert
into transport retainer.
DANGER!
disassembly error.
The pins 9 may not be unpinned until
the lock 43 has engaged and the manual
lever 16 has been secured with the safety
bracket 15.
with swing cylinder in all the way.
- Pin folding jib with the folding jib retainer: Pin
and secure pin 12.
- Release and disassemble spring-loaded pin
8
- Unpin the spring-loaded pin 8 and swing
in the folding jib support 18 until the spring-
loaded pin 8 engages.
- Secure the spring-loaded pin 8.
- Connect the hydraulic line to the hydraulic
cylinder at point E.
- Remove the auxiliary rope 17.
cylinder.
5-72
Equipment
SAC2200
B A
9
14
15
14
1 16
D
43
E
45
44
11
18 10
12
13
40
8
3
2 18
451
C
17
23
450
5-73
Equipment
SAC2200
5.2.8.6 Disassembly of the 3-piece folding

jib
DANGER!
When knocking out the pins, no one may
Pin and unpin the pins in the specified
sequence!
Attach auxiliary crane in such a way that
there is no diagonal pull!
Do not remove the folding jib until it has
been secured with the auxiliary crane to
prevent it from falling!
jib!
- Attach the reduction piece 2 on auxiliary

crane (and head piece 3).
- Dismount the reduction piece 2 (and the
head piece 3) from folding jib extension 4:
Release and unpin the pins 52 on both sides,
and place it into the transport retainer.
Release and unpin the pins 53 on both sides
5-74
Equipment
SAC2200
2
2
52 53 52 53
4
4
50 51 50 51
6 6
5-75
Equipment
SAC2200

piece 3 down.
- Attach folding jib extension 4 on the auxiliary
crane.
- Dismount the pins between folding jib
extension 4 and articulated piece 6:
- Place the folding jib extension down 4.

piece 3 on the auxiliary crane and guide into
the fork heads on the articulated piece 6.
- Pin the reduction piece 2 to the articulated
piece 6:
5-76
Equipment
SAC2200
2
2
52 53 52 53
4
4
50 51 50 51
6 6
5-77
Equipment
SAC2200
5.2.8.7 Disassembly of the 4-piece folding

jib
DANGER!
When knocking out the pins, no one may
Pin and unpin the pins in the specified
sequence!
Attach the cables in such a way that there
is no diagonal pull!
Do not remove the folding jib until it has
been secured with the auxiliary crane to
prevent it from falling!
jib!
- Attach the reduction piece 2 on auxiliary

crane (and head piece 3).
- Dismount the reduction piece 2 (and the
head piece 3) from folding jib extension 4:
Release and unpin the pins 54 on both sides,
Release the pins 55 on both sides and place it
into the transport retainer.
5-78
Equipment
SAC2200
2
2
54 55 54 55
52 53 52 53
5
5
50 51 50 51
6 6
5-79
Equipment
SAC2200

piece 3 down.
- Attach folding jib extension 4 on the auxiliary
crane
- Dismount the pins between folding jib
extension 4 and extension section 5:

- Attach the folding jib extension 5 on the
auxiliary crane
- Dismount the pins between the folding jib
extension 5 and articulated piece 6:
piece 3 on the auxiliary crane and guide into
the fork heads on the articulated piece 6.
- Pin the reduction piece 2 to the articulated
piece 6:
5-80
Equipment
SAC2200
2
2
54 55 54 55
52 53 52 53
5
5
50 51 50 51
6 6
5-81
Equipment
SAC2200
5.2.8.8 Disassembly of the separately

transported folding jib

met:
the head piece 3 is locked with the reduction
piece 2

- Tighten the ropes until the folding jib is
secured to prevent it from falling.
- Unpin the folding jib from the telescopic
boom:
Release and unpin pins 9 at the top and at the
bottom at point A.
Release and unpin pins 20 and 21 at the top
and the bottom at point B.
cylinder.
5-82
Equipment
SAC2200
20 21
5-83
Equipment
SAC2200
5.3 Winch 2
5.3.1 General
Winch2 may be attached to this crane for the

folding jib operation with a reeved telescopic
boom or for the dual hook operation.Winch2
has a weight of approximately 1750 kg with
the hoisting cable.
5.3.2 Assembly

met:
- the crane is properly supported and level
- an auxiliary crane is always available
5.3.3 Assemble winch2
- Attach the auxiliary crane to the lugs 3.

- Align the upper side bores on winch 2 with
the ones on winch 1, install pin 2 and insert
safety pin
- Align the lower side bores on winch 2 with
the ones on winch 1, install pin 4 and insert
safety pin
- Unhook the hoist rope on winch 2
DANGER!
Only unhook auxiliary crane after winch 2
is bolted and secured!
5-84
Equipment
SAC2200
3
4
4
2
5-85
Equipment
SAC2200
5.3.4 Connect supply lines
NO. Code Description Qty Remarks

Rubber pipe 4SH25-DKOS-SFS90-750 Balance valve inlet tube
Rubber pipe 2SN8-DKOL-900 Brake oil tube
Rubber pipe 1SN20-DKOL-DKOL45-900 Motor oil drain tube
Rubber pipe 4SH25-DKOS-SFS90-750 Side oil tube for motor lowering
- Create hydraulic connections to winch2.

Engine must be switched off before attaching
and releasing hydraulic pipes.
5.3.5 Dismantling

met:
- an auxiliary crane is available
5.3.6 Disconnecting the supply lines
The engine must be turned off prior to

connecting and disconnecting hydraulic lines.
- Remove hydraulic connections from winch2.
- Remove electrical connection for winch2.
- Disconnect the supply line for the central
lubricating system and secure them in the
transporting fixtures.
5-86
Equipment
SAC2200
5.3.7 Dismantling the winch 2
- Wind up the hoisting cable of winch 2.

- Secure hoisting cable.
- Block winch2 program “Control parameters”.
- Attach the auxiliary crane to the lugs 3.
- Release and remove bolts 4.
- Release and remove bolts 2.
- Attach winch 2 to auxiliary crane and place it
at proper position.
3
4
4
2
5-87
Equipment
SAC2200
5.4 Boom Nose
5.4.1 General
The operation using the boom nose is

equipped for quick lifts over the boom nose
whereby the hook block may remain reeved on
the telescopic boom.Please observe Chapter
4.12 during the operation with the boom nose.
The boom nose weights 110kg.
NOTICE!
No special load capacity tables are
available for boom nose operations.
The boom nose is generally run in the
telescopic boom operating mode. The load,
however, is reduced by the weight of the
boom nose, as well as that of the used load
lifting devices and lifting tackles.
5.4.2 Assembly
5.4.2.1 Move boom nose to operation

position
DANGER!
Accident hazard due to potentiall fall of
the boom nose! Fingers may be crushed
between the telescopic boom and the
boom nose when turning the boom nose.
Never unbolt the swivel pin 2!
- Release bolts 3 and bolts 4 and unbolt.

- Turn boom nose 1 until the bolt 4 can be
bolted at point B.
- Attach bolt 4 and secure.
5-88
Equipment
SAC2200
B A
1
3 2 4
4 3 2
5-89
Equipment
SAC2200
5.4.2.2 Reeving the hoisting cable
- Cable securing tubes 8 release and unbolt.

-Run hoist cable over pulley on the
telescopic boom and the cable pulley 5.
- Bolt in cable securing pipes 8 and secure.
- Reeve in the load hook or hook block.
- Attach hoisting limit switch weight.
5.4.2.3 Hoisting limit switch
The hoisting limit switch -S930, the wind

sensor and the air traffic warning light remain
attached to the telescopic boom head.
If the hoist limit switch -S931 is assembled
to the telescopic boom, dismantle the hoist
limit switch -S931 on the telescopic boom and
attach to the boom head.
5.4.2.4 Single hook operation
When working in the “single hook operation”,

the hoist limit switch -S930 that is not required
must be manually operated:
- Disassemble the hoist limit switch weight and
chain.
- Attach hoist limit switch S930 to fixed point 22.
- Manually operate hoist limit switch -S930.
5.4.2.5 Dual hook operation
In the dual hook operation, the hoist limit

switch -S930 on the telescopic boom and the
hoist limit switch -S931 on the boom head are
active!
The function check must be performed by the

crane operator before starting up the crane
and before lifting a load.The following checks
must be performed:
- Check that the hoist limit switch, wind sensor
and air traffic warning lamp connections are
properly connected.
- Check wind sensor operation on the monitor.
- Check operation of air traffic warning lamp.
5-90
Equipment
SAC2200
-S930
-S931
5-91
Equipment
SAC2200
5.4.3 Dismantling
5.4.3.1 Swivel boom nose to transporting

position
DANGER!
Accident hazard due to potential fall of
the boom nose! Fingers may be crushed
between the telescopic boom and the
boom nose when turning the boom nose.
Never unbolt the swivel pin 2!
- Release bolts 4 and unbolt.

- Turn boom nose 1 180 ° until the bolt 3 can
be bolted at point A.
5.5 Telescopic Boom Extension
5.5.1 General
In order to increase the hoisting height,

telescopic boom extension may be attached to
this crane.
5.5.1.1 Attachment points
A special attachment point is available for the

assembly/dismantling of the telescopic boom
extension.
The attachment point is marked by a tag.
Description Abbreviation Weight
Telescopic boom extension TV 0.7T
5-92
Equipment
SAC2200
4
3 2
A
B
1
3 2 4
5-93
Equipment
SAC2200
5.5.2 Assembly
DANGER!
People may not stand below the telescopic
boom extension when bolts are removed!
Remove or insert the bolts in the sequence
specified in the operating instructions!
Attach or remove bolts from the top down!

met:
- the counterweight is attached to the rotating
platform according to the load capacity table
- the telescopic boom is completely retracted
- the telescopic boom is lowered toward the
back or toward the side in 0°position
- an auxiliary crane must be available
5.5.2.1 Assembly process
- Telescopic boom extension, attach to

auxiliary crane and insert into yokes on the
telescopic boom.
- Bolt telescopic boom extension to telescopic
boom:
Attach bolts 10 on both sides from top down
and secure.
and secure.
- Attach folding jib to the auxiliary crane and

insert into the yokes at the telescopic boom
extension.
- Attach folding jib to the telescopic boom
extension:
and secure
and secure
- Complete assemble the folding jib (refer to
chapter 5.2)
5-94
Equipment
SAC2200
12 13
TV =0.7T
10 11
5-95
Equipment
SAC2200
5.5.3 Create electrical and hydraulic

connections
5.5.3.1 Create hydraulic connection
A hydraulic connection to the folding jib must

only be produced at a hydraulic angular
adjustment.
After operations with a hydraulic folding jib,
protect connections from pollutants.
5.5.3.2 Electrical connections
Insert cable plugs into corresponding sockets.
5.5.3.3 Test
Carry out test on electrical connections.
Hose Junction plate Hose drum

Junction plate
5-96
Equipment
SAC2200
5.5.4 Dismantling
DANGER!
If the following conditions are not fulfilled,
people may be fatally injured during the
assembly / disassembly:
People may not stand below the telescopic
boom extension when bolts are removed!
Remove or insert the bolts in the sequence
specified in the operating instructions!
Attach or remove bolts from the top down!

met:
- the counterweight is attached to the rotating
platform according to the load capacity table
- the telescopic boom is completely retracted
- the telescopic boom is lowered to the rear or
to the side in 0°position
- the folding jib is in 0°position
- the electrical and hydraulic lines are
disconnected
- an auxiliary crane must be available
5-97
Equipment
SAC2200
5.5.4.1 Disassembly procedure
- Attach telescopic boom extension on auxiliary

crane
- Release the bolts 12 on both sides and
disassemble them from top to bottom
NOTICE!
It is difficult to remove the bolts due to
angular tightening, excessive or low
hoisting force of the auxiliary crane!
Do not remove bolts by force!
- Release bolts 13 on both sides and unbolt

from the top down
- Store folding jib
- Attach telescopic boom extension to the
auxiliary crane and tighten the cables lightly:
Release bolts 10 on both sides and unbolt
from top down
Release bolts 11 on both sides and unbolt
from top down
- Store telescopic boom extension

The following actions are not necessary, if the
folding jib must be driven with the crane:
- Attach folding jib to the auxiliary crane and
insert in the yokes on the telescopic boom:
and secure
and secure
- Complete dismantle the folding jib (refer to
chapter 5.2).
5-98
Equipment
SAC2200
12 13
TV =0.7T
10 11
5-99
Equipment
SAC2200
E
G
PA
K
AN
BL
5-100
Additional Equipment
SAC2200
6 Additional Equipment
6.1 Heater / Engine Preheating....................................................................................... 6-2
6-1
SAC2200
6 ADDITIONAL EQUIPMENT
6.1 Heater / Engine Preheating
6.1.1 Heating the driver's cab
6.1.1.1 Temperature adjusting system
(1) Adjusting the temperature

The temperature may be set in different
temperature stages through the knob 30-2.
(2) Adjusting ventilation

The wind speed of fen may be set in different
(3) Adjusting the recirculated air / fresh air

The air recirculating mode and the supply of
fresh air into the cab or windscreen can be
controlled using the button 30-3.
6.1.2 Engine preheating
Chassis engine is equipped with automatic

preheating system. The engine will carry out a
check on temperature by itself and be heated
after the key switch has been turned on.
6-2
SAC2200
30 -1 30 -23 0 - 3
6-3
SAC2200
6.1.3 Heating the console
6.1.3.1 Air-conditioning system in console
(1) Switching on air-conditioning system

Switching on the air-conditioning system by
turning button 362-1 to the position “ON”
Switching off the air-conditioning system by
turning button 362-1 to the position “OFF”
(2) Adjusting temperature

The temperature may be set in different
temperature stages through the knob 362-2
(3) Adjusting ventilation

The wind speed of fen may be set in different
6.1.4 Engine preheating
Superstructure engine is equipped with

automatic preheating system. The engine will
carry out a check on temperature by itself
and be heated after the key switch has been
turned on.
6-4
SAC2200
362-1
362-2
362-3
6-5
SAC2200
6-6
Maintenance and Service
SAC2200

7 Maintenance and Service
7.1 General . .................................................................................................................. 7-2
7.2 Crane Chassis........................................................................................................... 7-8
7.3 Crane Superstructure.............................................................................................. 7-16
7.4 Crane Chassis Maintenance Guidelines................................................................ 7-23
7.5 Superstructure Maintenance Guidelines................................................................. 7-75
7.6 Lubrication Chart and Filling Quantity................................................................... 7-112
7.7 Oil And Grease Filling . ......................................................................................... 7-118
7-1
SAC2200
7 MAINTENANCE AND
SERVICE
7.1 General
CAUTION!
Damage of mobile crane components!
If mobile crane components are not
maintained according to the maintenance
intervals and maintenance guidelines in the
individual chapter, or if other lubricants are
used than specified in the lubrication chart,
the respective mobile crane components
can be damaged and/or fail.
Maintain mobile crane components
according to the data in the maintenance
intervals, the maintenance notes and the
lubrication chart!
DANGER!
Danger of fatal injury due to damaged
mobile crane components!
If mobile crane components, which were
damaged, for example due to maintenance
errors, are not replaced immediately,
personnel can be fatally injured!
Maintain mobile crane components
according to the data in the maintenance
intervals, the maintenance notes and the
lubrication chart!
Replace damaged mobile crane
components immediately!
7-2
SAC2200
7.1.1 SANY Customer Service for you
SANY mobile cranes - whether mobile, rough

terrain or all terrain cranes - are technically
advanced products, which prove their worth
daily even under tough conditions. The high
technical standards of these cranes provide
functional security, resistance to failure and
easy maintenance.
SANY is continuously developing the drive

and control components. The combination of
well proven units and modern manufacturing
methods produces cranes that are safe to
operate and easy to maintain.
Several hundred cranes are built every year
for the international market, supported by
international service.SANY's “After Sales
Service” plays an important role in ensuring
the operational readiness and high availability
of the cranes.
With SANY, service begins when the crane

is handed over. Your crane operators will be
professionally trained in line with their level of
knowledge, and we devote much time to this.
We also train your workshop staff in all crane-

specific matters, because we know that they
can deal with more than just minor repairs
themselves. Often there are specialists who
can quickly and reliably carry out crane
repairs.
We also have Enterprise Control Center (ECC)

which can help you to fix your on-site problems
creatively. This contact by telephone saves
time and money. In the event of problems, get
in touch as soon as possible.
7-3
SAC2200
Our service technicians are also specialists

with years of experience, and can be deployed
from local support points. Naturally these
product experts have special knowledge and
special tools.But before you call on these
people, it is worth making full use of the
facilities for getting advice from ECC.
CAUTION!
Customers claims for warranties and
refunds!
Only original SANY replacement parts
have been tested for operational use in
cranes, and they can be installed without
risking safety.The buyer only has a claim
to warranties and possible refunds if only
original SANY replacement parts are used
for SANY mobile cranes.
DANGER!
Exclusion of liability!
In the event that replacement parts are
used that are not original SANY parts,
SANY disclaims all liability, both for system
functionality and the replacement parts.
7-4
SAC2200
7.1.2 Cleaning and care of the crane
7.1.2.1 Instructions for sound damping

(soundproofing)
Sound damping in the area of engines and

other noise sources is an integral part of
construction. It is your task to limit the noise
generation of vehicles and the sound level in
the workplace to the legally prescribed values,
working on sound damping parts and the
design of the equipment. They are therefore
integral parts of the equipment. They must
not be removed, and if damaged, must be
replaced by original replacement parts.
They have been designed to be "maintenance-

free". They have been equipped with surfaces
that repel dirt, oil and water. They are fire-
resistant and some of them are fireproof.
For these reasons, these parts need

minimal care. Any small dirt deposits can be
disregarded, as the acoustic effectiveness of
the parts is not reduced.
Tools with sharp edges are not suitable. Steam

cleaners can be used with extreme caution,
always maintain sufficient distance with the
steam jet and use low water pressure. Do not
use solvents for cleaning.
Soiling with solvents, and large amounts of oil

