AC 665-1090-041 - en (Counterweight)

Counterweight 9
665--1090--041_en 1/33
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Z 30 419
Z 32 199
2/33 665--1090--041_en
Counterweight 9
9 Counterweight
9.1 General
(Z 30 419, Z 32 199)
When individual counterweight parts are being fitted and

removed, there is a danger of crushing between the indi-
vidual counterweight parts, between the counterweight
and superstructure frame as well as between the coun-
terweight and the chassis.
To avoid crushing, the safety instructions given in Sec-
tion 1.4.8 ”When Mounting and Dismantling the Crane
Components” must be observed.
In particular, maintain a safe distance. The mobile control
panel that is connected to socket “Q 60A” (Z 32 199) on
the left side of the superstructure frame is used for this
purpose.
The fitting and removal of the counterweight is carried
out with the aid of a further experienced person. As an
exception, this person also remains on the crane, along
with the crane operator, while the counterweights are be-
ing fitted or removed. The crane operator must remain in
constant eye contact with this person. Before the super-
structure is slewed, the crane operator must be abso-
lutely sure that this person has left the crane.
The raising and lowering of the counterweight can be best moni-

tored from the platform of the crane chassis.
Monitor indicator light (60) and buzzer (59) in the crane

operator’s cab. As soon as these come on or sound, the
position of the fitted counterweight combination is too
low (e.g. after long periods of extreme temperature fluc-
tuations, during which the crane has remained station-
ary). The buzzer first sounds, however, when an attempt
to slew the superstructure is made.
Determine the reason for the fault immediately and elimi-
nate it (e.g. by raising the counterweight again).
Accidents may otherwise occur.
665--1090--041_en 3/33
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Z 31 379
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Counterweight 9
9.2 Load Tables for Fitting and Removing the Counter-

weight Parts
As a rule, all counterweight combinations can be fitted and re-

moved using the main crane.
There are specific erection tables (629 777 40, 629 778 40) for
fitting and removing the counterweight parts.
These tables alone are valid for this purpose and must be strictly
observed.
Other load tables (such as with 0 t counterweight) may, UNDER
NO CIRCUMSTANCES, be used.
To fit and remove or modify the counterweight combina-

tions, the mobile crane must always be supported on outrig-
gers. Note Section 12 of the operating instructions of the
crane chassis (or the procedure described in the following,
if the special erection table 629 779 40 is to be used).
(Z 31 379)
Furthermore, there is the special erection table 629 779 40.
The fitting procedure described below is permitted only if this spe-
cial erection chart has been supplied together with the crane.
This special erection table applies only to the configuration

given on the opposite page and described in more detail in
the following, and to a counterweight combination of up to
52 t maximum.
Counterweight combinations of 76 t and 100 t may not be
fitted.
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Z 31 379
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Counterweight 9
(Z 31 379)
For fitting the counterweight sections according to special erec-

tion table 629 779 40, proceed as follows:
1. Drive the low--loader with counterweight sections to the front

of the crane driver’s cab.
2. Support the crane on outriggers.
2.1 Extend the outriggers horizontally to the outrigger sup-

port area given in the load table.
2.2 Extend the vertical outrigger cylinders until the wheels

are only just still in contact with the ground.
2.3 Align the crane correctly.
The detailed description given in Section 12 ”Outriggers” of

the operating instructions for the crane chassis must be ob-
served when supporting the crane on outriggers.
However, in this instance neither the ”Raise Axles” nor the
”Hold Axles” functions should be actuated.
Moreover, in contrast to what usually happens, axles 1 and
2 remain firmly on the ground when the crane is being sup-
ported on outriggers (to increase stability). Axles 3 -- 6 must
be depressurized.
3. Actuate the lower part of button (129) and (131) in the cab
of the crane chassis, and thus switch axles 3 -- 6 to ”Lower
Suspension Circuits”.
These axles actually remain on the ground. They are, however,

depressurized and will therefore not assume a supporting func-
tion when the next load is applied.
Monitor the corresponding pressure gauge. It must indicate

