6200_1 Superstructure Malfunctions

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16 Malfunctions on the superstructure

16.1 Superstructure emergency stop device

The GMK 5180 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 crane engine

You can turn off the crane engine from outside the crane cab by switching 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.

(2)

switch

control emergency stop switch

module in the crane cab.

G

Risk of overload if used improperly!

TheCrane control unit emergency stop switchis 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 theCrane 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 theCrane control emergency stop switchis 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 theCrane control emergency stop switchuntil it disengages. • Let go off all control levers and start the crane engine again. • Check if the crane movements are carried out as normal.

H

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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16.2 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 sectionSLI overriding

when doing so;

➠

p. 13-32.

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 lowered

• Secure the danger zone using cordons and assigned personnel. • 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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16.3 Electrical system

16.3.1 Plug-in modules and consoles

Pos. Designation of plug in module in E-circuit diagram Function 1 1.2 D

Monitors crane engine and hydraulic system / spotlight / windscreen washing system /

additional heating system (additional equipment)

2 5 D

Display, Input and emergency operation crane control / Telescoping gear / Lattice extension incline (only with additional equipment) Main hoist shutdown, Derricking gear, Telescoping gear /

Control lever function switchover

3 6 D

Anemometer (additional equipment) / switch-able display for electronic spirit level / super-structure lock / display for shutting down

(6)

Pos. Designation of plug-in module in the elec-tronic circuit diagram Function

1 7 D Sets constant crane engine speed

2

+BE 630. KR Control lever for telescoping, derricking and main hoist / Lattice extension incline (only with additional equipment)

switches off main hoist, derricking gear, telescoping gear /

changes control lever function Derricking↔Telescoping

3

+BE 630. KL Control lever for slewing gear, auxiliary hoist (additional equipment) /

switches off auxiliary hoist / fast speed for hoists /

slewing gear permanent brake / tilts crane cab

4 Safe load indicator (SLI)

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16.3.2 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 circuit diagram: F 1

Rating (A) Function

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

(8)

circuit diagram: F 2 1 10 No function 2 10 No function 3 10 No function 4 10 No function 5 10 No function 6 15 No function Designation in circuit diagram: F 3

1 10 Indicator and warning lamps for engine,

hydraulic system, flame start system (additional equipment)

2 15 Window wiper/washer system

3 5 Pressure sensor/switch

Crane control

4 10 Control lever, fast speed for derricking gear and telescoping gear, slewing gear, slewing gear superstructure lock

5 10 Crane engine diagnostic plug

6 10 Flame start system (additional

equipment)

1 5 Switches and indicator lamps

2 15 Working spotlight, switches and

indicator lamps for working spotlight and shutdown of derricking gear / telescoping gear / main hoist

3 5 Horn, Switch and indicator lamps for

auxiliary hoist shutdown, Slewing gear permanent brake and crane cab incline

4 10 Crane cab heating

5 15 Crane cab electronic spirit level, SLI early warning/shutdown

6 10 SLI deactivation,

Anchor-to-bracket-switch shutdown,

Dead man’s switch, Seat contact

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1 15 Crane control power supply

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

shutdown for telescoping gear

4 10 Control lever initial position

5 10 Slewing gear

6 10 Indicator/warning lamp counterweight

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circuit diagram: F 7

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

1 15 Crane cab heating

2 15 Radio

3 15 No function

4 5 Crane control unit 0

1 20 Oil cooler

2 5 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 F10 to F13 are located in the battery box. These fuse groups consists of only one fuse each.

• Open the lid of the battery box.

The fuse groups are attached to a mounting plate.

– The two fuses F 10 and F11 are in terminal box (1).

– The two fuses F 12 and F13 are in terminal box (2).

Terminal box

Name in circuit diagram:

1

F 10 50 Central fuse

SLI supply line

F 11 50 Protection for main fuse

superstructure (protection)

2

F 12 20 Protection for

Crane control power supply

F 13 20 Heating system

protection, Voltage

transformer/ Safety device for all consumer

equipment which is still supplied with current when the battery master switch is switched off.

(12)

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.

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.

Designation in circuit diagram:

S I 1 5 SLI internal

S I 2 5 SLI shutdown display

S I 3 5 Lift main hoist shutdown

S I 4 5 Shutdown lowering

S I 5 5 Shutdown extending

S I 6 5 Lift auxiliary hoist shutdown

S I 7 5 Shutdown raising

S I 8 5 Shutdown retracting

S I 9 5 Lower auxiliary hoist shutdown

S I 10 5 Lowering the lattice extension

S I 11 5 SLI early warning display

S I 12 5 Raising the lattice extension

S I 13 5 SLI central unit

H

If the fuse on an SLI outlet fails again, notify your local GROVE Product Support.

