Superstructure Malfunctions - EU PDF

Malfunctions on the superstructure
14.1 Superstructure emergency stop device
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14 Malfunctions on the superstructure

The GMK 5100 truck crane is equipped with two emergency stop devices
on the superstructure. With these devices you:
– can turn off the crane engine even when outside the crane cab
(e.g. with an ignition lock malfunction or when access to the crane cab
is blocked);
– can turn off the crane control when a crane movement can not be
switched off (e.g. when there is a crane control malfunction).
Switching off the You can turn off the crane engine from outside the crane cab by switching
crane engine off the battery master switch.
The battery master switch (1) is located on

the right-hand side of the superstructure,
under the battery box behind the side plate,
and is accessible from below.
• Switch off the main battery switch. Turn

the selector handle so that it can be pulled
off.
The crane engine switches off.
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Operating Instructions GMK 5100 2 084 530 en 14 - 1
Crane control In an emergency you can switch off the crane control with the Crane
emergency stop control emergency stop switch. The switch is located on the middle plug-in
switch module in the crane cab.
G
Risk of overload if used improperly!
The Crane control unit emergency stop switch is only intended for the emer-
gency when the crane functions cannot be braked or stopped by the
corresponding control lever movements. Never use this switch to brake
crane movements in normal crane operation.
The sudden stopping of the crane movement can lead to an overload of
the truck crane at high working speeds and unfavourable combinations
between the working position and rigging mode.
• Press the Crane control emergency stop switch. The switch clicks in.
The crane engine is immediately switched off; the crane functions are
abruptly stopped.
G
Risk of accidents when the load is suspended!
If a load is on the hook after the emergency stop, you must ensure that
no persons are in the danger area under the suspended load. Secure the
danger area if necessary if the fault cannot be rectified without delay and
you leave the work site.
Releasing crane functions again

As long as the Crane control emergency stop switch is engaged, the crane
functions remain blocked. Proceed as follows to check if the crane control
works normally after a new start:
• Turn off the ignition.

• Turn the Crane control emergency stop switch until it disengages.
• Let go off all control levers and start the crane engine again.
H
• Check if the crane movements are carried out as normal.
If the crane movements are not carried out as normal or if you need to
carry out an emergency shut down, notify the GROVE Product Support
responsible.
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14 - 2 2 084 530 en Operating Instructions GMK 5100

14.2 Troubleshooting for malfunctions that occur during crane operation
14.2 Troubleshooting for malfunctions that occur during

crane operation
If a malfunction occurs:
• Keep calm!
• If possible put down the load immediately. Retract the main boom
completely and set it down on the boom support.
• Use warning signs in the crane cab to prevent unauthorized use of the
truck crane. Remove the ignition key.
• Inform your supervisor.
G
Risk of accidents when the load is suspended!
Under no circumstances is repair work to be carried out with a suspended
load!
You may override the SLI to set down the load if SLI malfunctions occur.
Observe the warning and safety information in the section SLI overriding
when doing so; ➠ p. 12-32.
G
Risk of accidents!
Do not perform any crane movements that may increase the size of the
load moment when a load is on the hook block and the SLI is overriden.
• Try to repair the malfunction. Notify your local GROVE Product Support
if you cannot repair the problem yourself.
Load cannot be • Secure the danger zone using cordons and assigned personnel.
lowered
• Notify qualified repair personnel or local GROVE Product Support.
G
Accidents may occur due to inappropriate emergency operation!
Only trained, qualified personnel may carry out an emergency operation
if unrigging requires the manual operation of solenoid valves.
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14.2 Troubleshooting for malfunctions that occur during crane operation
Blank page
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14.3 Electrical system
14.3.1 Plug-in modules and consoles
Name in
Pos. the elec. Function
circ. diag.
1 1.6 D Monitoring of crane engine and hydraulicsystem
/ headlight / windscreen wiper/washing system /
additional heating system or additional heating
system with timer (both additional equipment)
2 5.2 D Display, input and crane control emergency stop
/ telescoping gear display / telescoping control
level function display, derrick / display and
counterweight hoist unit control
3 6.2 D Anemometer / spirit level or electronic level (can
be switched over) (additional equipment) /
superstructure lock / lifting limit switch shutoff
system display/ slewing gear permanent brake
display / SLI override, lifting limit switch /
outrigger pressure indicator (additional
equipment)
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Plug-in module
Pos. name in the Function
elec. circ. diag.
1 Safe load indicator (SLI)
7.1 D Set crane engine constant motor speed /

2
outrigger operation (additional equipment)
+BE 630. KR Control lever for telescoping, derricking
and main hoist / disconnect main hoist,
3 derricking gear, telescoping gear /
control level function change-over
derricking ↔ telescoping
+BE 630. KL Control lever for slewing gear, auxiliary
hoist (additional equipment) / disconnect
4
auxiliary hoist / slewing gear permanent
brake / incline crane cab
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14.3.2 Fuses
S
Risk of fire!
Never repair a blown fuse with a nail, with wire, aluminium foil or other
materials which conduct electricity.
Always replace defective fuses only with fuses of the indicated ratings.
The fuses are divided into the groups F1 to F13.
The fuse groups F1 to F9 can be accessed

from outside by opening the flap on the front
of the crane cab (8 mm hexagon spanner).
Each group consists of six fuses:
The following tables show the designations

of the individual fuses, their strength and
function. The designations 1 to 6 in the
following tables correspond to the order
from left to right (fuse 1 is always the left
fuse).
Designation in Rating (A) Function

circuit diagram:
F1
1 20 Crane engine E-control
2 10 Crane engine diagnostic plug
3 10 Flame start system (additional

equipment)
4 15 No function
5 10 Crane cab ceiling lamp,

cigarette lighter
6 10 No function
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circuit diagram:
F2
1 10 No function
2 10 No function
3 10 No function
4 10 No function
5 10 No function
6 15 No function

circuit diagram:
F3
1 10 Indicator and warning lamps for engine,

hydraulic system, flame start system
2 15 Windscreen wiper/washing system discs
3 5 Pressure sensors/
crane control switch /
sensors counterweight hoist unit
4 10 Control lever, high-speed, slewing
gear, slewing gear superstructure lock
5 10 Crane engine diagnostics plug /
counterweight hoist unit switch and
indicator lamps
6 10 Flame-start device (additional
equipment)
incline crane cab (additional
equipment)

circuit diagram:
F4
1 5 Switches and indicator lamps

2 15 Working area spotlight ,
switch and indicator lamps for working
area spotlight and derricking gear
shutdown / telescoping gear /
disconnect main hoist
Horn, Switch and indicator lamps for
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3 5
auxiliary hoist shutdown, Slewing gear
permanent brake and crane cab incline
4 10 Crane cab heating


circuit diagram:
F4
5 15 Crane cab electronic level (additional

equipment) / SLI pre-warning,
shutdown / outrigger pressure
indicator (additional equipment)
6 10 SLI deactivation, anchor-to-bracket-

switch shutdown,
dead man’s switch, seat contact

circuit diagram:
F5
1 15 Crane control power supply

circuit diagram:
F6
1 10 Shutdown of main hoist,

main hoist slewing indicator
2 10 Shutdown for auxiliary hoist,

auxiliary hoist slewing indicator
3 10 Shutdown for derricking gear

Telescoping gear locking/unlocking
4 10 Control lever initial position left
5 10 Slewing gear
6 10 Indicator/warning lamp counterweight

locked/unlocked in switch unit
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circuit diagram:
F7
1 10 SLI
2 10 Proximity switch telescoping cylinder
3 5 No function
4 10 Crane control display

emergency operation crane control
5 10 Crane control
6 10 Crane engine E-control

circuit diagram:
F8
1 15 Crane cab heating
2 15 Radio / voltage transformer
3 15 No function
4 5 Crane control unit 0

circuit diagram:
F9
1 20 Oil cooler
2 3 Oil cooler (relay)
3 15 No function
4 10 No function
5 5 Central lubrication system
6 10 No function
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H The fuse groups F 10 to F 13 are located in the battery box. These fuse
groups consists of only one fuse each.
• Open the lid of the battery box.

You can access fuses F10 (1) and F11 (2) if
you take the cover off the terminal box.
Fuses F12 (3) and F13 (4) are in the holder

behind the terminal box.
Pos. Designation Designation Function

in circuit in circuit
diagram: diagram:
1 F10 50 Central fuse for the SLI supply line
2 F11 50 Preliminary fuse for

central fuse
superstructure
3 F12 20 Preliminary fuse for crane control

power supply
4 F13 20 Heating system preliminary fuse,

voltage transformer /
fuse for all consumer equipment,
which is still supplied with power
when the battery master switch is
switched off.
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Blank page
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14.3.3 SLI fuses
On the SLI you will find a fuse for the central unit and several fuses for the
SLI outlets.
All outlets are individually protected by fuses. If one of the fuses is
defective you can no longer carry out the corresponding crane function.
Replacing fuses
S
Risk of fire!
Never repair a blown fuse with a nail, with wire, aluminium foil or other
materials which conduct electricity.
Always replace defective fuses only with fuses of the indicated ratings.
EKS 3 To change a fuse you need to remove the

SLI plug-in module.
• Remove the four retaining bolts at the

corners of the front plate of the SLI
plug-in module and pull out the plug-in
module.
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The fuses are on the back of the plug-in

module and are labelled S I 1 to S I 13.
The following table shows the assignment of

fuses. If a fuse is defective the relevant crane
movement can not be carried out.

circuit diagram:
SI1 5 SLI internal
SI2 5 SLI shutdown display
SI3 5 Lift main hoist shutdown
SI4 5 Shutdown lowering
SI5 5 Shutdown extending
SI6 5 Lift auxiliary hoist shutdown
SI7 5 Shutdown raising
SI8 5 Shutdown retracting
SI9 5 Lower auxiliary hoist shutdown
S I 10 5 free
S I 11 5 SLI early warning display
S I 12 5 free
H
S I 13 5 SLI central unit
If the fuse on an SLI outlet fails again, notify your local GROVE Product
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Support.