(motor oil, gear oil or hydraulic fluid) or fuels,
is dangerous, as these can easily catch fire.
Fire will severely degrade the behavior of the
sound damping materials.
7-5
SAC2200
7.1.2.2 Care instructions for the driver's

cab and the crane cab
The steering wheel, center console, dashboard

cover, floor cover, and dirty upholstery in the
driver's cab and the crane cab should only be
cleaned with warm water mixed with a little
dish washing liquid.
Do not use any scouring agents.
7.1.3 Taking the crane out of service for

job interruption

CAUTION!
Risk of corrosion to the hydraulic
cylinders!
Dismantle the crane if it will be out of
operation for a long period of time.
The hydraulic cylinders (support cylinders,
luffing cylinder, and telescoping cylinder)
may corrode in aggressive environmental
conditions, for example in coastal locations
where the air is especially salty.
Dismantle the crane!
Fully retract the hydraulic cylinders on the
crane!
Protect exposed sections of the piston rod
to prevent corrosion, such as applying
grease to these sections!
In particular, grease exposed sections of
the piston rod of the luffing cylinder!
7-6
SAC2200
7.1.4 Maintenance guidelines
! The maintenance tasks on the

crane chassis are carried out based either
on operating hours or by kilometers
traveled.
! The maintenance tasks on the crane
superstructure are carried out based
entirely on operating hours.
Refer to following chapters when performing

maintenance of the crane:
-Chapter 7.2 Maintenance intervals - crane
chassis 1
-Chapter 7.3 Maintenance intervals - crane
superstructure 1
-Chapter 7.4 Maintenance guidelines - crane
chassis 2
-Chapter 7.5 Maintenance guidelines - crane
superstructure 2
-Chapter 7.6 Lubrication chart, filling levels
-Chapter 7.7 Lubrication chart
1
These chapters contain a list of service
intervals for all maintenance work.
2
For individual units, the manufacturer's
specifications must be observed.
7-7
SAC2200
7.2 Crane Chassis
7.2.1 Crane chassis maintenance and

inspection plan
Regular maintenance, every Checks

After Minimum
first 200h/ 400h/ 800h/ maintenance
daily weekly
mainte nance 5000km 10000km 20000km annual
Hydraulic system
-Check hydraulic
●
system for leaks
-Check hydraulic tank

●
fluid level
-Oil change (oil

● ●
sample)
-Replace bleeder filter

100h ●
of hydraulic tank
-Return-line filter 100h ●
-Replace oil filter

100h ●
insert
-Check hydraulic
pressure, readjust, if ●
necessary
Hydraulic hose lines
-Check for leaks and

●
damage
-A safety check should

be performed by ●
experts
7-8
SAC2200

After Minimum
daily weekly
Steering
-Check that steering
gear and tie rods are
●
firmly attached, check
cotter pin
-Check hydraulic
steering system for ●
leaks
-Check axle
alignment, readjust, if ●1
necessary
-Replace pressure
100h ●
filter insert
-Check hydraulic
steering stop, adjust if ●
necessary
-Check steering using

●
test program
Hydraulic fan
-Replace pressure
filter insert of hydraulic 100h ●
fan
Hydraulic supports
-Check ease of
movement of sliding ●
beams/grease
-Check sliding beam

●
cables
-Grease sliding beam

●
cylinder fastening pins
-Check sight gauge,

●
readjust if necessary
7-9
SAC2200

After Minimum
daily weekly
Axle suspension
-Function test as
●
blocking cylinder
-Check pressure
accumulator
●4 ●4
pretension pressure
(nitrogen)
Automated shift transmission AS-Tronic, AS-Tronic HD

-Check oil level ●
-Check for leaks ●
every 3
-Oil change
years5
every 3
-Replace oil filter
years5
Converter/clutch unit TC 2
-Oil change ●
-Replace oil filter ●
Transfer gearbox
-Oil change 1000km ● ●
-Check or tighten
●
mounting screws
7-10
SAC2200
After Regular maintenance, every Minimum Checks

Daily Weekly
maintenance 5000km 10000km 20000km annual
-Check road gear/

off-road gear transfer ●
function
-Check all-wheel drive

●
enable function
every 2
-Have tachograph
years
checked
-Clean deaerating
● ●
nipple
Gear shafts and bearing block

-Check flange every 6
bolts and tighten if 100km 25000km months
necessary
every 6
-Visually check the
25000km months
gear shafts
-Visually check the

every 6
intermediate shaft
25000km months
bearing / bearing
block
-Check length
every 2
compensation of
100000km years
impermissible bending
play
-Lubricate gear every 2

bearings (if they can 100000km years
be lubricated)
-Lubricate length every 2

compensation (if it can 100000km years
be lubricated)
7-11
SAC2200

Daily Weekly
Axle, driven
-Oil level checks

at axle housing,
●
differential housing
and wheel hubs
-Grease steering
10000km ●
knuckle bearings
-Check attachment ●
every 2
-Oil change 1000km ●
years
-Replace wheel
bearing every 2
grease filling (if years
lubricated with grease)
-Clean deaerating
● ●
nipple at axle housing
Axles, non-driven
-Grease steering
10000km ●
knuckle bearings
-Check attachment ●
-Replace wheel hub

● ●
grease filling
-Adjust wheel
● ●
bearings
7-12
SAC2200

Daily Weekly
Electrical system
-Check vehicle lighting

●
for correct operation
-Check cable
connections and ●3
battery acid levels
Fuel system
-Check condition and

● ●
mountings
-Drain off water and

● ●
sediments
-Clean auxiliary fuel

● ●
pump preliminary filter
-Check fuel
every
preliminary filter, drain
50h
off water if necessary
-Replace fuel
●
preliminary filter
Tires
-Check for
●
external damage
-Check the tire

●
pressure
-Check tread wear

and depth(observe
●
governmental
regulations)
-nsure that
wheel nuts are
100km ●
tight, retighten if
necessary
7-13
SAC2200

Daily Weekly
Brake system
-Check brake
●
system
-Check brake
●
lining thickness
-Adjust brakes if
necessary, replace ●
linings if required
-Check the brake

●
discs
-Check the brake

●
drums
-Check operation
of parking brake ●
and service brake
Air pressure system

-Check operating
pressure of brake ●
system
-Check cut-off
●
pressure
-Drain air pressure

●
tank
-Replace air
drier granular ●
cartridges
7-14
SAC2200

After Minimum
daily weekly
-Clean air drier

●
preliminary filter
Driver cab
-Check armatures
/ instruments for ●
function
-Check control
●
lights for function
-Check motor
●
brake operation
-Check intarder
●
operation
-Grease boom
●
support
Emergency operation
-Check for correct

●
function
Support pads with equalization

-Replace grease
●
filling
-Perform function
●
test
1
every 500 km to 2000 km with frequent off-
road driving.
2
at least 1x per annum with frequent off-road
driving.
3
in hot climates twice a year.
4
Note chapter 7.4, Maintenance guidelines -
crane chassis.
5
only when using ZF-Ecofluid M, otherwise
every 2 years.
7-15
SAC2200
7.3 Crane Superstructure
7.3.1 Crane superstructure maintenance

and inspection plan

After Minimum
first maintenance
100 h 200 h 400 h 1200 h daily weekly
maintenance annual
Diesel engine
-Check the oil level

For all other
maintenance tasks,
●
follow the instructions
of the engine
manufacturer
-Check the coolant

level in the equalising ●
reservoir
every 2
-Replace coolant
years
Air filter
-Check monitoring
●
device
-Clean or change
(follow the instructions
of the engine
manufacturer)
Slewing ring connection

-Lubricate gearing ●
-Lubricate slewing ring

●1
connection
-Make sure that bolts

200h ● ●
are tight
-Check tilting free play ● ●
7-16
SAC2200

After Minimum
first maintenance
maintenance annual
Rope winches
-Check the oil level ●
-Check mounting
200h ● ●
screws for tight seating
every 4
-Oil change 3000h
years
Lattice components
-Check for cracks and

●
damage
Guy posts
-Check for cracks and

●
damage
Relapse supports
-Lubricate bearings ● ●
Relapse cylinder
-Check for leaks ●2,6
-Check pretension
pressure(nitrogen) ●2, 6 ● ●
-Check oil level ●2, 6 ● ●

Pneumatic springs
2, 5, 6
-Check function ● ● ●
A-bracket bearing
-Lubricate ●
Counterweight
-Check tightening
or 10000
torque of mounting 1000km
km
screws
7-17
SAC2200

After Minimum
first maintenance
maintenance annual
Ballasting
Press on pulleys of cable winches
-Grease guides ● ●
Rope pulleys
-Check for wear and

● ●
damage
-Lubricate rope pulleys ● ●
Crane ropes
-Check, grease if
● ●
necessary
Hook blocks
-Grease hook ● ●
-Check distance gap

● ●
(y)
Crane operator's cab
-Check armatures/
●
instruments for function
-Check control lights

●
for function
-Check fluid level in

expansion tank of ●
engine control
Crane cab, extendable or inclinable

-Check for correct
● ●
function
Overload protection
-Check for correct

●
function
7-18
SAC2200

After Minimum
first maintenance
maintenance annual
Electrical system
-Check cable
connections and ●3
battery acid levels
Fuel system
-Check condition and
●
mountings
-Drain off water and

●
sediments
Slewing gear
-Check mounting
250h ● ●
screws for tight seating
every 4
-Oil change 4000h
years
Turntable locking mechanism
-Check for correct

● ●
function
-Lubricate ● ●
Pump distributor gear
-Oil change 500h ● ●
7-19
SAC2200

first maintenance
maintenance annual
Hydraulic hose lines

-Check for leaks and
●
damage
-Check for safe

●
condition by expert
Hydraulic system
-Replace servo
pressure and replenish 250h ● ●
pressure filter inserts
-Replace return filter

inserts
250h ● ●
(only for cranes with
open hydraulic circuit)
-Replace bleeder filter

250h ● ●
of hydraulic tank
-Check hydraulic oil,

required degree of
purity: 20/18/15
500h ● ●
(take oil sample and
have it checked by oil
supplier)
Hydraulic cylinder
Hydraulic pressure accumulator (nitrogen)
-Check pretension
●4 ●4
pressures
Central lubrication system
-Check for correct
●
function
7-20
SAC2200

first maintenance
maintenance annual
Emergency operation
-Check for correct

●
function
Telematik telescopic boom system

-Check telescopic
boom for distortions ●
and cracks
-Check hydraulic
system components ●
for leaks
-Check telescoping
cylinder for proper ● ●
condition
-Check push out rod for

● ●
proper condition
-Check locking pins

and locking bores for ● ●
proper condition
-Check inner and outer

sliding surfaces for ● ●
proper condition
-Lubricate sliding
●5
surfaces
7-21
SAC2200

first maintenance
maintenance annual
Telescopic boom guying
-Check for distortions

●
and cracks
-Lubricate grease fitting every 3

on the month - s5, 6
guying
-Check the oil level on every 6

the guy winch months
-Change the oil on the every 4

guy winch months
1
every 3 months if the crane is not moved.
2
Carry out a visual inspection before every
startup in service.
3
in hot climates twice a year.
4
Note chapter 7.5, Crane superstructure
maintenance instructions.
5
when necessary
6
during assembly
7-22
SAC2200
7.4 Crane Chassis Maintenance

Guidelines
7.4.1 Driving motor
Under no circumstances must fuel lines be

stepped on during maintenance or repair work!
DANGER: FIRE!
Ensure that the engine area is kept free of
diesel fuel!
Extreme cleanliness is vital, particularly
during filter changes and deaerating. Wipe
up any spilled fuel!
When changing the filter it is advisable to
put down some waste wool before undoing
the filter to pick up fuel.
7-23
SAC2200
7.4.1.1 Engine oil
1. Checking the oil level

met:
the crane is horizontal.
the engine has been turned off and the oil has
collected in the oil sump.
-Remove and wipe off oil dipstick.
-Re-insert dipstick and pull out again.
The oil level must be between the Min. and
Max. marks on the oil dipstick.
-Check oil level.
CAUTION: danger of damaging

the engine!
If the oil level has dropped below the
Minimum mark, top up engine oil as shown
in the lubrication chart until the oil level
is between the Minimum and Maximum
marks.
Top up engine oil and check again.
-Re-insert oil dipstick.
2. Changing the oil

Refer to separate operating instructions “BENZ
diesel engines”.
7-24
SAC2200
Max .
Min .
7-25
SAC2200
7.4.1.2 Engine coolant
The coolant level on the expansion tank is

monitored with a water level probe. If the
coolant level is too low, the warning light 182
“Coolant level engine too low” lights up on the
display unit.
The coolant temperature of the drive motor
can be read on the display unit on the bar
chart via the warning light 231.
DANGER: FIRE!
Engine must be cold when performing
coolant check.
-Turn sealing cap on filler neck of water cooler

expansion tank to first detent.
-Release excess pressure.
-Remove sealing cap.
-Check the coolant level.
Top up water cooler equalizing reservoir with
coolant as shown in lubrication chart, always
using filler neck.
-Top up with coolant if required.
7.4.1.3 AIR FILTER

The air filter is monitored electrically. If the
vacuum in the intake pipe has increased
because of soiled air filter units, the warning
light 183 in the cab display unit illuminates.
-If warning light 183 illuminates:

Clean or replace filter unit.
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182 231 183
7-27
SAC2200
7.4.1.4 Turbocharger
Precaution for operation

Check whether the fixed screw and support bolt on turbocharger have been tightened.
Before start Check whether there is enough fuel for the diesel engine crank case.
Check whether there is crack or break-off on the intake or return oil pipelines.
Idle the starter for 2-3 times (10s for each time) to rotate the diesel engine, then restart the
During start
engine after the turbocharger has been fully lubricated by lubricating oil.
Make sure there is 3min left for idling before start, then accelerate the engine after the
turbocharger has been fully lubricated. (For the vehicle with turbocharger, never move it once
after start; do accelerate step by step but not sharply.)
During
operation The idling period for diesel engine should never exceed 10min.
Never shut down the running diesel engine sharply, otherwise, the turbocharger shaft may be
stuck with shaft sleeve caused by the cut-off of engine oil.
Before
Normalize the temperature and speed of engine by idling it for 3min.
shutdown
The lubricating oil should be clean without any foreign matter, of good-quality and indefectible.
Others For the new diesel engine or turbocharger, before start, do fill it with 50~60ml engine oil by
removing the pipeline joints, to effectively avoid the burnout of bearing at the moment of start
caused by oil starvation.
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Daily maintenance
Check whether there is any abnormal noise or severe vibration from the turbocharger.
Inspection method: after the shutdown of diesel engine, inspect the after-running of runner
through hearing. Generally, the period from the shutdown of engine to the stop of runner is
not less than 5s, otherwise, inspection should be conducted immediately.
Daily The temperature from the air compressor impeller end (cold end) and the housing should
inspection not be over high.
There should not be leakage from pipeline and joints.
Always keep the breather on crank case smooth, otherwise, with the increasing pressure on
crank case; the leakage of turbocharger may occur caused by the low back-flow velocity of
lubricating oil.
Regularly check the amount, quality of engine oil, besides, to guarantee the high-purity of it,
replace the deteriorated one timely and clean or replace the filter. Generally, the engine oil
and filter core should be replaced every 1500km (for break-in period), and every 10000km
Periodical (after break-in period).
inspection
Always keep the air-inlet pipeline on turbocharger clean and leakproof. The air filter core
should be replaced every 2 years or periodically based on mileage. Regularly check the
leakproofness of the systems of air-inlet and exhaust.
7-29
SAC2200
Fault Condition Cause Remedy
1. Check whether there is leak

source on the outer lubricating
High-
oil pipeline, especially on the
consumption
pipelines of oil-inlet, return;
of engine oil,
2. Check the side exterior
abnormal color Caused by the leakage of fuel pipeline
of exhaust outlet on the
of exhaust,
turbocharger, if there is any
normal power
leakage, it must be caused by
the damaged seal ring located
at one end of turbo.
1. Open up the connecting

The engine oil leaked from turbocharger pipeline between the air
enters into the combustion chamber with compressor and engine inlet
inlet and blazes up. Possible cause: pipeline to check whether there
High- 1. For the blockage of return pipeline on is engine oil on the pipe orifice
Leakage consumption turbocharger, the engine oil accumulated at or pipe wall, if so, check the
from of engine oil, the support of runner assembly flows into smooth of return pipeline on
turbocharger blue smoke the air compressor impeller through the turbocharger: there may be too
from exhaust, runner shaft; much engine oil accumulated
normal power 2. The engine oil leaked from the damaged at the central support;
seal ring near air compressor impeller and 2. If there is no problem on the
oil thrower enters into the air compressor smooth of pipeline, it must be
impeller. caused by the damaged seal
ring or oil thrower.
1. For the over large clearance between 1. Check whether there is

