Luffing 13

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106

110

Z 45 867

H30

Z 46 733

2/21 650--1130--028
 Luffing 13

13 Luffing

13.1 Luffing the Main Boom

13.1.1 General

- For luffing of the main boom, switch (110, ”selector hoist 2 to

right--hand control lever”) may not be actuated. The inte-
grated indicator light may not light up (Z 45 867).
If this indicator light lights up, luffing is not possible. In this
case, this control lever is used to actuate “hoist 2”.

- Luminous switch (106) is used to select which hydraulic cir-

cuit (1 or 2) will primarily be allocated for the luffing task
(Z 45 867):

− If switch (106) is not actuated, i.e. if the indicator light inte-

grated in the switch has gone out, the luffing gear is actu-
ated on hydraulic circuit “2”. To prevent automatic switch-
ing to another control circuit during the configuration pro-
cedure or during operation of the crane and the resulting
jerks caused by switching the system over, it is advisable
to switch the luffing gear to hydraulic circuit “2” if the func-
tions “luffing gear / hoist 1” or “luffing gear / telescopic sec-
tions” are to be actuated simultaneously.
− When switch (106) is actuated, ie when the indicator light
in the switch lights up, the luffing gear is switched to hy-
draulic circuit “1”. To prevent automatic switching to
another control circuit during the configuration procedure
or during operation of the crane and the subsequent jerks
caused by the system switching over, it is advisable to
switch the luffing gear to hydraulic circuit “1” if the function
“luffing gear / hoist 2” is to be actuated simultaneously.

- During operation of the crane, make sure that the shut--off le-
ver (H30) is opened in the secondary circuit ”retract luffing
gear” (Z 46 733). If the shut--off lever is closed there is a risk
of dynamic pressure on the rod side of the luffing cylinder,
which causes an incorrect load reading by the load limit de-
vice.

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128

Z 40 414

4/21 650--1130--028
 Luffing 13

- The drive mechanism of the luffing gear has two speed

ranges / levels:

− Level 1: Normal speed

− Level 2: High speed

In the following cases you may not switch on the high--speed

function:
-- with a load attached
-- with a fly jib or main boom extension fitted or during Su-
perlift operation
-- at a boom length above 30.5 m
-- to raise and lower the fully or partially extended boom
from the low position.

- If the hook has been raised fully and the hoist limit switch has
tripped, the main boom can no longer be lowered. The hoist
must be lowered first (see Sect. 14.2).

- If a prohibited overload condition has occurred, the load--mo-

ment--reducing movement ”raise main boom” is also
switched off by the load limit device. It can be activated after
luminous pushbutton (128) has been actuated in order to
move the freely suspended load out of the overload range
back into the normal operating range (Z 40 414).

This load--moment--reducing movement may only be car-

ried out if this does not result in a hazardous situation.
Pay attention to this before the luminous pushbutton is
pressed.
If the load is still in contact with the ground and raising
of the hoist has been shut down, the load is too heavy.
The movement ”raise main boom” may not be released
in this instance.

The movement ”raise main boom” may not, under any

circumstances, be used to raise the load!

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13

G
2 2

4.2

Z 40 415

l / ll
106

110

Z 45 868 Z 44 593

6/21 650--1130--028
 Luffing 13

13.1.2 Operation of the Luffing Gear

The main boom is raised and lowered by extending and retracting

the luffing cylinders.

Proceed as follows to luff the main boom:

1. With the engine running, preselect the preferred circuit for

the luffing gear using switch (106) (Z 45 868), (see Sect.
13.1.1).

2. Check to make sure that ”hoist 2” is not switched to the right--

hand control lever. The lamp in the switch (110) must have
gone out (Z 45 868).

3. Press button (4.1) or (4.2) and start the luffing movement by

actuating control lever (2).
− Lever (2) to the right ”H” (Z 44 593)
Retract luffing cylinder / lower main boom (Z 40 416).
− Lever (2) to the left ”G” (Z 44 593)
Extend luffing cylinder / raise main boom (Z 40 416).

-- To prevent the unintentional activation of crane movements,

both levers are fitted with an additional button (button “4.1” in
control lever “1”, button “4.2” in control lever “2”, “dead man’s
switch”). A crane movement can only be carried out as long
as one of these buttons is pressed.
-- Lever (2) automatically returns to the zero position when re-
leased.