0 bar.
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Z 31 379
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Counterweight 9
4. Actuate the top part of button (130) in the cab of the crane
chassis and thus switch axles 1 and 2 to ”Raise Suspension
Circuit”. This presses them to the ground.
They must remain in this position until the pressure on pres-
sure gauges (5) and (6) in the cab of the crane chassis is
10 -- 15 bar.
5. Actuate button (139) in the cab of the crane chassis and thus
lock the suspension. The indicator light in this switch must
come on.
When the ground surface is not level, the wheels of axles 1

and 2 must be supported in such a way that they are on the
same level as each other and in a roughly central position.
The outrigger pads must remain in contact with the ground.
The outrigger cylinders may not be retracted.
When raising and stacking the counterweight sections, a

pressure of 300 bar in one of the suspension circuits may,
under no circumstances, be exceeded.
6. Apply the mechanical superstructure locking device for posi-

tioning the main boom towards the front over the driver’s cab.
Special erection table 629 779 40 is only valid when the boom
is positioned ”to the front”, i.e. no movements may be made
using the slew gear.
7. Luff the main boom into high position, telescope out to a

length of 34.10 m (telescoping lengths T1 -- 0%, T2 -- 0%, T3
-- 90%, T4 -- 90%) and then lower again until the radius given
in the load table is reached.
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Counterweight 9
In this condition, the counterweight base plate may be lifted off

the low--loader first and then the individual 11.2 t counterweight
sections. They may then be placed on the chassis. This and the
actual fitting is described in detail on the following pages for the
individual counterweight combinations.
This special erection table applies only up to a 52 t counter-

weight combination.
The 76 t and 100 t counterweight combinations may not be
fitted.
Once all counterweight sections have been stacked on the sup-

port of the crane chassis, actuate the second lock--in position
”Raise Axles” by pressing luminous switch (140) in the crane
chassis cab
Raise all axles until all the wheels are clear of the ground.
Only after this has been done the crane outrigger system is ready
for further mounting the counterweight.
The counterweight sections are to be lowered onto the low--

loader analogously in reverse order.
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Z 30 404
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Counterweight 9
9.3 Counterweight Combination 0 t
No counterweight sections are needed with a counterweight

combination of 0 t.
Hoist 2 may be fitted. Details on how to fit hoist 2 are given in Sec-
tion 15.
9.4 Counterweight Combination of 11 t

(Z 30 404)
The counterweight combination of 11 t comprises the following

elements:
-- 1 Counterweight base plate 5.8 t (1)
-- 1 counterweight section 3.3 t (2)
-- Hoist 2 (4) (or spare weight)
The weight of hoist 2 with rope drum and rope is approx. 2.5 t.
9.4.1 Fitting the 11 t Counterweight Combination
1. Support the crane on outriggers and align it.
2. Position the counterweight section(s) on the low--loader next

to the crane.
Certain erection tables are designed specifically for re-

moving / setting down the counterweight section(s). The
values given in these tables for, for example, the support
area, load, radius, boom length, extension sequence etc.,
are to be strictly observed.
3. Set the corresponding code number on the electronic crane

information system ECIS.
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Z 30 410
16
15
Z 32 161
14/33 665--1090--041_en
Counterweight 9
(Z 30 410, Z 32 161)
4. Remove the 5.8 t counterweight base plate (1) from the low--
loader and place on the counterweight support on the crane
chassis.
The extension pieces of the rear guide rods (15) must be in
the lowered position. If this is not the case (extension pieces
locked in position for fitting hoist 2), raise the corresponding
extension piece by a small amount using the assembly aid
(16), turn slightly and lower over the elevation of the longitu-
dinal bore. Remove the assembly aid.
Damage may occur.