High-
piston and cylinder, the engine oil flows into any engine oil at the pipe
consumption
combustion chamber and blazes up; wall; whether there is any
of engine
2. For the over low pressure at air deformation on rubber hose;
oil, blue or
compressor inlet caused by increasing whether the air filter is smooth;
black smoke
resistance from the entering of air into the 2. Clean or replace the filter
from exhaust,
turbocharger, the engine oil is sucked into air core if there is any engine oil
decreased
compressor and moved into the combustion on the pipe orifice or the inner
power
chamber along with inlet air. wall.
7-30
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Fault Condition Cause Remedy
1. If clash appears, it may be caused by

the interference between the impeller and 1. Check each component
Black smoke
the shell of turbocharger: the deviated for the degree of wear, if it
from exhaust,
installation position of turbocharger may be is severe, have the wearing
decreased
caused by the damaged runner bearing or component replaced
power,
thrust bearing; immediately;
abnormal
2. If the noise of airflow appears, it may be 2. If it is the noise of airflow, do
noise from
the noise from rotation of runner, or the repair the leaky parts based on
turbocharger
noise of air leakage from the inlet, exhaust condition.
interface.
1. Check the bearing inside

turbocharger for degree of
Abnormal 1. For the increasing resistance from the
Loud noise wear, if it is severe, have the
noise rotation of runner, the inner bearing of
from parking, wearing component replaced
turbocharger is damaged;
no ease with immediately;
2. Foreign matters may have entered into
start 2. Check whether there is
the turbocharger.
any foreign matters inside the
pipeline.
Clear pipeline, and replace the

The air-inlet pipeline may be blocked or too
filter core immediately, if no
much foreign matters accumulate at the
Turbocharger effect appears after the above
air filter; too much dust accumulate on the
surges operation, check and clear
impeller; for the squeal, it may be caused by
with squeal the impeller; do operate the
the sharp change in engine load and speed,
sometimes engine correctly to effectively
if it appears with no abnormal power, black
avoid sharp acceleration,
smoke or oil leakage.
deceleration and load change.
1. It may be caused by the deficiency of

Damaged engine oil pressure and flow capacity: 1. Check engine oil pressure
turbocharger a. low oil content between turbocharger and oil content;
bearing, journal and thrust bearing; 2. Replace the lubricating oil
decreased b. deficient engine oil between runner periodically as required;
engine journal and bearing; 3. Do use the lubricating oil
Damaged power, high- c. deficient oil supplied to turbocharger when appointed by manufacturer,
turbocharger consumption of it is under high speed operation; never mix lubricating oil;
bearing engine oil, black 2. Too much foreign matters have been 4. Shut down to cool down
smoke, the mixed into the lubricating oil; the engine and the continue
turbocharger 3. Lubricating oil has deteriorated: operation once temperature
cannot operate a. incorrect engine oil; becomes normal, keep close
when bearing b. water has been mixed with lubricating oil; attention on temperature
is severely c. Too much mixture of oil and gas has change, never operate with
damaged. entered into combustion chamber caused by overheated engine.
the overheated engine.
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7.4.1.5 Fuel preliminary filter
1. Draining the fuel preliminary filter
NOTICE!
The water separator at the fuel preliminary
filter must be drained at regular intervals.
- Turn off the engine.

- Place collecting container beneath water
separator.
- Open the drain tap 2 and drain water until
fuel comes out.
- Close the drain tap 2.
- Remove collection container and dispose of
fluid.
2. Cleaning the filter strainer
DANGER: danger of fire and

explosion!
! Do not smoke.
! Avoid naked flame.
! Work only when the diesel engine is turned
off.
! Maintain extreme cleanliness during all work.
-Turn off the engine.

-Place the collecting container under the fuel
preliminary filter.
-Open the drain tap 2 until no more fuel comes
out.
-Close the drain tap 2
-Remove collection container and dispose of
fluid.
-Dismantle caps.
-Remove the filter strainer and clean it
properly.
-Insert the cleaned filter strainer properly.
-Install the cover with seals properly.
-Open the vent screw.
- O p e r a te t h e h a n d p u m p a n d p r o p e r l y
deaerate the fuel filter.
-Properly tighten the vent screw.
-Start engine and check fuel preliminary filter
for leaks.
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SAC2200
7.4.2 Automated shift transmission

the transmission!
! Maintain extreme cleanliness during
all work to prevent dirt from entering the
transmission system.
! Check transmission for leaks at regular
intervals.
! Have leaking transmission sealed
immediately and professionally.
7.4.2.1 Checking the oil level at automatic

transmission

met:
-the crane is horizontal
-gear oil has cooled down (less than 40 ° C)
Unbolt and remove level control screw 1.
Oil level must be up to the edge of the hole.
- Perform visual inspection.
If the level control screw cannot be seen due
to structural reasons, oil must be added at
the oil filler plug 4, until it escapes at the level
control screw.
CAUTION: danger of gear

damage!
Too little oil causes lubricating problems
and reduces the service life of the
t r a n s m i s s i o n . To o m u c h o i l c a u s e s
more displacement work and therefore
transmission overheating.
! Top up oil up to the overflow level of the
level control screw 1 in accordance with
the lubrication chart and re-check level.
- Screw in level control screw 1 with new
gasket and tighten.
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7.4.2.2 Replacing the oil of automatic

transmission unit
NOTICEN!
! Vehicle must not be braked with the
intarder before carrying out the oil change.

met:
- The crane is horizontal.
- Transmission is warmed up and ready for
operation.
- Unbolt and remove level control screw 1.
- Unbolt oil filler plug 4.
- Unbolt oil drain plug 2 and oil drain plug 3
and drain oil.
- Clean magnets at oil drain plugs.
- Screw in oil drain plug 2 and oil drain plug 3
with new gasket and tighten.
- Top up with oil as shown in the lubrication
chart on the oil filler plug 4 until it starts to
overflow at the level control screw.
- After topping up the oil, screw in oil filler plug
4 and level control screw 1 with new gasket
and tighten.
- Test drive the vehicle.
- Check oil level and add oil if necessary.
7.4.2.3 Changing the fine filter
The fine filter 5 must be changed during

every oil change. Ensure that no pollutants
or oil sludge can penetrate the circuit when
changing the fine filter 5.
- Unscrew the retaining screw for the fine filter.
- Dismantle the old fine filter.
- Properly assemble the new fine filter.
- Screw in and tighten the retaining screw.
- Test drive the vehicle without the intarder.
- Check oil level and add oil if necessary.
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7-37
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7.4.3 Transfer gearbox
Please maintain extreme cleanliness during

7.4.3.1 Checking the oil level

met:
- the crane is horizontal
- unbolt and remove level control screw 2.
- the oil level must be up to the edge of the
hole for the level control screw 2.
- perform visual inspection.
CAUTION: danger of gear

damage!
Too little oil causes lubricating problems
and reduces the service life of the
t r a n s m i s s i o n . To o m u c h o i l c a u s e s
more displacement work and therefore
transmission overheating.
! Top up oil up to the overflow level of the
level control screw 2 in accordance with
the lubrication chart and re-check level.
- Screw in level control screw 2 with new
gasket and tighten.
7-38
SAC2200
2
3
7-39
SAC2200
7.4.3.2 Changing the oil

met:
- the transmission has warmed up
- Unbolt and remove oil filler plug 1 and level
control screw 2.
- Remove the oil drain plug 3, drain the oil and
determine the oil quantity.
- Remove the supply and return lines to the
oil cooler drain the oil and determine the oil
quantity.
- If necessary, carefully blow out the oil lines
with maximum 4 bar to drain all the oil.
- Remove the non-return valves from the
hoses and from the oil cooler and check for
function and leaks.
CAUTION!
!When installing the non-return valves,
note the flow direction!
- Install the non-return valves properly and
tighten.
- Install the supply and return lines to the oil
cooler properly and tighten.
- Install the oil drain plug 3 with new seal and
tighten.
- Pour oil into the filler plug 1 or the level
control screw 2 in accordance with the
lubrication chart until it starts to overflow from
the edge of the level control screw 2 hole.
- Screw in filler plug 1 and level control screw
2 with new gasket and tighten.
CAUTION!
!The oil cooler is filled with oil after
traveling approx. 10 kilometers.
!Check the oil level as described above and
add oil, if necessary.
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SAC2200
2
3
7-41
SAC2200
7.4.4 Hydraulic system
Extreme cleanliness must be maintained when

topping up the oil.
7.4.4.1 Hydraulic tank

met:
- the support cylinders and sliding beams have
been fully retracted
- the vehicle has been lowered to the lowest
axle suspension level
DANGER!
Danger of accident if hydraulic pump is
damaged!
If the oil level is too low the hydraulic pump
may be damaged, which will increase the
danger of accident because of incapacity
to steer.
The cylinders cannot be fully extended and the

vehicle cannot be leveled.
- Check oil level and top up if necessary.
The oil level must be in the middle of the oil
level inspection window 1.
- Checking oil level in oil level inspection
window 1 of hydraulic fluid reservoir.
Troubleshooting
No oil visible in the oil level inspection window
1?
- Top up oil as shown in lubrication chart using
a fine-meshed filter until oil level is in middle of
oil level inspection window 1.
2. Checking the aeration/vent filter

-Open screw-on cover.
-Check filter 2 for impurities (visual inspection).
-In the event of heavy soiling: replace filter 2.
-Close screw-on cover.
-Start engine.
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SAC2200
-Perform all crane movements slowly.

-Check oil level again and add oil if necessary.
3. Pressure filters
The pressure filters 5 are equipped with a
maintenance indicator. If the red bar indicator
is visible when the oil is warmed up and ready
for operation, the filter cartridge must be
replaced.
- Release filter cartridge and collect escaping
oil in a suitable container.
- Unscrew, remove and dispose of filter
cartridge.
- Clean the sealing surface on the filter
bracket.
- Oil the rubber sealing ring on the new filter
cartridge.
- Screw on and tighten new filter cartridge.
- Start engine and check for leaks.
Result:
- This deaerates the hydraulic system.
- Check oil level again and add oil if necessary.
4. Changing the oil

Oil quality should be periodically checked
during crane operation. 1st time check should
be done on new vehicle after 400hs’ operation,
2nd time should be done after 1200hs’
operation afterwards, at least one time per
year. Immediate check must be carried out
once impurities and quality problem has been
found out.
Sample oil should be taken from return filter,
hydraulic tank bottom or defected hydraulic
components for quality check.
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7-45
SAC2200
① Contaminating grade check

According to GB/T 14039-93, the
contaminating grade for hydraulic system
solid particle is 18/15, that is to say: the ﹥5μm
particle number in 1ml hydraulic oil should be
1300~2500; the ﹥15μm number should be
160~320.
Filtrate the hydraulic oil with strainer of a 5μm
filtering accuracy once particle number is
found over standard. Such hydraulic oil can
only be used once qualified.
② Quality check
Replace the hydraulic oil once changes
appear on oil color (the color except for brown
is unacceptable).
When oil color appears milk white: once oil
color appears milk white because of mixture
with water, keep the sampling oil into some
long transparent container: if some percent of
upper liquid above the oil appears transparent
after 24hs, it indicates that the oil has been
mixed with water and should be replaced
immediately.
Filtrate or replace hydraulic oil according to
JB/T9737.3-2000 once pollutant is found.
③ Hydraulic oil mode: Great Wall Abrasion

Resistance (no dust) 6146 (with a NAS8
cleanliness)
④ Maximum operating temperature for

hydraulic oil: 80℃
⑤ Hydraulic oil volume: 850L for hydraulic

tank, 1150L for the crane.
Oil volume check should be carried out before
the crane operation. The volume should be
at the upper limit of lever meter, fill oil once
volume falls below the lower limit.
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7-47
SAC2200
7.4.4.2 Diaphragm reservoirs of axle

suspension / axle locking system
Diaphragm reservoirs have been installed

in the hydraulic system. The pre-loading
pressures are specified in the hydraulic circuit
diagram and on the individual diaphragm
reservoirs. The pre-loading pressure must
be measured separately in each diaphragm
reservoir.
CAUTION: risk of chassis

damage!
If the outside temperature fluctuates
considerably, e.g. after transportation
to extremely hot or cold countries or in
countries with considerable differences
between the summer and winter
temperatures, the gas reservoir pressures
may change. Inadequate gas pre-loading
may cause the reservoir diaphragms to be
overstressed. If the pre-loading is too high,
the springing effect of the axle suspension
if no longer guaranteed.
! Check gas reservoir pressures and
correct if necessary.
7-48
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7-49
SAC2200

met:
- the axle suspension/axle locking system is in
the suspended position
- the function control on button 130 is not
illuminated
- lower vehicle down as far as possible using
button 119, button 120, button 135, button 136
and ENTER 143 until the oil has drained from
the diaphragm reservoirs.
DANGER: danger of explosion!

The pressure in the nitrogen cylinder
must be less than the maximum permitted
operating pressure of the reservoir or the
pressure gauge. Otherwise fit a pressure
reducer between the cylinder and the filling
device.
! Do not use air or oxygen to fill the
diaphragm reservoir!
The pre-loading pressure in the hydraulic

reservoirs must be always be checked by
an expert with appropriate training and
equipment. The national pressurized container
regulations most also be complied with.
- Check pre-loading pressure using a testing
and filling device and correct if necessary.
- Press Level button 129 and ENTER 143 until
function control in Level button 129 flashes.
Result:
The vehicle is at the level setting for road
driving.
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7.4.4.3 Hydraulic hoses
The hydraulic hoses must be checked by an

experienced technician or expert mechanic, as
required depending on the duration of use and
the operating conditions, but at least once per
annum.
NOTICE!
!The applicable national regulations must
also be complied with!
1. Examples of possible faults in hose systems
DANGER: risk of fire or accident!

If problems are discovered during checking
they must be remedied immediately or
suitable measures taken. Failure to do this
can result in serious injury to persons,
death or damage to property.
! Remedy problems or take suitable
measures!
- Damage to the outer layer as far as the

intermediate layer (e.g. chafing, cuts and
cracks).
- Outer layer brittleness (hose material
cracking).
- Deformation that differs from the natural
shape of the hose or hose system when
depressurized or pressurized or when the
hose is bent (e.g. layer separation, bubbling,
crushing or kinking).
- Leaks.
- Failure to follow installation instructions.
- Damage or deformation of hose fittings that
inhibit the operation and strength of the fitting
or the hose / fitting connection.
- Hose slipping out of fitting.
- Fitting corrosion that inhibits operation and
strength.
- Storage time or usage period exceeded.
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7-53
SAC2200
2. Hose system maintenance

- It is advisable to check all hoses, hose
systems and screw-in connections daily, but at
least every two weeks for leaks and external
signs of damage.
- Damaged parts must be replaced
immediately! Oil spray can lead to injuries and
fires.
- Hydraulic lines and hoses must not be
repaired.
- Hoses that have already been used in a
hose system must not be re-installed in hose
systems.
- Always use original SANY spare parts when
replacing hoses and hose systems.
- Always ensure that the hoses are free of
torsion when routing. If high-pressure hoses
are being used, attach screw of clamps or full
flange at both ends of hose and then tighten.
- When using high-pressure hoses with a bent
fitting, tighten the end with the bent fitting first
when tightening the flanges, then the end with
the straight fitting.
- Only then must any fastening clamps in the
middle of the hose be attached and tightened.
- Route the hoses such that chafing with
other hoses or other structures is prevented.
Maintain minimum clearance of approximately
½ the outer diameter of the hose from other
parts. The clearance must never be less than
10 to 15 mm.
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3. Replacing the hose systems

Failure to replace hose systems at
appropriate intervals can cause serious
injury to persons, death or damage to
property.
! Replace hose systems at appropriate
intervals!
This must be documented in the crane's
inspection log by the expert or the
authorized inspector.The service life
of a hose system may not exceed six
years, including a storage period of a
maximum of two years. (pay attention to
manufacturing date of hose). The duration
of use can also be defined by the expert
or authorized inspector in accordance
with existing test and empirical data in
the individual application areas taking the
usage conditions into consideration.
Steering
CAUTION: risk of accident!

! Damaged or leaking hydraulic hoses must
be replaced immediately.
Check hydraulic hoses 2 from the steering
centering cylinder 1 to control block of
third, fourth and fifth axles for cracks,
damage and leaks.
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7.4.5 Compressed air and brake system

air dryer
7.4.5.1 Replacing the granular cartridge
CAUTION!
DANGER!
The granular cartridge of the air dryer 1 is
under spring tension.
! Caution when replacing the cartridge.
- Replace granular cartridge once per year.
7.4.6 Tires / wheels
DANGER: risk of accident!

! Check the tires at regular intervals for
correct condition, correct tread depth and
uniform tire pressure.
7.4.6.1 Checking the tires
- Check tires for damage.

Tread depth must not drop below the legally
prescribed minimum depth.
- Check depth of tread.
The tire must be inflated to the pressure that
is specified for the tires. Check tire inflation
pressure on cold tires. Tire inflation pressure
information can be found in chapter 1.3.
- Check tire inflation pressure.
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7.4.6.2 Inflating the tires

met:
- the tires are correctly fitted to the disk wheel
- the clamp collar 2 is correctly seated
DANGER: risk of accident!

