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GMK 5100

ECOS
ECOS Overview...................................................................................................................... 1
1 ECOS Units ......................................................................................................................... 2
2 ECOS unit identity .............................................................................................................. 3
3 ECOS chip replacement...................................................................................................... 4
4 Input signals........................................................................................................................ 5
5 ECOS display ...................................................................................................................... 6
6. Telescope cylinder control for cylinder access...................................................................7
6.1 Telescope cylinder control for boom access ..........................................................................9
7 ECOS brake parameters:.................................................................................................. 12

RC. August. 2000

GMK 5100. Training Information. ECOS. August. 2000

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ECOS Overview

A3502 EKS 4 ECOS

Length sensor RCI Display Unit

CAN-Bus

ECOS ECOS ECOS Joysticks

Unit 2 Unit 1 Unit 0

Electrical connections

Auxiliary Slewing Telescope Derricking Auxiliary Main

Drive System System System Hoist Hoist

Valves and sensors Counterweight

Source: TK4

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1 ECOS Units

Three electronic modules control all primary functions:

Unit 0 = Auxiliary hoist & main hoist – Identification resistor = 100Ω

Unit 1 = Telescope, boom & swingaway jib functions – Identification resistor = 200Ω

Unit 2 = Auxiliary drives & slew – Identification resistor = 300Ω

Unit 0 is the most important as it carries the recorded crane data (hours etc.).

To change and reset an ECOS unit:

1. Ignition off
2. Disconnect all ECOS units
3. Place ECOS unit/s to be reset into unit 2 position
4. Ignition on
5. Verify question “RESET EEPROM?” if question is not displayed, the unit is not in the
ECOS 2 position.
6. Quickly press enter key three times to write to EEPROM, after message “RESET
EEPROM” wait for ‘OK’ message. Use the same procedure to reset any additional units.
7. Ignition off.
8. Place the reset unit/s in ECOS positions 1 and/or 2. NOTE: if a reset unit is placed in
ECOS position 0 the ECOS system will not operate.
9. A good original ECOS unit or slave must be in ECOS position 0. Position 0 can be
identified by the connection plug having two small rubber coated cables in addition to the
braided cables.
10. With units correctly connected in all three positions, turn on ignition.
11. The ECOS display should show “update EEPROMS” observe process bar until complete,
only then proceed to step 12.
12. Ignition off

NOTE: if a slave unit was used in ECOS position 0, remove it and replace it with a unit taken
from ECOS position 1 or 2. Replace the removed unit with a reset unit and begin again from
step 10.

Unless the slave unit was a new one, once the ignition is cycled on/off, the newly reset units
will acquire the serial number from the unit used in ECOS position 0. An un-serial numbered
ECOS unit can have the language & some basic parameter values changed via the ECOS
keypad. Once the units are serial numbered, you can only change the parameters with a PC.

If an ECOS unit is borrowed from another crane, you must reset the unit to remove the serial
number (steps 1 – 8). The ECOS system will not function if it has units with two serial
numbers. Should the borrowed unit have to be returned to the original crane, you will have to
reset it on that crane to remove the serial number it has now acquired.

On initial start up the ECOS units put out 10 mA from pin 10 to verify unit via the identifier
resistors. Once recognised, the output falls to 4mA. Should there be a resistor fault, the output
will rise and remain at 20 mA.

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2 ECOS unit identity

Unit 1 Unit 2
Unit 0

Figure 1: Installed view of ECOS units in crane cab

The identifier resistors for

ECOS units are here in
+BE630 .A5 directly below
the fuse panel

Ω
Unit 0 = 100Ω
Ω
Unit 1 = 200Ω
Ω
Unit 2 = 300Ω

Figure 2: Resistor location in +BE630. .A5

ECOS unit outputs = 4 Amp or 0.25 Amp to control solenoids or warning lights respectively.

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3 ECOS chip replacement

The ECOS units each have two replaceable EPROMS. One EPROM is low byte and the other
is high byte.

With the unit removed from the crane and the cover then removed, you can see both
EPROMS. They are normally retained with a cable tie.

Both chips are beside each other with the high byte chip being slightly higher.

If replacing chips, ensure that the chip orientation is correct by locating the chip in the board
with the chip indent towards you.

Figure 3a: Installed view of chips

High byte
Low byte

Figure 3:View of ECOS unit with cover removed

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4 Input signals

All switched inputs to ECOS units are all routed through resistor boards to continuously
check the integrity of the input circuit.