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l / ll

108

Z 40 417

22

Z 40 418

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 Luffing 13

13.1.2.1 Operation at Level 1 (S1)

The luffing gear is operated in level 1 over pump circuit 1 or pump

circuit 2. Switch (108) may not be actuated in this case. The inte-
grated indicator light has gone out (Z 40 417).

13.1.2.2 Operation at Level 2 (S2)

The luffing gear is operated in level 2 over both pump circuits.

Switch (108) is actuated to activate a 2nd pump. This is shown
by the indicator light in the switch lighting up. Activation of this
pump causes the luffing speed to be doubled when raising the
main boom, but only as long as the maximum permitted output
of the diesel engine is not exceeded (Z 40 417).
The luffing force remains identical as for operation at speed level
1.

-- Luffing speed: V (S2) = 2 x V (S1)

-- Luffing force: F (S2) = F (S1)

13.1.3 Precision Control of the Luffing Gear

By actuating knob (22), the pilot control behaviour of the luffing

gear can be precisely controlled (Z 40 418).

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13

”S44.2”

”S92.1”
Z 40 410 Z 40 412

113

Z 45 869 Z 46 721

10/21 650--1130--028
 Luffing 13

13.1.4 Bridging ”Lower Luffing Gear”

When a boom angle of 15° is reached when lowering the main

boom, the sensor “S92.1” switches off the crane movement
“lower luffing gear” (Z 40 410).

”Lower luffing gear” is bridged by pressing button (113). Release

is confirmed by the lamp in the button lighting up (Z 45 869).

Lowering the main boom below 15° boom angle is prohibited

in the area of the outriggers. The main boom would collide
with the outrigger struts.

When the superstructure is in the 0° or 180° position and the me-

chanical superstructure locking device is applied, “lower luffing
gear” is not shut down at a main boom angle of 15°. In this case,
the sensor “S44.2” is activated, the main boom can be lowered
completely (Z 40 412).

When the superstructure is in the 180° position and the main

boom has been lowered completely, there is a RISK OF DAM-
AGE for the luffing cylinders as a result of the cylinder sup-
ports which may have been attached on the crane chassis
(optional, Z 46 721).

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13

12/21 650--1130--028
 Luffing 13

13.1.5 Luffing the Main Boom with a Luffing Fly Jib Fitted

13.1.5.1 Luffing with suspended load

In the computer of the load limit device, the values are pro-
grammed for an 83° and a 73° and 65° position of the main boom
with a luffing fly jib fitted.

If the load limit device trips while the main boom is being tilted for-
wards (load limit device shuts down), the hazardous situation
must be remedied by raising the fly jib. The main boom may only
be tilted further when the indicator of the load limit device is back
in the permissible range.

If a safe condition is not reached by moving the fly jib

into the high position (load limit device is not released),
the load is too heavy for the boom to be tilted forwards.

13.1.5.2 Lowering the Main Boom

When the fly jib is positioned in a high position, the movement

”lower main boom” can be shut down. First the rope of hoist 2
must be paid out to allow the fly jib to move out of its end position.
The movement ”lower main boom” is now possible.

13.1.5.3 Raising the Main Boom

With the lowest position of the fly jib, the movement ”raise main
boom” may be switched off. First the rope of hoist 2 must be
drawn in so that the fly jib moves out of its end position. The
movement ”raise main boom” is now possible.

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13

106

109 110

Z 45 870

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 Luffing 13

13.2 Luffing the Fly Jib

13.2.1 General

The fly jib is raised and lowered using ”hoist 2”. Before the fly jib
is luffed, the main boom must be standing in its highest position.

By pressing switch (109) the control of ”hoist 2” is switched to con-

trol lever (1), the integrated indicator light must light up
(Z 45 870).

-- This switchover enables operation of hoist 2 (raise / lower fly

jib) with the left hand and hoist 1 (raise / lower load) and luffing
gear (raise / lower main boom) with the right hand.
-- With operation of “hoist 2” on the left--hand control lever (1),
telescoping of the main boom is no longer possible.
-- With fly jib operation and when configuring the luffing fly jib,
simultaneous activation of the luffing gear and hoist 2 can oc-
cur. Consequently, it is advisable to switch the luffing gear to
hydraulic circuit “1”; this avoids jerking when the system is
switched over. This is achieved by actuating luminous switch
(106), the integrated indicator light must light up (see section
13.1.1), (Z 45 870).
-- When the hook block has triggered the hoist limit switch, the
fly jib can no longer be lowered. First lower the hook block
(see section 14.2).