If the extension pieces are not lowered, when the crane is
slewed, they may collide with the 3.3 t counterweight which
is bolted to the superstructure frame.

area, load, radius, boom length, extension sequence etc.,
are to be strictly observed.
The counterweight sections are correctly positioned by aligning

the corresponding bores of the counterweight base plate with the
two positioning cams on the counterweight support.
5. Fit hoist 2.
It is essential that hoist 2 be fitted since it is part of the 11 t

counterweight combination.
If there is no hoist 2 on the crane, then the spare weight of
2 t must be screwed into the 3.3 t counterweight section.
The procedure for fitting and removing hoist 2 is described in Sec-

tion 15.
After hoist 2 has been fitted, the configuration must again be that
which is described in point 4..
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1
Z 31 896
Z 34 383
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Counterweight 9
Following this, the 3.3 t counterweight section must first be fitted.

Counterweight sections are also needed for this, which are not
needed for the counterweight combination of 11 t (four parts,
11.2 t each). These must be removed again after the 3.3 t coun-
terweight section has been fitted.
(Z 31 896)
6. Place four 11.2 t counterweight sections (3) on a 5.8 t coun-
terweight base plate, one after the other.
Each counterweight section is marked with the construction num-

ber of the crane and an additional number. This number shows
the order in which each counterweight section is to be placed on
the whole counterweight stack. When fitting the counterweight
sections, therefore, ensure that they are stacked according to
these numbers.
Proceed with caution. Danger of crushing.

Ensure that the counterweight sections are lying correctly.
This is facilitated by positioning cams.

area, load, radius, boom length, extension sequence etc.
must be strictly observed.
(Z 34 383)
7. Place the 3.3 t (2) counterweight section on the existing
counterweight stack.
Proceed with caution. Danger of crushing.

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2 5 2
8 8
Z 34 384 Z 30 409
Z 30 417 Z 30 418
18/33 665--1090--041_en
Counterweight 9
(Z 34 384)
If there is no hoist 2 on the crane, the 2 t spare weight (5) is to be
screwed into the 3.3 t (2) counterweight section using 2 screws
(8).
8. Slew the superstructure such that the superstructure frame

with the counterweight lift cylinders is located above the
counterweight section.
9. Apply the superstructure locking device by actuating lever

(33) in the crane operator’s cab.
(Z 30 409)
10. Connect the mobile control panel to socket ”Q 60 A” on the
left side of the superstructure frame.
(Z 30 417)
11. Press self--return rocker switch (9) in the mobile control
panel in the direction of the black arrow up / forwards and
hold it down until the counterweight lift cylinders (1) have
been completely extended up to the stay bars (2).
As soon as the counterweight cylinders begin to extend, indicator

light (60) in the crane operator’s cab comes on.
(Z 30 418)
12. Pin lock the counterweight lift cylinders to the stay bars by
pressing self--return rocker switch (9) in the mobile control
panel in the direction of the black arrow up / forwards and at
the same time hold down button (10) in the mobile control
panel until both pin locking cylinders (3) are fully extended.
It is possible to retract the counterweight lift cylinders only when

both pin locking cylinders have reached their final position.
13. Press self--return rocker switch (9) in the mobile control

panel in the direction of the white arrow down / towards the
rear and hold it down until the counterweight lift cylinders are
fully retracted to the stop.
Indicator light (60) in the crane operator’s cab must then go
out.
Ensure that this remains in a horizontal position when the

counterweight stack is being raised.
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Z 31 361 Z 31 898
Z 36 724
20/33 665--1090--041_en
Counterweight 9
(Z 31 361, Z 31 898, Z 36 724)