The drawing below illustrates the principle of the resistor board circuit

Battery voltage 24 V

The test meter would indicate the following values:

0 1.1 V = Short to ground

1.1 3.3 V = Switch open
3.3 6.35 V = Switch closed
6.35 24 V = Short to battery voltage

Note: If a cable break were to occur between the voltmeter and the resistor board, the
measured value would be approximately 7.2 volts.

The resistors have the following values:

Ω
R1 = 3.16 kΩ 1% 0.4W

R2 = 20.5 kΩ 1% 0.4W

R3 = 1.5 kΩ 1% 1W

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5 ECOS display

Figure 4: Installed view of the ECOS display & keypad unit

Language change & Metric to lbs. & ft

1. Put in dongle
2. Press & hold F1, then turn on ignition
3. Press F3 to select required language: use the Î key to scroll.
4. Press enter

The change from metric units to lbs & feet follows the same format: use the Í to scroll.

The ECOS display is configured for its application by setting dip switches on the underside of
the unit.

Dip switches

5100 configuration:
switches 1, 3 & 5 set to On

Figure 5: Unit removed for access to dip switches

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6. Telescope cylinder control for cylinder access

Instructions for creating an ECOS Error for Emergency Operation to

perform maintenance without a Dongle or laptop
1. Ensure that the correct counterweight is installed on the crane to allow safe operation to
work with telescope section1 extended 50% and the boom finally lowered to + 5 degrees
while carrying out the following procedure.
2. With the main boom fully retracted and at a minimum angle of 45 degrees, extend boom
section number 1 to 50 % and pin it. Do not attempt this procedure without a fully
retracted boom.
3. With engine running & EKS 4 operational, disconnect the ECOS precision length cable
connection at the plug adjacent to the main control block. The correct plug is a 5-pin plug
(see fig.6).

The graphic (fig.6) shows the location of the

bulkhead connection (1) for all the boom
electrical connections. This is adjacent to the
main control block in the centre of the
turntable.

The precision length sensor plug is normally

the third from the top. However, check
carefully that you have a 5-pin plug connector. 1

Figure 6: Bulkhead plugs

4. This will automatically cause ECOS to default to: ERROR MESSAGE / LOCKING
SYSTEM / A3502 00000001 /STATUS: 00010000.
5. On EKS 4, press & hold F1 and touch Info2. A numeric value will be displayed in the
information window. This value represents the telescope cylinder length. Note down this
value (e.g.4.8m (15.7 ft)). Do not confuse this with actual boom length.
6. Acknowledge Error Message (A3502) on the ECOS display by pushing Enter key on the
ECOS panel. This will then display GMK 5100/ ECOS – V1.01/ SYSTEM OK.
7. Press F4 on the ECOS panel, display WILL SHOW: TELESCOPE STATUS / STATUS:
001 / EMERG. OPER. ACCESS / KEY CODE
8. ECOS now requires an access Keycode. The Keycode is: Enter, Up arrow ½, Down
arrow ¾, Enter. When entering the Keycode an * will appear on the ECOS display for
each digit of the Keycode. If the Keycode is entered correctly, ECOS will display a
maximum time value of 360 seconds in the bottom left corner of the ECOS display. This
value will then begin to decrease. This is the amount of time you will have available to
complete any Emergency Operation function you wish to carry out.
9. Manually push the rocker switch for ‘telescope cylinder unlock’. ECOS will unlock the
telescope cylinder pins and allow you to retract the telescope cylinder. Before retracting
the telescope cylinder, observe and note down (as in step 5) the numeric value displayed
in the Information display (e.g.4.8m (15.7 ft)) of EKS 4. You will need this value as a
reference for returning the telescope cylinder to the number 1 Boom section. Once you
have begun retracting the telescope cylinder you will lose the in-position indicator lights

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on the instrument panel. Observe the numeric value in the information display of EKS 4.
When this numeric value is approximately 0.7m /2.0ft the pinning head of the telescope
cylinder will be just forward of the front edge of the manhole in the boom.
10. Wait until time countdown has expired, select derricking and lower the boom to + 50. It
will be necessary to use the override key at some point depending on counterweight and
crane rating.
11. Shut off crane engine and ignition; take all necessary safety precautions
(RED TAG: ‘UNDER REPAIR’) and make necessary repairs and/or adjustments as
needed.

To return the telescope cylinder to the number 1 boom section.