When checking the tire inflation pressure
on the vehicle or after fitting tires, please
ensure beforehand that the clamp collar 2
is correctly assembled on the disk wheel.
! If the clamp collar 2 is not correctly
seated, please obtain the assistance of a
specialist.
- Check that disk wheels are in correct working
order before starting to drive the vehicle.
The maximum permitted tire pressure must
not be exceeded.
- Inflate tires.
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7.4.6.3 Safety and maintenance instructions

for disk wheels
The following safety and maintenance

instructions are the manufacturer's
recommendations for avoiding safety risks
caused by damaged disk wheels. The wheel is
one of the most important safety components
on the vehicle. For this reason, please check
the wheels at the rim and the disk wheel for
the following when changing the tires:
- Excessive rust or corrosion
- Bent disk wheel flanges
- Cracks in the disk wheel
- Cracks in the brake drum fastening on the
inside or outside of the disk wheel
- Weld seam connection on inside or outside
of disk wheel
- Damage to side and clamp collars
- Damaged wheel pins or nuts
DANGER: risk of overload

breakage!
Disk wheels with worn pin holes must be
scrapped immediately. Repairing these
highly-stressed disk wheel components
causes structural transformations in
the material that can lead to premature
overload breakage.
! No welding work is permitted on rims and
wheel disks, particularly repairs to worn
pin holes.
- If damaged disk wheel parts are discovered

during checking:
Remove them and replace them with new
parts.
- If paint damage or minor rust formation is
found:
Make good the wheels by removing the rust
using commercially available paint. Pay
special attention to having a perfect surface in
the tire seating areas.
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7.4.6.4 Changing the wheel
- Release wheel nuts of defective wheel and

support crane in accordance with regulations.
Supports refer to Chapter 3.5.
- Wheels that are on their side are extremely
difficult to lift up. For this reason, do not put
the wheels down when changing a wheel.
- Lift spare wheel using a crane, put down next
to defective wheel and prevent from rolling
away or toppling over.
- Unscrew wheel nuts.
- Replace defective wheel with spare wheel.
See “Safety and maintenance instructions for
disk wheels”.
DANGER: risk of accident if wheel

nuts are overtightened!
The maximum permitted wheel nut
tightening torque is 600 Nm.
! Do not overtighten wheel nuts.
- Refit wheel nuts and tighten crossways.

Please also refer to Chapter 9.2.
- Recheck that wheel nuts are firmly seated
after the first 50 km that are driven and again
after 100 km.
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7.4.7 Axles
Please maintain extreme cleanliness during all
work to prevent dirt from entering the interior
of the axle mounts.
7.4.7.1 Axle mounts
The position of oil filler plug 1, oil filler plug 2

as well as the position of oil drain plug 3 and
oil drain plug 4 depends on the type of axle.
met:

- Unbolt oil filler plug 2. Oil level must be up to
the edge of the hole.
CAUTION: danger of damage!

If the oil level has dropped, always top
up with the oil specified in the lubrication
chart up to the overflow of the oil filler plug
2.
! Top up oil and check again.
- Screw in oil filler plug 2 with new sealing
ring and tighten.
2. Changing the oil

- Unbolt and remove oil filler plug 1 and oil
filler plug 2.
- Unbolt oil drain plug 4 and drain oil.
- Screw in oil drain plug 4 with new sealing
ring and tighten.
- Pour oil into the oil filler plug 1 or the oil filler
plug 2 in accordance with the lubrication chart
until it starts to overflow from the edge of the
oil filler plug 2 hole.
- Screw in oil filler plug 2 with new sealing ring
and tighten.
and tighten.
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7.4.7.2 Wheel hubs

met:
- the crane is supported

- Turn each driven wheel until the oil drain
plug 7 reaches its lowest point, and the line 6
is exactly horizontal.
- Oil level must be up to the edge of the hole.

If the oil level has dropped, always top
up with the oil specified in the lubrication
chart up to the overflow of the oil filler plug
5.
! Top up oil and check again.
- Screw in oil filler plug 5 with new sealing
ring and tighten.
2. Changing the oil

- Turn each driven wheel until the oil drain
plug 7 reaches its lowest point, and the line 6
is exactly horizontal.
- Unbolt oil drain plug 7 and drain oil.
ring and tighten.
- Top up with oil as shown in the lubrication
chart using the oil filler plug 5 until it starts to
overflow at the edge of the hole.
and tighten.
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7.4.8 Axle alignment
7.4.8.1 Checking the axle alignment
The axle alignment must be checked at regular

intervals. Failure to perform this check can
result in increased tire wear. If extremely high
stress has occurred such as driving against
curbs, it is extremely important to check the
axle alignment.
- Always have the axle alignment checked by
a trained expert.
7.4.9 Electrical system - lighting
The maintenance of the electrical system is

essentially limited to replacing defective fuses
and bulbs and maintaining the batteries.
CAUTION: risk of damage to

electrical system!
! Always replace defective fuses with fuses
for the same current strength.
7-70
SAC2200
7.4.9.1 Battery maintenance
DANGER: danger of fatal injury!

! Always disconnect the batteries from
the power circuits when working on the
electrical system of the crane, and during
all welding work.
- Keep batteries dry and clean.

- Do not bring oil, grease, fuel or solvents into
contact with the battery casting compound.
- Undo soiled terminals, clean and grease with
an acid-free and acid-resistant grease.
- Check electrolyte levels in batteries at least
once per annum. Check in summer and twice
per annum in hot zones.
- With conventional batteries, check electrolyte
level at regular intervals and top up with
distilled water to specified “max mark” if
necessary.
- If topping up with distilled water:
- Measure electrolyte concentration after
30 minutes. The best acid temperature for
measuring is + 20 °C.
Proceed as follows when checking the battery

charge:
Spec. gravity(Kg/L) Charge

1.28/1.23* Well charged
*
1.20/1.16 Semi-charged, recharge
*
1.12/1.08 Empty, charge immediately
*
in tropical countries
Reduced battery performance is an indication
of greater power requirements.
- Ensure that battery is well charged,
particularly during the colder months.
7-71
SAC2200
7.4.9.2 Mixing battery acid
- Ensure that working area is well ventilated.

! When mixing battery electrolyte, always
pour distilled water into the container first,
then the concentrated sulphuric acid.
! Stick to this order, otherwise explosions
and spattering can occur.
-Stir mixture with acid-proof stick (glass or
plastic).
Required electrolyte
1.23 1.24 1.25 1.26 1.27 1.28
concentration kg/l
Volume by ratio of
concentrated sulphuric acid 1:3.8 1:3.6 1:3.4 1:3.2 1:3.0 1:2.8
(96%) to distilled water
When pouring in the battery acid, the acid

level should be 15 mm above the top edge of
the battery plates and the temperature of the
acid should be approximately 15 °C.
- Pour acid into battery.
- Connect battery after approximately 20
minutes.
7-72
SAC2200
7.4.9.3 Removal and recharging
WA R N I N G : d a n g e r o f b o d y
injuries!
! Do not place tools on battery, and keep
out of sunlight.
1. Removal
met:
- all electrical consumers have been turned off
CAUTION: risk of damaging the

generator!
! Do not disconnect batteries unless engine
has been turned off.
- Carry out work in well ventilated rooms and

avoid sparks.
- Disconnect negative terminal first (earth
lead), then the positive terminal.
- Avoid sparks caused by electrostatic
discharge. Do this by touching earthing point
in cab.
- Do not tilt or shake battery.
7-73
SAC2200
2. Recharging

battery!
! Only perform using direct current, the
strength of which does not exceed 1/10 of
the battery capacity.
Recharging example: A battery with 170 Ah

should be charged with a maximum charging
current of 17.0 A.
- Froze batteries must be thawed out before
charging.
- Remove all sealing plugs before charging.
- Provide ventilation during charging (risk of
oxyhydrogen gas explosion!).
- Connect battery to a charger (positive to
positive and negative to negative).
- Turn on charger after connecting battery.

Stop charging immediately if:
- Electrolyte temperature exceeds 55°C
(casing more than warm to the touch).
- Battery starts to give off gas.
- The electrolyte concentration or the charge
has not changed for 2 hours.
Switch charger off after charging, then detach
individual connecting cables from battery and
charger.
3. Installation
- Install battery in vehicle again.
- Avoid sparks caused by electrostatic
discharge. Do this by touching earthing point
in cab.
- First connect positive terminal to battery, then
negative terminal (ground lead).
- Check that terminals are firmly attached (low
contact resistance).
- Grease terminals with acid-free and acid-
resistant grease (and also corrosion protection
for modern maintenance-free batteries).
7-74
SAC2200
7.5 Superstructure Maintenance

Guidelines
7.5.1 Crane engine
Under no circumstances must fuel lines be

stepped on during maintenance or repair work!
DANGER: danger of fire!

! Ensure that the engine area is kept free of
diesel fuel.
! Extreme cleanliness is vital, particularly
during filter changes and deaerating. Wipe
up any spilled fuel.
! When changing the filter it is advisable to
put down some waste wool before undoing
the filter to pick up fuel.
7-75
SAC2200
7.5.1.1 Engine oil

met:
- the engine has been turned off and the oil
has collected in the oil sump
- Remove and wipe off oil dipstick 1.
- Re-insert oil dipstick 1 and pull out again.
Max. marks on the oil dipstick 1.
- Check oil level.

the engine!
If the oil level has dropped below the
Minimum mark, top up engine oil as shown
in the lubrication chart until the oil level
is between the Minimum and Maximum
marks.
!Top up engine oil and check again.
-Re-insert oil dipstick 1.
2. Changing the oil

Refer to separate operating instructions “BENZ
diesel engines”.
7-76
SAC2200
Max.
Min.
7-77
SAC2200
7.5.1.2 Engine coolant
The coolant level is monitored by the computer

system. If the coolant level is too low the“Low
coolant level” icon appears on the LICCON
monitor.
The crane's engine coolant temperature can
be read on the monitor in [°] on the “Engine
coolant temperature” icon.
DANGER: danger of fire!

! Engine must be cold when performing
coolant check.
- Turn sealing cap 1 on filler neck of water

cooler expansion tank to the 1st detent.
- Release excess pressure.
- Remove sealing cap 1.
- Check the coolant level.
Top up water cooler equalizing reservoir with
coolant as shown in lubrication chart, always
using filler neck.
- Top up coolant to overflow level if necessary.
7.5.1.3 Air filter
The air filters are monitored by the computer

system. If the vacuum increases in the intake
line due to soiled filter units, the “Air filter
soiled” icon is displayed on the LICCON
monitor.
- If the “Air filter soiled” icon is displayed:
Clean or replace filter unit.
7-78
SAC2200
83℃
7-79
SAC2200
7.5.2 Hydraulic system

Extreme cleanliness must be maintained when
topping up the oil.
7.5.2.1 Hydraulic tank

met:
- the luffing cylinder and the telescoping
cylinder are fully retracted the oil level must be
in the middle of the oil level inspection window
1.
Troubleshooting
No oil visible in the oil level inspection window
1?
- Top up oil as shown in lubrication chart using
a fine-meshed filter until oil level is in middle of
oil level inspection window 1.
7-80
SAC2200
2. Checking the aeration/vent filter

- Open screw-on cover.
- Check filter 2 for impurities (visual
inspection).
- In the event of heavy soiling:
Replace filters 2.
- Close screw-on cover.
- Start engine.
- Perform all crane movements slowly.
7-81
SAC2200
7.5.2.2 Pressure filters in crane hydraulics
The pressure filter 4 and pressure filter 5 are

equipped with a maintenance indicator. If
the red bar indicator is visible when the oil is
warmed up and ready for operation, the filter
cartridge must be replaced.
- Release filter cartridge and collect escaping
oil in a suitable container.
- Unscrew, remove and dispose of filter
cartridge.
- Clean the sealing surface on the filter
bracket.
- Oil the rubber sealing ring on the new oil filter
cartridge.
- Screw on and tighten new filter cartridge.
- Start engine and check for leaks.
- Perform all crane movements slowly.
Result:
- This deaerates the hydraulic system.
7-82
SAC2200
5
4
7-83
SAC2200
7.5.2.3 Diaphragm reservoirs
Various diaphragm reservoirs have been

installed in the hydraulic system. The pre-
loading pressures are specified in the
hydraulic circuit diagram and on the individual
diaphragm reservoirs. The pre-loading
pressure must be measured separately in
each diaphragm reservoir.

hydraulic system!
If the outside temperature fluctuates
considerably, e.g.after transportation
to extremely hot or cold countries or in
countries with considerable differences
between the summer and winter
temperatures, the gas reservoir pressures
may change.
! Check gas reservoir pressures and
correct if necessary.

met:
- the crane engine is turned off
This relieves the diaphragm reservoir at the
fluid side.


The pressure in the nitrogen cylinder must
be below than the maximum permitted
operating pressure of the reservoir or the
pressure gauge. Otherwise fit a pressure
reducer between the cylinder and the filling
device.
! Do not use air or oxygen to fill the
diaphragm reservoir.
The pre-loading pressure in the hydraulic

reservoirs must be always be checked by
an expert with appropriate training and
equipment. The national pressurized container
regulations most also be complied with.
- Check pre-loading pressure using a testing
and filling device and correct if necessary.
7-84
SAC2200
7.5.2.4 Hydraulic hoses
The hydraulic hoses must be checked by an

experienced technician or expert mechanic, as
required depending on the duration of use and
the operating conditions, but at least once per
annum.
CAUTION!
! The applicable national regulations must
also be complied with!
1. Examples of possible faults in hose systems

If problems are discovered during checking
they must be remedied immediately or
suitable measures taken. Failure to do this
can result in serious injury to persons,
death or damage to property.
! Remedy problems or take suitable
measures!
- Damage to the outer layer as far as the

intermediate later (e.g. chafing, cuts and
cracks)
- Outer layer brittleness (hose material
cracking)
- Deformation that differs from the natural
shape of the hose or hose system when
depressurized or pressurized or when the
hose is bent (e.g. layer separation, bubbling,
crushing or kinking)
- Leaks
- Failure to follow installation instructions
- Damage or deformation of hose fittings that
inhibit the operation and strength of the fitting
or the hose / fitting connection
- Hose slipping out of fitting
- Fitting corrosion that inhibits operation and
strength
- Storage time or usage period exceeded
7-85
SAC2200
2. Hose system maintenance

- It is advisable to check all hoses, hose
systems and screw-in connections daily, but at
least every two weeks for leaks and external
signs of damage.
- Damaged parts must be replaced
immediately! Oil spray can lead to injuries and
fires!
- Hydraulic lines and hoses must not be
repaired!
- Hoses that have already been used in a
hose system must not be re-installed in hose
systems.
- Always use original SANY spare parts when
replacing hoses and hose systems.
- Always ensure that the hoses are free of
torsion when routing. If high-pressure hoses
are being used, attach screw of clamps or full
flange at both ends of hose and then tighten.
- When using high-pressure hoses with a bent
fitting, tighten the end with the bent fitting first
when tightening the flanges, then the end with
the straight fitting.
- Only then must any fastening clamps in the
middle of the hose be attached and tightened.
- Route the hoses such that chafing
with other hoses or other structures is
prevented. Maintain a minimum clearance
of approximately ½ the outer diameter of the
hose from other parts. The clearance must
never be less than 10 to 15 mm.
7-86
SAC2200
3. Replacing the hose systems

Failure to replace hose systems at
appropriate intervals can cause serious
injury to persons, death or damage to
property.
!Replace hose systems at appropriate
intervals!
This must be documented in the crane's

inspection log by the expert or the authorized
inspector.
The service life of a hose system may not
exceed six years; including a storage period
of a maximum of two years (observe the
manufacturing date on the hoses). The
duration of use can also be defined by the
expert or authorized inspector in accordance
with existing test and empirical data in the
individual application areas taking the usage
conditions into consideration.
7-87
SAC2200
7.5.2.5 Troubleshooting on hydraulic

system
No. Location Condition Cause Remedy

Lack of oil Add oil
Air in oil-intake pipeline Repair and exhaust the air
Hydraulic Loose construction bolt Tighten the bolt
1 Noise
pump Hydraulic oil polluted Change or filter the oil
Transmission shaft vibration Repair
Universal joint worn out Replace
Low pressure of chassis

Adjust to 20MPa
overflow valve
No operation Valve core of chassis overflow

Disassemble and clean
valve is blocked by dirt
Fault of chassis multi-way valve Repair
Disassemble and clean

Valve core stroke of chassis
the valve core, adjust the
multi-way valve unfulfilled
draw-bar mechanism
Slow operation
2 Outrigger Pressure of overflow valve is

Adjust
set too low
Ineffective bidirectional Disassemble and clean or

Vertical oil hydraulic lock replace
cylinder
automatically
extends out
Replace the relevant
or withdraws Internal leakage or external
sealing parts or replace the
in hoisting or leakage of oil cylinder
whole part
traveling status
7-88
SAC2200

Hydraulic motor damaged Repair or replace
Fault of reducer or brake of
Repair
swing mechanism
No swing Low pressure of chassis Disassemble and clean or

overflow valve adjust
Fault of swing control solenoid Disassemble and clean or

valve replace
Low pressure of chassis Disassemble and clean or

overflow valve adjust
Slow swing Severe leakage of hydraulic

Repair or replace
operation motor
Severe internal leakage of Check and replace the

valve or reversing unfulfilled sealing part
Swing
3 Adjust the balance valve
mechanism
Fault of swing balance valve and check the damping
inside the valve
Great shock of Check the damping inside

swing, unstable Fault of one-way throttle valve the valve and pressure of
accumulator
Fault of swing brake Inspect and repair

Swing mechanism worn out
Inspect and repair
severely
Free slide solenoid valve
Unable to
blocked, unable to reverse or Inspect, repair
practice free
fault of solenoid valve circuit
slide – lock in
changeover
Adjust the pressure of low-
of swing Low pressure of oil intake pipe
pressure oil source of main
mechanism of brake
valve
7-89
SAC2200
Pressure of multi-way overflow

valve on superstructure is set Adjust
too low
No luffing up
Severe internal leakage of oil
operation Inspect and repair
cylinder
Severe internal leakage of main

Inspect and repair
pump
Same as causes 1, 2, 3 of no
Inspect and repair
luffing up operation
Luffing No luffing down Valve core of balance valve

4 Clean or replace
mechanism operation blocked
Control oil circuit of balance

Clean
valve blocked
Fault of balance valve Clean and adjust

Boom shaking
when luffing High pressure of luffing down
Adjust
down secondary overflow
Automatic Internal leakage of oil cylinder Repair or replace

withdrawal of
Internal leakage of balance
telescoping Clean or replace
valve
cylinder
7-90
SAC2200
Low pressure of main valve