The switches (109, “selector hoist 2 to the left--hand control

lever”) and (110, “selector hoist 2 to right--hand control le-
ver”) may never be actuated at the same time. If this were the
case, the following crane movements would no longer be
possible:
-- Retract / extend telescopic sections
-- Retract / extend luffing cylinders
-- Raise / lower hoist 2

It is prohibited to raise a load by raising the luffing fly jib

-- actuating hoist 2.
The load may only be raised from the ground using hoist
1.

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13

1 4.1
31

Z 40 422

”S96” 128

Z 45 871 Z 40 414

16/21 650--1130--028
 Luffing 13

13.2.2 Operation ”Hoist 2”

The luffing fly jib is raised and lowered be reeling the rope ”hoist
2” in and out:

The luffing fly jib is raised and lowered using control lever (1) (Z
40 422).
− Lever (1) automatically returns to the ”O” position when re-
leased.
− Touch the hoist rotation indicator (31) when actuating control
lever (1).
As soon as the hoist begins to rotate you will be able to feel
a distinct vibration (Z 40 422).
The signal is transferred by means of the proximity switch
“S96” on the hoist (Z 45 871).
− To prevent unintentional crane movements being carried out,
both control levers are fitted with an additional button (button
“4.1” in control lever “1”, button “4.2” in control lever “2”, “dead
man’s switch”). A crane movement can only be carried out as
long as one of these buttons is pressed.
− If a prohibited overload condition has occurred, the load--mo-
ment--reducing movement ”raise fly jib with hoist 2” is
switched off by the load limit device. It can be moved after lu-
minous pushbutton (128) has been actuated in order to move
the freely suspended load out of the overload range back into
the normal operating range (Z 40 414).

This load--moment--reducing movement may only be car-

ried out if this does not result in a hazardous situation.
Pay attention to this before the luminous pushbutton is
pressed.
If the load is still in contact with the ground and raising
of the hoist has been shut down, the load is too heavy.
The movement ”raise fly jib” may not be released !

Under no circumstances may the movement ”raise fly

jib” be used to raise the load!

650--1130--028 17/21
13

Z 40 425

l / ll

109

Z 45 865 Z 40 426

18/21 650--1130--028
 Luffing 13

Proceed as follows to raise and lower the luffing fly jib:

1. With the engine running, press switch (109) to switch opera-

tion of “hoist 2” to the left--hand control lever; the indicator
light integrated in the switch lights up (Z 45 865).

2. Press button (4.1) or (4.2) and start the luffing movement by

carefully actuating control lever (1).
− Lever (1) forwards ”A” (Z 40 425)
Lower fly jib (Z 40 426)
− Lever (1) backwards ”B” (Z 40 425)
Raise fly jib (Z 40 426)

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13

101
1

33
l / ll

Z 40 427

30

Z 40 428

20/21 650--1130--028
 Luffing 13

13.2.2.1 Operation at Level 1 (S1)

(Z 40 427)

Operation of the hoist at level 1 is carried out using pump circuit

2. In this case, the button (33) in the control lever (1) may not be
actuated. Indicator light (101) has gone out.

13.2.2.2 Operation at Level 2 (S2)

(Z 40 427)

The hoist is operated at level 2 using pump circuit 2 and by means

of additional trimot setting. The angle of the hoist motor is ad-
justed by pressing button (33) in control lever (1).
Indicator light (101) lights up.
This trimot setting causes the luffing speed of the fly jib to be
doubled, but only as long as the maximum permitted output of the
diesel engine is not exceeded.

In comparison to operation at level 1, the luffing force is halved.

-- Luffing speed: V (S2) = 2 x V (S1)

-- Luffing force F (S2) = F (S1 / 2)

This high speed may only be switched on without load and

with a short fly jib.

13.2.3 Precision Control of Hoist 2

(Z 40 428)

By pressing knob (30) the pilot control setting of hoist 2 can be

precisely regulated. This guarantees jerk--free operation of the
crane with the luffing fly jib.

650--1130--028 21/21