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16.4 Troubleshooting and malfunction correction

16.4.1 Crane engine malfunctions

Malfunction Cause Action

Engine does not start (starter motor does not turn over)

Battery master switch not switched on

Switch battery master switch on;

➠

p. 12-5.

Ignition switched off Switch on ignition;

➠

p. 12-9. Engine does not start

(starter motor turns over)

Batteries not charged enough Charge batteries Fuel tank empty 1. Fill fuel tank,

➠

p. 12-7.

2. Bleed fuel system,

➠

Mercedes-Benz Operating manual Fuse F1/1 or F7/6defective Check fuse, replace if

necessary;

➠

p. 16-7.

Flame-start system indicator

lamp does not go on, fuse F1/3 faulty

Check fuses and replace if necessary.

➠

p. 16-7. Engine coolant temperature

too high

Coolant level too low Top up coolant

Radiator dirty outside Clean outside of radiator V-belt for coolant pump on

engine slack

Tighten V-belt, refer to Mercedes-Benz Operating manual

Engine oil pressure too low Engine oil level too low Check oil level, fill if necessary;

➠

p. 12-3 and

Maintenance manual

Engine can not be turned off with the ignition key

Malfunction in the electronics Turn off engine with emergency stop device,

➠

p. 16-1 Indicator lampCrane engine

air filterlights up

Crane engine air filter is dirty Replace crane engine air filter

Indicator lampFlame start systemlights up when crane engine is running

problem with flame-start system

Notify GROVE Product Support or Mercedes-Benz Service and have the flame start system checked

(16)

Motor electronicswarning lamp goes on during driving, the engine performance gets worse and worse

Malfunctions in the motor electronics cause engine

performance to decrease continuously. The engine will not switch off, however so lowering the load and unrigging the truck crane can still be done.

Coolant level too low, Oil level too low, Air filter dirty.

Coolant level;

➠

p. 11-4; Oil level;

➠

p. 11-3; Air filter;

➠

V-belt too loose Check V-belt tension;

➠

Operating manual Mercedes-Benz

Plug or cable on the control unit loose

Check plug on control unit (near the diagnostic plug);

➠

p. 11-58 Cabling behind the

accelerator damaged

Check cable, Notify GROVE Product Support of any damage

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16.4.2 Main hoist malfunctions

Main hoist not functioning or malfunctioning (lifting, lowering or fast speed not functioning)

Rocker switchShutdown main hoistswitched on

Switch off rocker switch

Shutdown main hoist

Fuse F3/4 OW or F6/1 OW defective

Check fuse, replace if necessary

Dead man’s switch not activated

Press dead man’s switch

Fuse F4/2 OW or F4/3 OW defective

Check fuse, replace if necessary;

➠

p. 16-7. A control unit of the crane

control has failed (error message is displayed)

Acknowledge error message once;

➠

p. 13-89.

If the error message is repeated, change the connections on the control units;

➠

p. 16-59.

Crane control emergency stop switchpressed in

Release crane functions again;

➠

p. 16-2. Main hoist lowering not

func-tioning (In addition, check all causes in the “Main hoist not functioning” section!)

Lowering limit switch triggered

Leave shutdown area, Lift main hoist

Main hoist lifting not functioning

(In addition, check all causes in the “Main hoist not func-tioning” section!)

Lifting limit switch triggered (warning lamp on)

Leave shutdown area, lower main hoist

SLI shutdown (warning lamp on)

Leave shutdown area;

➠

p. 13-16. Fuse F4/6 OW or F7/1 OW

defective

➠

p. 16-7. Lifting, lowering or fast speed

do not function

Corresponding function is blocked by the crane control (error message is displayed)

➠

p. 13-89.

If this happens again, note down the number codes and inform GROVE Product Support;

➠

p. 16-60. Corresponding function is

blocked from the crane control (no error message is displayed)

Switch off ignition briefly then switch on again.

If this happens again, note down the status display’s stored number codes and

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No lifting or lowering, or pos-sible only at very low speed

Maximum speed set too low Increase maximum spees on the displayEnter power unit speed;

➠

p. 13-85.

Lifting or lowering function can not be switched off

Malfunction on the crane control

Stop the movement with the

Crane control emergency stop switch;

➠

p. 16-2.