Disassemble, clean and
extending secondary overflow
adjust
valve
No extending Same as causes 1, 2, 3 of no

operation Inspect and adjust
Fault of telescoping control Check relevant circuit and

valve inspect the control valve
Low pressure of main valve

Disassemble, clean and
withdrawing secondary overflow
adjust
valve
Telescoping
5
mechanism
Valve core of balance valve
Repair or replace
No withdrawing blocked
operation
Same as causes 1, 2, 3 of no
Inspect and adjust
Fault of telescoping control Check relevant circuit and

valve inspect the control valve
Boom
Fault in balance valve, unable
withdraws Repair
to lock
naturally during
operation Internal leakage of oil cylinder Repair
7-91
SAC2200
Pressure of multi-way overflow

valve on superstructure is set Adjust
too low
Fault of hydraulic motor Inspect and repair
Severe internal leakage of main

No hook lifting/ Inspect and repair
Hoisting pump
6 lowering
mechanism
operation Control oil circuit of balance
Clean
valve blocked
Fault of moment limiter signal Inspect and repair
Fault of main valve brake oil

Inspect and repair
circuit
Fault of overflow valve Clean and adjust

Oil pump damaged Inspect and repair
System
pressure Fault of central swing joint Inspect and repair
cannot build up Fault of master control solenoid Inspect and repair the
valve circuit and solenoid valve
7 Others Severe internal leakage of main

High Inspect and repair
pump
temperature of
hydraulic oil,
Severe leakage of hoisting
slow operation Inspect and repair
motor
of actuating
mechanism
Fault of radiator Inspect and repair
7-92
SAC2200
7.5.3 Central lubricating system
The crane superstructure is equipped with

a central lubrication system. All lubricating
points (refer to the guide on the left), the roller
slewing ring, the bearing of the articulated
piece, the bearings of the luffing cylinder
and the hoisting winches are automatically
supplied with the correct grease quantity. If
the crane has not been moved for more than
3 months, it must be greased at 3-monthly
intervals using an external greasing pump until
grease exits from all greasing points. Then the
relevant crane movement must be repeated
several times and the greasing procedure
repeated.
Pump operation period: 6 cycles
Turn signals: 3 hours
CAUTION!
! Cleaning in cleaning plants or with a
steam cleaner is permitted!
7-93
SAC2200
7.5.3.1 Components of the system
- Grease container 1
- Grease fitting 2: Filling the central lubricating
pump
- Grease fitting 3: Filling the lube lines
- Pump outlet 4
- Pressure relief valve 5
- Pump element 6
- Push button 7
- Controls 8
- LED 9 (green): Function display
- Latched switch 10: Interval time (h)
- Latched switch 11: Cycles
- LED 12 (red): Fault display
7.5.3.2 Setting the lubrication and interval

times
The LED 9 on the engine protection housing

flashes in a 0.5 second cycle during the
lubrication process.
The lubrication and interval time is set at the
factory. The times may possibly be changed
by using the latched switch 10 and latched
switch 11.
- Turn on the engine ignition.
Result:
- When turning on the ignition, the LED 9 lights
up for approximately 2 seconds and displays
the operation readiness of the control unit 8.
7-94
SAC2200
7-95
SAC2200
- Start the engine.

- Trigger 2 or 3 greasing pulses using the
pushbutton 7.
Result:
- Lubricant escapes from the lubricating points.
- The lubricant escapes through the pressure
relief valve 5 with the system blocked, but
otherwise properly functioning electric pump.
7.5.3.4 Cycle control
The central lubrication system is progressively

monitored. This means that a proximity switch
converts the piston strokes of the central
lubricating system distributor into electrical
control signals and relays them to the control
unit. If the control signals are not present or
incomplete, the control light 340 displays a
malfunction or a failure by flashing.
1. Flashing code - cycle control

During operation:
- Ignition on, ready for operation:
Control light 340 illuminates for 1.5 s and goes
off.
- Active lubrication:
Control light 340 illuminates for 0.5 s and is off
for 0.5 s etc.
- Error monitoring time cycle input, lubrication

time larger monitoring time cycle input
The control light 340 lights up for 1 s and is 1
s off and so on.
- Error CPU, Error memory

The control light 340 lights up for 0.5 s and is
0.5 s off and so on.
7-96
SAC2200
7-97
SAC2200
7.5.3.5 Intervention in the automatic

lubrication (intermediate lubrication)
This allows intermediate lubrication processes

to be carried out after crane washing, or the
grease lines are re-filled with grease after a
repair.
- Push red button 7 on the engine protection
housing of the pump while the ignition is on.
7.5.3.6 Filling grease container
WARNING: risk of damage from

inadequate lubrication!
!There must be plenty of grease in the
grease container 1 at all times.
!Pay attention to cleanliness when filling
the grease container 1!
- Fill the grease container 1 with a grease

pump via the grease fitting 2 on the central
lubrication pump.
7.5.3.7 Venting the central lubrication

system
If the grease container 1 has been emptied

it may be necessary to bleed the central
lubricating system.
- Fill the grease container.
- Unscrew main line from pump outlet 4.
- Trigger the additional lubricating pulse until
a bubble-free lubricant escapes at the pump
outlet 4.
- Connect main line again.
- Release additional lubricating process.
7-98
SAC2200
7-99
SAC2200
7.5.3.8 Filling the grease lines
WARNING: risk of damage from

inadequate lubrication!
The lubricant lines must be filled
after making any repair to a greased
components. If this is not observed, the
component may run dry.
! Sufficient grease must be available in the
grease lines after every repair on greased
assembly units.
! Pay attention to cleanliness when filling
the grease lines!
- Fill using an external grease pump via the

lubricating nipple 3.
or
- Push red button 7 on the engine protection
housing of the pump while the ignition is on.
7-100
SAC2200
7.5.3.9 Central lubricating system,

troubleshooting
Problem Cause Remedy
Integrated electronic control Replace lower part of motor

Pump is not working defective, electrical line protection housing, replace
interrupted, pump defective electrical line, replace pump
Air cushion in delivery piston

Pump operates, but does not Bleed pump, fill reservoir, re-
has dropped below minimum fill
deliver place pump element
level, pump element defective
See “Pump not operating” , re-

Pump not operating, interval time
No grease collar on all lube duce interval time or increase
too high or cycle time too short,
points number of cycles, refer to“Grease
system blocked
emerges on pressure relief valve”
Supply lines to secondary distri-

No grease collar on several lube Replace lines, tighten or replace
butors broken or leaking, screw
points screw connections
connections leaking
No grease collar on one lube Associated lube line broken or Replace line, tighten or replace
point leaking, screw connection leaking screw connection
Check system / bearing points,no

Higher system pressure, lower
Pump speed reduced damage: try 1 or 2 intermediate
ambient temperature
greasing operations
System pressure too high, pro- Check system, replace distribu-

Grease emerges on pressure gressive distributor blocked, tor, repair blocked / seized
relief valve system blocked, defective valve bearing point, replace pressure
spring relief valve
Red LED lights up in 0.5 second

Error CPU / memory Consult SANY customer service
interval
Red LED and control light blink Defect in the monitoring period
Consult SANY customer service
in 1 second interval from cycle start
7-101
SAC2200
7.5.4 Slewing ring connection
7.5.4.1 Greasing the slewing ring
Perform lubrication with extreme care before

and after long operating intervals, particularly
before and after any winter break, in order to
provide the best possible corrosion protection.
If the crane has not been moved for more than
3 months, it must be greased at 3-monthly
intervals using an external greasing pump until
grease exits from all greasing points. Then the
relevant crane movement must be repeated
several times and the greasing procedure
repeated.
- Grease exterior of slewing ring
7.5.4.2 Tilting free play of roller slewing

ring
The wear of the roller slewing ring connection

is determined by measuring the “tilt play” with
the ring installed.
DANGER: danger of accident if tilt

play of roller slewing ring connection is too
large!
If the permissible tilt play of 2.0 mm is
exceeded, then safe crane operation is no
longer possible.
! Replace the roller slewing ring connection
if the tilt play is larger than 2.0 mm.
7-102
SAC2200
7-103
SAC2200
7.5.5 Winches

7.5.5.1 Overflow container
When the oil heats up in the hydraulic motor of

winch 2, the oil can enter the overflow container
via a non-return valve, but cannot flow back
into the hydraulic system after cooling. For
this reason the oil that has collected in the
overflow container must be disposed of at
regular intervals.
7.5.5.2 Hoist gear transmission

met:
- the hoist gear is inactive

- Inspect the centralized lubricating system 3
Max. marks on the oil dipstick.
- Check oil level.
2. Lubrication
Immediately refill the electric pump in
centralized lubricating system 3 with lubricating
oil once there is no enough, ensuring the oil
level must be between the Min. and Max.
marks on the oil dipstick.
7-104
SAC2200
Max
油尺标记线
Min
7-105
SAC2200
7.5.6 Slewing gear transmission

7.5.6.1 Changing the oil
Ensure that the following prerequisites are met:

- the transmission has warmed up
- Unscrew oil drain plug 2 with the sealing ring
and drain oil.
- Clean oil drain plug 2 and sealing surface on
the housing.
ring and tighten.
- Pour in oil as shown in the lubrication chart
at the oil filler opening until the oil level is
between the two notches on the oil dipstick.
- Close oil filler opening by screwing in the oil
dipstick.
- Check oil level as described above.
7.5.7 Electrical system - lighting

Maintain electrical system and lighting in
crane superstructure in accordance with the
maintenance information in chapter 7.4.
WARNING: loss of the settings if

the power supply has been interrupted!
! The winch and the slewing gear must be
re-calibrated after the power supply has
been interrupted from the central unit or
the power unit in the crane superstructure.
7-106
SAC2200
7-107
SAC2200
7.5.8 Telescopic boom
7.5.8.1 Greasing the telescopic boom

met:
- The crane is properly supported and level.
- The overload protection has been adjusted
as per the information in the load chart.
The inner sliding surfaces of the telescopic
sections (plastic sliding bearing plates) are
lubricated using lubricating nipples in the
bearing shoes.
These lubricating nipples can be accessed
from the outside via inspection openings at
both sides of the articulated piece and the
telescopic sections.
- Telescope out telescopic section 5 to 92 %
and pin in position.
- Unpin telescopic cylinder, retract into
telescopic section 4 and pin to telescopic
section 4.
- Telescope telescopic section 4 out until the
lubricating nipples of telescopic section 5
become visible in the inspection openings at
92 %.
- Lubricate telescopic section 5 at the
inspection openings.
- Retract telescopic section 4 to 0 % and pin
telescopic cylinder in position.
- Telescope out telescopic cylinder and pin to
telescopic section 5.
- Telescope in telescopic section 5 to 46 %
and pin in position.
7-108
SAC2200
46%
92%
100%
7-109
SAC2200
- Unpin telescopic cylinder and retract into

telescopic section 4.
- Pin telescopic cylinder with telescopic section
4.
- Telescope telescopic section 4 out until the
lubricating nipples of telescopic section 5
become visible in the inspection openings at
46 %.
- Lubricate telescopic section 5 at the
inspection openings.
- Telescope in telescopic sections 4 and 5 to 0
%.
- Lubricate telescopic sections 4, 3 and 2 in
the same way as telescopic section 5.
- Pin telescopic cylinder into telescopic section
1.
- Telescope out telescopic section 1 to 46 %,
pin and lubricate.
- Telescope out telescopic section 1 to 92 %,
pin and lubricate.
Use the special grease that is specified in the
lubrication chart to grease the inner and outer
sliding surfaces of the telescopic sections.
After spraying on the special grease, allow to
harden for 4 to 8 hours.
- Spray special grease onto the outer sliding
surfaces of the telescopic sections.
7-110
SAC2200
46%
92%
100%
7-111
SAC2200
7.6 Lubrication Chart and Filling

Quantity
7.6.1 Crane chassis
Lubrication chart legend:

1——Engine oil
2——Lubricating grease
3——Gear oil
4——ATF
5——Synthetic gear oil
6——Diesel fuel
Fill chart
The specified filling quantities are orientation
values. The markings on the measuring sticks,
inspection holes and inspection glasses are
decisive for filling.

! Do not mix synthetic oils with mineral
oils.
7-112
SAC2200
7-113
SAC2200
Name Medium Dosage

Driving motor Engine oil 40.0L
Driving motor with complete cooling circuit Coolant 120.0L
Fuel tank Diesel fuel 475.0L
Automatic gear box (oil change volume) Synthetic gear oil 21.0L
Oil cooler with lines Synthetic gear oil 4.5L
Transfer gearbox Gear oil 5.5L
Oil cooler with lines Gear oil 2.5L
1st axle, axle drive Gear oil 16L
1st axle, per wheel side Gear oil 1.4L
2nd axle, axle drive Gear oil 20.0L
2nd axle, per wheel side Gear oil 1.4L
3rd axle, non-driven Lubricating grease
4th axle, axle drive Gear oil 20.5L
4th axle, per wheel side Gear oil 1.4L
5th axle, axle drive Gear oil 16L
5th axle, per wheel side Gear oil 1.4L
Hydraulic fluid reservoir, support/axle

Hydraulic oil 185.0L
suspension/steering1 (oil change volume)
Contents lines Hydraulic oil 165.0L
7-114
SAC2200
1
Before checking the level of the hydraulic
fluid: retract all hydraulic cylinders and lower
the crane carrier by retracting the suspension
cylinders. The oil level must be in the middle
of the inspection glass.
7-115
SAC2200
Lubrication chart legend:

1——Engine oil
2——Lubricating grease
3——Gear oil
4——ATF
5——Synthetic gear oil
6——Diesel fuel
Fill chart
The specified filling quantities are orientation
values. The markings on the measuring sticks,
inspection holes and inspection glasses are
decisive for filling.

! Do not mix synthetic oils with mineral
oils.
Name Medium Dosage

Crane engine Engine oil 29L
Crane engine cooling system Coolant 80L
Fuel tank Diesel fuel 265.0L
Winch 1, winch 2 Synthetic gear oil 10.0L
Winch brake Synthetic gear oil 6L
Hydraulic fluid reservoir of the crane
ATF 830.0L
hydraulic tank1
Central lubricating system Special grease 2.0kg
Friction bearing of boom Special grease 3.0kg
1
Before checking the level of the hydraulic
fluid: retract all hydraulic cylinders and lower
the crane carrier by retracting the suspension
cylinders. The oil level must be in the middle
of the inspection glass.
7-116
SAC2200
4
52
2
2
1
5
2
6
4
7-117
SAC2200
7.7 Oil and Grease Filling
Oil and Grease Filling

Ambient temperature for travel and crane operation
Intended use
- 25℃ → + 50° - 40℃ → + 30℃
15W/40CH-4GB11121 SAE 10W-40

1 Diesel engine
Below -15℃ with preheating Below -20℃ with preheating
Driving axle with

2 differential, planetary gears ASX75W-90 SAE 75W-80
and flanged transfer case
ZF-Ecofluid M02E
Below -20℃ warm up in ATF IID
3 ZF gear box
accordance with operating Below -20℃ with preheating
instructions.
4 Chassis wheel hub,bearing 2# Lithium-based grease Mobil synthetic grease 220
Hydraulic oil for systems

of steering, support,
5 suspension and oil Shell anti-wearing VG46 Hydraulic oil Shell Tellus Arctic32
radiation
Superstructure hydraulic oil
Winch Industrial gear oilL-CKD220 Mobil synthetic gear oil 220

6
Slewing gear Do not mix with mineral oil! Do not mix with mineral oil!
7-118
SAC2200
Oil and Grease Filling

Ambient temperature for travel and crane operation
Intended use
- 25℃ → + 50° - 40℃ → + 30℃
Centralized lubricating
system
7 Boom locking Special grease EP2 Mobil synthetic grease 220
Slewing ring rolling
bearings
Synthetic sliding bearings

of the telescopic boom
Synthetic sliding bearings
8 Special grease EP2 Mobil synthetic grease 220
of the outriggers
Outrigger plates with
compensation
Radiator filling for diesel