14. Attach the 3.3 t counterweight section to 2 mountings on the
superstructure frame on the right hand side (Z 31 361) and
to 1 mounting on the left hand side (Z 31 896), insert double
conical pins and guard using locking springs.
Pinning the 3.3 t counterweight section serves only to put the

crane into the “Technical driveability” condition. Only the de-
scribed counterweight stack of base plate and 4 x 11.2 t sec-
tions are to be used for this procedure. The 12 t auxiliary
weights must not, under any circumstances, be fitted addi-
tionally on the side.
This condition is brought to attention additionally by plate
(Z 36 724) located on the right- hand side of the superstruc-
ture frame near the front pinning point of the 3.3 t counter-
weight section.
If the max. possible counterweight (100 t) is to be fitted, the
3.3 t section - if not already pin locked to the superstructure
frame - can simply be placed on top of this stack. It does not
then need to be pin locked to the superstructure frame.
15. Lower the remaining counterweight stack onto the counter-

weight support on the crane chassis again, unpin the coun-
terweight lift cylinders and retract again.
Proceed analogously in reverse order as described in points
8. -- 13..
16. Remove four 11.2 t counterweight sections one after the

other.
17. Connect the lower 5.8 t counterweight section to the counter-

weight lift cylinder and raise it.
Repeat once again the procedure described in points 8. -- 13.
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Counterweight 9
18. Disconnect the mobile control panel from the socket ”Q 60 A”

and set down the control panel (e.g. in the crane operator’s
cab).
19. Check the crane level and adjust, if required (see sect. 12,
Outriggers, in the operation manual of the crane chassis).
20. Set the code number according to the current crane configu-
ration (e.g. 11 t counterweight) and the desired operating
mode.
21. Release the superstructure locking device by actuating lever

(33) in the crane operator’s cab.
9.4.2 Removing the 11 t Counterweight Combination
This counterweight combination is to be removed analogously in

reverse order.
The crane must be supported on outriggers and aligned

for the counterweight to be removed.
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3
3
1
Z 30 405
1
Z 30 420
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Counterweight 9

(Z 30 405, Z 30 420)
The 31 t counterweight combination comprises the following ele-

ments:
-- 1 counterweight base plate 5.8 t (1)
-- 2 counterweight sections each weighing 11.2 t (3)
tion 15.
This counterweight combination is -- in principle -- fitted in the

same way as the 11 t counterweight combination.
Differences
Hoist 2 need not be fitted (nor the spare weight).
In addition to the 11 t counterweight combination, two 11.2 t coun-

terweight sections must be placed on the 5.8 t counterweight
base plate.
Certain erection tables are specifically designed for re-

must be observed.

This counterweight combination is removed analogously in re-

verse order.

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3
3
1
Z 32 116
26/33 665--1090--041_en
Counterweight 9
9.6 Counterweight Combination 42 t (Optional)

(Z 32 116)
The 42 t counterweight combination (optional) comprises the fol-

lowing elements :
-- 3 counterweight sections 11.2 t each (3)
tion 15.

Differences
Hoist 2 (or spare weight) need not be fitted.
In addition to the 11 t counterweight combination, three 11.2 t

counterweight sections must be placed on the 5.8 t counter-
weight base plate.

must be observed.


verse order.

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2
3
3
3
3
1
Z 30 406
1
Z 31 896
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Counterweight 9

(Z 30 406, Z 31 896)

ments:
-- 4 counterweight sections of 11.2 t (3) each
tion 15.

Differences
Hoist 2 (or spare weight) need not be fitted.
In addition to the 11 t counterweight combination, four 11.2 t

counterweight sections must be placed on the 5.8 t counter-
weight base plate.

must be observed.


verse order.

665--1090--041_en 29/33
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4 4
Z 30 407
12 t
Z 30 421
30/33 665--1090--041_en
Counterweight 9

(Z 30 407, Z 30 421)

ments:
-- 53 t Counterweight combination comprising:
-- 1 counterweight base plate 5.8 t
-- 1 counterweight section 3.3 t
-- 4 counterweight sections of 11.2 t each
-- 2 auxiliary weights (4) of 12 t each
tion 15.
The 76 t counterweight combination is initially fitted in the same

way as the 53 t counterweight combination (Section 9.7).
After all the counterweight sections have been stacked on the
counterweight support of the crane chassis, the auxiliary weights
(4) are suspended on the left and right hand side of the top 11.2
t counterweight sections, before the superstructure is swung into
the fitting position.
There are left--hand and right--hand auxiliary weights.

must be observed.
9.8.2 Removing the 76 t Counterweight Combination 76 t

verse order.

665--1090--041_en 31/33
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5 4 4 5
Z 30 408
32/33 665--1090--041_en
Counterweight 9

(Z 30 408)
The 100 t counterweight combination comprises the following

elements:
-- 53 t counterweight combination, comprising:
-- 1 counterweight base plate 5.8 t
-- 1 counterweight section 3.3 t
-- 4 counterweight sections of 11.2 t each
-- 4 auxiliary weights (4) and (5) of 12 t each
tion 15.
The 100 t counterweight combination is initially fitted in the same

way as the 76 t counterweight combination, i.e. after the 53 t
counterweight combination has been fitted, first both the inner
auxiliary weights (4) are to be fitted (suspended).
Only when both the inner auxiliary weights (4) have been sus-
pended, may the outer auxiliary weights (5) also be mounted on
the inner weights.

area, load, radius, boom length, extension sequence, etc.
are to be observed.
This counterweight combination is to be removed analogously in

reverse order.

665--1090--041_en 33/33

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Counterweight 9

When individual counterweight parts are being fitted and

The raising and lowering of the counterweight can be best moni-

Monitor indicator light (60) and buzzer (59) in the crane

9.2 Load Tables for Fitting and Removing the Counter-

As a rule, all counterweight combinations can be fitted and re-

To fit and remove or modify the counterweight combina-

This special erection table applies only to the configuration

For fitting the counterweight sections according to special erec-

1. Drive the low--loader with counterweight sections to the front

2. Support the crane on outriggers.

2.1 Extend the outriggers horizontally to the outrigger sup-

2.2 Extend the vertical outrigger cylinders until the wheels

2.3 Align the crane correctly.

The detailed description given in Section 12 ”Outriggers” of

These axles actually remain on the ground. They are, however,

Monitor the corresponding pressure gauge. It must indicate

When the ground surface is not level, the wheels of axles 1

The outrigger pads must remain in contact with the ground.

The outrigger cylinders may not be retracted.

When raising and stacking the counterweight sections, a

6. Apply the mechanical superstructure locking device for posi-

7. Luff the main boom into high position, telescope out to a

In this condition, the counterweight base plate may be lifted off

This special erection table applies only up to a 52 t counter-

Once all counterweight sections have been stacked on the sup-

The counterweight sections are to be lowered onto the low--

9.3 Counterweight Combination 0 t

No counterweight sections are needed with a counterweight

9.4 Counterweight Combination of 11 t

The counterweight combination of 11 t comprises the following

9.4.1 Fitting the 11 t Counterweight Combination

1. Support the crane on outriggers and align it.

2. Position the counterweight section(s) on the low--loader next

Certain erection tables are designed specifically for re-

3. Set the corresponding code number on the electronic crane

Damage may occur.

Certain erection tables are designed specifically for re-

The counterweight sections are correctly positioned by aligning

It is essential that hoist 2 be fitted since it is part of the 11 t

The procedure for fitting and removing hoist 2 is described in Sec-

Following this, the 3.3 t counterweight section must first be fitted.

Each counterweight section is marked with the construction num-

Proceed with caution. Danger of crushing.

Certain erection tables are designed specifically for re-

Proceed with caution. Danger of crushing.

8. Slew the superstructure such that the superstructure frame

9. Apply the superstructure locking device by actuating lever

As soon as the counterweight cylinders begin to extend, indicator

It is possible to retract the counterweight lift cylinders only when

13. Press self--return rocker switch (9) in the mobile control

Ensure that this remains in a horizontal position when the

(Z 31 361, Z 31 898, Z 36 724)

Pinning the 3.3 t counterweight section serves only to put the

15. Lower the remaining counterweight stack onto the counter-

16. Remove four 11.2 t counterweight sections one after the

17. Connect the lower 5.8 t counterweight section to the counter-

18. Disconnect the mobile control panel from the socket ”Q 60 A”