14.4 Troubleshooting and malfunction correction
14.4.1 Crane engine malfunctions
Malfunction Cause Action
Engine does not start (starter Battery master switch not Switch battery master switch
motor does not turn over) switched on on; ➠ p. 11-7.
Ignition switched off Switch on ignition;
➠ p. 11-11.
Engine does not start Batteries not charged enough Charge batteries
(starter motor turns over) Fuel tank empty 1. Fill fuel tank,
➠ p. 11-9.
2. Bleed fuel system,
➠ Crane engine manu-
facturer’s operating
manual
Fuse F1/1 SS, F1/2 SS or F7/6 Check fuse, replace if
SS defective necessary; ➠ p. 14-7.
Flame-start system indicator Check fuses and replace if
lamp does not go on, fuse necessary; ➠ p. 14-7.
F1/3 faulty
Engine coolant temperature Coolant level too low Top up coolant
too high Radiator dirty outside Clean outside of radiator
V-belt for coolant pump on Tension V-belts, see crane
engine slack engine manufacturer’s
operating manual
Engine oil pressure too low Engine oil level too low Check oil level, fill if
necessary; ➠ p. 11-4 and
Maintenance manual
Engine can not be turned off Malfunction in the electronics Turn off engine with
with the ignition key emergency stop device,
➠ p. 14-1
Indicator lamp Crane engine Crane engine air filter is dirty Replace crane engine air filter
air filter lights up
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Indicator lamp Flame start Problem with flame-start Inform GROVE Product
system lights up when crane system Support or the service
engine is running department of the crane
engine manufacturer and
have the flame-start device
checked.
No function, rane engine Fuse F3/5 SS faulty
diagnostics plug
Engine electronic system Malfunctions in the motor electronics cause engine

warning lamp lights during performance to decrease continuously. The engine will not
operation, the power of the switch off, however so lowering the load and unrigging the
engine continuously drops truck crane can still be done.
Coolant level too low, Coolant level; ➠ p. 11-8;
Oil level too low, Oil level; ➠ p. 11-4;
Air filter dirty. Air filter;
➠ Maintenance manual
V-belt too loose Check V-belt tension;
➠ Crane engine manufacturer’s
operating manual
Plug or cable on the control Check plug on control unit
unit loose (near the diagnostic plug);
➠ p. 10-58
Cabling behind the Check cable, Notify GROVE
accelerator damaged Product Support of any
damage
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14.4.2 Main hoist malfunctions
Main hoist not functioning Rocker switch Shutdown main Switch off rocker switch
or malfunctioning (lifting, hoist switched on Shutdown main hoist
lowering or fast speed not
Fuse F3/4 SS, F4/2 SS or Check fuse, replace if
functioning)
F6/1 SS defective necessary; ➠ p. 14-7
Dead man’s switch not Press dead man’s switch
activated
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-92.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 14-57.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 14-2.
Main hoist lowering not func- Lowering limit switch Leave shutdown area,
tioning (in addition, check all triggered Lift main hoist
causes in the “Main hoist not
functioning” section!)
Main hoist lifting not Lifting limit switch triggered Leave shutdown area, lower
functioning (warning lamp on) main hoist
(in addition, check all causes
SLI shutdown Leave shutdown area;
in the “Main hoist not func-
tioning” section!)
(warning lamp on) ➠ p. 12-29.
Fuse F4/6 Superstructure or Check fuse, replace if
F7/1 Superstructure defective necessary; ➠ p. 14-7.
Lifting, lowering or fast speed Corresponding function is Acknowledge error message
do not function blocked by the crane control once; ➠ p. 12-92.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
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Lifting does not function Fuse on corresponding SLI Replace if necessary;

outlet defective ➠ p. 14-7.
s
No lifting or lowering, or pos- Maximum speed set too low Increase maximum speed on
sible only at very low speed the display Enter power unit
speed; ➠ p. 12-87.
Lifting or lowering function Malfunction on the crane Stop the movement with the
can not be switched off control Crane control emergency stop
H
switch; ➠ p. 14-2.
If a malfunction occurs, first check whether it applies in both directions of

movement.
In this case also check the causes listed in the Main hoist not functioning
section!
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14.4.3 Auxiliary hoist malfunctions
Auxiliary hoist not Rocker switch Shutdown Switch off rocker switch
functioning or malfunctioning auxiliary hoist switched on Shutdown auxiliary hoist
(lifting, lowering or fast speed Fuses F3/4 Superstructure or Check fuses, replace if
not functioning) F4/3 Superstructure or F6/2 necessary; ➠ p. 14-7.
Superstructure defective
Dead man’s switch not Press dead man’s switch;
activated ➠ p. 10-62.
units; ➠ p. 14-57.
Auxiliary hoist lowering not Lowering limit switch Leave shutdown area,
functioning (Also check all triggered Lift main hoist
causes in the “Auxiliary hoist
not functioning” section!)
Auxiliary hoist lifting not Lifting limit switch triggered Leave shutdown area,
functioning (Also check all (warning lamp on) Lower the auxiliary hoist
causes in the “Auxiliary hoist SLI shutdown Leave shutdown area;
not functioning” section!) (warning lamp on) ➠ p. 12-29.
Lifting, lowering or fast speed Corresponding function is Acknowledge error message
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No lifting or lowering, or pos- Maximum speed set too low Increase maximum speed on
sible only at very low speed the display Enter power unit
speed; ➠ p. 12-87.
Lowering does not function Fuse on corresponding SLI Replace if necessary;
outlet defective ➠ p. 14-13.
Lifting or lowering function Malfunction on the crane Stop the movement with the
can not be switched off control Crane control emergency stop
H
switch; ➠ p. 14-2.

movement.
In this case also check the causes listed in section Auxiliary hoist not
functioning!
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14.4.4 Derricking gear malfunctions
Derricking gear not func- Dead man’s switch system Press dead man’s switch,
tioning or malfunctioning not activated ➠ p. 10-62.
(raise boom, lower boom or
fast speed not functioning)
Right-hand control lever set to Set control lever to Derricking
Telescoping function or Derrick- function
ing lattice extension switched on
Rocker switch Shutdown Switch off rocker switch
derricking gear switched on Shutdown derricking gear
control has failed (error once; ➠ p. 12-92. If the error
message is displayed) message is repeated, change
the connections on the
control units; ➠ p. 14-57.
Lower boom not functioning Lifting limit switch triggered Leave shutdown area,
(Also check all causes in the (warning light on) raise boom
“Derricking gear not func-
SLI shutdown Leave shutdown area;
tioning” section!)
(warning lamp on) ➠ p. 12-29.
F7/1 Superstructure defective necessary
Raising or lowering the boom Corresponding function is Acknowledge error message
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Raising or lowering the boom Fuse on corresponding SLI Replace if necessary;

does not function outlet defective ➠ p. 14-13.
No raising or lowering the Maximum speed set too low Increase maximum speed on
boom, or possible only at the display Enter power unit
very low speed speed; ➠ p. 12-87.
Raising or lowering the boom Malfunction on the crane Stop the movement with the
function can not be switched control Crane control emergency stop
H
off switch; ➠ p. 14-2.

movement.
In this case also check the causes listed in the Derricking gear not
functioning section!
14.4.5 Telescoping gear malfunctions
Telescoping gear not Dead man’s switch system Press dead man’s switch;
functioning or malfunctioning not activated ➠ p. 10-62.
(telescope in, telescope out or Fuse F7/2 Superstructure or Check fuses, replace if
fast speed not functioning) F3/4 Superstructure or F6/3 necessary; ➠ p. 14-7.
Superstructure defective
Right-hand control lever set to Set control lever to Telescoping
Derricking function
Telescoping gear shutdown Switch off rocker switch
rocker switch switched Shutdown telescoping gear;
➠ p. 10-37.
units; ➠ p. 14-57.
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Telescope section and tele- Valve defective Note down the Display status –
scoping cylinder do not locking number code on the
display and inform GROVE
lock/unlock any functions
Product Support; ➠ p. 14-58.
Extension of the telescoping SLI shutdown Leave shutdown area;
not functioning (warning lamp on) ➠ p. 12-29.
(Also check all causes in the Fuse F4/6 Superstructure or Check fuse, replace if
“Telescoping gear not F7/1 Superstructure defective necessary; ➠ p. 14-7.
functioning” section!) Lifting limit switch triggered Leave shutdown area,
(warning lamp on) Lower hoist
Telescope retracting not Insufficient boom lubrication Lubricate boom,
functioning (Also check all ➠ Maintenance manual
causes in the “Telescoping Boom too flat Raise boom
gear not functioning”
section!)
Telescope section does not Telescope section is still Unlock telescope section;
move when the control lever locked ➠ p. 12-69.
is extended
Telescoping cylinder is not Lock telescope cylinder;

locked ➠ p. 12-66.
Lock telescope section/ Defective hydraulics/electrics Note down the number code
telescoping cylinder not on the status display when
functioning locking and inform GROVE
Product Support; ➠ p. 12-83.
Telescoping out or in or fast Corresponding function is Acknowledge error message
speed not functioning blocked by the crane control once; ➠ p. 12-92.
Retracting or extending does Fuse on corresponding SLI Replace if necessary;
not function outlet defective ➠ p. 14-13.
No retracting or extending, or Maximum speed set too low Increase maximum speed on
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possible only at very low the display Enter power unit

speed speed; ➠ p. 12-87.
s
Retracting or extending Malfunction on the crane Stop the movement with the
function can not be switched control Crane control emergency stop
off switch; ➠ p. 14-2.
The boom can no longer be The electric controller of the Retract the telescope section
extended, the locking/un- hydraulic system is using hydraulic emergency
locking mechanism no longer interrupted (e.g. a cable in the mode; ➠ Retracting emergency
reacts to the control instru- main boom is broken) mode, p. 14-42.
ments in the crane cab
The boom can no longer be The hydraulic supply is Extend the telescope section
extended, the telescoping interrupted with mechanical emergency
cylinder can no longer be mode; ➠ Retracting emergency
H
moved mode, p. 14-42.