9 G48BASF Mobil antifreeze fluid - 45℃
engines and heatings
7-119
SAC2200
E
G
PA
K
AN
BL
7-120
Crane Inspections
SAC2200
Crane Inspections
8 Crane Inspections
8.1 Periodic Inspection.................................................................................................... 8-2
8.2 Inspection of Crane Wire Ropes ............................................................................ 8-43
8.3 Inspection on Crane Rope....................................................................................... 8-51
8.4 Inspection .............................................................................................................. 8-56
8.5 Inspection on Air Brake System.............................................................................. 8-60
8-1
Crane Inspections
SAC2200
8. CRANE INSPECTIONS
8.1 Periodic Inspection
General:
This crane was tested at the manufacturer's
facilities prior to shipment in accordance with
the latest ISO, FEM and DIN Standards and
VGB9 (ZH1/21).
The safety level achieved during initial

commissioning may not be attainable during
operation.Examples of the root cause of
such deviations include; e.g., wear and
tear, corrosion, effects of forced operations,
changes in the environment and changes to
the mode of operation.
The operator is responsible for taking the

necessary steps to ensure that the maximum
level of safety is maintained. After it has been
licensed, the crane operator must have the
crane inspected by a competent inspector,
as necessary. The inspection frequency
varies with the application situations and the
operating conditions, but the minimum interval
is one year. See also: ISO 9927-1, EU89/655,
and VBG9.
The crane must be inspected by an authorized

inspector every four years after it has been
licensed. After the 12th year of operation,
the crane must be inspected annually by an
authorized inspector.
WARNING!
There is a risk of weakening the supporting
components when major changes or
repairs are made to the crane!
! In such cases, the operator must have the
crane inspected by a competent inspector
before putting it back into service.
8-2
Crane Inspections
SAC2200
Respective local regulations also apply.
A competent inspector is someone who

has a thorough understanding of cranes
based on technical training and experience
and is knowledgeable about the relevant
national occupational safety regulations,
OSH regulations, and accident prevention
regulations and generally accepted
engineering principles and is able to assess
that the crane is safe to operate.
An authorized inspector is someone who

is experienced in design, manufacture and
maintenance of crane. They carry out check
on equipments with special tools to ensure the
crane is safe for future operation.
Periodic inspection is principally a visual

inspection, wherein the inspector (either type)
appraises the condition of the crane and its
components.
The purpose of the inspections is to prevent

inspectors must be documented, corrected,
and subsequently reinspected.
8-3
Crane Inspections
SAC2200
A number of important examples of items that

are particularly important during the periodic
crane inspections are listed in the following:
We wish to advise that the two different types
of inspectors take sole responsibility for the
inspections that they carry out. This chapter
does not necessarily cover the entire scope of
the inspections.
A checklist for periodic inspections

recommended for SANY vehicles and crawler
cranes is included in the appendix to assist the
inspectors.
If the inspector has any questions they should

be directed to SANY Mobile Cranes’ technical
department.
DANGER!
! Adhere to the following inspection
guidelines and intervals.
8-4
Crane Inspections
SAC2200
8.1.1 Steel bearing structures

inspection
Steel bearing components such as telescopic

booms, turntables, chassis, outrigger
equipment (e.g., sliding beams or movable
stanchions) must be carefully inspected, at the
very least during the annual recommended
crane inspections. Even though weld joints
are not normally situated at maximum load
locations, it is nevertheless important that they
be inspected with particular care during the
periodic inspections.
Please refer to DIN 15018, Part 3, Item 1,

which shows the stress tolerances for high
tensile fine grained steel when used for steel
support structures. This determines the design
life of the steel support structures. The life is
not determined solely by the number of stress
cycles. It also depends on the loads applied
during operation (duty cycle).
SANY cranes are designed for assembly

operation. The design is based on the
following theoretical values (DIN 15018, Part
3):
Duty cycle: SO (light)
Stress cycles: 25 000
8-5
Crane Inspections
SAC2200
Therefore, the load-bearing steel components

and the weld joints require thorough appraisal
by the authorized inspector during the
specified periodic inspections.
If the crane was subjected to excessive

operating loads; e.g., due to an unusual
impact, the load-bearing components must be
inspected immediately.
If damage (e.g., cracks) are apparent in any

part of the steel structure, the total extent of
the damage must be determined by qualified
specialists using appropriate material test
methods; e.g., magnetic crack detection,
ultrasound or x-rays. The specialists should
then advise whether or not the damaged area
can be repaired by welding or other means.
The following diagrams are samples of the

load-bearing weld designs. The welds or steel
structural zones that require inspection may
be present more than once and in various
forms. The joints or zones must be inspected
all around at the locations identified by arrows.
CAUTION!
! The scope and extent of all inspections
remain the sole responsibility of the
inspectors. The following diagrams are
provided to assist the inspector. The
diagrams are only examples and are not
necessarily 100% complete!
8-6
Crane Inspections
SAC2200
8.1.1.1 Repair welds
If defects such as cracks or permanent

deformation are detected on load-bearing
steel components, they should be immediately
reported to SANY Customer Service
Department.
Furthermore, the defect must immediately

be appraised by an authorized inspector in
accordance with standard welding practice
rules. The inspector must immediately
ascertain whether or not the crane can
continue to be operated safely until the time of
the repair.
8-7
Crane Inspections
SAC2200
8-8
Crane Inspections
SAC2200
8-9
Crane Inspections
SAC2200
8-10
Crane Inspections
SAC2200
8-11
Crane Inspections
SAC2200
8-12
Crane Inspections
SAC2200
8-13
Crane Inspections
SAC2200
8.1.1.2 Inspection of the disk wheels (rims)
The wheels, and therefore the rims, are

important vehicle safety related components.
The rim construction is a welded steel
design and must be tested in accordance
with paragraph 1, “Testing load-bearing steel
structures”.
Furthermore, compliance is required with

Chapter 7.4, “Maintenance recommendations
for the crane chassis”, the paragraph “Safety
and maintenance recommendations for disk
wheels (rims)”.
In addition, disk rims must be inspected for

cracks on both the outside and the inside, at
the very least during the annually specified
crane inspection. We recommend using the
dye check method. Immediately replace any
rims that show evidence of cracks or crack
formation.
After driving a maximum of 40,000 km, the

operator shall routinely inspect the rims,
regardless of the actual duty cycle they were
exposed to.
In particular, the rims should be inspected

for cracks that are developing in the basic
material, as well as at the locations indicated
by the arrows.
8-14
Crane Inspections
SAC2200
8.1.2 Inspecting the hoist and luffing

winches
The hoist and luffing winches are designed

using integrated planetary gears. The
gearboxes are sized for long life and the
drive shafts and gear wheels are rated for
endurance.
Even though the hoist and luffing winches

are designed for long life, an external visual
inspection is not adequate, since their life can
be significantly affected by bad maintenance
(insufficient oil), using oil that does not meet
specification requirements, defective seals,
improper operation or overloading. The
inspection must therefore be carried out by a
competent inspector in accordance with the
following requirements.
8-15
Crane Inspections
SAC2200
8.1.2.1 Inspections
(1) Inspection intervals

1000 hours of operation, minimum once per
year.
(2) Inspecting oil level

Check oil level. For hoist and luffing winches,
we recommend that the oil be drained and the
amount compared to the specified oil quantity.
(3) Evaluating oil color

Assume that the oil has been overheated if it
is black and/or a burnt oil smell is detected.
Change the oil.
(4) Checking for foreign substances

This inspection should be carried out by
a qualified laboratory. The used oil shall
be dribbled onto the specified woven filter
medium. Visual inspection using a magnifying
glass may reveal coarse particles.
If particles are detected, all the oil's properties
must be examined by a qualified laboratory.
(5) Evaluation of foreign substances found in

the oil
A qualified laboratory shall be used to assess
the oil.
The maximum permissible quantity of foreign
material measured by weight is 0.15% of
total oil weight. Maximum permissible foreign
particle size from fine abrasion is 0.25
microns.
If above values are exceeded, the gearbox
must be dismantled to determine the root
cause of the excessive abrasion. Damaged
components shall be replaced and the gearbox
refilled with fresh oil.
WARNING!
! Repairs may only be carried out by
specialists with appropriate equipment
knowledge.
8-16
Crane Inspections
SAC2200
(6) Visual inspection

The gearboxes shall be checked for leakage,
since loss of oil, in addition to polluting the
environment, can lead to gearbox failure.
(7) Inspecting the gearbox brakes

Check the brakes each time the gearboxes
are inspected.
If the brakes cannot hold the specified test
load of 33% rope tension increase on a single
rope strand and fully spooled drum, they
shall be dismantled to determine the cause.
Whenever a planetary gearbox is dismantled
because of increased abrasion, the brakes
shall also be inspected.
CAUTION!
! Only qualified personnel with specialized
knowledge shall be used to assess
gearboxes and brakes.
(8) Documenting the completed inspection and

tests
The results of the annual inspections and
maintenance work, including the steps taken,
shall be documented by the competent or
authorized inspector, including attachments
from the inspection labs and qualified service
companies if any.
This documentation shall be filed in the crane
inspection log under the heading "Periodic
inspections".
8-17
Crane Inspections
SAC2200
8.1.2.2 Requirements for monitoring the

winches
(1) Design life

The designer of crane used a theoretical total
operating time when designing and sizing the
winches. This resulted in the design life of the
equipment.
Crane winches are classified according to DIN
technical report1, ISO 4301/1 or
FEM 9.511 as follows:
Power train group: M3(1Bm)
Duty cycle: Q1(L1)
Duty cycle factor Km: 0.125
Design life D: 3200h
CAUTION!
! The “design life” is not equal to the real
(true) life of a winch!
The actual life of the winch is affected by many

additional outside factors; for example:
- Overloads caused by unapproved use of the
crane
- Inadequate maintenance: oil is not changed
in a timely manner
- Improper operation:
• Extreme acceleration or braking of the load
• Load falling onto the cables
- Improper maintenance:
• Using the wrong type of oil
• Too much or too little oil
• Contamination during oil changes
- Assembly errors during repair and
maintenance
- Undetected leakage
- Incorrectly set safety devices
- Hidden damage from accidents
- Extreme environmental conditions:
• Extreme temperatures
• Corrosive atmosphere
• Dust and dirt
8-18
Crane Inspections
SAC2200
(2) Actual usage component of the design life

The crane operator is obligated to carry out
an inspection of the crane at least once a year
(ISO 9927-1 and VBG8).
At this time, the actual usage component of

the design life shall be calculated. If necessary,
the crane operator shall subcontract this work
to an authorized inspector.
The actual operating conditions (duty

cycle) and the winch operating hours at
each inspection interval are required to
determine the proportion of the design life
that has actually been used. The operator
is responsible for maintaining the crane
inspection log documentation.
Determining the operating conditions (duty

cycle)
The duty cycle of the crane is classified into
two groups. Refer to DIN technical report 1,
ISO 4301/1 or FEM 9.511.
One of the following duty cycles shall be
selected and recorded in the crane inspection
log for the respective inspection interval
based on knowledge of the actual operating
conditions.
CAUTION!
Duty cycle L1 (Q1) with duty cycle factor
Km = 0.125 is normally applied to mobile
cranes used for assembly operations.
8-19
Crane Inspections
SAC2200
Duty cycle Operating time Duty cycle

Definition Graph
class components factor
10% of the time at

Power train or
maximum load (dead
parts thereof
load and 1/1 working
Light are subjected to
load)
Q1 maximum loading in
40% of the time with Km=0.125
exceptional cases,
L1 dead load and 1/3
but normally only
working load
operate at very light
50% of the time only
loads.
with dead load
1/6 of the time at

maximum load (dead
Power train or
load)
parts thereof
1/6 of the time with dead
Medium are subjected to
Q2 maximum loading Km=0.25
load
L2 relatively often, but
1/6 of the time with dead
normally operate at
light load.
load
with dead load
Power train or
50% of the time at
parts thereof are
maximum load (dead
Heavy frequently subjected
Q3 to maximum loading Km=0.5
load)
L3 and normally
operate at medium
with dead load
load
90% of the time at

Power train or parts maximum load (dead
Very heavy
thereof are regularly load and 1/1 working
Q4 Km=1
subjected to near load)
L4
maximum load 10% of the time only
with dead load
8-20
Crane Inspections
SAC2200
Determining the effective operating hours Ti

The effective operating hours calculated
using the following method shall be entered
into crane inspection log for the respective
inspection interval.
There are four different scenarios:
1.) Elapsed time meter installed on every

winch
If an elapsed time meter is installed on every
winch, the effective operating hours Ti can be
read directly during each inspection.
2.) Elapsed time meter installed for the overall

crane drive
The winch proportion of the total
superstructure operating hours must be
estimated.
For mobile cranes used in assembly
operations, the operating time for the hoist
winches can be estimated at 20% of the total
operating hours of the superstructure.
3.) One elapsed time meter is used for both

the crane engine and the crane drive
The winch proportion of the total crane
operating hours must be estimated.
For mobile cranes used in assembly
operations, the operating time for the
superstructure can be estimated at 60% of the
total operating hours of the crane. If the hoist
winch proportion is estimated at 20% of the
superstructure operating hours (see previous
item), the resulting hours as a percent of the
total crane operating hours is: 12%.
4.) No elapsed time meter installed

In this case the operator must estimate and
document the actual operating hours of the
winch. The approximate percentages stated
above normally apply to main hoist winches.
For auxiliary hoist winches or luffing winches,
the proportion of the total operating hours can
be significantly less and should therefore be
estimated by the operator.
8-21
Crane Inspections
SAC2200
Determining the actual usage proportion of the

design life
For an inspection interval i (max. 1 year
according to ISO 9927-1 or VBG 8), the
actually used proportion Si of the design life is
given by the following formula:
Si=( Kmi/Km )*Ti
Km = duty cycle factor that was used to select
the winch ratings. This factor is given in the
operating manual.
Kmi = duty cycle factor for inspection interval
i according to Chapter “Determining the
operating conditions”
Ti = effective operating hours for inspection
interval i according to Chapter “Determining
the effective operating hours Ti ”
The actually used hours proportion is

subtracted from the remaining design life Di
after each inspection interval (see example).
If the remaining design life is not long enough
to cover the next projected operating period, a
general overhaul of the winch is required.
If the design life D has been reached (see
chapter on “Design life”), the winch may only be
operated after conducting a general overhaul.
A general overhaul of the winch is required not

later than 10 years after commissioning.
The general overhaul shall be arranged
by the operator and carried out by the
manufacturer or the manufacturer's authorized
representatives and must be documented in
the inspection log.
After the general overhaul, the manufacturer or
the manufacturer's authorized representative
will define a new design life D.
8-22
Crane Inspections
SAC2200
In such a case, the crane authorized inspector

must thoroughly inspect the winch. This
comprises at least:
Outer visual inspection (leakage, damage,
deformation, etc.)
Oil inspection, particularly looking for metal
residues
Load test at minimum and maximum cable
tension, at maximum speed in both cases. At
least one layer shall be spooled. Pay particular
attention to any unusual noises during the load
test.
The crane's authorized inspector must confirm
this inspection in the crane inspection log and
must make a statement regarding suitability
of the winch for continued operation. The next
inspection shall take place at the end of the
12th operating year, and thereafter annually.
(3) Example
According to the manufacturer's operating
manual, a mobile crane with a separate
elapsed time meter for the crane engine and
the crane drive is classified as follows:
Power train group: M3
Duty cycle: light L1, Km=0.125
Design life: D = 3200h
8-23
Crane Inspections
SAC2200
Actual usage proportion S of the design life

is calculated using the individual inspection
intervals as follows:
First inspection (year 1)

The crane was used for assembly work during
the elapsed year:
Duty cycle L1; i.e., Km1 = 0.125.
The superstructure elapsed time meter
indicates 800 hours. The winch operated
about 20% of the time; i.e., T1 = 160.
The actual usage proportion S of the design
life at the time of the first inspection is
therefore:
S1 = (0.125/0.125)×160h = 160h
D1 = 3200 – 160 = 3040 h
The above values shall be recorded in the
crane inspection log.
Second inspection (year 2)

The crane was used at a harbor for unloading
work:
2000 h – 800 h = 1200 h (800 h were used
during the first year of operation)
The winch operated about 40% of the time;
i.e., T2 = 480 h.
life at the time of the second inspection is
therefore:
S2 = (0.5/0.125) ×480 = 1920h
D2 = 3040 – 1920 = 1120h
8-24
Crane Inspections
SAC2200
Third inspection (year 3)

The crane was used for assembly work and
occasionally at a harbor for unloading work:
3000 h – 2000 h = 1000 h (2000 h were used
during the first two years of operation) The
winch operated about 30% of the time; i.e., T3
= 300 h.
life at the time of the third inspection is
therefore:
S3 = (0.25/0.125) ×300 = 600h
D3 = 1120 – 600 = 520h
The above values are kept in test charts.
8-25
Crane Inspections
SAC2200
8.1.3 Inspection of the load hooks
The load hooks must be inspected annually by

a competent inspector.

inspector must be documented, corrected, and
subsequently reinspected.
8-26
Crane Inspections
SAC2200
8.1.3.1 Inspection and monitoring

procedure
(1) Deformation
The hook should be inspected for distortion as
required and measure at the hook jaw at least
once a year. The jaw distortion should neither
exceed 10% of the original dimensions nor
exceed (y1) and (y2).
DANGER!
Hook jaw distortion may not exceed 10% of
the original dimensions (y) or (y1) and (y2).
! Do not use a load hook that exhibits
greater distortion.
! Advise the SANY Customer Service
Department.
CAUTION!
The original value “y”, “y1” or “y2” are
given on the hook itself. Carry out measure
between the punch marks as shown in
graph.
(2) Corrosion
Unscrew the nut from the hook shank so that
the threads can be inspected for corrosion and
wear and tear.
DANGER!
Risk of accidents caused by thread
corrosion / wear and tear!
! Stop using the load hook.
! Advise the SANY Customer Service
Department.
8-27
Crane Inspections
SAC2200
8.1.4 Inspection of the rope feed

mechanics in the telescopic boom
8.1.4.1 Inspection of the pre-tension on the

luffing ropes
See Chapter 7.5, “Crane superstructure

maintenance notes”
8.1.4.2 The rope discard time
The rope discard time is as per DIN 15020 or

ISO 4309, see Chapter 8.4, “Inspection of the
crane ropes”
8.1.5 Testing the operation of the inner

and outer interlocking systems of the
telescopic boom
For cranes with a pneumatic interlocking

system: Bolt pattern, wear and tear and safety
interlocking, see Chapter 8.11.
8-28
Crane Inspections
SAC2200
8.1.6 Testing the interlocking system or

limit switches on the jib stops and the
boom A frames
See Chapter 8.12.
8.1.7 Testing the nitrogen storage tank

for specified gas pressure, particularly
for job stops and suspension storage
tanks (comply with specifications)
See Chapters 7.4, 7.5, 8.13, 8.14.
8.1.8 Inspecting the cable pulleys
8.1.8.1 Inspect the entire cable pulley

assemblies for damage and cracks once a
year
If cable pulleys are subjected to any impacts