1. Turn on ignition and start the crane engine, clear all errors and set points on EKS 4 and
raise the boom to an angle of 45 degrees (Use override key if necessary).
2. With engine and ignition switched off, reconnect the precision length measuring system
plug adjacent to the main control block (see fig.6).
3. Turn on ignition and start the crane engine, clear all errors and set points on EKS 4, then
press & hold F1, and touch Info2. A numeric value will be displayed in the information
window. This value represents the telescope cylinder length. Do not confuse this with
actual boom length.
4. Select telescope function with the rocker switch (on joystick base) and set the ‘telescope
cylinder lock/unlock’ switch to the centre position, then press F4 on the ECOS display.
5. Accept the telescope status by pressing enter, then confirm the status with the keycode
entry (the status must be 50, 0, 0, 0).
6. Visually, through manhole and electrically on instrument panel via lights, check that the
telescope cylinder locking pins are functioning correctly. Make sure the telescope
cylinder rocker switch is in the ‘centre position’ and the pins are fully retracted.
7. Extend the cylinder to 50% where the cylinder will re-lock to the section. While
extending the telescope cylinder, observe the numeric value in the information display of
EKS 4. This should give an indication of the telescope length on approach to the locking
position of 50% that compares to the original telescope length that you noted down in
step 5.

Note: The target length reference check for 50% is approximately 4.8m (15.7 ft).
The cylinder should automatically lock to section 1. If, for whatever reason the
cylinder does not lock, do not continue to extend the cylinder through the other
sections.

8. Retract/extend boom as needed.

NOTE:
Should the Telescope Displays on the EKS 4 start to flash, make sure that ECOS is displaying
the proper Telescope Status. If the proper telescope status is not displayed i.e.: 50, 0, 0, 0 then
enter this status on the ECOS panel and press Enter and then confirm with the key code entry.
Once the correct telescope status is confirmed, if there is a length error between EKS 4 and
ECOS make sure the EKS 4 reeving and operating modes are acknowledged: press and hold
F1 + F2 and touch CE on EKS 4. This will re-synchronise the ECOS and EKS 4 computers.
Cycle the ignition power off then on to reconfirm that the two computers see the same
telescope status.

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6.1 Telescope cylinder control for boom access

Instructions for creating an ECOS Error for Emergency Operation to

perform maintenance with a Dongle & connected laptop

1. Ensure that the correct counterweight is installed on the crane to allow safe operation to
work with telescope section1 extended 50% and the boom finally lowered to + 5 degrees
while carrying out the following procedure.
2. With the main boom fully retracted and at a minimum angle of 45 degrees, extend boom
section number 1 to 50 % and pin it.
3. With engine running and EKS4 operational, disconnect the ECOS precision length cable
connection at the plug near the control block. The correct plug is a 5-pin plug. Disconnect
on the rear side of the bulkhead adjacent to the main control block (see fig.6)
4. This will automatically cause ECOS to default to: ERROR MESSAGE / LOCKING
SYSTEM / A3502 00000001 /STATUS: 00010000.
5. On EKS 4, press & hold F1 and touch Info2. A numeric value will be displayed in the
information window. This value represents the telescope cylinder length. Note down this
value. Do not confuse this with actual boom length.
6. Start the laptop and apply a mask to input S2118N in the pinning window (see fig.7).

NOTE:
Should there be any malfunction of the input S2118N and it is active (light green) prior
to applying the mask, do not proceed. Resolve the switch/wiring error prior to
continuation of this procedure.

Release tele cyl, extending 4.7m

50

Access Emergency Operation

To apply the mask the check boxes “Mask active” &

“Mask value On” must both be checked and then click on
“set temporary”.
Caution! This mask must be removed in tele 2.
See caution in step 12.
To remove the mask the check boxes “Mask active” and
“Mask value On” must be unchecked –“Off” is checked
and then click on “Set temporary”

Figure 7: View of mask applied to S2118N (release tele cyl, extending)