movement.
If the malfunction occurs in both directions of movement you must also
check the causes listed in the Telescoping gear not functioning section!
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14.4.6 Slewing gear malfunctions
Slewing gear does not Mechanical superstructure Disengage lock;

function lock engaged ➠ p. 12-6.
Slewing gear permanent Release slewing gear
brake applied permanent brake; ➠ p. 12-46.
Dead man’s switch not Press dead man’s switch;
activated ➠ p. 10-62.
Fuses F6/5 Superstructure or Check fuses, replace if
units; ➠ p. 14-64.
Slewing to left or right not Corresponding function is Acknowledge error message
functioning blocked by the crane control once; ➠ p. 12-92.
Slewing is not, possible, or Maximum speed set too low Increase maximum speed on
only at a very low speed the display Enter power unit
speed; ➠ p. 12-87.
Slewing can not be Malfunction on the crane Stop the movement with the
switched off control Crane control emergency stop
switch; ➠ p. 14-2.
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14.4.7 Malfunctions at the counterweight hoist unit
No function, counterweight A control unit of the crane Acknowledge error message

hoist unit control has failed (error once; ➠ p. 12-92.
message will be shown) If the error message is
units;
➠ p. 14-57.
switch pressed again; ➠ p. 14-2.
Counterweight hoist unit is Press down the Release counter-
not released weight hoist unit rocker switch.
Fuse F 3/5 SS faulty Check fuses, replace if
necessary; ➠ p. 14-7.
Corresponding function is Acknowledge error message
blocked by the crane control once; ➠ p. 12-92.
Indicator lamps for “lifting The electronic system has recognised an electrical or a logic
cylinder extended” or indica- error; ➠ Indication of a malfunction, p. 13-58.
tor and warning lamps for
locking/unlocking are
flashing simultaneously
No function, lock/unlock Counterweight lifting cylinder Counterweight lifting cylinder

counterweight hoist unit retracted extended
No function, extend/retract Counterweight hoist unit not Completely lock or unlock

counterweight lifting cylinder locked or unlocked in end counterweight hoist unit
position (indicator or warning lamp
must light)
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14.4.8 Crane control malfunctions
The Crane control display re- One or more of the following Check the fuses, replace if
mains dark even though the superstructure fuses is necessary; ➠ p. 14-7.
ignition is switched on. defective:
F5 1 / 2 / 3 / 4 / 5 / 6
F7 4 / 5 or F8 4 / 5 / 6
On the Crane control display Length indicator or proximity With emergency operation,
the EMERGENCY OPERATION switch defective or no retract the main boom and
message appears connection any more (e.g. drive to a repair station;
cable broken or damaged) ➠ p. 14-42.
At the Crane control display, The electrical connection Establish the plug connection
the NOT CONNECTED messa- between the main boom and under the main boom before
ge appears the turntable is interrupted the derricking cylinder foot
(plug connection not made or axis or check the cable for
cable damaged or broken) damage and have it repaired.
In the Crane control display The current telescoping or Acknowledge error (the
the two ECOS number codes locking status does not agree display automatically changes
appear one above the with the values stored in the to the Enter telescoping after
other. control system (e.g. after emergency operation menu) and
ECOS: 00001000 telescope with emergency enter the current telescoping;
H
STATUS: 0 0 0 0 0 0 0 1 operation) ➠ p. 14-76.
If there are further malfunctions on the crane control, the corresponding

error messages will appear on the Crane control display; ➠ p. 14-57.
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14.4.9 Hydraulic system / hydraulic oil cooler malfunctions
Hydraulic oil temperature Hydraulic system under Stop crane operations and
above 80 °C severe strain allow the crane engine to run
Fan in hydraulic oil cooler is until the oil has cooled down.
running.
Hydraulic oil temperature Fuse F 9/1 SS or F 9/2 faulty Check fuses, replace if
over 80 °C necessary; ➠ p. 14-7.
Fan in the hydraulic oil cooler
Thermostat valve of the fan Have thermostat valve
not running
defective replaced
Hydraulic oil filter control Hydraulic oil filter Change hydraulic oil filter;
circuit warning lamp lights ➠ Maintenance manual
Hydraulic oil return flow filter Hydraulic oil filter dirty Change hydraulic oil filter;
warning lamp lights ➠ Maintenance manual
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14.4.10 Malfunctions on the SLI
S
You must halt crane operation immediately when SLI error messages
appear!
Repairs to the SLI may only be carried out by properly qualified

personnel.
If malfunctions cannot be eliminated by means of the actions described

on the following page, you must notify the local GROVE Product Support.
If you have to contact GROVE Product Support, a precise and extensive
description of the malfunction is extremely useful.
The precise description of the malfunction, as well as the answers to the
following questions, can help to optimise troubleshooting:
1. During which crane operation did the malfunction occur?

2. What is indicated on the SLI status display?
3. What is indicated on the SLI information display?
4. What is shown in the status displays Rigging mode and Reeving?
5. What is indicated on the information display when the information
selector switch is moved to different positions?
6. Have the fuses been replaced?
Other malfunc-
tions on the SLI
SLI does not function Power supply switched off Switch on ignition
(displays not lit, no buzzer
Fuse F7/1 Superstructure or Check fuses, replace if
signal)
(fuses behind the flap on the
front panel of the crane cab)
Fuse S I 13 defective
(fuse at the rear on the SLI
plug-in module)
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SLI error The following table shows the different error messages on the SLI, the
message table cause of the error and how you can help if necessary.
Error messages from error group 1, sensory mechanism
Error Cause Action

message
1. 01. 1 Pressure sensor A, lower Check line; ➠ p. 14-40.

chamber does not react If line is O.K., switch off
pressure sensor 1;
➠ p. 14-38 and notify
GROVE Product Support
1. 01. 2...6 Pressure sensor A, lower Switch off pressure sensor 1;

chamber reports error ➠ p. 14-38 and notify
1. 01. 7 Notify GROVE Product Support
1. 01. 8 Information message; Message remains as long as

You have switched off the ignition is switched off
pressure sensor A because of
an error message
1. 02. 1 Pressure sensor B, lower Check line; ➠ p. 14-40

chamber does not react If line is O.K., switch off
pressure sensor 2;
1. 02. 2...6 Pressure sensor B, lower Switch off pressure sensor 2;

chamber reports error ➠ p. 14-38 and notify GROVE
Product Support

You have switched off the ignition is switched off
pressure sensor B because of
an error message
1. 03. 1 Pressure sensor upper Check line; ➠ p. 14-40. If line

chamber does not react is O.K., notify GROVE Product
Support
1. 03. 2...6 Notify GROVE Product Support

28.01.2000

1. 04. 1 Angle sensor A, Check line; ➠ p. 14-40.

basic section does not react If line is O.K., switch off angle
sensor A; ➠ p. 14-38 and
notify GROVE Product Support
1. 04. 2...6 Angle sensor A, Switch off angle sensor A,

basic section reports error basic section; ➠ p. 14-38 and

You have switched off angle the ignition is switched off
sensor A, basic section
because of an error message
1. 05. 1 Angle sensor B, Check line; ➠ p. 14-40.

basic section does not react If line is O.K., switch off angle
sensor B; ➠ p. 14-38 and
1. 05. 2...6 Angle sensor B, Switch off angle sensor B,

basic section reports error basic section; ➠ p. 14-38 and

You have switched off angle the ignition is switched off
sensor B, basic section
because of an error message
1. 06. 1 Length indicator A for Check line; ➠ p. 14-40.

telescope section IV does not If line is O.K., switch off
react length indicator A; ➠ p. 14-38
and notify GROVE Product
Support
1. 06. 2...6 Length indicator A for Switch off length indicator A

telescope section IV reports for telescope section V;
an error ➠ p. 14-38 and notify

28.01.2000
s

You have switched off length the ignition is switched off
indicator A for telescope
section IV because of an error
message
1. 07. 1 Length indicator B for Check line; ➠ p. 14-40.

telescope section IV does not If line is O.K., switch off
react length indicator B; ➠ p. 14-38
Support
1. 07. 2...6 Length indicator B for Switch off length indicator B

telescope section IV reports for telescope section V;
an error ➠ p. 14-38 and notify GROVE
Product Support

indicator B for telescope
section IV because of an error
message
1. 08. 1 Length indicator A of the Check line; ➠ p. 14-40.

telescoping cylinder does not If line is O.K., switch off
react length indicator A of the
telescoping cylinder;
1. 08. 2...6 Length indicator A of the Switch off length indicator A

telescoping cylinder reports of the telescoping cylinder;

indicator A of the telescoping
cylinder because of an error
message
1. 09. 1 Length indicator B of the Check line; ➠ p. 14-40.

telescoping cylinder does not If the line is O.K., switch off
react length indicator B of the tele-
28.01.2000
scoping cylinder; ➠ p. 14-38

Support

1. 09. 2...6 Length indicator B of the Switch off length indicator B

telescoping cylinder reports of the telescoping cylinder;

indicator A of the telescoping
cylinder because of an error
message
1.15.1...6 Inform GROVE Product Support
1.19. 1 Differences between main Check, length indicator, plug

boom length and length connections and supply lines;
indicator are too large. ➠ p. 14-40
The Actual load and Current Test telescope diagram from
radius displays are flashing outside.
Notify GROVE Product
Support if necessary.
1.21. 1 Differences between rope Notify GROVE Product

indicator and cable drum in Support.
the main boom are too large
The Actual load and Current
radius displays are flashing
Error messages from error group 2, digital inlets

Error Cause Remedy
message
2. 01. 1 Recognition of locking point
for telescopic section line
breakage
Check supply line; ➠ p. 14-40.
for telescopic section earth
contact
2. 01. 5 Inform GROVE Product Support
28.01.2000
s
2. 05. 1 Line breakage recognition

between SLI and rocker
switch Disconnect main hoist
2. 05. 4 Loose connection recognition Check supply line.
in the line between SLI and
rocker switch disconnect main
hoist
2. 06. 1 (only for additional
equipment)
line breakage recognition Check supply line
between SLI and
superstructure lock
2. 06. 4 (only for additional
equipment)
loose connection recognition Check the supply line
in the line between the SLI
and the superstructure lock
between SLI and rocker
switch Disconnect auxiliary hoist
2. 07. 4 Loose connection recognition Check supply line.
in the line between SLI and
rocker switch Disconnect
auxiliary hoist
for telescopic section line
breakage
for telescopic section earth Check supply line; ➠ p. 14-40.
contact
2. 11. 5 Inform GROVE Product
Support
2. 12. 1 Telescopic part locked
recognition (at the
telescoping cylinder) line
breakage
2. 12. 4 Telescopic part locked
recognition (at the
28.01.2000
telescoping cylinder) loose

connection


telescoping cylinder left
locked
2.13. 4 Loose connection recognition
telescoping cylinder left locked
2.13. 5 Inform GROVE Product Support
2.14. 1 Line breakage recognition
telescoping cylinder right
locked
2.14. 4 Loose connection recognition
telescoping cylinder right
locked
2.14. 5 Inform GROVE Product Support
2.17. 1 Key switch recognition Remove line SLI override or
Override line breakage check the supply line;
➠ p. 14-40.
2.17. 4 Key switch recognition Remove line SLI override or
Override loose connection check the supply line;
➠ p. 14-40.
Error messages from error group 3, kinematic system
Error Cause Remedy

message
3.02. 2 Communication with crane Check supply line; ➠ p. 14-40.

control interrupted
3.02. 4 Communications with crane Acknowledge fault and call up

control interrupted during teleautomatism again.
telescoping with
teleautomatism
3. 06. 3 Differences occurred in when the current telescope

comparison with the crane status is indicated on the
control telescope status; crane control display, take
(e.g. if the current telescope over telescoping from the
status was entered on the crane control; ➠ p. 14-40.
Crane control display after If neither the SLI not the Crane
mechanical emergency control display shows the
operation) current telescoping, inform
GROVE Product Support.
28.01.2000
s
Error messages from error group 5, Range of cranes

Error Cause Remedy
message
5. 03. 4 Main boom angle too small, Raise main boom
when working with jib
5. 04. 4 Main boom angle too small Raise main boom
5. 04. 6 Main boom angle too great Lower the main boom
Error messages from error group 6,

Display / fuses / relay
Error Cause Remedy
message
6. 09. 1...6 Fuse no. 1...6 defective Change respective fuse (1 to
12) on the rear of the SLI plug-
6. 10. 1...6 Fuse no. 7..12 defective
in module;
➠ Operating manual, chapter
on operational malfunctions of
the superstructure.
6. 20. 6...7 Excess temperature in the Improve ventilation in the
EKS-4 crane cab, Open maintenance
cover at the front of the crane
cab and wait until the error
message can be
acknowledged
Error messages from error group 8, software

Error Cause Remedy
message
8. 06. 4 Voltage on the SLI too low Load superstructure battery,
Test supply lines if necessary
11.05.2000
28.08.2000

Error Cause of error Countermeasure

message
9.01.2 The newly entered value for Confirm reeving and/or
the reeving or the rigging rigging mode
mode was not yet confirmed.
9.03.6 SLI is overridden Error message goes out
when the override is removed
H If further malfunctions not appearing in this table are displayed, contact

the GROVE Product Support responsible.
28.01.2000

Switch off sensor/ The SLI works with a two-channel sensory system in which most pressure
indicator during sensors, length indicators and angle sensors are in duplicate. If there is an
malfunction error on one of these sensors or indicators with a corresponding error
message, you can switch it off and thus cancel the SLI shutdown.
H
Then you can continue to work with the other channel without delay.
If you have switched off a sensor or pickup because of a malfunction,

immediately inform the GROVE Product Support responsible and have
the cause of error rectified as quickly as possible.
Switching off sensors or indicators

• Press the membrane switch Error information until the error message of
r the sensor or indicator which should be switched off appears on the
display Information.
This error message always ends with a sensor or indicator on one of the
!0"4 numbers 1 to 6 (e. g. the error message for the pressure sensor 2, lower
chamber).
• Press the membrane switch input mode and also the membrane switch
no Switch on 2nd level. Keep both membrane switches pressed.
• Press the Acknowledge membrane switch once and let go of all mem-
p brane switches again.
The last number in the error message now changes to an 8.
!0"8 With this final number you can see that a sensor or indicator is switched off.
H After switching off a sensor/indicator, you should check that the remai-
ning sensor/indicator is functioning correctly; ➠ p. 14-39.
Releasing shutdown
The sensor or indicator remains switched off until the ignition is switched off.
If you turn the ignition back on before the error has been eliminated, a
new error message will appear for this sensor or indicator (with a final
number of 2 to 6) and there will be another SLI shutdown.
28.01.2000

Check that the The Error message table ( ➠ page 14-30) shows next to the error mes-
remaining sage if the sensor/indicator which was switched off is
sensor/indicator – a pressure sensor,
is working – an angle sensor,
H
– a length indicator.
With the tests described here you can briefly test for the presence of the
function of the remaining sensor/indicator but there is no measuring accu-
racy.
Check pressure sensor

• Hoist the hook block without a load.
The remaining pressure sensor is functioning if the status display Actual
# !2 t load indicates the approximate weight of the hook block.
H The weight of the hook block is stated in the technical data in the operat-
ing instructions.
Checking an angle sensor

• Place the retracted main boom in the boom support.
The remaining angle sensor is functioning if the status display Current
# =0 n° main boom angle indicates 0° when the truck crane is aligned horizontally.
Checking the length indicator of the telescoping cylinder

• Completely retract the main boom and mechanically lock the tele-
scoping cylinder in telescope section I.
• Press the Entry mode membrane switch and the Hydraulic oil pressure
nl derricking cylinder lower chamber sensor B membrane switch.
The remaining length indicator is functioning if the Information display
# =0 indicates a length of approx. 0 m.
Checking the length indicator for telescope section IV

• Fully retract the main boom.
• Press the Entry mode membrane switch and the Hydraulic oil pressure
nk derricking cylinder lower chamber sensor A membrane switch.
The remaining length indicator is functioning if the Information display
28.01.2000
# =0 indicates a length of approx. 0 m.
s
Accepting the The SLI and the crane control detect the telescope status independently.
telescope status The SLI compares its displayed telescope status with the value which the
from the crane control has detected. If the values differ, the SLI deactivates, the sta-
crane control tus display Current telescope status flashes and the error message 3.06.3 is
displayed.
The error message can have two causes:

– Either, the malfunction is on the length indicators, the SLI or the crane
control
– or a telescope status was manually entered on the crane control display
which does not agree with the SLI display (e.g., after an emergency ope-
ration).
• Compare the current telescope status with the telescope status indi-
cated on the Crane control display:
– If the current telescope status is not indicated, a malfunction has occur-
red. Notify GROVE Product Support.
– If the Crane control display indicates the actual telescope status, you can
accept this telescope status into the SLI.
Accepting the telescope status

• Press the membrane switch Error information until the error message
r 3.06.3 is indicated on the status display Information.
§0&3
• Press the Entry mode membrane switch and additionaly Switch on 2nd level
no membrane switch. Hold down both membrane switches.
Press Acknowledge membrane switch and release all membrane switches
p again.
The telescope status from the crane control is now accepted and indicated
on the status display Current telescope status.
Checking SLI If there is an error message which indicates that a sensor or indicator
lines and connec- does not react any more or there is a line breakage or short circuit to
tions frame, the cause may be
28.01.2000
– a loose plug connection or

– a damaged line.

The defective sensor or indicator can be found in the error tables, the
following diagrams show where to find the control boxes with the plug
connections for the sensors and indicators and the central connections.
• Check the plug connections and their electric lines outside on the main
boom or the lattice extension (additional equipment).
1 Control box pressure sensors upper chamber and lower chamber
2 Plug connections under the main boom on the inner side of the
turntable (connection of indicators in the main boom)
3 Derricking cylinder lower chamber pressure sensor
4 Derricking cylinder upper chamber pressure sensor
5 SLI connecting box
6 Length indicator
7 Angle sensor basic section control box A and B

28.01.2000

14.4.11 Retraction emergency operation
If the locking mechanism on the head of the telescoping cylinder does not
react to the operating instruments in the crane cab any longer, malfunc-
tions in the electrical control system of the locking mechanism, the mecha-
nical system or the hydraulic system could be the cause. For these cases,
there is
– a mechanical emergency activation system with which you can
manually lock and unlock the telescope sections. This emergency mode
is for cases where the telescoping cylinder can no longer be moved
hydraulically. In this case you need one or two auxiliary cranes.
– a hydraulic emergency mode with which you can move the locking and
unlocking mechanism on the head of the telescoping cylinder directly.
This emergency mode is for cases where the telescoping cylinder can
still be moved but you cannot control the locking mechanism from the
with the operating instruments.
In the worst case, emergency operations must be carried out by trained
specialists because the risk of injury and damage to the main boom is too
great if one proceeds incorrectly. These cases are described later in the
section. Always check the following possibility first.
Check before all First check whether the main boom may be lowered into the horizontal po-
emergency sition with the current telescoping status and the current rigging mode of
operation the truck crane (if a lattice extension or a boom extension is rigged, the
main boom must be fully retracted for this purpose.) Proceed as follows:
• Enter the rigging code for the current rigging mode of the truck crane
on the SLI according to the Lifting capacity table.
H
• Lower the main boom.
If it is possible to lower but there is not sufficient space, you can check
whether the truck crane can be driven in the current rigging mode;
➠ Driving with the crane rigged, p. 12-97.
If the SLI allows lowering to the horizontal position,
danger from the raised truck crane is impossible and you can:
– check whether it is possible for you to carry out hydraulic emergency
operation in the horizontal position; ➠ When can hydraulic emergency
operation be carried out?, p. 14-46.
– carry out mechanical emergency operation without an auxiliary crane
using a personal transport vehicle because you can reach the locking
points with the extendable ladder.
28.01.2000

If the SLI switches off before you can lower the main boom to the
horizontal position,
you must:
– check whether it is possible for you to carry out hydraulic emergency
operation; ➠ When can hydraulic emergency operation be carried out?,
p. 14-46.
– have two auxiliary cranes ready for mechanical emergency operation,
one of them a registered personal transport vehicle.
Procedure for There are different procedures for retracting in emergency mode. Which
retracting procedure is is the best for your particular case depends both on which
functions are still possible and on the circumstances at the site.
You can e.g.:
– unlock the telescope sections in mechanical emergency mode if the

locking mechanism on the head of the telescoping cylinder is defective
and retract with an auxiliary crane (up to the section in which the tele-
scoping cylinder is located) or
– first extend the main boom with one or two auxiliary cranes far enough
that the main boom can be lowered to the horizontal position and then
retract the rest of the telescope sections in the horizontal position or
– if the electrical controller for the head of the telescoping cylinder is
defective, retract the telescope sections using hydraulic emergency
operation (with the main boom raised or horizontal, depending on
circumstances).
Not all possible situations can be described here, only activities for mech-
anical emergency operation and hydraulic emergency operation under
certain circumstances.
Select the best procedure for your particular case and seek advice from
the responsible GROVE Product Support specialists. This applies espe-
cially if the conditions for hydraulic emergency operation are different
than described here.
28.01.2000
s
Mechanical emer- Mechanical emergency mode must be used if the telescoping cylinder can
gency operation no longer be moved.
For manual unlocking and locking of the telescope sections, a screw is
screwed into the telescope section on each side above the locking pin.
This screw actuates a lever mechanism which pulls the locking pins into
the telescope section and thus unlocks the telescope section.
This screw is unscrewed again for manual locking.
The main boom is designed so that emergency activation of the locking
H
devices can be achieved from the outside at all possible fixed lengths.
If the telescoping cylinder is in the foot section of the telescope section, it

will not be possible to lock and unlock this telescope section by hand.
The following prerequisites must be fulfilled before you manually release

the locking device on a telescope section:
– The telescope section which is to be unlocked is slung onto an auxiliary
crane with sufficient load bearing capacity and is therefore secured
against independent retraction
– or the main boom is lowered to the horizontal position so that the tele-
scope section cannot retract independently.
For manual unlocking a total of eight M 20 set screws and an appropriate

screwdriver are supplied with the truck crane. For every telescope section
their are two set screws with the following lengths:
Unlocking of Length of the

corresponding threaded
pin M 20
telescopic part I 130 mm
telescopic part II 100 mm
telescopic part III 65 mm
telescopic part IV 65 mm
28.01.2000

You can manually lock or unlock a telescope

section only if the recess (2) in the locking
pin does not engage the telescope section
above it any longer.
• Extend the telescope section approx. 2 cm

(with an auxiliary crane if necessary). The
locking pin (1) must be in the center of the
opening and the recess (2) must not en-
gage the telescope section above it any
longer.
Releasing the lock

• Screw a screw into the bore (1).
The locking pin (2) is retracted.
• Screw in the screw against the spring
weight so that the locking pin (2) is
inserted as far as possible and is behind
the side panel of the telescope section (3).
Now the lock has been manually released on
this side.
• Also release the lock on the other side of

the telescope section.
Locking telescope sections

• Retract the telescope until the locking pin
(2) is in the middle of the opening.
• Unscrew the screw from the bore (1).
The locking pin (2), under spring weight, is
pushed out of the opening.
• Continue to retract the telescope section

until it is set onto the recesses on the
locking pin.
28.01.2000
s
Hydraulic emer- If the electrical supply line on the head of the telescoping cylinder is cut,
gency operation the locking and unlocking functions for the telescoping cylinders and the
telescope section can no longer be controlled from the crane cab. The
truck crane is equipped with a hydraulic emergency mode for this case.
When can hydraulic emergency operation be carried out?
You may only carry out hydraulic emergency operation if:
– the truck crane is in a state in which emergency operation can be
carried out without damaging the boom and
– you can still see the current status of the telescoping cylinder in the
crane cab.
• First check the status of the truck crane using the following diagram. Go
through the questions in the diagram consecutively and compare the
specifications with the status of your mobile crane and go to the next
question depending on the answer (yes/no).
The Crane control display shows:
– either in the third line the message - NOT CONNECTED

(and before the error message UNIT 01 : 00000010 was shown
➠ Error messages via control units, p. 14-57.)
– or in the second line the number string starting with 1 - STATUS : 1 0 0
(in this case you are asked to enter a keycode;
➠ Emergency program submenu, p. 14-70.)
Yes No
Check whether the current status of the telescoping cylinder can still
be read in the crane cab; ➠ p. 14-47.
None of the measures

in the section Malfunc-
Yes tions of the telescoping
No gear, p.14-22 lead to a
correction of the
problem.
Check if the telescoping cylinder is locked with the telescope
section:
– unlocked telescope section can be telescoped
– or, if the telescope section is locked, the length data for
– the telescoping cylinder does not change during telescoping
Yes No
Consult GROVE
Product Support
Prepare necessary equipment ➠p. 14-48.
28.01.2000
and prepare truck crane for emergency operation

S
Risk of damage to the main boom!
If you reach a field where you are referred to GROVE Product Support,
you may not carry out hydraulic emergency operation because the main
boom could be damaged. In this case hydraulic emergency operation can
only be carried out with the help or consultation of trained and properly
qualified personnel.
Consult GROVE Product Support!
Check if length data can be read

You may only carry out hydraulic emergency operation if the extended
length of the telescoping cylinder is still shown.
• Check if the current extended length of the

bottom right telescoping cylinder is shown
in the Crane control display (e.g. 9.31 m).
TELESCOPING If nothing more is displayed here, you can

have the extended length displayed on the
STATUS: 001
SLI.
EMERGENCY OPERATION
TELE: –– L: 9.31 m
• Press the Entry mode membrane switch and the Hydraulic oil pressure of
no derricking cylinder lower chamber sensor B membrane switch.
• Check if the extended length of the telescoping cylinder is now shown
)3 in the Information display.
• Check if the displays are activated. To do this move the control lever for
telescoping out and check if the value for the extended length changes.
If the telescope section is locked you must press valve Y 2306;
➠ p. 14-49.
S
Never carry out hydraulic emergency operation if no display is available.
Otherwise you no longer have any possibility to monitor and can damage
components in the boom or put the boom in a condition in which it can
no longer be extended or retracted.
28.01.2000
s
Connections, equipment and operating elements for emergency operation

Two hydraulic hoses (1) are delivered for
hydraulic emergency operation.
The first ends of the hoses are connected
directly with two connections (4) on the head
of the telescoping cylinder.
The other ends of the hoses are connected
alternately to the emergency supply (2).
The corresponding hydraulic circuit is
cleared via ball valves (5).
The required function can then be controlled
with the control unit of the counterweight lift-
ing gear (3).
Then the required function can be actuated
with the Superstructure lock (3) rocker switch.
Preparing the truck crane for emergency operation

During emergency operation, you have to actuate the Superstructure lock
rocker switch, among other things. In order that the superstructure is not
unintentionally unlocked or that the locking pin does not move needlessly
on the carrier, you should secure it.
For this purpose, there is the safety tap (1)

between the storage box and the turntable at
the superstructure lock.
• Close the safety tap (1). The tap is closed

when the handle is diagonal to the line.
The locking pin can now no longer be moved.
To connect the hoses for emergency operation, you must retract the tele-
scopic section with which the telescoping cylinder is locked. You have to
28.01.2000
override the SLI in order to retract.

G
Risk of accidents from overridden SLI!
If you override the SLI to retract in emergency mode, crane operation is
no longer monitored. Always put down the load for emergency operation.
• Put down the load.

• Override the SLI. To do this turn the Override key-operated switch to the
right.
If the telescope section is located at a locking point at the beginning of

telescoping or moves over a locking point during telescoping, the tele-
scope section locks there.
To unlock telescopic section , the hydraulic

valve Y 21 33 has to be pressed.
The valve (1) is on the valve block, in front of
the hydraulic tank.
• Have a second person hold valve Y 21 33

pressed.
• Press the Superstructure lock rocker switch
(§) down and keep it in this position.
• Move the control lever to retract.
Pressure now builds up on the locking me-
chanism; the telescope section is unlocked
and retracted.
As soon as the telescopic section has moved further about 10 cm, the
Y 21 33 valve and the Superstructure lock rocker switch can be let go. The
locking pins move again and come to rest against the inside wall of the
H
telescopic section which is above this.
If the locking pins cannot be retracted, the telescope section is stuck in the
recesses of the locking pins.
In this case extend the telescope section approx. 3 cm so that the locking
28.01.2000
pins can be retracted.
s
Connecting the hydraulic connections for emergency operation

• Raise the main boom until the rear
opening (3) can be reached.
• Put the two delivered hydraulic hoses (2)
in the middle of the turntable. Make sure
that the hoses do not become twisted or
knotted together.
• Guide both ends (1) to the oil cooler via
the side of the turntable.
• Guide the two other hose ends through the
rear opening (3) into the basic section.
These ends are connected to the telescop-
ing cylinder.
S
Risk of damaging the hydraulic hoses!
Always guide the hydraulic hoses through the rear opening in the basic
section. If you guide the hydraulic hoses through the manhole at the top
of the basic section the hydraulic hoses will be cut during retracting.
In order to connect the hydraulic hoses, you reach the telescoping

cylinder:
– either through the rear opening in the basic section
– or, if you can extend telescope section I approx. 2 m, through the man-
hole at the top of the basic section.
G
Risk of crushing from unintentional retraction!
Secure the main boom against unintentional retraction before you reach
into or enter the manhole in order to connect the hydraulic hoses. During
retraction, the telescope sections move into the area of the manhole and
can crush you or your limbs.
28.01.2000

The hydraulic hoses are connected directly

to the head of the telescoping cylinder.
• Insert the quick couplings in the two con-

nections (2) and (3).
• Close the two valves (1) and (4). The
valves are closed if the handles are per-
pendicular to the lines.
• Mark a hose on the other end. For emer-
gency operation it is important that you
know which hose is connected with the
right connection (2) and which hose with
the left connection (3).
Operating the locking/unlocking mechanism in emergency mode

The connection (1) for the emergency supply
is on the left side of the turntable, in front of
the tilt cylinder of the counterweight hoist
unit.
One of the two hydraulic hoses is connected

to this connection for emergency operation.
The following table shows which telescoping
cylinder connection you must connect with
the emergency supply so that you can lock
and unlock the telescope section or the tele-
scoping cylinder.
Function Make connection between

emergency supply and
Lock/unlock telescope section hose on connection 2 of the

telescoping cylinder (right)
Lock/unlock telescoping cylinder hose on connection 3 of the

28.01.2000
telescoping cylinder (left)
s
H A hydraulic/mechanical safety circuit blocks the simultaneous unlocking

of the telescope section and the telescoping cylinder. You can only unlock
the telescoping cylinder if the telescope section is locked. The telescope
section can only be unlocked when it is locked with the telescoping
cylinder.
• Attach the appropriate hose for the

required locking/unlocking.
– To lock/unlock the telescoping cylinder,
the left connection (3) on the telescoping
cylinder must be connected with the emer-
gency supply.
– To lock/unlock the telescope section, the
right connection (2) on the telescoping
cylinder must be connected with the emer-
gency supply.
Unlocking
To unlock a telescopic section, you have to telescope out the telescopic
section about 3 cm.
• Press the Superstructure lock rocker switch down. The locking pins will be
§ drawn in.
Locking
• Let the Superstructure lock rocker switch go. The locking pins will extend
§ again.
28.01.2000

Retracting with hydraulic hoses connected

If you have retracted the telescope section in which the telescoping cylin-
der was locked when the malfunction occured and the hoses are connec-
ted for hydraulic emergency operation, you can retract the main boom
completely.
S
If the telescope sections I and II are both extended to 100 % or telescope
section I to 50 % and telescope section II to 50 % you must not unlock
and retract the telescoping cylinder. In this way you can prevent the end
of the telescoping cylinder coming out of the guide in telescope section II
and falling into telescope section I.
In this case the main boom could no longer be extended or retracted.
S
Risk of damaging the hydraulic hoses!
While you telescope the main boom, a second person must ensure that
the two hoses run through the rear hole in the basic section and back out
without blockage or kinks.
Always stay in visual contact with this person during telescoping so that
you can stop telescoping immediately in an emergency.
S
Risk of damaging the hydraulic hoses when raising!
When raising the main boom the hydraulic hoses may get crushed. Be-
fore you raise the main boom you must therefore remove the hydraulic
hoses or place them so that they can not be crushed during the raising
process.
H
• Retract the telescope section until it has reached its locking point at 0 %.
If the telescopic section locks at the locking point at 50 % during retract-

ing, then unlock it. Press the Superstructure lock rocker switch down, tele-
scope in about 10 cm and let go of the rocker switch again.
When the telescope section has reached the locking point at 0 %, it is

locked by the spring force.
• Put the telescope section on the recesses of the locking pins. To do this
retract the telescope section slowly until the value for the extended
length of the telescoping cylinder no longer changes).
Now the telescopic section retracted and locked, and you can move the
telescoping cylinder to the next telescopic section. Proceed as follows:
28.01.2000
s
• Make the necessary connection for the emergency supply for locking/
unlocking the telescoping cylinder (left connection).
• See the table Extended lengths of the telescoping cylinder at the locking points
(➠ p. 14-55) for the length data for the locking point of the next exten-
ded telescopic section.
• Unlock the telescoping cylinder. To do this, press the Superstructure lock
§
H
rocker switch down and keep is in this position.
Keep the Superstructure lock rocker switch depressed while you extend the
telescoping cylinder. If you release the rocker switch, the locking pins ex-
tend and the telescoping cylinder will not reach the locking point of the
next telescopic section because the locking pins will strike the foot section
beforehand.
• Extend the telescoping cylinder until it is at the locking point.

If the Telescoping cylinder at locking point indicator lamps are still activated,
8 you can also recognisze the position of the telescoping cylinder in relation
to the locking point as well as details regarding length; ➠ p. 10-39
9
• Lock the telescoping cylinder to the telescopic part by letting go of the
§ Superstructure lock rocker switch.
H If the Telescoping cylinder at locking point indicator lamps are not activated,
you can check as follows if the telescoping cylinder is locked:
At the locking point at 0% in the basic section you can see the locking pins
of telescopic section I. Extend the telescoping cylinder slowly. The tele-
scoping cylinder is locked when the locking pins of telescopic section I
also move.
Now you can unlock the telescopic section.
• Make the necessary connection for the emergency supply for locking/
unlocking the telescopic section (right connection).
• Extend the telescopic section approx. 3 cm so that the telescopic secti-
on is no longer on the recesses.
• Unlock the telescopic section by pressing the Superstructure lock rocker
switch down and keep is in this position.
• Retract the telescopic part. As soon as the telescopic section has moved
further by about 10 cm, you can let go of the Superstructure lock rocker
switch. The locking pins extend further and come to rest against the in-
28.01.2000
side wall of the telescopic section above this point.

• Repeat all steps in the Section Retracting with connected hydraulic hoses until
all telescope sections are retracted or until enough telescope sections
have been retracted for the main boom to be placed.
After telescoping in hydraulic emergency mode

When you retract the main boom while the electrical connection to the
head of the telescoping cylinder is cut, you must enter the current tele-
scope status in the crane control system after the repair; ➠ Entering tele-
scope status after emergency operation menu, p. 14-76.
Extended lengths of the telescoping cylinder at the locking points
Telescope section Locking point Extended length of

at fixed length the telescoping
[%] cylinder [m]
0 0.00
T1 50 4.78
100 9.55
0 0.31
T2 50 5.08
100 9.85
0 0.60
T3 50 5.37
100 10.14
0 0.88
T4 50 5.65
100 10.42
• After emergency operation, reopen the safety tap at the superstructure

lock; ➠ Prepare the truck crane for emergency operation, p. 14-48.
28.01.2000

Blank page
28.01.2000

14.5 Crane control error messages
14.5.1 Error messages about control units
Three control units belong to the crane

control: If one control unit fails, the Crane
control display displays an error message as
in the diagram opposite:
ERROR MESSAGE SYSTEM is in the second line. In the third
SYSTEM line you will find UNIT 0, 1 or 2, for the
UNIT 1: 00000010 control units on the connections 0 to 2.
The number code in the fourth line is of
STATUS: 0 0 0 0 0 0 1 0
secondary importance.
The following table shows which crane functions are out of operation
when the control unit fails on a connection:
Error message Error and Action

on the display effect
Control unit defective at By reconfiguring the

connection 0, function of connection lines to
UNIT 0: the crane control, main another control unit, the
and auxiliary hoist truck crane can be rigged
blocked for on-the-road mode;
➠ Reconfiguring the
Control unit defective at connections for the control
connection 1, function of units, p. 14-64
UNIT 1: telescoping gear function,
derricking gear blocked
Control unit defective at

connection 2, slewing
gear and high-speed
function, counterweight
UNIT 2: lifting cylinder and locking
pins, superstructure lock
and (for additional
equipment) crane cab
incline blocked
28.01.2000

14.5.2 Error messages about power units
If there is an error message about power

units it will appear in the second line of the
affected power unit (e.g. the telescoping
gear). You also get different entries and num-
ERROR MESSAGE
ber codes in the two bottom lines.
TELESCOPING GEAR
J3502: 01000000
STATUS: 0 0 0 0 0 0 0 1
If you have already acknowledged the error message, you can call up the
+ Display states menu and then
>the memory error submenu and view the
error message there again; ➠ Display states menu - Memory error submenu,
p. 12-84.
In the first line you will see the message

ERROR MEMORY and the number of the
error (e.g. 3). The displays in the other lines
are the same as with the error message.
MEMORY ERROR 3
TELESCOPING GEAR The messages here are only an example
Y2301: 00 000001 which will be dealt with at the end of the
following sections.
STATUS: 0 0 0 0 0 1 0 0
Using the messages in the bottom two lines you can

– determine the part on which the error occurred; ➠ Determining defective
part, p. 14-59.
– determine the area of the error, depending on the detected part;
➠ Determining error area, p. 14-60.
– locate more precisely the cause of the error; ➠ Error causes and effects,
H
p. 14-61.
In the following sections you will find more information on the displayed
errors. If, in the sections, you are asked to contact GROVE Product Sup-
port, please note down the number code beforehand and have it ready.
When you have noted down the error codes you can acknowledge the
Ö error message. To do this press the ENTER key.
After you have carried out the acknowledgement process, the display
shows the indication which was displayed before the error message.
28.01.2000

Determining The first message in the third line of the display describes the defective
defective part part (e.g. Y2301). The following table shows all the possible messages
and their meaning.
Message Error Further troubleshooting
J3501
Error on a control lever
J3502
A3502 Error on length indicator Determine cause of

error; ➠ Error causes and
Error with the
effects, p. 14-61.
A100 communication with the
SLI
Logic error detected by

ECOS
crane control
Error on another part Determine error area;

Other message
(e.g. Y3201)
(valve, digital input, ➠ Determining error area,
pressure sensor) p. 14-60.
Example
In the display used as an example there is the

message Y2301; according to the table there is
an error on a part whereby you must first deter-
ERROR MEMORY 3 mine the area of the error before you can deter-
TELESCOPING GEAR
mine the cause of the error.
Y2301: 01000000
STATUS: 0 0 0 0 0 1 0 0
28.01.2000
s
Determining With some parts (e.g. a valve), you must first determine the error of the
error area area in order to get to the cause of the error.
The area where the error is is shown by the number code in the last line
behind STATUS (e.g. 0 0 0 0 0 1 0 0 ). The following table shows possible
number codes and the corresponding areas.
Number code Error in area Further troubleshooting
00000001 Control lever
00000010 Digital input
00000100 Output
Determine cause of error
00001000 Analogue input in the affected area;
➠ Error causes and effects,
CAN-Bus (always p. 14-61.
00010000 displayed together with
ECOS, A100 or A3502)
ECOS (also displayed as

10000000
a part)
Example
In the display used as an example the number

code 0 0 0 0 0 1 0 0 is in the last line.
The table assigns this number code an error in
ERROR MEMORY 3 the output area.
TELESCOPING GEAR The “output” area is in the table in the next sec-
Y2301: 01000000 tion. Here you can determine the cause of the
STATUS: 0 0 0 0 0 1 0 0 error in this area.
28.01.2000

Error causes and Once you have determined the defective part or the area where the error
effects is, the table will give you more information on the cause and the effects.
In this table the number code in the third line behind the part
(e.g. 0 0 0 0 0 0 0 1 behind Y 2301) is decisive.
Defective Number code in Cause of error Effect/

part the third line on Remedy
or area the display
00000001 Analogue
indicator in
00000010 control lever
defective Control lever
Earth contact/ emergency
00000100 programme is
Control lever line breakage
activated;
J3501 or
J3502
00001000 24V short ➠ p. 14-68.
Earth contact/
00010000 Notify GROVE
line breakage
Product Support
00100000 24V short
Mechanical
01000000
error
Length No data
00000001 Inform GROVE
indicator reception
Product Support
A3502 00000010 Hardware error
00000001 When there is no
Communica- No data
display on the SLI,
tion with SLI reception from
00000010 check fuse SI13;
A100 SLI
➠ p. 14-13.
After acknow-
ledgement start
Locking status the menu
00000001
unrealistic Emergency operation
ECOS access;
➠ p. 12-90.
displayed
00001000 telescope status ➠Telescoping error
messages, p. 14-63
incorrect
Line breakage/
00000001 Inform GROVE
Digital input 24V short
Product Support
00000010 Earth contact
28.01.2000
s
Defective Number code in Cause of error Effect/

part the third line on Remedy
or area the display
Line breakage/
00000001
24V short
00000010 Earth contact
00000100 Line breakage Inform GROVE
Output
Product Support
Output
00001000
overloaded
Output
00010000
underloaded
00000001 24V short
Analogue Notify GROVE
input Earth contact/ Product Support
00000010
line breakage
Example
In the display used as an example the number

code 0 0 0 0 0 0 0 1 is in the third line.
In the previous section we determined that the

MEMORY ERROR 3
error was in the output area.
TELESCOPING GEAR According to the table this number code means
Y2301: 00000001 that there is a line breakage or 24V short.
STATUS: 0 0 0 0 0 1 0 0 In this case you must inform GROVE Product
Support and have the supply line checked.
28.01.2000

14.5.3 Telescoping error messages
If the crane control recognises a divergence between the displayed and

the current telescope status, the following crane movements will be
switched off:
– retracting and extending,
– locking and unlocking telescoping cylinders,
– locking and unlocking telescope sections.
The error message Divergent telescope status is

displayed by the following number codes:
ECOS 00001000
ERROR MESSAGE
STATUS 10000000
LOCKING SYSTEM
ECOS : 00001000
STATUS : 10000000
• Acknowledge the error message.

Ö
If the Display telescope status and teleautomatism
menu was selected before the error message
occurred, the crane control switches directly
to the menu to enter the telescope status.
SET TELESCOPING
> T1 < T2 – T3 – T4 –
– ● – 0 – 0 – 0 –
H If you had selected another menu before the error message, select:
– either the Show telescoping and teleautomatism menu at (
ä
the crane control changes directly to the menu for entering the
telescoping
),
– or you directly select the Enter the telescoping after emergency operation
menu (3 x
Ä).
• Enter the current telescoping in the crane control;

➠ Entering telescoping after emergency operation, p.14-76.
28.01.2000

14.5.4 Changing the connections in the control units
Connections and The control units are behind the crane operator’s seat.
control units
S
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove connec-
tions from or insert them in the control units. If the ignition remains
switched on, data necessary for the operation of the crane (e.g. the tele-
scope status) can become lost or damaged.
If this data is not available there will be malfunctions during the next
crane operation.
Crane control Slewing gear, fast traverses,
main hoisting gear, Telescoping gear, counterweight lifting cylinder
auxiliary lifting gear (additional derricking gear and locking, cabin inclining,
equipment) superstructure locking
Control unit Control unit Control unit
The crane control has three connections which are labelled 0, 1 and 2.
Each connection is inserted into a control unit and connects this with the
different power units. If this control unit fails, the power units connected
with it can no longer be driven. You can activate the power units again in
an emergency by changing this connection to another control unit. You
can thus unrig the truck crane when there is a defect on the control unit,
as described in the following.
Unrigging If, for example, the control unit under the 0 connection fails, you can no
mobile crane longer move the power units on this connection (main hoist, auxiliary
with defective hoist) and the whole crane control is blocked. You can therefore not move
control unit any more power units.
The display shows an error message over UNIT 0.
28.01.2000

H At least two control units must be still intact to unrig the truck crane. If
two control units fail you will need at least one new control unit to be able
to unrig the truck crane. It is possible to put down a load without a control
unit, however.
If, for example, the control unit is defective at connection 0, you can reac-
tivate the crane control and the failed driving gears by pulling out the con-
nection from another control unit (e.g. 2) and inserting connection 0 in
this control unit;
➠ Inserting and removing connections, p. 14-67.
e.g. defective
H After connection 2 has been removed, the crane control shows the rele-
vant error message UNIT 2. You can acknowledge this error message.
You can now carry out all crane movements connected with connections
0 and 1:
– putting down the load with the main and auxiliary hoist,
– telescoping and
– derricking.
All driving gears which are linked to connection 2 will now be out of oper-
ation (slewing gear, fast speed, counterweight lifting cylinder and locking
device, superstructure lock, incline cab (additional equipment).
If you need the slewing gear when unrigging, you must change the con-
nections again.
28.01.2000
s
To drive the slewing gear, for example, remove connection 1 from the
control unit and insert connection 2 into this control unit.
e.g. defective
H Do not remove connection 0, this connection serves the crane control

and must always be inserted in an intact control unit. Depending on the
required crane movement, always insert either connection 1 or 2 in the
intact control unit.
You can thus carry out all crane movements for unrigging the truck crane
after each other. There are only two ways in which the connections need
to be inserted for a required crane movement:
– either connections 0 and 1 (for main/auxiliary hoist,

slewing gear and fast speeds)
– or connections 0 and 2 (for main hoist/auxiliary hoist,

derricking gear, telescoping gear
superstructure lock,
Counterweight lifting gear and
H
locking bolts, tilt cab)
As long as a connection is removed, the crane control shows the

corresponding malfunction (UNIT 1 or UNIT 2). You can acknowledge the
malfunction for unrigging so that you can, for example, track the tele-
scoping on the display.
Replace the defective control unit before the next job!
28.01.2000

Inserting All connections are equipped with plugs and safety holders.
and removing
connections
• Turn the ignition off in the crane cab before you remove connections
from or insert them in the control units.
S
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove con-
nections from or insert them in the control units. If the ignition remains
switched on, data necessary for the operation of the crane (e.g. the tele-
scope status) can become lost or damaged.
If this data is not available there will be malfunctions during the next
crane operation.
All connections are equipped with plugs and safety holders.
Removing connections
• Remove the holder (1) and then the plug
(3) from the control unit (2).
Inserting connections
• Check if the holder (1) is pulled out.
• Put the plug (3) on the control unit (2).
• Push the holder (1) in until you hear it
engage.
28.01.2000

14.5.5 Control lever emergency program
If a control lever is blocked because of a malfunction, the Crane control dis-

play shows one of the two following messages in the third line:
J3501: 0 0 0 0 0 0 0 1 or J3502: 0 0 0 0 0 0 0 ; ➠ Error messages via power
units, p. 14-58.
Indications on
the display
• Call up the menu Control lever emergency program on the Crane control
ü display. To do this press the membrane switch Control lever emergency
program once.
In this menu you will see the message
EMERGENCY PROGRAM in the first line.
In the second line the control lever to which
the messages in the two lower lines refer
EMERGENCY PROGRAM (e.g. RIGHT CONTROL LEVER) is displayed.
RIGHT CONTROL LEVER
X AXLE: OFF
Y AXLE: ON
By repeatedly pressing the membrane switch Control lever emergency

ü program the message alternates between the left and the right control lever.
The message X axle indicates the extension

to the left and right.
The message Y axle indicates the extension

EMERGENCY PROGRAM forward and back.
RIGHT CONTROL LEVER
X AXLE: OFF If the emergency program for a control lever
extension is switched on, ON appears next
Y AXLE: ON
to the corresponding control lever extension.
The emergency program is switched on auto-
matically with the displays of the error
message.
In the example illustrated here, the message ON is next to the Y AXLE of

the right hand control lever. The functions which are controlled by extending
this control lever forward or back are thus blocked. You can therefore carry out
the main hoist functions Lift and Lower only with the emergency programme.
28.01.2000

Carrying out To carry out the emergency program you must extend the defective
emergency control lever and also press a membrane switch.
program
• Press the membrane switch Control lever emergency program until the
ü defective control lever is indicated on the display (message ON).
• Extend the control lever in the desired direction (e.g. the right hand
lever forward – to Lower the main hoist).
• Also press the corresponding membrane switch next to the display:
Press this membrane switch also when you have extended the control
: lever forward (in this example you would need to activate this switch).
In addition, press the membrane switch when you have extended the
< control lever back.
* control lever to the left.
+ control lever to the right.
As soon as you activate the corresponding switch for extending the

control lever, the crane movement (e.g. lower main hoist) starts.
H
• Let go of the switch or the control lever to stop the crane movement.
In the emergency program all crane movements are restricted to 10 % of

the maximum speed.
28.01.2000

14.5.6 Emergency operation submenu
Emergency operation serves the purpose of allowing you to retract the

main boom for on-road driving, so that the machine can be driven to a lo-
cation where repair can take place.
Emergency operation is not designed for crane operation and therefore
can be used only for a limited time.
Emergency operation is started only when the respective error message
has been confirmed followed by entry of the correct key code in the Access
emergency operation submenu.
The submenu can be recognised by the mes-

sage EMERGENCY OPERATION in the third
line.
TELESCOPING
The remaining running time is displayed on
STATUS: 0 0 1 the left in the fourth line (e.g. 180 secs.).
EMERGENCY OPERATION When the time has run out, the display
switches again to the Access emergency opera-
T: 180 s L: 8.40 m tion submenu and you can re-start emergen-
cy operation.
The three-digit number code (e.g. 001) after

the message STATUS in the second line indi-
cates which error the crane control recog-
TELESCOPING
nized.
STATUS: 0 0 1
EMERGENCY OPERATION
T: 180 s L: 8.40 m
Deciphering the number code:

0 0 1: – Length indicator faulty
0 1 0: – Proximity switch faulty or signals received through
locking status are unrealistic
1 0 0: – Error recognised in a valve for the locking mechanism.
When multiple errors occur simultaneously, all errors are displayed simul-
H
taneously with a 1 at the respective position.
If a 1 is displayed at the first position of the number code (e.g. 1 0 0),

the locking and unlocking mechanism can no longer be operated. In this
case, consult the responsible GROVE Product Support. As long as this
28.01.2000
error is present, you can only retract the main boom with mechanical
emergency operation; ➠ Retract emergency operation, p. 14-42.

G
Never telescope the main boom if both the length indicator and the proxi-
mity switch have failed, i.e. with the number code 1 0 1 or 1 1 1. Other-
wise you will no longer have any possibility to monitor and can damage
components in the boom or put the boom in a condition in which it can
no longer be extended.
S
Depending on which error has occurred, you can only track the telescop-
ing with certain warning and indicator lights. Use as a guide only the
lights which are stated for the respective error in the following sections.
If you observe the incorrect indicator and warning lights, boom compo-
nents could be damaged or you could put the main boom in a condition
in which telescoping is no longer possible.
When you are in the Emergency operation menu, all functions for tele-
scoping in the main boom are still released as long there are no other
errors (hydraulic or mechanical).
If the error is due to a proximity switch (number code 0 1 0);

➠ Retracting with an error on the proximity switch, p. 14-74.
If the error is due to a length indicator (number code 0 0 1), retract the
main boom as described in the following section:
Retracting with If the error is on the length indicator, you can no longer read the extended
an error on the length of the telescoping cylinder on the Crane control display.
length indicator The following status display elements are still available:
Check the position of the locking pins of the telescoping cylinder and tele-
ihjj scope section with the red warning/green indicator lamps Telescoping cylin-
der unlocked and locked and Telescope section unlocked and locked.
Check the telescoping at the SLI display

1 2 3 4 Current telescoping telescopic section I to IV.
!= != != != C0645
28.01.2000
s
H To have the current extended length of the telescoping cylinder displayed

by the SLI in the Information display, proceed as follows:
Press the Entry mode membrane switch and the Hydraulic oil pressure of
no derricking cylinder lower chamber sensor B membrane switch.
The display Information now indicates the current extended length in

/2 meter of the telescoping cylinder.
The table on page 14-75) shows at which length the telescoping cylinder
is at the locking points of the individual telescope sections.
Before you telescope:

– both indicator lamps Telescoping cylinder at locking point must be lit (then
89 the telescoping cylinder is at the locking point); ➠ p. 10-39
– the telescoping cylinder has to be locked with the telescopic section;
h the Telescoping cylinder locked indicator lamp has to light;
– the telescopic section has to be unlocked; the telescopic section unlocked
j warning lamp has to light;
– the Select locking/unlocking rocker switch has to be pressed upwards in
. the Unlock telescopic section position.
Retracting the telescope section
S
As you are telescoping the telescope section, you must not activate the
rocker switch Select locking/unlocking. If you switch the rocker switch to the
central position the locking pins on the telescope section are slid out im-
mediately and they can damage or tear the electrical or hydraulic compo-
nents in the main boom.
• Only telescope the telescope section slowly.

• Telescope in the telescope section as far as possible.
• Extend the locking pins on the telescope section by putting the rocker
switch Select locking/unlocking in the central position.
28.01.2000

The locking pins on the telescope section are slid out, the green indicator
jj lamp Telescope section locked lights up and the red warning lamp Telescope
section unlocked goes out.
• Unlock the telescoping cylinder. To do this press the Select locking/unlock-

. ing rocker switch down.
Extending the telescoping cylinder without the telescope section
S
As you are extending or retracting the telescoping cylinder, you must
never operate the rocker switch Select locking/unlocking. If you switch the
rocker switch to the central position, the locking pins on the telescoping
cylinder are slid out immediately and they can damage or tear the elec-
trical or hydraulic components in the main boom.
• Extend the telescoping cylinder slowly.

• Extend the telescoping cylinder to the locking point of the nearest foot
section. The locking point has been reached if both Telescoping cylinder at
locking point indicator lamps are lit.
89 The Information display shows the respective extended length of the
%08 telescoping cylinder (e.g. 5.08 m for the locking point of telescope sec-
tion II at 50 %, values ➠ p. 14-75)
S
Risk of damaging the telescoping gear!
To check the position of the telescoping cylinder in relation to the locking
point, always observe both display elements (indicator lamp and display
Information).
In this way, you avoid going beyond the locking point and damaging the
telescoping gear in case a display element fails (e.g. if the position light is
faulty or if a proximity switch fails).
• When you have reached the locking point, lock the telescoping cylinder.
. To do this move the rocker switch Select locking/unlocking to the central
position.
When the telescoping cylinder is locked, the green indicator lamp Telesco-
h ping cylinder locked lights up.
28.01.2000
s
H If you have retracted the main boom with a defective length indicator, the
current telescope status does not correspond with the last telescope sta-
tus stored from the crane control. You must input the current telescoping
status on the Crane control display after repairs and before the next crane
operation; ➠ Enter telescope status after emergency operation menu, p. 14-76.
Retracting with If the error is on a proximity switch of the locking pins, one or more of the
an error on the following warning and indicator lamps no longer display the actual values:
proximity switch
– Warning lamp Telescoping cylinder unlocked,
i – Warning lamp Telescope section unlocked,
j – Indicator lamp Telescoping cylinder locked,
h – Indicator lamp Telescope section locked.
j When locking the telescoping cylinder, observe the following:
• Always move the telescoping cylinder to
the correct length for the locking point be-
fore you lock it with the telescope section.
The length is indicated on the Crane control
TELESCOPING
display (e.g. 5.08 m for the locking point of
– 0 – 0 – 0 – 0 telescope section II at 50%, values
EMERGENCY OPERATION ➠ p. 14-75)
T. 180 s L: 5.088 m
• After locking, check that both locking pins are extended:

Carefully try to extend or retract the telescoping cylinder. If both locking
pins are extended, the indicated length L must not change.
Otherwise, you can retract the main boom exactly as with an error on a
H
length indicator (➠ p. 14-75).
Some warning and indicator lamps may show correct displays of the
locking status. While locking and unlocking, you can check if individual
H
lamps still display correctly.
When there is an error on a proximity switch, the hydraulic/mechanical

safety circuit continues to prevent the simultaneous unlocking of the tele-
scope section and the telescoping cylinder, but this is no longer electron-
ically monitored.
28.01.2000

Table for The following table shows the extended length of the telescoping cylinder
approaching the at the locking positions of the various telescope sections.
locking points
Telescope section Locking point Extended length of the

at fixed length telescoping
[%] cylinder [m]
0 0.00
T1 50 4.78
100 9.55
0 0.31
T2 50 5.08
100 9.85
0 0.60
T3 50 5.37
100 10.14
0 0.88
T4 50 5.65
100 10.42
28.01.2000

14.5.7 Entering telescope status after emergency operation menu
When you have retracted the main boom with the emergency operation,
or when the power supply on the crane control is interrupted during the
storage process, the indicated telescope status no longer corresponds
with the actual status of the telescope sections.
In this case you must enter the actual telescope status in the crane control
(e.g. the values from the Telescoping SLI display).
The menu is started:
– If you press the Enter telescope status after emergency operation membrane
Ä switch three times (within about 3 seconds) or
– If the Divergent telescope status error message was confirmed and the
Ö Display telescope status and teleautomatism menu is selected.
In the first line there is the message SET

TELESCOPE STATUS.
In the second line there are telescope sec-
tions T1 to T4 and in the line underneath the
SET TELESCOPE STATUS numerical value 0 is displayed for every tele-
> T1 < T2 – T3 – T4 – scope section.
> ● < 0 – 0 – 0 – In addition, the entry request (●) flashes on
the numerical value for T1.
You can enter the actual telescope status for every telescope section with
the membrane switches View and entry display, located to the right, next to
the display.
You can only enter the value on which the entry request flashes.
• Press one of these two membrane switches as many times as necessary

+ until the entry request flashes on the numerical value which you would
like to enter.
*
28.01.2000

• Enter the actual telescope status for the telescope section with these
: two membrane switches. The following values are available:
For T1 : 0 50 100 >n<
< For T2 : 0
For T3 : 0
50 100 >n<
50 100 >n<
For T4 : 0 50 100 >n<
n here represents the displayed numerical value of the last saved current
H
intermediate length (e.g. 37%)
If a telescope section is at an intermediate length, select the indicated

value n between the two angular brackets.
• Enter the actual telescope status for all telescope sections.

• If you have entered an incorrect telescope status, you can restart the
ö menu by pressing the Enter telescope status after emergency operation mem-
brane switch three times quickly.
• If you have entered the actual telescope status correctly, press the Enter
Ö key once.
The message KEYCODE is in the last line
and the input prompt (—) flashes.
To confirm the entered telescope status, you

SET TELESCOPE STATUS must enter in this line the same key code
> T1 < T2 – T3 – T4 – which you need to start the emergency pro-
– 100 – 0 – 0 – 0 – gram;
KEYCODE:
➠ Access emergency operation menu, p. 12-90.
The crane control now saves the entered telescope status and switches to
the Display telescope status and teleautomatism menu.
If the crane control recognises an error in the entered telescope status,

the display shows the error message Divergent telescope status; ➠ p. 14-63.
Ö H The crane control accepts the newly set telescope status only when you
store the new values with the ENTER key and enter the appropriate key
code after making your selection.
28.01.2000
s
S
Risk of damage during telescoping!
Before working with the crane, check that the telescope status now indi-
cated corresponds with the actual telescope status. If you accidentally
enter an incorrect telescope status, then you must enter the actual value
again.
In this way you prevent the crane control unit from using an incorrect
value for calculations which could lead to damage and malfunctions
during telescoping.
The Enter telescope status after emergency operation menu remains switched
>@üä on until you select another menu with the respective membrane switch,
ö exit the menu with the membrane switch

occurs. ö or until an error message
28.01.2000

Superstructure Malfunctions - EU PDF

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Malfunctions on the superstructure

14.1 Superstructure emergency stop device

14 Malfunctions on the superstructure

14.1 Superstructure emergency stop device

The battery master switch (1) is located on

• Switch off the main battery switch. Turn

Releasing crane functions again

• Turn off the ignition.

14 - 2 2 084 530 en Operating Instructions GMK 5100

14.2 Troubleshooting for malfunctions that occur during

Operating Instructions GMK 5100 2 084 530 en 14 - 3

14 - 4 2 084 530 en Operating Instructions GMK 5100

14.3 Electrical system

14.3.1 Plug-in modules and consoles

1 Safe load indicator (SLI)

7.1 D Set crane engine constant motor speed /

14 - 6 2 084 530 en Operating Instructions GMK 5100

The fuses are divided into the groups F1 to F13.

The fuse groups F1 to F9 can be accessed

Each group consists of six fuses:

The following tables show the designations

Designation in Rating (A) Function

1 20 Crane engine E-control

2 10 Crane engine diagnostic plug

3 10 Flame start system (additional

5 10 Crane cab ceiling lamp,

Designation in Rating (A) Function

Designation in Rating (A) Function

1 10 Indicator and warning lamps for engine,

Designation in Rating (A) Function

1 5 Switches and indicator lamps

14 - 8 2 084 530 en Operating Instructions GMK 5100

Designation in Rating (A) Function

5 15 Crane cab electronic level (additional

6 10 SLI deactivation, anchor-to-bracket-

Designation in Rating (A) Function

1 15 Crane control power supply

2 15 Crane control power supply

3 15 Crane control power supply

4 15 Crane control power supply

5 15 Crane control power supply

6 15 Crane control power supply

Designation in Rating (A) Function

1 10 Shutdown of main hoist,

2 10 Shutdown for auxiliary hoist,

3 10 Shutdown for derricking gear

4 10 Control lever initial position left

6 10 Indicator/warning lamp counterweight

Designation in Rating (A) Function

2 10 Proximity switch telescoping cylinder

4 10 Crane control display

6 10 Crane engine E-control

Designation in Rating (A) Function

1 15 Crane cab heating

2 15 Radio / voltage transformer

4 5 Crane control unit 0

5 5 Crane control unit 1

6 5 Crane control unit 2

Designation in Rating (A) Function

2 3 Oil cooler (relay)

5 5 Central lubrication system

14 - 10 2 084 530 en Operating Instructions GMK 5100

• Open the lid of the battery box.