(e .g ., w i th b u i l d i n gs) or a re o th e r w i s e
overloaded, they must be immediately visually
inspected for damage or cracks.
DANGER!
Risk of accident when damaged or
cracked!
! Replace cable pulley as soon as possible.
8.1.8.2 Also check for wear on the rope

groove
Replace the pulley if the bottom of the rope

groove has worn down more than 1/4 of the
rope diameter.
8-29
Crane Inspections
SAC2200
8.1.9 Testing overload protection

operation
8.1.9.1 Position the longest booms at

minimum and maximum radius: Check the
load indicator, using the hook block as a
test load

than 10% off the true load value at these two
extreme positions.
8.1.9.2 Measure the indicated radius for the

longest boom at its minimum radius and at
a boom angle of 45°

than 10% off the measured projection.
8.1.10 Testing the roller slewing ring
8.1.10.1 Tilting free play measurement
See Chapter 7.5.
8-30
Crane Inspections
SAC2200
8.1.11 Inspecting the mounting of the

load bearing equipment
Check that the mounting bolts for the roller

slewing ring, winches, slewing gears and hitch
are properly seated.
8.1.11.1 Slewing ring connection mounting

bolts are pre-stressed at the factory, so
that no loosening of the bolted connections
will occur during normal crane operation
However, the bolted connection may become

overloaded and the bolts may be permanently
stretched if the crane is overloaded or if a
fixed load is pulled free.
It is therefore important to check these bolts
for proper seating during the annual crane
inspection or after an overload has occurred.
Completely remove loose bolts, plus the two
adjacent ones, and immediately check for
damage.
Inspect the bolts, particularly for cracks or
permanent distortion.
Replace any bolts that have stretched more
than 0.2% (referred to their original length) or
that have cracks or other damage. If any bolts
have stretched or are otherwise damaged,
also replace the two adjacent bolts.
8-31
Crane Inspections
SAC2200
8.1.12 Inspecting the oil and fuel

reservoirs
Oil and fuel reservoirs shall be inspected at

least once a year and checked all around for
leakage during the periodic inspections every
four years.
Repairs shall only be carried out by trained
and knowledgeable specialists.
Improper repairs; e.g., welding, hard or soft
soldering is not permitted, particularly if the
Customer Service Department at SANY has
not been consulted!
8.1.13 Inspection of the auxiliary

reeving winch, towing winch and spare
wheel winch
Determine the design life of the auxiliary

reeving, towing and spare wheel winches from
their respective original manufacturer.
Inspection recommendations for periodic

i n spections of SANY mobile crane s i n
accordance with section 26 (1) or (2) UV
“Cranes” (VBG9)
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Company: Inspector: Date:

Crane manufacturer: SANY Crane type: S/N:
Year of manufacture: Serial number:
Inspection category 1: Crane document

Crane inspection log
Operating and installation instructions
Crane register
Load chart manual
Operation planner
Inspection category 2: Signs / labeling
Factory nameplate
Loading information
Operating specifications label
Warning labels and instructions
Other safety labels
Inspection category 3: Traveling devices
Frame 2)
Bearing 2)
Axles
Wheels
Tires
Bearings
Gearboxes
Drive shaft
Leaf springs / springs
Shock absorbers
Steering
Brakes
Hydraulic suspension
A: present / complete B: condition / maintenance C: function

D: repair / replace E: reinspection required
satisfactory = × unsatisfactory = - not required = 0
Inspection recommendations for periodic inspections of SANY mobile cranes in accordance with
section 26 (1) or (2) UV “Cranes” (VBG9)
8-33
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Inspection category 4: Chassis 1)

Enclosures
Treads
Counterweight holders
Suspension equipment
Ladders
Bottle holder 2)
Boom storage 2)
Inspection category 5: Carriage cab 1)
Doors
Windows / glazing
Windshield wipers
Mirror
Seat
Heater
Ventilation
Soundproofing
Trip recorder
First aid kit
Spare lamps
Alarming triangle
Safety vest

8-34
Crane Inspections
SAC2200

Inspection category 6: Carriage engine 1)

Combustion engine
Exhaust system
Fuel tank
Filter
Soundproofing
Engine mounting
Oil levels
Fuel lines
Inspection category 7: Carriage hydraulics 1)
Oil reservoirs
Filters
Pumps
Motors
Valves
Piping
Hoses
Cylinders
Pressure relief valves
Inspection category 8: Carriage compressed air system 1)
Compressor
Filters
Air tanks
Valves
Piping
Hoses
Cylinders

8-35
Crane Inspections
SAC2200

Inspection category 9: Carriage electrical system 1)

Motors
Generators
Battery
Switches
Wiring
Fuses
Resistors
Lighting
Brake lights
Indicator lights
Tail lights
Working lights
Signaling systems
Monitoring lights
Battery switch
Limit switches: Gearbox, steering, engine
A: present / complete B: ondition / maintenance C: function

8-36
Crane Inspections
SAC2200

Inspection category 10: Carriage control systems 1)

Engine control
Transmission
Couplings
Circuits
Brakes
Steering
Outrigger controls
Axle suspension
Crane leveling
Rear axle steering
Inspection category 11: Superstructure
Frame
Enclosures
Treads
Bearings
Counterweights
Jib stops
Slewing ring connection: Tilting free play
Slewing ring connection: Mounting bolts
Slewing ring connection: Gearing
Slewing gear: Mounting bolts
Slewing gear: Gearing

8-37
Crane Inspections
SAC2200

Inspection category 12: Superstructure crane operator's cab

Doors
Windows / glazing
Windshield wipers
Mirror
Seat
Heater
Ventilation
Soundproofing
Operating and control joysticks
Gear shifting
Safety: Crushing / shear locations
Inspection category 13: Superstructure hand-hold and protection systems
Grab handles and treads
Enclosures
Covers
Hatches
Inspection category 14: Superstructure engine
Combustion engine
Exhaust system
Fuel tank
Filters
Soundproofing
Engine mounting
Fuel lines

8-38
Crane Inspections
SAC2200

Inspection category 15: Superstructure hydraulic system

Oil reservoirs
Filters
Pumps
Motors
Valves
Piping
Hoses
Cylinders
Pressure relief valves
Counter-balance valve
Brake controls: Hoist gear
Brake controls: Slewing gear
Inspection category 16: Superstructure electrical system
Motors
Generators
Batteries
Switches
Wiring
Fuses
Resistors
Lighting

8-39
Crane Inspections
SAC2200

Inspection category 17: Superstructure control equipment

Engine control
Gearboxes
Flexible couplings
Circuits
Inspection category 18: Superstructure rope drives
Winch I 3)
Winch II 3)
Winch III 3)
Winch IV 3)
Rope pulleys
Rope end connection
Rope for Winch I
Rope for Winch II
Rope for Winch III
Rope for Winch IV
Stay ropes
Inspection category 19: Superstructure hook
Pulleys
Pulley guard
Axle support
Load hook
Load hook mounting
Hook safety device

8-40
Crane Inspections
SAC2200

Inspection category 20: Superstructure safety and switching systems

Hoist emergency limit switch I
Hoist emergency limit switch II
Lowering emergency limit switch I
Lowering emergency limit switch II
Boom emergency limit switch I
Boom emergency limit switch II
Luffing jib: Boom limit switch I
Luffing jib: Boom limit switch II
Load torque limiter
Angle indicator: Boom
Angle indicator: Luffing jib
Angle indicator: Slewing gear
Safety devices: Controls
Operating range limiter
Pressure sensor
Speed sensor
Wind sensor
Sliding beam monitoring
Slope indicator
Length indicator: Projection, boom length
Emergency stop
Emergency stop

Inspection recommendations for periodic inspections of SANY mobile cranes in accordance with section 26
(1) or (2) UV “Cranes” (VBG9)
8-41
Crane Inspections
SAC2200

Crane manufacturer: SANY Crane type: S/N：
Inspection category 21: Boom

Weld joints
Rope pulleys
Luffing cylinders
Telescoping cylinders
Boom extension ropes
Boom retraction ropes
Boom bearings
Boom assembly bolts
Guy posts
Braking cylinders


Comments:
1) Inspection of the crane carrier vehicle roadworthiness is also fulfilled if it has already been
certified by the road traffic department certification authority. For mobile cranes that are not
certified for use on public roads, a competent

or authorized inspector must conduct the
required tests to validate the vehicle's
roadworthiness (see also UVV (vehicles)”
(VBG112)).
2) These inspections must be carried out by a
competent inspector even if it has passed the
road traffic department test and is certified.
3) Inspection of the winches with respect to
the actually used proportion of their design life.
8-42
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SAC2200
8.2 Inspection of Crane Wire

Ropes
DANGER!
Danger of fatal injury due to defective
crane ropes!
! Do observe the following criteria.
The rope should be considered to be a

wearing part of a crane that must be replaced
if checking shows that its strength has reduced
to such an extent that continued use thereof
may be dangerous. Regular checking of the
rope is required in order to safely carry loads
using correctly deployed equipment, meaning
that the rope must be stop being used at an
appropriate point in time.
The take-down criteria with regard to rope
breaks, wear, corrosion and deformation
can be applie immediately under all usage
conditions. The different factors are dealt
with in ISO 4309, which is intended to serve
as a guideline to competent experts who are
involved in maintaining and testing cranes.
The criteria that are dealt with are intended
to provide appropriate safety for transporting
loads with cranes until the rope is taken down.
Wire rope
Condition before installing
The rope is usually replaced with a rope that
is of the same type as the original. If the spare
part is of another type, the user must ensure
that the rope characteristics are at least as
good as those of the rope that was taken
down.
Before installing a new wire rope the grooves
of the rope drums and pulleys must be
checked in order to ensure that they can
accommodate the spare part correctly (see
section entitled “Checking”).
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Crane Inspections
SAC2200
Installing
When the rope is removed from the spool
or unwound from a reel, it must be ensured
that the rope is not twisted, otherwise loops,
reverse bends or kinks may occur.
If the rope is reeled over any part of the
system when it is not under strain, these areas
must be protected accordingly.
Before starting to use the rope on the system
the user must ensure that all components
that are functionally associated with the rope
have been set up in such a way that they will
operate correctly. The crane should be used
for lifting at approximately 10% of the normal
load in order to stabilise the rope.
Maintenance
The ropes are maintained depending on the
type of crane, the deployment thereof, the
environment and the type of rope that is used.
Unless other instructions from the crane or
rope manufacturer apply, wherever possible
the rope should be cleaned and lubricated with
grease or oil, particularly in areas in which the
rope is subjected to bending when it runs over
pulleys.
The lubricant that is used must be suitable for
steel ropes.
Lack of maintenance will reduce the service
life of the rope, particularly if the crane is used
in a corrosive environment and if re-lubricating
is not possible because of the nature of the
respective deployment of the crane.
8-44
Crane Inspections
SAC2200
Checking
Frequency
Daily checking
If possible, all visible parts of the ropes must
be checked for general wear and deformation
on every working day. Special attention must
be made to the rope end connections. Any
suspected changes in the condition of the rope
must be reported and the rope checked by a
trained expert in accordance with the section
entitled “Points to check on the rope”.
In the event that the lower rope lays on the
drum are used infrequently or not at all,
periodically unwind and rewind the entire drum
at the appropriate tension. A rope is most cost-
effective when the entire length is used. An
appropriate rope length should therefore be
used when operating the crane over longer
periods.
Special checking as described in section

“Points to check on the rope”
The rope must be checked after any events
that may have led to damage to the rope and /
or the rope ends and whenever the rope starts
to be used again after being taken down and
then re-installed.
Checking the spooling behavior of the rope on

the cable drum
To avoid spooling errors and connected rope
damage, it is necessary to check the spooling
behavior daily. As a precaution, the rope
should be spooled off and on again regularly.
Possible spooling errors:

- Cutting into the lower rope layers
- Loop formation in the lower rope layers
8-45
Crane Inspections
SAC2200
8.2.1 Take-down time for broken rope
8.2.1.1 Anti-twist rope
Hoisting rope I, II
Number of broken wires

Rope Number of carrying requiring rope removal, over a
Crane Lay direction
diameter rope length of
6 × rope φ 30 × rope φ
SAC2200 23 Lang lay 126 3 6
8-46
Crane Inspections
SAC2200
8.2.2 Inspection
The entire length of rope must be regularly

checked especially right after installation.
Besides, detailed inspection should be carried
out in the condition that when rope is under
special stress, invisible damage exists or
damage appears just a short time ago.
The safe use of the rope is assessed in

accordance with the following criteria;
- Number and type of wire breaks (refer to
diagram)
- Broken wire nests
- Rope diameter reduction
- Wear, corrosion and deformation to rope
- Damage causes by the effects of heat
- Total storage time
Apart form the above items, the connection
between the suspended rope and the rope
end should be check periodically, some
individual rope drive components, rope roller
and pulley are supposed to rotate flexibly on
the corresponding installation position and no
visible impression is allowed on the movement
track of rope.
CAUTION!
The channel radius for roller and pulley
should be 0.595×rope rated diameter.
Due attention should be paid on any
change in rope condition.
DANGER!
The serious damage to rope appearing
when rope is reeved with hook is caused
by added rotation stress to non-twisting
ropes, producing special stress and
tension to hoisting rope in heavy load
condition.
NOTICE: Refer to “torque for non-twisting

rope and the cancellation thereof” for
detailed information.
8-47
Crane Inspections
SAC2200
8.2.3 Take-down time
DANGER!
Rope should be taken down if one of the
following problems is found!
- One broken strand

- Wire breaks within a limited range
- The number of broken wire reaches a
specified quantity
- Corkscrew deformation reaches 1/3 of rope
diameter (figure 1)
- Vault (figure 2)
- Hair-shaped wire and wire strand protruding
from rope (figure 3)
- Diameter reduced by 15% or 10% of nominal
- Corrosion and / or wear appears (figure 4)
- Rope appears loose (figure 4)
- Retraction occurs (figure 5)
- Reeling and Compression occurs (figure 6 +
8)
- Deformation occurs (figure 7)
Find out and remedy the faults before

replacing the rope once special damage is
found.
Take the damage and wear on crane as
important evidence.
WARNING!
Stop crane operation and turn to
authorized person once any doubt exists in
safe operation of the crane.
8-48
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8-49
Crane Inspections
SAC2200
8-50
Crane Inspections
SAC2200
8.3 Inspection on Crane Rope
8.3.1 Rope storage
DANGER!
Replace the original rope with a one of the
same type and diameter.
It is a must to gain crane manufacturer’s
permission if a rope of other type is to be
applied.
Clean, dry rope storage facilities must be

provided in order to prevent damage to ropes
that are not in use; it must also be ensured that
the ropes can be clearly and unambiguously
assigned to their checking logs.
The rope can only operate normally with under

reel-free and damage-free conditions.
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Crane Inspections
SAC2200
8.3.1.1 Reeving
The rope can be directly reeved on drum shaft

and rolled objects (figure 1).
Do not reeve the rope sideways for stress
from such operation may damage the rope.
The best way to reeve the rope is to reeve the
rope onto the strain shaft from a hoisted drum
shaft (figure 2).
Reeve the rope in accordance with the
bending direction thereof, ensuring the rope is
well reeved onto the strain shaft.
WARNING!
Do not tow rope on ground!
Do connect the rope with articulated head to

avoid the rotation of non-twisting rope caused
by external force.
If the rope is reeved into many layers, 1% -2%
of the rope minimum breaking load should be
taken as preloaded force for the lowest layer
of the rope. Such preloaded force can be
obtained through drum brake.
As for composite pulley, the hoisting rope
should be reeved in the same direction as
the way reeved in drum. The rope should be
placed on ground and protected from torsion
when load hook is being reeved.
Test the rope with some light load and retract
it by repeated hoisting operations, making the
rope to switch over between the loaded hook
and unloaded one after the rope has been well
stored. Such operation can adapt the rope to
the bending direction and radius of the pulley
and drum.
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Crane Inspections
SAC2200
8.3.2 Maintenance
The safe operation of the crane can be

ensured and the service life of the rope can
be substantially increased through periodic
maintenance on the rope.
Lubricate the rope especially the corners
on the drum and pulley within some certain
intervals.
The curvature of a well lubricated rope is 4
times than that of the unlubricated rope.
The lubricate grease should be consistent with
the original one.
CAUTION!
The grease recommended by crane
manufacturer should be applied on the
rope, refer to lubrication chart for detailed
information.
Frequently clear the rope with brush.