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7. Acknowledge Error Message (A3502) on the ECOS display by pushing Enter key on the
ECOS panel.
8. Press F4 on the ECOS panel
9. ECOS will ask for an access Keycode. The Keycode is: Enter, Up arrow ½, Down
arrow ¾, Enter. When entering the Keycode an * will appear on the ECOS display for
each digit of the Keycode. If the Keycode is entered correctly, ECOS will display a time
value of 360 seconds in the bottom left corner of the ECOS display. This value will then
begin to decrease. This is the amount of time you will have available to complete any
Emergency Operation function you wish to carry out.
10. Manually push the rocker switch for telescope cylinder unlock. ECOS will unlock the
telescope cylinder pins. Before extending the telescope cylinder, observe and note the
numeric value displayed in the Information display of EKS 4(as in step 5). You will need
this value (e.g. 4.8) as a reference for returning the telescope cylinder to the number 1
boom section. Observe the locking position indicator lights; <too low>, <too high> on the
instrument panel (should currently be on in any combination).
11. Very slowly, extend the telescope cylinder while observing the locking position lights:
<too low>, <too high>. As you leave telescope section 1, you will lose the locking
position indicator lights: <too low>, <too high>. Look for the <too low> light on entering
telescope section 2 and stop telescoping when you see the <too high> light. This only
amounts to a very short telescoping distance: approximately 30cm (1.0 ft).
12. With the laptop, remove the mask from input S2118N in the pinning window.
Caution: It is critical for the safety of the telescope cylinder that the mask is removed
at this point.
13. Continue to slowly extend the cylinder through sections 3 to 4 by observing the locking
position light sequence for each section - stop extending when you see <too low> / <too
high> in telescope 4 (the <too high> light may flash to indicate motion cut by ECOS).
The total telescoping length from unpinning in telescope 1 to positioning the cylinder in
telescope 4 is approximately 0.9 m (3.ft). Typical reference on EKS 4 is 5.7m (18.7 ft);
however, remember that the critical reference is approximately 0.9m (3ft) of telescope
cylinder extension and the observation (counting) of the <too low> & <too high> lights
through the sections.
14. Wait until the time countdown has expired, select derricking & then lower the boom to +
50. It will be necessary to use the override key at some point depending on counterweight
and crane rating.
15. Shut off crane engine and ignition, take all necessary safety precautions
(RED TAG: ‘UNDER REPAIR’) and make necessary repairs and/or adjustments as
needed.

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To return the telescope cylinder to the number 1 boom section.

1. Turn on ignition and start the crane engine, clear all errors and set points on EKS 4 and
raise the boom to an angle of 45 degrees (use EKS 4 override if necessary).
2. With engine and ignition switched off, reconnect the precision length measuring system
plug at the main control block (see fig.7).
3. Turn on ignition and start the crane engine, clear all errors and set points on EKS 4. On
EKS 4, press & hold F1, and then touch Info 2. A numeric value will be displayed in the
information window (e.g. 5.7-m 18.7-ft)). This value represents the telescope cylinder
length. Do not confuse this with actual boom length.
4. Select telescope function with the rocker switch (at joystick base), then press F4 on the
ECOS display.
5. Accept telescope status by pressing enter and then confirm the status with the keycode
entry (the status must be 50, 0, 0, 0).
6. Make sure the telescope cylinder rocker switch is in the ‘unlock cylinder’ position
(down). ECOS now displays cylinder length of 5.67-m (18.6-ft).
7. In the semiautomatic mode, begin to retract the cylinder, while retracting, place the
telescope cylinder rocker switch to the centre position and continue retracting to 50%
where the cylinder will re-lock to the section. While retracting the telescope cylinder,
observe the numeric value in the information display of EKS 4. This should give an
indication of the telescope length on approach to the locking position of 50% that
compares to the original telescope length that you noted down in step 5 (e.g. 4.8-m (15.7-
ft) on EKS 4) prior to extending the telescope cylinder. The total telescoping length from
telescope 4 to pinning in telescope 1 is approximately 0.9-m (3.0-ft). The length
information is now also available from ECOS and is approximately 4.78-m (15.6-ft)
when pinned to section 1.
8. Retract/extend boom as needed

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7 ECOS brake parameters:

Brake Parameters:

Braking area 4 = 50 mm approach to pin hole target.

Speed = 5 % setting for control block delivery (area 4)

Braking area 3 = 10 mm approach to pin hole target.

Speed = 13% setting for control block delivery (area 3)

Braking area 2 = Control block ramp down from joystick command to (3) 13%.
This dimension // is 200 mm on extending and 360 mm on retracting.

Braking area 1 = Inhibit high speed & reduce to joystick command level.
This dimension // is 250 mm on extending and 550 mm on retracting.

During normal operation, the telescope system will automatically cut off high speed & ramp
off the control block delivery as it approaches a pin position (Brake parameters).

Brake parameters 1 - 4

100% of joystick command

Brake ranges 1 & 2 are
dependent on engine speed

13% (3)
5 % (4)

10 mm 50 mm Pin hole

Brake Brake Brake Brake

range 1 range 2 range 3 range 4

Offset boom pins: = Distance for tele cyl to pick up section = + 5 mm & + 18 mm
for tele cyl to move boom section pin to hole centre = 23 mm

Section 1
Boom section pin
Tele cyl pin will now needs 18 mm to
travel 5 mm to pick lift section off pin
up boom section and reach hole centre
Base

Max speed foot section: = Telescope cylinder speed is reduced to 40% within
‘In-position’ proximity switch area in foot section.

Note: The above information is only to assist with understanding ECOS functionality. No
attempt should be made to change the pre-set parameters.

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