H

If a malfunction occurs, first check whether it applies in both directions of movement.

In this case also check the causes listed in theMain hoist not functioning

section!

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16.4.3 Auxiliary hoist malfunctions

Auxiliary hoist not

functioning or malfunctioning (lifting, lowering or fast speed not functioning)

Rocker switchShutdown auxiliary hoistswitched on

Shutdown auxiliary hoist

Fuses F3/4 OW or F4/2 OW or F6/2 OW defective

Check fuses, replace if necessary;

➠

p. 16-7. Dead man’s switch not

activated

Press dead man’s switch;

➠

p. 13-89.

➠

p. 16-59.

➠

p. 16-2. Auxiliary hoist lowering not

functioning (Also check all causes in the “Auxiliary hoist not functioning” section!)

Lowering limit switch triggered

Leave shutdown area, Lift main hoist

Auxiliary hoist lifting not functioning (Also check all causes in the “Auxiliary hoist not functioning” section!)

Lifting limit switch triggered (warning lamp on)

Leave shutdown area, Lower the auxiliary hoist SLI shutdown

(warning lamp on)

Leave shutdown area Fuse F4/6 OW or F7/1 OW

defective

➠

p. 16-7. Lifting, lowering or fast speed

do not function

➠

p. 13-89.

➠

If this happens again, note down the status display’s stored number codes and inform GROVE Product Support;

➠

p. 13-81.

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No lifting or lowering, or pos-sible only at very low speed

Maximum speed set too low Increase maximum speed on the displayEnter power unit speed;

➠

p. 13-85.

Lowering does not function Fuse on corresponding SLI outlet defective

Replace if necessary;

➠

p. 16-12. Lifting or lowering function

can not be switched off

➠

p. 16-2.

H

In this case also check the causes listed in sectionAuxiliary hoist not functioning!

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16.4.4 Derricking gear malfunctions

Derricking gear not func-tioning or malfuncfunc-tioning (raise boom, lower boom or fast speed not functioning)

Dead man’s switch system not activated

Press dead man’s switch,

➠

p. 11-63. Fuse F3/4 OW or F6/3 OW

defective

➠

p. 16-7. Right-hand control lever set to

Telescopingfunction

Set control lever toDerricking

function Rocker switchShutdown

derricking gearswitched on

Shutdown derricking gear

A control unit of the crane control has failed (error message is displayed)

➠

p. 13-89. If the error message is repeated, change the connections on the control units;

➠

p. 16-59.

➠

p. 16-2. Lower boom not functioning

(Also check all causes in the “Derricking gear not func-tioning” section!)

Lifting limit switch triggered (warning light on)

Leave shutdown area, raise boom

Leave shutdown area;

➠

p. 13-16 Fuse F4/6 OW or F7/1 OW

defective

Check fuse, replace if necessary

Raising or lowering the boom do not function

➠

p. 13-89.

➠

p. 13-81.

(22)

Raising or lowering the boom does not function

Fuse on corresponding SLI outlet defective

➠

p. 16-12. No raising or lowering the

boom, or possible only at very low speed

➠

p. 13-85.

Raising or lowering the boom function can not be switched off

➠

p. 16-2.

H

In this case also check the causes listed in theDerricking gear not functioningsection!

16.4.5 Telescoping gear malfunctions

Telescoping gear not

functioning or malfunctioning (telescope in, telescope out or fast speed not functioning)

Dead man’s switch system not activated

➠

p. 11-64. Fuse F7/2 OW or F3/4 OW or

F6/3 OW defective

➠

p. 16-7. Right-hand control lever set to

Derrickingfunction

Set control lever toTelescoping

Rocker switchShutdown telescoping gearorLattice extension inclineswitched on

Shutdown telescoping gear;

➠

p. 13-89.

➠

p. 16-59.

➠

p. 16-2. Telescope section and

tele-scoping cylinder do not lock/unlock any functions

Valve defective Note down theDisplay status – lockingnumber code on the display and inform GROVE Product Support;

➠

p. 16-60.

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Extension of the telescoping not functioning

(Also check all causes in the “Telescoping gear not functioning” section!)

Leave shutdown area Fuse F4/6 OW or F7/1 OW

defective

➠

p. 16-7. Lifting limit switch triggered

(warning lamp on)

Leave shutdown area, Lower hoist

Telescope retracting not functioning (Also check all causes in the “Telescoping gear not functioning” section!)

Insufficient boom lubrication Lubricate boom,

➠

Boom too flat Raise boom

Telescope section does not move when the control lever is extended

Telescope section is still locked

Unlock telescope section;

➠

p. 13-67.

Telescoping cylinder is not locked

Lock telescope cylinder;

➠

p. 13-64. Lock telescope section/

telescoping cylinder not functioning

Defective hydraulics/electrics Note down the number code on the status display when locking and inform GROVE Product Support;

➠

p. 13-81. Telescoping out or in or fast

speed not functioning

➠

p. 13-89.

➠

p. 13-81. Retracting or extending does

not function

Fuse on corresponding SLI outlet defective

➠

p. 16-12. No retracting or extending, or

possible only at very low speed

➠

p. 13-85.

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The boom can no longer be extended, the locking/un-locking mechanism no longer reacts to the control instru-ments in the crane cab

The electric controller of the hydraulic system is

interrupted (e.g. a cable in the main boom is broken)

Retract the telescope section using hydraulic emergency mode;

➠

Retracting emergency mode, p. 16-43.

The boom can no longer be extended, the telescoping cylinder can no longer be moved

The hydraulic supply is interrupted

Extend the telescope section with mechanical emergency mode;

➠

Retracting emergency mode, p. 16-43.

H

If the malfunction occurs in both directions of movement you must also check the causes listed in theTelescoping gear not functioningsection!

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16.4.6 Slewing gear malfunctions

Slewing gear does not function

Mechanical superstructure lock engaged

Disengage lock;

➠

p. 13-8. Slewing gear permanent

brake applied

Release slewing gear permanent brake, rocker switch;

➠

p. 13-45. Dead man’s switch not

activated

➠

p. 11-63. Fuses F6/5 OW or F3/4 OW

defective

➠

p. 13-89.

➠

p. 16-66.

➠

p. 16-2. Slewing to left or right not

functioning

➠

p. 13-89.

➠

p. 13-81. No slewing, or possible only

at very low speed

Maximum speed set too low Increase maximum speed on the displayEnter power unit speed;

➠

p. 13-85.

Slewing can not be switched off

Crane control emergency stop

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Counterweight lifting gear/ lock not functioning

A control unit of the crane control has failed (error message is displayed)

➠

p. 13-89.

➠

p. 16-59.

➠

p. 16-2. Counterweight lifting cylinder

or lock not functioning

Hydraulic connection on the 4.4 t base plate not made

Make hydraulic connection;

➠

blocked by the crane control (error message is displayed)

➠

p. 13-89.

➠

p. 13-81. Locking pins cannot be

retracted/extended

Safety tap is closed Open safety tap;

➠

p. 10-57.

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16.4.8 Lattice extension malfunctions

Lattice extension cannot be inclined

Hydraulic system not connected to right side of boom head

Connect the hydraulic system;

➠

p. 15-34. Hydraulic system not

connected to left side of boom head

Connect the hydraulic system;

➠

p. 15-59. Electrical connection not

connected to right side of boom head

Connect the electrical connection;

➠

p. 15-57. Lattice extension cannot be

inclined and SLI indicates error message

5.02.05 or 5.02.6

Lattice extension is at the maximum or minimum permissible angle

With error message 5.02.5 Lower the lattice extension With error message 5.02.6 Raise the lattice extension Lifting limit switch on the 43

ft or 72 ft lattice extension does not function

Lifting limit switch not connected

Connect lifting limit switch;

➠

p. 15-64. No electrical connection

between boom head and lattice extension or between 43 ft section and 29 ft section

Establish electrical connection;

➠

p. 15-57.

Short-circuit plug not inserted on main boom head terminal box

Insert short-circuit plug;

➠

p. 15-64. When operating with a 72 ft

lattice extension or boom extension the short-circuit plug is not inserted on the head of the 41 ft section.

Insert short-circuit plug;

(28)

Hydraulic oil temperature above 80 °C (176 °F)

Fan in hydraulic oil cooler is running

Hydraulic system under severe strain

Stop crane operations and allow the crane engine to run until the oil has cooled down.

Hydraulic oil temperature above 80 °C (176 °F)

Fan in hydraulic oil cooler not running

Fuse F1/1 OW, F1/2 OW or F1/6 OW blown

Check fuses and replace if necessary;

➠

p. 16-7. Fan’s thermostat valve

defective

Switch fan thermostat to emergency operation;

➠

p. 16-56. Warning lamp for feed circuit

or control circuit hydraulic oil filter lights up

Hydraulic oil filter dirty Replace hydraulic oil filter;

➠

Warning lamp for hydraulic oil return filter or return fine filter lights up

Hydraulic oil filter dirty Replace hydraulic oil filter;

➠

16.4.10 Crane control malfunctions

TheCrane control display

remains unlit even though the ignition is switched on

One or more of the following superstructure fuses is defective:

F5 1 / 2 / 3 / 4 / 5 / 6 F7 / 5 or F8 4 / 5 / 6

➠

p. 16-7.

On theCrane control display

you can see the message EMERGENCY OPERATION

Length indicator or proximity switch defective or no

connection any more

(e. g. cable torn or damaged)

Use emergency operation to retract the main boom and drive to a repair;

➠

p. 14-71.

On theCrane control display

you can see the message NOT CONNECTED

Electric connection between the main boom and the turntable interrupted (plug connection separated or cable damaged or torn)

Make plug connections under the main boom in front of the derricking cylinder foot axle or check the cable for damage and have it repaired

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In theCrane control display

the two number codes appear one below the other:

ECOS 0 0 0 0 1 0 0 0 STATUS: 0 0 0 0 0 0 0 1

The current telescope or locking status does not match that in the control system saved values (e. g. after telescoping with emergency operation).

Acknowledge error (the

display changes automatically to the Enter telescope status after emergency operation menu) and enter the current telescope status;

➠

p. 16-80.

H

If there are further malfunctions on the crane control, the corresponding error messages will appear on theCrane control display;

➠

p. 16-59.

16.4.11 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 displaysRigging mode andReeving? 5. What is indicated on the information display when the information

selector switch is moved to different positions? 6. Have the fuses been replaced?

(30)

SLI does not function (displays not lit, no buzzer signal)

Power supply switched off Switch on ignition Fuse F7/1 OW or F4/6 OW

defective (fuses behind the flap on the front panel of the crane cab)

➠

p. 16-7.

Operating instructions - Part 2, Malfunctions on the superstructure

Fuse SI13 defective (fuse at the rear on the SLI plug-in module)

SLI error message table

The following table shows the different error messages on the SLI, the cause of the error and how you can help if necessary.

Error messages from error group 1, sensory mechanism Error

message

Cause Action

1. 01. 1 Pressure sensor 1, lower chamber does not react

Check line;

➠

p. 16-41. If line is O.K., switch off pressure sensor 1;

➠

p. 16-38 and notify GROVE Product Support

1. 01. 2...6 Pressure sensor 1, lower chamber reports error

Switch off pressure sensor 1;

➠

1. 01. 7 Notify GROVE Product Support 1. 01. 8 Information message;

You have switched off

pressure sensor 1 because of an error message

Message remains as long as the ignition is switched off

1. 02. 1 Pressure sensor 2, lower chamber does not react

Check line;

➠

p. 16-41 If line is O.K., switch off pressure sensor 2;

➠

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1. 02. 2...6 Pressure sensor 2, lower chamber reports error

Switch off pressure sensor 2;

➠

1. 02. 7 Notify GROVE Product Support

1. 02. 8 Information message; You have switched off

pressure sensor 2 because of an error message

1. 03. 1 Pressure sensor upper chamber does not react

Check line;

➠

p. 16-41. If line is O.K., notify GROVE Product Support

1. 03. 2...6 Notify GROVE Product Support 1. 04. 1 Angle sensor A,

basic section does not react

Check line;

➠

p. 16-41. If line is O.K., switch off angle sensor A;

➠

p. 16-38 and notify GROVE Product Support 1. 04. 2...6 Angle sensor A,

basic section reports error

Switch off angle sensor A, basic section;

➠

p. 16-38 and notify GROVE Product Support 1. 04. 7 Notify GROVE Product Support

1. 04. 8 Information message; You have switched off angle sensor A, basic section because of an error message

1. 05. 1 Angle sensor B,

basic section does not react

Check line;

➠

p. 16-41. If line is O.K., switch off angle sensor B;

➠

p. 16-38 and notify GROVE Product Support 1. 05. 2...6 Angle sensor B,

basic section reports error

Switch off angle sensor B, basic section;

➠

p. 16-38 and notify GROVE Product Support 1. 05. 7 Notify GROVE Product Support

1. 05. 8 Information message; You have switched off angle sensor B, basic section because of an error message

(32)

telescope sectionVdoes not react

If line is O.K., switch off

length indicator A;

➠

1. 06. 2...6 Length indicator A for

telescope sectionVreports an error

Switch off length indicator A for telescope sectionV;

➠

You have switched off length indicator A for telescope sectionVbecause of an error message

1. 07. 1 Length indicator B for

telescope sectionVdoes not react

Check line;

➠

p. 16-41. If line is O.K., switch off

length indicator B;

➠

1. 07. 2...6 Length indicator B for

telescope sectionVreports an error

Switch off length indicator B for telescope sectionV;

➠

You have switched off length indicator B for telescope sectionVbecause of an error message

1. 08. 1 Length indicator A of the telescoping cylinder does not react

Check line;

➠

p. 16-41. If line is O.K., switch off length indicator A of the telescoping cylinder;

➠

1. 08. 2...6 Length indicator A of the telescoping cylinder reports an error

Switch off length indicator A of the telescoping cylinder;

➠

18.

03.

(33)

1. 08. 8 Information message;

You have switched off length indicator A of the telescoping cylinder because of an error message

1. 09. 1 Length indicator B of the telescoping cylinder does not react

Check line;

➠

p. 16-41. If the line is O.K., switch off length indicator B of the tele-scoping cylinder;

➠

1. 09. 2...6 Length indicator B of the telescoping cylinder reports an error

Switch off length indicator B of the telescoping cylinder;

➠

1. 09. 8 Information message;

You have switched off length indicator A of the telescoping cylinder because of an error message

1.10. 1 Angle sensor A,

Lattice extension does not react

Check line;

➠

p. 16-41. If line is O.K., switch off angle sensor A, luffing jib;

➠

1.10. 2...6 Angle sensor A,

Lattice extension reports error

Switch off angle sensor A, luffing jib;

➠

p. 16-38 and notify GROVE Product Support 1.10. 7 Notify GROVE Product Support

1.10. 8 Information message; You have switched off angle sensor A, luffing jib because of an error message

1.11. 1 Difference angle sensor, lattice extension does not react

test supply line;

➠

p. 16-41. If supply line is O.K., switch off difference angle sensor;

➠

(34)

lattice extension gives error message

sensor;

➠

p. 16-38 and notify GROVE Product Support 1.11. 7 Notify GROVE Product Support

1.11. 8 Information message; You switched off the

difference angle sensor on the lattic extension because of an error message

Message remains if the ignition is switched off

1.12. 1 Lattice extension pressure sensor

lower chamber does not react

Check line;

➠

p. 16-41. If necessary notify GROVE Product Support

1.12. 2...6 Lattice extension pressure sensor

lower chamber reports error

Notify GROVE Product Support

1.12. 7 Notify GROVE Product Support

1.13. 1 Lattice extension pressure sensor,

upper chamber reacts

Check line;

➠

p. 16-41. If necessary notify GROVE Product Support

1.13. 2...6 Lattice extension pressure sensor,

upper chamber reports error

Notify GROVE Product Support

1.13. 7 Notify GROVE Product Support 1.15.1...6 Notify GROVE Product Support

1.16.1...6 Notify GROVE Product Support

1.18.1...6 Notify GROVE Product Support 1.19. 1 The difference between the

main boom length and the length control is too great. The displayActual loadand

Actual radiusflash

Test length indicator, plug connection and supply line;

➠

p. 16-41.

Test telescope diagram from outside.

Notify GROVE Product Support if necessary. 1.21. 1 Differences between rope

indicator and cable drum in the main boom are too large The displaysActual loadand

Current radiusflash

Notify GROVE Product Support.

18.

03.

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Error messages from error group 2, digital inputs Error

message

2. 01. 1 Recognition of locking point for telescope section line breakage

Check supply line;

➠

p. 16-41. 2. 01. 2 Recognition of locking point

for telescope section earth contact

2. 01. 5 Inform GROVE Product Support 2. 05. 1 Line breakage

Check supply line;

➠

p. 16-41. 2. 05. 2 Earth contact

2. 05. 5 Inform GROVE Product Support 2. 07. 1 Line breakage

Check supply line;

➠

p. 16-41. 2. 07. 2 Earth contact

2. 07. 5 Inform GROVE Product Support 2. 12. 1 Recognition of telescope

sec-tions locked (on telescoping cylinder) line breakage

Check supply line;

➠

p. 16-41. 2. 12. 2 Recognition of telescope

sec-tions locked (on telescoping cylinder) earth contact

2. 12. 5 Inform GROVE Product Support 2. 13. 1 Recognition of left

telescoping cylinder locked line breakage

Check supply line;

➠

p. 16-41. 2.13. 2 Recognition of left telescoping

cylinder locked earth contact 2.13. 5 Notify GROVE Product Support 2.14. 1 Recognition of right

telescop-ing cylinder locked line breakage

Check supply line;

➠

p. 16-41. 2.14. 2 Recognition of right

telescoping cylinder locked earth contact

(36)

switchOverrideearth contact supply line;

➠

p. 16-41.

Error messages from error group 3, kinematic system Error

message

3.02. 2 Communication with crane control interrupted

Test supply line;

➠

p. 16-41. 3.02. 3 Communication with crane

control interrupted during telescoping with teleautomatic

Confirm error and invoke teleautomatic again.

3. 06. 3 Differences occured in comparison with the crane control telescope status; g. if the current telescope status was entered on thecrane control displayafter mechanical emergency operation)

When the current telescope status is indicated on the crane control display, take over telescoping from the crane control;

➠

p. 16-40. If neither SLI nor crane control display show the current telescope status, notify GROVE Product Support.

Error messages from error group 5, range of cranes Error

message

5. 02. 4 Main boom angle during operation with lattice extension is too small.

Lower the main boom

5. 02. 5 Lattice extension angle too small

Lower the lattice extension

5. 02. 6 Lattice extension angle too large

Raise the lattice extension

5. 04. 5 An attempt was made to lock a telescope section at an intermediate length

Telescope to a fixed length

5. 07. 1 Force in derricking cylinder of lattice extension too great

Lower load

5. 07. 2 Load for derricking the lattice extension too great

Lower load 18.

03.

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Error messages from error group 6, Display / safety devices / relay Error

message

6. 09. 1...6 Fuse no. 1...6 faulty Change respective fuse (1 to 12) on the rear of the SLI plug-in module;

➠

Operating instructions, Chapter: Malfunctions on the superstructure

6. 10. 1...6 Fuse no. 7..12 defective

6. 20. 6...7 Excess temperature in the EKS-4

Improve ventilation in the cab, open maintenance cover at the front of ther crane cab and wait until the error message is acknowledged

Error messages from error group 8, Software Error

message

8. 06. 4 Voltage on the SLI too low Load superstructure battery, test supply line if necessary

Error message

Cause of error Countermeasure

9.01.2 The newly entered value for the reeving or the rigging mode was not yet confirmed.

Confirm reeving and/or rigging mode

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.

(38)

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. Then you can continue to work with the other channel without delay.

H

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

r

• Press the membrane switchError informationuntil the error message of the sensor or indicator which should be switched off appears on the displayInformation.

This error message always ends with a sensor or indicator on one of the numbers 2 to 6 (e. g. the error message for the pressure sensor 2, lower chamber).

no

• Press the membrane switchinput mode and also the membrane switch Switch on 2nd level. Keep both membrane switches pressed.

p

• Press theAcknowledge membrane switch once and let go of all

mem-brane switches again.

The last number in the error message now changes to an 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 functioremai-ning correctly;

➠

p. 16-39.

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.

!0"4

!0"8

18.

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Check that the remaining sensor/indicator is working

The Error message table (

➠

page 16-39) shows next to the error messa-ge if the sensor/indicator which was switched off is

– a pressure sensor, – an angle sensor, – a length indicator.

H

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 displayActual loadindicates 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 displayCurrent 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 sectionI.

n l

• Press theEntry mode membrane switch and the Hydraulic oil pressure derricking cylinder lower chamber sensor B membrane switch.

The remaining length indicator is functioning if theInformation display

indicates a length of approx. 0 ft.

Checking the length indicator for telescope sectionV

• Fully retract the main boom.

n k

• Press theEntry mode membrane switch and the Hydraulic oil pressure derricking cylinder lower chamber sensor A membrane switch.

The remaining length indicator is functioning if theInformation display

# !2

t

# =0

n°

(40)

from the crane control

crane control has detected. If the values differ, the SLI deactivates, the sta-tus displayCurrent telescope statusflashes 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 thecrane control display

which does not agree with the SLI display (e. g., after an emergency operation).

• Compare the current telescope status with the telescope status indica-ted on theCrane control display:

– If the current telescope status is not indicated, a malfunction has occur-red. Notify GROVE Product Support.

– If theCrane control displayindicates the actual telescope status, you can accept this telescope status into the SLI.

Accepting the telescope status

r

• Press the membrane switchError informationuntil the error message 3.06.3 is indicated on the status display Information.

no

• Press theEntry mode membrane switch and additionaly Switch on 2nd level

membrane switch. Hold down both membrane switches.

p

PressAcknowledge membrane switch and release all membrane switches

again.

The telescope status from the crane control is now accepted and indicated on the status displayCurrent telescope status.

§0&3

18.

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Checking SLI lines and connec-tions

If there is an error message which indicates that a sensor or indicator does not react any more or there is a line breakage or short circuit to frame, the cause may be

– 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).

On the lattice extension (additional equipment)

1 Electric control box with plug connections

2 Lattice extension angle sensor A

3 Lattice extension difference angle sensor

(42)

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 Lattice extension connection / boom extension (both additional equipment)

7 Length indicator

8 Angle sensor basic section control box A and B

18.

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16.4.12 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 emergency operation

First check whether the main boom may be lowered with the current extension and the current rigging mode of the truck crane (if a boom extension or a luffing jib 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 theLifting capacity table.

• Lower the main boom.

H

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. 13-95.

If the SLI allows lowering to the horizontal position,

danger from the raised truck crane boom is not applicable 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. 16-47.

– 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.

(44)

you must:

– check whether it is possible for you to carry out hydraulic emergency operation;

➠

When can hydraulic emergency operation be carried out?,

p. 16-47.

– have two auxiliary cranes ready for mechanical emergency operation, one of them a registered personal transport vehicle.

Procedure for retracting

There are different procedures for retracting in emergency mode. Which 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 ope-ration (with the main boom raised or horizontal, depending on circum-stances).

Not all possible situations can be described here, only activities for mecha-nical 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 especial-ly if the conditions for hydraulic emergency operation are different than described here.

18.

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Mechanical emer-gency operation

Mechanical emergency mode must be used if the telescoping cylinder can 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 devices can be achieved from the outside at all possible fixed lengths.

H

If the head of the telescoping cylinder is in the foot section of a telescope section, this telescope section cannot be manually locked and unlocked.

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 ten 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 Length of the

corresponding set screws (inches)

Telescope sectionI 8.27

Telescope sectionII _7.09

Telescope sectionIII _5.51

Telescope sectionIV _3.94

(46)

pin does not engage the telescope section above it any longer.

• Extend the telescope section approx. 0.8 inch

(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 inser-ted 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.

18.

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Hydraulic emer-gency operation

If the electrical supply line on the head of the telescoping cylinder is cut, 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).

TheCrane control display shows:

– either in the third line the message - NOT CONNECTED (and before the error messageUNIT 01 : 00000010was shown

➠

Error messages via control units, p. 16-59.)

–or in the second line the number string starting with 1 -STATUS : 10 0

(in this case you are asked to enter a keycode;

➠

Emergency program submenu, p. 16-74.)

Yes _No

None of the measures in the section Malfunc-tions of the telescoping gear, p.16-22 lead to

a correction of the problem. Check whether the current status of the telescoping cylinder can still

be read in the crane cab;

➠

p. 16-48.

Yes

No

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

Consult GROVE Product Support

➠

(48)

S

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 theCrane control display(e. g. 30.5 ft). If nothing more is displayed here, you can have the extended length displayed on the SLI.

n o

• Press theEntry modemembrane switch and theHydraulic oil pressure of derricking cylinder lower chamber sensor Bmembrane switch.

• Check if the extended length of the telescoping cylinder is now shown in theInformationdisplay.

• 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 Y2133;

➠

p. 16-50.

S

Risk of damage to the main boom!

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.

TELESCOPING – 100 – 100 – 0 – 0 – 0 Emergency operation TELE: –– L: 30.5 ft

# =0

18. 03. 1999

(49)

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 clea-red via ball valves (5).

The required function can then be controlled with the control unit of the counterweight lift-ing gear (3).

Preparing the truck crane for emergency operation

To connect the hoses for emergency operation you must retract the tele-scope section with which the telescoping cylinder is locked. To retract you must override the SLI.

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 theOverride key-operated switch to the

right.

If the telescope section is located at a locking point at the beginning of te-lescoping or moves over a locking point during tete-lescoping, the telescope section locks there.

(50)

The valve is located on the valve block (1) on the left side of the turntable behind the crane cab.

• Have a second person hold valve Y 21 33 pressed.

• 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 telescope section has moved about 0.3 ft further, valve Y 21 33 can be released, the locking pins extend again and move against the inner panel of the above telescope section.

H

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. 1.2 inches so that the locking pins can be retracted.

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 telesco-ping cylinder.

18.

03.