The wire below the drum is loosened and
restrained with preloaded force if it is of
rare use or even no use. It is suggested to
select the rope length in accordance with the
operation if the crane is to be involved in a
long period’s operation.
If some certain section of the rope is much
more used than other sections, the rope
should be turned over after a period of time
for next use. That is to say, connect the former
head to the drum, taking the new section
under more use while idling the former used
section. Such operation can substantially
increase the service life of the rope.
If wears appear obvious on the rope reeved
on the Lebus drum, the service life of the rope
can be increased by shortening 1/3 of the rope
length.
8-53
Crane Inspections
SAC2200
8.3.2.1 Increase and cancellation of non-

twisting rope torque
Adjust not only the changed torque occurring

during the storage of the new rope but also the
one caused by the recovery of stretching and
configuration after a period’s use.
The torque should be adjusted when pulley
group is under multi-magnification operation,
when load is being lowered and / or external
strand of the rope appears loose, and arch
occurs in serious condition.
It is recommended to install an anti-twist
device on the fixed position of hoisting rope
when crane has operates with a single
magnification for a long period.
WARNING!
The rope may be damaged if the above
item is not complied with.
8-54
Crane Inspections
SAC2200
8-55
Crane Inspections
SAC2200
8.4 Inspection
8.4.1 Adjust rope torque
1. Lower the load hook

Lower the load hooks as possible, adjusting
the rope between head pulley and hook pulley
at the longest length. (torsion, point 4)
2. Determine the rotation direction

Determine the pulley is rotated towards which
direction.
The rotation direction is indicated with real line
arrow in diagram.
Rotate the pulley along the direction of broken
arrow to check for determination on rotation
direction appears difficult especially when
hoisting rope is stretched long. The reeled
rope can be released at last.
3. Release the rope at the fixed position

Release the rope on the fixed points of
hook pulley once the rotation direction is
determined.
CAUTION!
Reeling the hook pulley in odd or even
manner makes it convenient in the torque
adjustment. Under such condition, the
fixed points can easily touch the load hook
and be released.
8-56
Crane Inspections
SAC2200
4. Turn the rope end from the position of 180°

to 360°, adjust the rotation of pulley group.
Mark the rotation adjustment with real line
arrow at rope end.
CAUTION!
It is decisive for the crane operator to hold
the rope in front of him to select correct
reference point.
Reeve in the right-rotating rope (Z) in figure 1

and the left-rotating rope (S) in figure 4. Reeve
out the right-rotating rope (Z) in figure 2 and
the left-rotating rope (S) in figure 3.
The principle for torque adjustment goes like:
the looped rope can be released by rotating
the rope end along the direction apposite the
rotation direction.
WARNING!
The rotating rope should be long as
possible. The rotation of rope can be
realized on the full length of rope through
the unloaded hoisting operation.
The rope configuration may be seriously
damaged if some certain section of rope is
rotated with external force.
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Crane Inspections
SAC2200
5. Connect the rope on the fixed points

It is a must to connect the rope end to the
fixed points and secure after the rope has
been rotated.
6. Carefully hoist the load hook, hoist with no

load, repeat the procedure if necessary.
Since the rope which can not be much
stretched is relatively safe for operation
(normally, the torque will not exceed the pulley
head), carry out hoisting operation with no
load.
Reconnect the rope end to the fixed points and
repeat the unloaded hoisting operation after
the torque adjustment is carried out on rope
end. Such operation can make the adjustment
effect go to the entire rope through the head
pulley.
CAUTION!
When rope is substantially stretched (the
lower pulley has been multi rotated and / or
loose external strands appear on a longer
section of rope or some points), repeat
such procedure in accordance with rope
length if necessary.
8-58
Crane Inspections
SAC2200
8-59
Crane Inspections
SAC2200
8.5 Inspection on Air Brake

System
DANGER!
Danger of fatal injury due to erroneous
maintenance or repair on the wheel brake!
Incorrect maintenance or repair of the
wheel brake can cause serious traffic
accidents and subsequent death.
! All wheel brake maintenance and repair
work may only be carried out by authorized
and trained expert personnel!
! Use only original SANY spare parts!
! After completion of work on the brake
system, carry out a brake function test on
all wheels! If possible, we recommend a
function test on the brake test bench.
The air disk brake systems on mobile
cranes must be inspected annually.
In Germany, the main inspection and safety
tests must be conducted in accordance
with 29STVZO.
The corresponding national regulations
apply for other countries.
8-60
Crane Inspections
SAC2200
8.5.1 Visual inspection
Check that the following requirements are met:

1.1 Pipe and hose lines are not damaged, not
corroded and are properly routed
1.2 Devices are properly installed and
fastened
1.3 The air pressure tank is not damaged and
no external corrosion is visible
The tank is labeled as specified.
No welding nor heat treatments be conducted
on the tank walls.
1.4 Water has been removed from the air
pressure tank
1.5 Dust seals are not damaged
1.6 Articulated head is fastened tightly with no
damage
1.7 Coupling devices are weld-free with no
deformation and damage
1.8 The wheel brakes are properly adjusted
(vent clearance, brake cylinder stroke, lining
thickness)
DANGER!
Danger of accidents due to overheating
wheel brake!
WARNING!
Welding and heating operation on the air
tank is extremely prohibited.
8.5.2 Function and performance test
8.5.2.1 Function test
1. Pressure regulator, air cylinder

Check turn on pressure, shut off pressure and
delivery rate
2. Pressurized air system: Check for leaks and

supply pressure
3. Multi-circuit safety valve, overflow valves

and warning device: Check function
8-61
Crane Inspections
SAC2200
8.5.2.2 Performance test
Check the function of the wheel brake:

– Press down the brake pedal: Both brake
shoes contact the brake disk
– Release the brake pedal: Brake shoes
immediately return to their starting position
Check effectiveness of wheel brake:
1.) Measure delay
2.) Measure brake path
3.) Determine brake performance on brake
test bench
1. Determine delay with a decelerometer

At an applied pressure of 6.5 bar, the
measured average delay dm should be larger
than 4.5m/s2
2. Measure brake path

At an applied pressure of 6.5 bar, the brake
path s should be smaller than the value given
in the chart.
Test speed V [km/h] Brake path S [m]

20 6.5
30 12.5
40 19.8
50 29.0
8-62
Crane Inspections
SAC2200
3. Measuring the braking performance on the

brake test bench
When the brake forces are measured on
the vehicle axles, determine the brake
performance as follows:
z = F1×i1+F2×i2…Fn×in /Gz ×100 [%]
Gz = allowable total vehicle weight [N]
z = brake performance [%]
F1 = brake force of the first axle, which was
determined at pressure P1 [N]
F2 = brake force of the second axle, which
was determined at pressure P2 [N]
Fn = brake force of last axle, which was
determined at pressure Pn [N]
i1 = pN1-0.4 / p1-0.4
in = pNn-0.4 / pn-0.4
pN1…n = max. brake pressure of corresponding
axle [bar]
p 1…n = brake pressure, which is actually
applied into the wheel cylinder at the
corresponding axle [bar], during the brake test
8.5.2.3 Internal inspection of the wheel

brake
CAUTION!
Check the brake pads and the brake disks
in regular intervals, depending on the
vehicle use, during maintenance interval
as well as within the framework of lawful
regulations.
! Check the condition of the brake pads
every 3 months.
! Check the condition of the brake disks
every 12 months.
! At least every 24 months, replace the
retaining springs as well as seal rings,
caps and convoluted rubber gaiters.
8-63
Crane Inspections
SAC2200
Checking the brake pads!
DANGER!
Worn brake pads or brake disks can lead
to a reduction of the brake force or failure
of the wheel brake. This can result in
accidents with fatal injuries.
! Observe the wear limits of the brake pads
and the brake disks!
! Replace worn brake pads or brake disks!
! Replace the wheel brake if significantly
damaged or if the castings are worn (for
example, if they show cracks)!
! Change burnt, slick or oily brake pads as
quickly as possible!
! Always replace all the brake pads on each
axle!
The brake pads are electrically monitored
and can also be optically checked on the
brake pads.
Checking the brake pads electrically

If the warning light 204 on the display unit
lights up, it is a sign that at least one brake
pad on the crane is worn and has reached the
wear limit.
To find the worn brake pad, see chapter 20.20.
DANGER!
Danger of fatal injury in case of worn brake
pads!
As soon as the warning light 204 lights
up, the worn brake pads must be localized
and replaced. If this is not done, the
wheel brake can fail, which can cause
fatal accidents, or the brake disks can be
damaged.
! Replace worn brake pads!
! Perform visual check on brake pads!
8-64
Crane Inspections
SAC2200
DANGER!
Danger of fatal injury in case of worn brake
pads!
Replace brake pads no later than when the
weakest point measures 2 mm of brake
pad thickness over the brake pad carrier
plate. The remaining pad thickness may
not fall below 2 mm. If this is not done,
the wheel brake can fail, which can cause
fatal accidents, or the brake disks can be
damaged.
! Replace worn brake pads!
! If the remaining pad thickness A is less
than 2 mm it is imperative that the brake
pads are replaced.
Checking the brake disks

Checking brake disk wear
DANGER!
1. If the brake disk reaches the wear limit
of D = 5.5 mm, then it must be changed
immediately!
! Replace worn brake pads or brake disks
with Jurid 546 and Bremsker 16275!
For these asbestos-free brake pads are not
solid enough, secure and bind the brake
pads.
DANGER!
! We recommend to change all the brake
disks on each axle.
8-65
Crane Inspections
SAC2200
2. Brake hub should be turned over for reuse
CAUTION!
The turning over value that does not
exceed 0.75% of the specified diameter is
permitted!
For example:
Specified diameter: 500.00mm
Permitted turning size: 3.75mm
Permitted inner diameter: 503.75mm
DANGER!
Replace the brake hub once the inner
diameter exceeds 503.75, otherwise, fatal
injury may occur!
3. A maintenance-free automatic adjustment

device is equipped to adjust the wear on brake
pads and align the brake.
DANGER!
Replace the automatic adjustment device
and take the use of the one inside the
repair pack.
4. Replace the compression spring, stretch

spring, seal ring, cap and dust-proof cover
every 2 years.
DANGER!
All maintenance and repair work on brake
system should be done by authorized
personnel.
5. Carry out visual and performance inspection

after the assembly of brake system.
8-66
General Notes
SAC2200
General Notes
9. General Notes
9.1 Application Regulation for the Overload Protection Devices of Crane with Telescopic
Boom............................................................................................................................... 9-2
9-1
General Notes
SAC2200
9. GENERAL NOTES
9.1 Application Regulation for the

Overload Protection Devices of
Crane with Telescopic Boom
9.1.1 Inspection procedures
The engine room must be inspected prior to

every operation; i.e., daily Check that all oil
and fuel lines are leak-free and dry. The fuel
filter, oil filter and injection pumps shall also be
inspected for leakage. Every day, check that
the hydraulic equipment, fan drive hydraulic
motors and their supply lines are properly
sealed and do not leak.
Inspect the exhaust system, particularly the

exhaust flanges and exhaust flap retention
straps, and make sure that they seal and move
properly. The return springs that open the
exhaust flaps must function properly, because
seized (therefore closed) exhaust flaps during
engine operation will result in considerable
overheating.
Inspect electrical wiring and ensure that there

is sufficient clearance to hot exhaust system
piping. Ensure that it is properly fastened and
that there is no insulation damage.
9-2
General Notes
SAC2200
To reduce noise emission, noise reducing

mats are installed in the motor and gearbox
rooms for certain types of cranes. These are
very flame-resistant and some, depending on
application, are fireproof.
Inspect the soundproofing mats for soiling

from solutions and large quantities of oil or
fuel, as well as other damage.
Immediately remove any soundproofing mats

that are excessively damaged or soiled and
replace them with new ones.
Observe the care instructions in Chapter 7.1

regarding sound damping when cleaning the
engine or gearbox room.
9-3
General Notes
SAC2200
9.1.2 Exercise care when conducting

maintenance and repairs
Ta k e p a r t i c u l a r p r e c a u t i o n s r e g a r d i n g
cleanliness when replacing diesel and oil
filters. Any diesel fuel or oil that has leaked
shall be completely cleaned up. Perform a test
run on the systems to ensure that there are no
leaks.
The diesel engine V-room must be inspected

regularly, and any oil or diesel fuel must be
cleaned up, particularly after repairs and
servicing. Any fuel that has collected in V-room
can spread throughout the engine room while
the crane is traveling on the road and can
ignite if it comes into contact with hot surfaces.
We again stress that all electrical wiring must
be installed according to code and be properly
fastened. Examine all wiring insulation or
casings for signs of chafing or brittleness as a
result of operational activities. Any wiring that
is not in perfect condition shall be immediately
and professionally replaced. Note that over
the years, fuel and oil lines can become brittle
or porous as they age. Any hoses that appear
to be excessively porous should be replaced
immediately. (Also refer to specifications
regarding the design life of hoses).
It is especially important to note that under no

circumstances may piping and hoses installed
in the engine room be stepped upon during
repairs and servicing. This is particularly
important for injection piping. Protect the
engine with some type of cover (e.g., a board)
if stepping on the hoses is unavoidable during
assembly.
9-4
General Notes
SAC2200
9.1.3 Important servicing
To avoid running hot, the drive shafts shall be

regularly lubricated according to specifications
and using roller bearing grease as specified
by SANY.
Regularly inspect the drive shaft bolts and
ensure that they are seated properly.
Check gearbox and engine oil levels regularly.
Add oil as required during normal operation.
If oil consumption or loss is unusually high,
determine the cause and correct.
9.1.4 Maintenance notes for

replacement parts
When replacing drive components such as

the diesel engine, gearboxes or axles, etc., be
sure to refill with the correct type of oil to the
proper fill level. Refer to the nameplate and
lubrication chart to determine the oil type.
Conduct initial maintenance according to
Chapter “Periodic maintenance”; thereafter,
maintain in accordance with the specified
periodic maintenance intervals.
Be sure to adhere to the break-in

specifications.
9-5
General Notes
SAC2200
9.1.5 Recommendations for travel

operation
CAUTION!
Risk of damaging the engine!
! Do not exceed the permissible engine
rpm.
9.1.6 Disposal
Engine, gearbox and hydraulic fluids, grease,

fuel: these may not be disposed of in the
ground or in any types of waters: wastewater
systems, sewers or groundwater.
Comply with the regulations specified by local
authorities before disposing of any of these
items or substances.
Radiator fluids for diesel engines and heating
systems:
Undiluted antifreeze / corrosion protection
substances must be treated as hazardous
waste. Follow the regulations of the local
authorities when disposing of used cooling
fluids (mixture of antifreeze / corrosion
protection solution and tap water).
9-6
General Notes
SAC2200
9.1.7 Wheel changes
Crane vehicle tires are subjected to differing

loads during operation.
The loads are a function of where the wheels
are installed on the crane; for example,
– nondriven steering and fixed axles
– driven steering and fixed axles
– more lightly or less lightly loaded wheel
positions
Depending on the tire profile, different wear

patterns occur based on where it is located.
Tire rotation is recommended to ensure that all
the vehicle's tires wear uniformly. Tires should
be rotated as soon as uneven wear patterns
are detected. We recommend intervals in the
range of
5,000 km and 10,000 km. Tires should be
rotated in a crosswise pattern (see following
diagrams). The location should also be
selected so that tires that are evenly worn are
installed in locations where the wear pattern is
uneven.
This process has a positive impact on driving
comfort and tire life.
9-7
General Notes
SAC2200
9.1.8 Tire changes

Tires shall only be changed by authorized
specialists. This applies both to dismounting
and mounting of the tire on the wheel disk
(rim).
All rim components shall be cleaned and
inspected for damage! Use a new clamp collar
and O-ring when mounting the tire.
Danger!
Increased risk of accident!
If the clamp collar is not properly installed,
it can be violently ejected when the tire is
inflated!
! Check that the tire, side ring and clamp
collar are properly seated.
9-8
General Notes
SAC2200
9-9
General Notes
SAC2200
9-10
General Notes
SAC2200
9-11
General Notes
SAC2200
E
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9-12
www.sanygroup.com
SANY Mobile Cranes Co.,Ltd.

SANY Industry Town, Changsha Jinzhou Development Zone, Hunan, China
410600
Phone: 0086-21-58592902 Fax: 0086-21-58596210

E-mail: sanyservice@sany.com.cn
Service hotline: 0086-21-58592902 Complaint hotline: 0086-21-58590631

SAC2200

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Quality Changes the World

All Terrain Crane

SAC2200 All Terrain Crane

2.4.6 Slopes and Ditches.........................................................................................2-26

2.9.6 Transporting Components..............................................................................2-84

2.10.15 Inspection on Wire Rope..........................................................................2-154

3 Crane Chassis Operation

3.2.1.3 Checking Coolant Level........................................................................3-16

3.4.3.9 Finishing Driving Operations................................................................3-54

4 Crane Superstructure Operation

4.3.4 Superstructure Control System After Engine Start.........................................4-66

4.6.2 Reeving the Hook Block in and out.............................................................4-102

5.2.2.7 Assembly of the 4-Piece Folding Jib......................................................5-40

5.4.2 Aassembly .....................................................................................................5-88

7 Maintenance and Service

7.2 Crane Chassis...........................................................................................................7-8

7.5 Superstructure Maintenance Guidelines.................................................................7-75

8.2.1.1 Anti-twist Rope.......................................................................................8-46

●SANY built All Terrain Cranes offer high-

●SANY built All Terrain Cranes are widely

●SANY is a leading manufacturer of

This operator ’s manual provides safety,

Items addressed in this manual are designed

•Understand the structure and performance of

• Reduce improper operation and point out

• Increase equipment efficiency during

• Prolong the service life of equipment.

• Reduce maintenance costs.

Always keep this manual nearby and have

If you sell the machine, be sure to give this

Continuing improvements in the design of this

0.2 Your Documentation Package

The documentation for this machine includes

• Safety, Operation & Maintenance Manual

• Parts Book —This publication consists of

• Load Charts —These sheets graphically

0.2.1 Recommendations on using the

• This documentation applies only to this

• To ensure that the documentation is always

• Keep all pages inside its binder (if shipped

• Insert SANY replacement pages immediately

0.2.2 Documentation storage

Always keep the operator manual and load

The parts book is best left shelved indoors and

0.2.3 Operation manual organization

The operator’s manual is designed for the use

5. Accessories and miscellanous

0. 3 Your Sany Machine

0.3.1 Breaking in a new machine

Your machine has been thoroughly adjusted

During the break-in period:

• Let the machine warm up prior to any

• Avoid operating with severe loads and at high

• Avoid sudden starts, fast movements and

• Always let the machine cool down at the end of

0.3.2 Directional reference of the

All views are taken from the operator’s seat

Superstructure operator cab

0.3.3 Machine information

The serial numbers and model numbers on

1. Product identification plate

1) Product data plate

On the right side of the chassis panel behind

Max. Rated Lifting Capacity/Working Radius: