6200 - 1 Superstructure Malfunctions

Malfunctions on the superstructure
16.1 Superstructure emergency stop device
16
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.
18.03.1999
The crane engine switches off.
s
Operating Instructions GMK 5180
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16 - 1

16.1 Superstructure emergency stop device
Crane control
emergency stop
switch
In an emergency you can switch off the crane control with the Crane
control emergency stop switch. The switch is located on the middle plug-in
module in the crane cab.
Risk of overload if used improperly!
The Crane control unit emergency stop switch is only intended for the emergency 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.
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.
16 - 2
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.
18.03.1999
Check if the crane movements are carried out as normal.
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16.2 Troubleshooting for malfunctions that occur during crane operation
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
G
Load cannot be
lowered
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. 13-32.
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.
Secure the danger zone using cordons and assigned personnel.
Notify qualified repair personnel or local GROVE Product Support.
18.03.1999
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

16.2 Troubleshooting for malfunctions that occur during crane operation
18.03.1999
Blank page
16 - 4
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16.3 Electrical system
16.3
Electrical system
16.3.1
Plug-in modules and consoles
Pos.
18.03.1999
Designation
of plug in
module in Ecircuit diagram
Function
1.2 D
Monitors crane engine and hydraulic system /

spotlight / windscreen washing system /
additional heating system (additional equipment)
5D
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
6D
Anemometer (additional equipment) / switchable display for electronic spirit level / superstructure lock / display for shutting down
lifting limit switch / outrigger pressure display
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16 - 5

7D
Sets constant crane engine speed
+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
+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
16 - 6
Function
18.03.1999
Pos.
Designation of
plug-in module
in the electronic circuit
diagram
Safe load indicator (SLI)
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16.3.2
Fuses
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).
18.03.1999
Designation in
circuit diagram:
F1
Rating (A)
Function
20
Crane engine E-control
10
Crane engine diagnostic plug
10
Flame start system (additional

equipment)
15
No function
10
Crane cab ceiling lamp,

cigarette lighter
10
No function
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16 - 7

Function
10
No function
10
No function
10
No function
10
No function
10
No function
15
No function
Designation in
circuit diagram:
F3
Rating (A)
Function
10
Indicator and warning lamps for engine,

hydraulic system, flame start system
(additional equipment)
15
Window wiper/washer system
Pressure sensor/switch
Crane control
10
Control lever, fast speed for derricking

gear and telescoping gear, slewing
gear, slewing gear superstructure lock
10
Crane engine diagnostic plug
10
Flame start system (additional

equipment)
Designation in
circuit diagram:
F4
16 - 8
Rating (A)
Rating (A)
Function
Switches and indicator lamps
15
10
Working spotlight, switches and

indicator lamps for working spotlight
and shutdown of derricking gear /
telescoping gear / main hoist
Horn, Switch and indicator lamps for
auxiliary hoist shutdown, Slewing gear
permanent brake and crane cab incline
Crane cab heating
15
10
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Crane cab electronic spirit level,

SLI early warning/shutdown
SLI deactivation, Anchor-to-bracketswitch shutdown,
Dead mans switch, Seat contact
18.03.1999
Designation in
circuit diagram:
F2

Designation in
circuit diagram:
F5
Rating (A)
Function
15
Crane control power supply
15
15
15
15
15
Designation in
circuit diagram:
F6
Rating (A)
Function
10
Shutdown of main hoist,

main hoist slewing indicator
10
Shutdown for auxiliary hoist,

auxiliary hoist slewing indicator
10
Shutdown for derricking gear

shutdown for telescoping gear
10
Control lever initial position
10
Slewing gear
10
Indicator/warning lamp counterweight

locked/unlocked in switch unit
18.03.1999
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16 - 9

Designation in
circuit diagram:
F7
Function
10
SLI
10
Proximity switch telescoping cylinder
No function
10
Crane control display

emergency operation crane control
10
Crane control
10
Crane engine E-control
Designation in
circuit diagram:
F8
Rating (A)
Function
15
Crane cab heating
15
Radio
15
No function
Crane control unit 0
Rating (A)
Function
20
Oil cooler
Oil cooler (relay)
15
No function
10
No function
Central lubrication system
10
No function
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18.03.1999
Designation in
circuit diagram:
F9
16 - 10
Rating (A)

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:
Rating (A)
Function
F 10
50
Central fuse
SLI supply line
F 11
50
Protection for main fuse

superstructure
(protection)
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.
18.03.1999
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16 - 11

16.3.3
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
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.
18.03.1999
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.
16 - 12
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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.
18.03.1999
Designation in
circuit diagram:
Rating (A)
Function
SI1
SLI internal
SI2
SLI shutdown display
SI3
Lift main hoist shutdown
SI4
Shutdown lowering
SI5
Shutdown extending
SI6
Lift auxiliary hoist shutdown
SI7
Shutdown raising
SI8
Shutdown retracting
SI9
Lower auxiliary hoist shutdown
S I 10
Lowering the lattice extension
S I 11
SLI early warning display
S I 12
Raising the lattice extension
S I 13
SLI central unit
If the fuse on an SLI outlet fails again, notify your local GROVE Product
Support.
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16 - 13

18.03.1999
Blank page
16 - 14
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16.4 Troubleshooting and malfunction correction
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.
Batteries not charged enough
Charge batteries
Fuel tank empty
1.
Fill fuel tank,

p. 12-7.
2.
Bleed fuel system,

Mercedes-Benz
Operating manual
Engine does not start

(starter motor turns over)
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.
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 lamp Crane engine

air filter lights up
Crane engine air filter is dirty
Replace crane engine air filter
Indicator lamp Flame start

system lights 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
18.03.1999
Engine coolant temperature

too high
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16 - 15

Malfunction
Cause
Action
Motor electronics warning

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; p. 11-4;
Oil level; p. 11-3;
Air filter;
Maintenance manual
V-belt too loose
Check V-belt tension;

Operating manual MercedesBenz
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
18.03.1999
Coolant level too low,

Oil level too low,
Air filter dirty.
16 - 16
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16.4.2
Main hoist malfunctions
Malfunction
Cause
Action
Main hoist not functioning

or malfunctioning (lifting,
lowering or fast speed not
functioning)
Rocker switch Shutdown main

hoist switched on
Switch off rocker switch

Shutdown main hoist
Fuse F3/4 OW or
F6/1 OW defective

necessary
Dead mans switch not

activated
Press dead mans switch
Fuse F4/2 OW or F4/3 OW

defective

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

switch pressed in
Release crane functions

again; p. 16-2.
Main hoist lowering not functioning (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 functioning 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.

defective

necessary; p. 16-7.
Lifting, lowering or fast speed Corresponding function is

do not function
blocked by the crane control
(error message is displayed)
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 displays
stored number codes and
inform GROVE Product
Support; p. 13-81.
Fuse on corresponding SLI

outlet defective
Replace if necessary;
p. 16-7.
18.03.1999
Lifting does not function

once; p. 13-89.
down the number codes and
Support; p. 16-60.
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16 - 17

Malfunction
Cause
Action
No lifting or lowering, or possible only at very low speed
Maximum speed set too low
Increase maximum spees on

the display Enter 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

switch; p. 16-2.
18.03.1999
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!
16 - 18
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16.4.3
Auxiliary hoist malfunctions
Malfunction
Cause
Action
Auxiliary hoist not

functioning or malfunctioning
(lifting, lowering or fast speed
not functioning)
Rocker switch Shutdown

auxiliary hoist switched 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.

activated
Press dead mans switch;

p. 11-63.


once; p. 13-89.
units; p. 16-59.

switch pressed in

again; p. 16-2.
Auxiliary hoist lowering not

functioning (Also check all
causes in the Auxiliary hoist
not functioning section!)
Lowering limit switch

triggered

Lift main hoist
Auxiliary hoist lifting not

causes in the Auxiliary hoist
not functioning section!)

(warning lamp on)

Lower the auxiliary hoist
SLI shutdown
(warning lamp on)
Leave shutdown area

defective

necessary; p. 16-7.
Lifting, lowering or fast speed Corresponding function is

do not function
18.03.1999
displayed)

once; p. 13-89.
Support; p. 16-60.
switch on again.
Support; p. 13-81.
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16 - 19

Malfunction
Cause
Action
No lifting or lowering, or possible only at very low speed
Increase maximum speed on

speed; p. 13-85.
Lowering does not function

outlet defective
p. 16-12.
Lifting or lowering function

can not be switched off

control

switch; p. 16-2.
18.03.1999

movement.
In this case also check the causes listed in section Auxiliary hoist not
functioning!
16 - 20
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16.4.4
Derricking gear malfunctions
Malfunction
Cause
Action
Derricking gear not functioning or malfunctioning

(raise boom, lower boom or
fast speed not functioning)
Dead mans switch system

not activated
Press dead mans switch,

p. 11-63.

defective

necessary; p. 16-7.
Right-hand control lever set to Set control lever to Derricking

Telescoping function
function
Lower boom not functioning

(Also check all causes in the
Derricking gear not functioning section!)

Shutdown derricking gear


once; p. 13-89. If the error
message is repeated, change
the connections on the
control units; p. 16-59.

switch pressed in

again; p. 16-2.

(warning light on)

raise boom
SLI shutdown
(warning lamp on)
Leave shutdown area;

p. 13-16

defective

necessary

once; p. 13-89.
Support; p. 16-60.
displayed)

switch on again.
Support; p. 13-81.
18.03.1999
Raising or lowering the boom

do not function

derricking gear switched on
s
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16 - 21

Malfunction
Cause
Action

does not function

outlet defective
p. 16-12.
No raising or lowering the

boom, or possible only at
very low speed

speed; p. 13-85.

function can not be switched
off

control

switch; p. 16-2.
16.4.5

movement.
In this case also check the causes listed in the Derricking gear not
functioning section!
Telescoping gear malfunctions
Malfunction
Cause
Action
Telescoping gear not

functioning or malfunctioning
(telescope in, telescope out or
fast speed not functioning)
Dead mans switch system

not activated

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

F6/3 OW defective

necessary; p. 16-7.
Telescope section and telescoping cylinder do not

lock/unlock any functions
16 - 22

telescoping gear or Lattice
extension incline switched on

Shutdown telescoping gear;
p. 7-36.


once; p. 13-89.
units; p. 16-59.

switch pressed in

again; p. 16-2.
Valve defective
Note down the Display status

locking number code on the
display and inform GROVE
Product Support; p. 16-60.
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18.03.1999
Right-hand control lever set to Set control lever to Telescoping

Derricking function

Malfunction
Cause
Action
Extension of the telescoping

not functioning
(Also check all causes in the
Telescoping gear not
functioning section!)
SLI shutdown
(warning lamp on)
Leave shutdown area

defective

necessary; p. 16-7.

(warning lamp on)

Lower hoist
Telescope retracting not

causes in the Telescoping
gear not functioning
section!)
Insufficient boom lubrication
Lubricate boom,
Maintenance manual
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
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

once; p. 13-89.
Support; p. 16-60.
displayed)

switch on again.
Support; p. 13-81.

outlet defective
p. 16-12.
Retracting or extending does

not function
18.03.1999
Lock telescope cylinder;
No retracting or extending, or Maximum speed set too low

possible only at very low
speed

speed; p. 13-85.
Retracting or extending
function can not be switched
off

switch; p. 16-2.

control
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16 - 23

Malfunction
Cause
Action
The boom can no longer be

extended, the locking/unlocking mechanism no longer
reacts to the control instruments 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.
18.03.1999

movement.
If the malfunction occurs in both directions of movement you must also
check the causes listed in the Telescoping gear not functioning section!
16 - 24
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16.4.6
Slewing gear malfunctions
Malfunction
Cause
Action
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.

activated

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

defective

necessary; p. 16-7.


once; p. 13-89.
units; p. 16-66.

switch pressed in

again; p. 16-2.

once; p. 13-89.
Support; p. 16-60.
displayed)

switch on again.
Support; p. 13-81.
No slewing, or possible only

at very low speed
Increase maximum speed on

speed; p. 13-85.
Slewing can not be

switched off

control

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

functioning
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16 - 25

16.4.7
Counterweight lifting gear / lock malfunctions
Malfunction
Cause
Action
Counterweight lifting gear/

lock not functioning


once; p. 13-89.
units; p. 16-59.

switch pressed in

again; p. 16-2.
Counterweight lifting cylinder Hydraulic connection on the

or lock not functioning
4.4 t base plate not made

once; p. 13-89.
Support; p. 16-60.
displayed)

switch on again.
Support; p. 13-81.
Safety tap is closed
Open safety tap;

p. 10-57.
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Locking pins cannot be

retracted/extended
Make hydraulic connection;

p. 13-48.
16 - 26
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16.4.8
Lattice extension malfunctions
Malfunction
Cause
Action
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
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;

p. 15-64.
18.03.1999
With error message 5.02.6

Raise the lattice extension
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16 - 27

16.4.9
Hydraulic system / hydraulic oil cooler malfunctions
Malfunction
Cause
Action
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.
Fans 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;

Maintenance manual
Warning lamp for hydraulic

oil return filter or return fine
filter lights up
Hydraulic oil filter dirty
Replace hydraulic oil filter;

Maintenance manual
16.4.10
Crane control malfunctions

Cause
Action
The Crane 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

necessary; p. 16-7.
On the Crane 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 the Crane 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
18.03.1999
Malfunction
16 - 28
2 085 291 en

Malfunction
Cause
Action
In the Crane control display

the two number codes appear
one below the other:
ECOS
00001000
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
16.4.11
If there are further malfunctions on the crane control, the corresponding

error messages will appear on the Crane control display; p. 16-59.
Malfunctions on the SLI

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?
18.03.1999
6. Have the fuses been replaced?
2 085 291 en
16 - 29

Other malfunctions on the SLI

Malfunction
Cause
Action
SLI does not function

(displays not lit, no buzzer
signal)
Power supply switched off
Switch on ignition

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

necessary; p. 16-7.
Operating instructions - Part 2,
Fuse S I 13 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;

Product Support
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

Check line; p. 16-41

pressure sensor 2;
Product Support
18.03.1999
1. 01. 7
16 - 30
2 085 291 en

1. 02. 2...6 Pressure sensor 2, lower

chamber reports error
Switch off pressure sensor 2;

Product Support
1. 02. 7
1. 02. 8
You have switched off
pressure sensor 2 because of
an error message

1. 03. 1
Pressure sensor upper

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
1. 04. 2...6 Angle sensor A,

basic section reports error

If line is O.K., switch off angle
sensor A; p. 16-38 and
notify GROVE Product Support
Switch off angle sensor A,
basic section; p. 16-38 and
1. 04. 7
1. 04. 8
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

sensor B; p. 16-38 and
1. 05. 2...6 Angle sensor B,

basic section reports error
1. 05. 8
sensor B, basic section
because of an error message

18.03.1999
1. 05. 7
Switch off angle sensor B,

basic section; p. 16-38 and
2 085 291 en
16 - 31

1. 06. 1
Length indicator A for

telescope section V does not
react

length indicator A; p. 16-38
and notify GROVE Product
Support
1. 06. 2...6 Length indicator A for

Switch off length indicator A
telescope section V reports an for telescope section V;
error
Product Support
1. 06. 7
1. 06. 8
You have switched off length
indicator A for telescope
section V because of an error
message

1. 07. 1
Length indicator B for

telescope section V does not
react

length indicator B; p. 16-38
Support
1. 07. 7
1. 07. 8
indicator B for telescope
section V because of an error
message

1. 08. 1
Length indicator A of the

telescoping cylinder does not
react

length indicator A of the
telescoping cylinder;
Product Support
1. 08. 2...6 Length indicator A of the

telescoping cylinder reports
an error
1. 08. 7
16 - 32
Switch off length indicator A

of the telescoping cylinder;
Product Support
2 085 291 en
18.03.1999
1. 07. 2...6 Length indicator B for

Switch off length indicator B
telescope section V reports an for telescope section V;
error
Product Support

1. 08. 8
indicator A of the telescoping
cylinder because of an error
message

1. 09. 1
Length indicator B of the

telescoping cylinder does not
react

If the line is O.K., switch off
length indicator B of the telescoping cylinder; p. 16-38
Support
1. 09. 2...6 Length indicator B of the

telescoping cylinder reports
an error
Switch off length indicator B

of the telescoping cylinder;
Product Support
1. 09. 8
indicator A of the telescoping
cylinder because of an error
message

1.10. 1
Angle sensor A,
Lattice extension does not
react

sensor A, luffing jib;
Product Support
1.10. 2...6
Angle sensor A,
Switch off angle sensor A,
Lattice extension reports error luffing jib; p. 16-38 and
1.10. 7
1.10. 8
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;
Product Support
18.03.1999
1. 09. 7
2 085 291 en
16 - 33

16 - 34
1.11. 2...6
Difference angle sensor,

lattice extension gives error
message
1.11. 7
1.11. 8
Message remains if the
You switched off the
ignition is switched off
difference angle sensor on the
lattic extension because of an
error message
1.12. 1
Lattice extension pressure

If necessary notify GROVE
sensor
lower chamber does not react Product Support
1.12. 2...6

sensor
lower chamber reports error
1.12. 7
1.13. 1

sensor,
upper chamber reacts

If necessary notify GROVE
Product Support
1.13. 2...6

sensor,
upper chamber reports error

Support
1.13. 7
1.15.1...6
1.16.1...6
1.18.1...6
1.19. 1
The difference between the

main boom length and the
length control is too great.
The display Actual load and
Actual radius flash
Test length indicator, plug

connection and supply line;
p. 16-41.
Test telescope diagram from
outside.
Support if necessary.
1.21. 1
Differences between rope

indicator and cable drum in
the main boom are too large
The displays Actual load and
Current radius flash

Support.
2 085 291 en
Switch off difference angle

sensor; p. 16-38 and notify
GROVE Product Support
18.03.1999

Support

18.03.1999
Error messages from error group 2, digital inputs

Error
message
Cause
Action
2. 01. 1
Recognition of locking point

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

for telescope section earth
contact
2. 01. 5
Inform GROVE Product Support
2. 05. 1
Line breakage
2. 05. 2
Earth contact
2. 05. 5
2. 07. 1
Line breakage
2. 07. 2
Earth contact
2. 07. 5
2. 12. 1
Recognition of telescope sections locked (on telescoping

cylinder) line breakage
2. 12. 2
Recognition of telescope sections locked (on telescoping

cylinder) earth contact
2. 12. 5
2. 13. 1
Recognition of left
telescoping cylinder locked
line breakage
2.13. 2
Recognition of left telescoping

cylinder locked earth contact
2.13. 5
2.14. 1
Recognition of right telescoping cylinder locked line

breakage
2.14. 2
Recognition of right
telescoping cylinder locked
earth contact
2.14. 5
2.17. 1
Recognition of key-operated
switch Override line breakage
2 085 291 en
Check supply line; p. 16-41.
Lift SLI override or check

supply line; p. 16-41.
16 - 35

2.17. 2
Recognition of key-operated
switch Override earth contact
lift SLI override or check

supply line; p. 16-41.
Error messages from error group 3, kinematic system

Error
message
Cause
Action
3.02. 2
Communication with crane

control interrupted
Test supply line; p. 16-41.
3.02. 3
Communication with crane

Confirm error and invoke
control interrupted during
teleautomatic again.
telescoping with teleautomatic
3. 06. 3
Differences occured in
comparison with the crane
control telescope status; g. if
the current telescope status
was entered on the crane
control display after 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.
16 - 36
Error
message
Cause
Action
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 Lower load

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

lattice extension too great
2 085 291 en
Lower load
18.03.1999
Error messages from error group 5, range of cranes

Error messages from error group 6,

Display / safety devices / relay
Error
message
Cause
Action
6. 09. 1...6 Fuse no. 1...6 faulty

6. 10. 1...6 Fuse no. 7..12 defective
6. 20. 6...7 Excess temperature in

the EKS-4
Change respective fuse (1 to

12) on the rear of the SLI plugin module; Operating
instructions, Chapter:
Malfunctions on the
superstructure
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

Cause
Action
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
If further malfunctions not appearing in this table are displayed, contact

the GROVE Product Support responsible.
18.03.1999
Error
message
2 085 291 en
16 - 37

Switch off sensor/

indicator during
malfunction
H
r
!0"4
no
p
!0"8
The SLI works with a two-channel sensory system in which most pressure
sensors, length indicators and angle sensors are in duplicate. If there is an
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.
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
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
numbers 2 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
Switch on 2nd level. Keep both membrane switches pressed.
Press the Acknowledge membrane switch once and let go of all membrane 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.
After switching off a sensor/indicator, you should check that the remaining sensor/indicator is functioning correctly; p. 16-39.
Releasing shutdown
18.03.1999
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.
16 - 38
2 085 291 en

Check that the

remaining
sensor/indicator
is working
The Error message table ( page 16-39) shows next to the error message if the sensor/indicator which was switched off is
a pressure sensor,
an angle sensor,
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 accuracy.
Check pressure sensor
Hoist the hook block without a load.
# !2
The remaining pressure sensor is functioning if the status display Actual

load indicates the approximate weight of the hook block.
The weight of the hook block is stated in the technical data in the operating instructions.
Checking an angle sensor
Place the retracted main boom in the boom support.
# =0
The remaining angle sensor is functioning if the status display Current

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 telescoping cylinder in telescope section I.
nl
# =0
Press the Entry mode membrane switch and the Hydraulic oil pressure
derricking cylinder lower chamber sensor B membrane switch.
The remaining length indicator is functioning if the Information display
indicates a length of approx. 0 ft.
Checking the length indicator for telescope sectionV
Fully retract the main boom.
18.03.1999
nk
# =0
Press the Entry mode membrane switch and the Hydraulic oil pressure
derricking cylinder lower chamber sensor A membrane switch.
The remaining length indicator is functioning if the Information display
indicates a length of approx. 0 ft.
s
2 085 291 en
16 - 39

Accepting the
telescope status
from the
crane control
The SLI and the crane control detect the telescope status independently.
The SLI compares its displayed telescope status with the value which the
crane control has detected. If the values differ, the SLI deactivates, the status 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
operation).
Compare the current telescope status with the telescope status indicated on the Crane control display:
If the current telescope status is not indicated, a malfunction has occurred. 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
3.06.3 is indicated on the status display Information.
0&3
no
p
Press the Entry mode membrane switch and additionaly Switch on 2nd level
membrane switch. Hold down both membrane switches.
Press Acknowledge membrane switch and release all membrane switches
again.
18.03.1999
The telescope status from the crane control is now accepted and indicated
on the status display Current telescope status.
16 - 40
2 085 291 en

Checking SLI
lines and connections
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)
Electric control box with plug connections
Lattice extension angle sensor A
Lattice extension difference angle sensor
Lattice extension pressure sensor
18.03.1999
s
2 085 291 en
16 - 41

on the truck crane
Control box pressure sensors upper chamber and lower chamber
Plug connections under the main boom on the inner side of the
turntable (connection of indicators in the main boom)
Derricking cylinder lower chamber pressure sensor
Derricking cylinder upper chamber pressure sensor
SLI connecting box
Lattice extension connection / boom extension (both additional

equipment)
Length indicator
Angle sensor basic section control box A and B

18.03.1999
16 - 42
2 085 291 en

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, malfunctions in the electrical control system of the locking mechanism, the mechanical 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 the Lifting capacity table.
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. 13-95.
If the SLI allows lowering to the horizontal position,
danger from the raised truck crane boom is not applicable and you can:
18.03.1999
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.
s
2 085 291 en
16 - 43

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. 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 telescoping 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).
18.03.1999
Not all possible situations can be described here, only activities for mechanical 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 especially if the conditions for hydraulic emergency operation are different than
described here.
16 - 44
2 085 291 en

Mechanical emergency 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.
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 telescope 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)
8.27
Telescope section II
7.09
Telescope section III
5.51
Telescope section IV
3.94
Telescope section V
2.56
18.03.1999
Telescope section I
s
2 085 291 en
16 - 45

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. 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 engage 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.
18.03.1999
Continue to retract the telescope section

until it is set onto the recesses on the
locking pin.
16 - 46
2 085 291 en

Hydraulic emergency 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).
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. 16-59.)
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. 16-74.)
Yes
No
Check whether the current status of the telescoping cylinder can still
p. 16-48.
be read in the crane cab;
Yes
No
None of the measures

in the section Malfunctions of the telescoping
gear, p.16-22 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
18.03.1999
No
Prepare necessary equipment

p. 16-49.
and prepare truck crane for emergency operation
Consult GROVE
Product Support
s
2 085 291 en
16 - 47

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. 30.5 ft).
TELESCOPING
100
100
If nothing more is displayed here, you can

have the extended length displayed on the
SLI.
Emergency operation
TELE:
no
# =0
L: 30.5 ft
Press the Entry mode membrane switch and the Hydraulic oil pressure of
Check if the extended length of the telescoping cylinder is now shown
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 Y2133;
p. 16-50.
18.03.1999

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.
16 - 48
2 085 291 en

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 lifting gear (3).
Preparing the truck crane for emergency operation

To connect the hoses for emergency operation you must retract the telescope section with which the telescoping cylinder is locked. To retract you
must override the SLI.
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.
18.03.1999
If the telescope section is located at a locking point at the beginning of telescoping or moves over a locking point during telescoping, the telescope
section locks there.
s
2 085 291 en
16 - 49

To unlock the telescope section the hydraulic

valve Y21 33 must be pressed.
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 mechanism; 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.
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.
18.03.1999
Guide the two other hose ends through the

rear opening (3) into the basic section.
These ends are connected to the telescoping cylinder.
16 - 50
2 085 291 en

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.
You can reach the connections on the telescoping cylinder

either through the rear opening in the basic section
or, if you can extend telescope section I approx. 6.5 ft, through the manhole at the top of the basic section.
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.
The hydraulic hoses are connected directly

to the head of the telescoping cylinder.
Insert the quick couplings in the two connections (2) and (3).
Close the two valves (1) and (4). The valves are closed if the handles are perpendicular to the lines.
18.03.1999
Mark a hose on the other end. For emergency operation it is important that you
know which hose is connected with the
right connection (2) and which hose with
the left connection (3).
s
2 085 291 en
16 - 51

The connection (1) for the emergency supply

is on the left side of the turntable above the
oil cooler.
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 telescoping 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

telescoping cylinder (left)
Check whether the safety cock (1) for the

counterweight locking mechanism is closed and close it if necessary.
18.03.1999
The safety cock must be closed so that the

hasps cannot move into the unlocked position
during emergency operation, causing the
counterweight to fall down.
16 - 52
2 085 291 en

Risk of accidents from falling counterweight!

Always close the safety cock before carrying out hydraulic emergency
operation.
If the safety cock is open, the hasps move into the unlocked position when
unlocking with hydraulic emergency operation and the counterweight can
fall down.
Operating the locking/unlocking mechanism in emergency mode

The locking/unlocking process is controlled
with the counterweight lifting gear switch
unit (1).
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 emergency supply.
18.03.1999
To lock/unlock the telescope section, the

right connection (2) on the telescoping
cylinder must be connected with the emergency supply.
2 085 291 en
16 - 53

H
S
You must always press the button whose symbol shows the opposite movement to carry out a movement in emergency operation. In emergency
operation you must therefore press the Unlock counterweight button to lock
and vice versa.
Always carry out the locking movement before you remove a hose from
the emergency supply connection so that the hose is depressurized. If the
hose is under pressure, the quick coupling can no longer be inserted and
you can not continue emergency operation.
Unlocking
Turn the Release switch unit knob to the right and hold it down.
In addition press the Lock counterweight button and hold it down until the
locking process is finished.
To unlock the telescope section you must extend the telescope section
approx 1.2 inches.
Locking
Turn the Release switch unit knob to the right and hold it down.
In addition press the Unlock counterweight switch and hold it down until the
locking process is finished.
The positions of the locking pins on the telescoping cylinder and the telescope sections has no effect on the indicator and warning lamps in the
buttons. These lights always show the position of the hasp.
Retracting with hydraulic hoses connected
S
16 - 54
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.
2 085 291 en
18.03.1999
If you have retracted the telescope section in which the telescoping cylinder was locked when the malfunction occured and the hoses are connected for hydraulic emergency operation, you can retract the main boom
completely.

S
S
H
Risk of damaging the hydraulic hoses!

While you telescope the main boom, a second person must ensure that
the double hose is 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.
Risk of damaging the hydraulic hoses when raising!

When raising the main boom the hydraulic hoses may get crushed. Before 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.
Retract the telescope section until it has reached its locking point at 0%.
If the telescope section locks at the locking point at 50% during retracting,
unlock it with the corresponding buttons on the Counterweight lifting gear
switch unit.
When the telescope section has reached the locking point at 0%, it is lokked 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).
Depressurize the connected hydraulic hose. To do this turn the Release
switch unit knob to the right and also press the Unlock counterweight button.
Make the necessary connection for the emergency supply for locking/
unlocking the telescoping cylinder (left connection).
18.03.1999
Unlock the telescoping cylinder. To do this turn the Release switch unit
knob to the right and also press the Lock counterweight button.
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2 085 291 en
16 - 55

See the table Extended lengths of the telescoping cylinder at the locking points
( p. 16-57) for the length data for the locking point of the next extended telescope section.
The locking pins on the telescoping cylinder sometimes slide back out
when you are extending the telescoping cylinder.
Therefore extend the telescoping cylinder only until it is approx. 1.6 ft in
front of the locking point.
Fully retract the locking pins again. To do this turn the Release switch unit
knob to the right and also press the Lock counterweight button.
Extend the telescoping cylinder until it is at the locking point.
8
9
If the telescoping cylinder at locking point indicator lamps are still activated,
you can also detect the position of the telescoping cylinder in relation to
the locking point as well as details regarding length. p. 7-38
Lock the telescoping cylinder with the telescope section. To do this turn
the Release switch unit knob to the right and also press the Unlock counterweight button.
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 telescope section I. Extend the telescoping cylinder slowly. The telescoping cylinder is locked when the locking pins of telescope section I
also move.
Make the necessary connection to the emergency supply for locking/

unlocking the telescopic part (right connection).
16 - 56
2 085 291 en
18.03.1999
Depressurize the connected hydraulic hose. To do this turn the Release

switch unit knob to the right and also press the Unlock counterweight button.

Extend the telescope section approx. 1.2 inches so that the telescope
section is no longer on the recesses.
Unlock the telescope section by turning the Release switch unit knob to
the right and also pressing the Lock counterweight switch.
Retract the telescope section until it has reached the locking point at 0
%.
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 telescope status in the crane control system after the repair; Entering telescope status after emergency operation menu, p. 16-80.
Extended lengths of the telescoping cylinder at the locking points
18.03.1999
Telescope section
Locking point
at fixed length
[%]
Extended length of
the telescoping
cylinder [ft]
T1
0
50
100
0.03
15.3
30.5
T2
0
50
100
1.1
16.3
31.6
T3
0
50
100
2.2
17.5
32.7
T4
0
50
100
3.2
18.5
33.7
T5
0
50
100
4.1
19.4
34.6
2 085 291 en
16 - 57

18.03.1999
Blank Page
16 - 58
2 085 291 en

16.5 Crane control error messages
16.5
Crane control error messages
16.5.1
Error messages about control units
ERROR MESSAGE
SYSTEM
UNIT 1:
00000010
STATUS: 0 0 0 0 0 0 1 0
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:
SYSTEM is in the second line. In the third
line you will find UNIT 0, 1 or 2, for the
control units on the connections 0 to 2.
The number code in the fourth line is of
secondary importance.
The following table shows which crane functions are out of operation
when the control unit fails on a connection:
Error message
on the display
Error and
effect
UNIT 1:
Control unit on
connection 1 defective,
telescoping gear,
derricking gear,
counterweight lifting
cylinder and locking pins,
superstructure lock and
tilt crane cab and, with
additional equipment,
derricking of lattice
extension blocked.
UNIT 2:
Control unit on
slewing gear and fast
speeds blocked.
18.03.1999
UNIT 0:
Control unit on
function of the crane
control, main hoist and
auxiliary hoist blocked.
2 085 291 en
Action
The truck crane can be

rigged by changing the
connection lines on
another control unit in
on-the-road mode;
Changing the connections
in the control units, p. 16-66.
16 - 59

16.5.2
Error messages about power units

If there is an error message about drive units
it will appear in the second line of the affected drive unit (e. g. the telescoping gear).
You also get different entries and number
codes in the two bottom lines.
ERROR MESSAGE
TELESCOPING SYSTEM
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. 13-82.
>
MEMORY ERROR
TELESCOPING SYSTEM
J3502:
01000000
STATUS: 0 0 0 0 0 1 0 0
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.
The messages here are only an example
which will be dealt with at the end of the
following sections.
Using the messages in the bottom two lines you can

determine the part on which the error occurred; Determining defective
part, p. 16-61.
determine the area of the error, depending on the detected part;
Determining error area, p. 16-62.
In the following sections you will find more information on the displayed
errors. If, in the sections, you are asked to contact GROVE Product Support, please note down the number code beforehand and have it ready.
When you have noted down the error codes you can acknowledge the
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.
18.03.1999
locate more precisely the cause of the error; Error causes and effects,
p. 16-63.
16 - 60
2 085 291 en

Determining
defective part
The first message in the third line of the display describes the defective
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
A100
Error with the

communication with the
SLI
ECOS
Logic error detected by

crane control
Other message
(e. g. Y2301)
Error on another part

(valve, digital input,
pressure sensor)
Determine cause of
error; Error causes and
effects, p. 16-63.
Determine error area;

Determining error area,
p. 16-62.
Example
MEMORY ERROR
TELESCOPING GEAR
Y2301:
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 determine the area of the error before you can determine the cause of the error.
00000001
18.03.1999
STATUS: 0 0 0 0 0 1 0 0
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2 085 291 en
16 - 61

Determining
error area
With some parts (e. g. a valve), you must first determine the error of the
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
00000001
Control lever
00000010
Digital input
00000100
Output
00001000
Analogue input
00010000
CAN-Bus (always
displayed together with
ECOS, A100 or A3502)
10000000
ECOS (also displayed as

a part)
Further troubleshooting
Determine cause of error

in the affected area;
Error causes and effects,
p. 16-63.
Example
MEMORY ERROR
TELESCOPING GEAR
Y2301:
00000001
The output area is in the table in the next

section. Here you can determine the cause of the
error in this area.
18.03.1999
STATUS: 0 0 0 0 0 1 0 0
In the display used as an example the number

code 0 0 0 0 0 0 0 1 is in the last line.
The table assigns this number code an error in
the output area.
16 - 62
2 085 291 en

Error causes and

effects
Once you have determined the defective part or the area where the error
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
part
or area
Number code in Cause of error

the third line on
the display
00000001
00000010
Control lever
J3501 or
J3502
Length
indicator
A3502
Communication with SLI
A100
Analogue
indicator in
control lever
defective
00000100
Earth contact/
line breakage
00001000
24V short
00010000
Earth contact/
line breakage
00100000
24V short
01000000
Mechanical
error
0 0 0 0 0 0 01
No data
reception
00000010
Hardware error
0 0 0 0 0 0 01
Control lever
emergency
programme is
activated;
p. 16-70.
Notify GROVE
Product Support
Inform GROVE
Product Support
No data
reception from
SLI
When there is no
display on the SLI,
check fuse SI13;
p. 16-12.
00000001
Locking status
unrealistic
After acknowledgement start

the menu
Emergency operation
access;
p. 13-88.
00001000
displayed
telescope status
incorrect
00000001
Line breakage/
24V short
00000010
Earth contact
00000010
ECOS
Telescoping error
messages p.16-65
Inform GROVE
Product Support
18.03.1999
Digital input
Effect/
Remedy
2 085 291 en
16 - 63

Defective
part
or area
Output
Analogue
input
Number code in Cause of error

the third line on
the display
00000001
Line breakage/
24V short
00000010
Earth contact
00000100
Line breakage
00001000
Output
Low resistance
00010000
Output
High resistance
0000000 1
24V short
00000010
Earth contact/
line breakage
Effect/
Remedy
Inform GROVE
Product Support
Notify GROVE
Product Support
Example
In the display used as an example the number
code 0 0 0 0 0 0 0 1 is in the third line.
MEMORY ERROR
TELESCOPING GEAR
Y2301:
00000001
In the previous section we determined that the error was in the output area.
According to the table this number code means
that there is a Line breakage or a 24V short.
In this case you must inform GROVE Product
Support and have the supply line checked.
18.03.1999
STATUS: 0 0 0 0 0 1 0 0
16 - 64
2 085 291 en

16.5.3
Telescoping error messages

If the crane control recognises a difference 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 Difference telescope status is

displayed by the following number codes:
ECOS
STATUS
ERROR MESSAGE
00001000
1 0 0 0 0 0 0 0.
LOCKING SYSTEM
ECOS
00001000
STATUS
10000000
Acknowledge the error message.

If the Display telescope status and teleautomatic
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
T4
T5
If another menu was selected before the error message occurred, select
either the Display telescope status and teleautomatism menu (
) and the
crane control switches directly to the menu to enter the telescope status
or select the Enter telescope status after emergency operation menu directly (3
x
).
18.03.1999
T3
2 085 291 en
16 - 65

16.5.4
Connections and
control units
Changing the connections in the control units

The control units are behind the crane operators seat.
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove connections 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 telescope
status) can become lost or damaged.
If this data is not available there will be malfunctions during the next
crane operation.
Crane control
Telescoping gear, derricking
main hoisting gear,
gear, counterweight lifting cylin-
Slewing gear,
auxiliary hoist gear (additional
der and locking, cabin inclining,
High-speed
equipment)
superstructure locking
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 drive units. If this control unit fails, the drive units connected
with it can no longer be driven. You can activate the drive 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.
If, for example, the control unit under the 0 connection fails, you can no
longer move the drive units on this connection (main hoist, auxiliary
hoist) and the whole crane control is blocked. You can therefore not move
any more drive units.
The display shows an error message over UNIT 0.
18.03.1999
Unrigging
mobile crane
with defective
control unit
16 - 66
2 085 291 en

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.
You can re-activate the crane control and the failed drive units in this case
by removing the connection from one of the two other control units (e. g.
connection 2) and inserting connection 0 on this control unit;
Inserting and removing connections, p. 16-69.
Crane control
main hoisting gear,
Slewing gear,
High-speed
equipment)
After connection 2 has been removed, the crane control shows the relevant 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,
derricking and
moving the auxiliary drive units (counterweight lifting cylinder and
locking pins, superstructure lock, tilt crane cab).
18.03.1999
All drive units which are connected with connection 2 are now out of operation (slewing gear and fast speeds).
If you need the slewing gear when unrigging, you must change the connections again.
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2 085 291 en
16 - 67

To drive the slewing gear, for example, remove connection 1 from the
control unit and insert connection 2 into this control unit.
Crane control
main hoisting gear,
Slewing gear,
High-speed
equipment)
Do not remove connection O, 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)
r connections
(for main hoist/auxiliary hoist,

derricking gear, telescoping gear
superstructure lock,
Counterweight lifting gear and
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 telescoping on the display.
Replace the defective control unit before the next job!
18.03.1999
0 and 2
16 - 68
2 085 291 en

Inserting
and removing
connections
All connections are equipped with plugs and safety holders.
Turn the ignition off in the crane cab before you remove connections
from or insert them in the control units.
Risk of malfunctions due to data loss!

Always turn the ignition off in the crane cab before you remove connections 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 telescope 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).
18.03.1999
Push the holder (1) in until you hear it

engage.
2 085 291 en
16 - 69

16.5.5
Control lever emergency program

If a control lever is blocked because of a malfunction, the Crane control display 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 drive
units, p. 16-60.
Indications on
the display
Call up the menu Control lever emergency program on the Crane control
display. To do this press the membrane switch Control lever emergency
program once.
EMERGENCY PROGRAM
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
(e. g. RIGHT CONTROL LEVER) is displayed.
RIGHT CONTROL LEVER

X AXIS:
OFF
Y AXIS:
ON
By repeatedly pressing the membrane switch Control lever emergency

program the message alternates between the left and the right control lever.
The message X axis indicates the extension
to the left and right.
EMERGENCY PROGRAM
The message Y axis indicates the extension

forward and back.
RIGHT CONTROL LEVER

X AXIS:
OFF
Y AXIS:
ON
If the emergency program for a control lever

extension is switched on, ON appears next
to the corresponding control lever extension.
The emergency program is switched on automatically with the displays of the error
message.
18.03.1999
In the example illustrated here, the message ON is next to the Y axis 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.
16 - 70
2 085 291 en

Carrying out
emergency
program
To carry out the emergency program you must extend the defective
control lever and also press a membrane switch.
Press the membrane switch Control lever emergency program until the
defective control lever is indicated on the display.
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.
In the emergency program all crane movements are restricted to 10 % of

the maximum speed.
18.03.1999
Let go of the switch or the control lever to stop the crane movement.
2 085 291 en
16 - 71

16.5.6
Manual monitoring of stop for telescope section V

In the foot section of telescope section V there is a proximity switch sequence which monitors and switches off the extending of the telecoping
cylinder when the telescoping cylinder is extended beyond the locking
point of telescope section V. This prevents the telescoping cylinder being
extended out of the guide mechanisms in the foot section and damaging
the telescoping cylinder and telescope section.
If there is an error on this proximity switch sequence, the extending of the
telescoping cylinder in telescope section V must be especially monitored.
Damage may occur to the telescoping cylinder and telescope section!

When the Crane control display for the telescoping gear displays the error
message 0 0 0 0 0 0 0 1, the unintentional extension of the telescoping cylinder is no longer automatically prevented.
If you still want to continue crane work be very careful when you move
the telescoping cylinder in telescope section V and observe the following
points.
With extended telescope section V
h
g
gh
g
Select locking immediately when you extend the telescoping cylinder to

lock it in foot section V.
Reduce the speed to as low as possible with the control lever as soon
as the position light Telescoping cylinder in foot section V flashes.
Monitor the locking process:

When the position light Telescoping cylinder in foot section V lights up,
the crane control locks the telescoping cylinder and the indicator lamp
Telescoping cylinder locked lights up.
If the indicator lamp Telescoping cylinder locked does not light up and the
indicator lamp Telescoping cylinder in foot section IV flashes again, stop the
telescoping cylinder immediately.
In this case the telescoping cylinder is extended beyond the locking point,
can sling on the head of the telescope section and become damaged.
When the telescoping cylinder has extended beyond the locking point:
Slowly retract the telescoping cylinder.
18.03.1999
Monitor the locking process again.
16 - 72
2 085 291 en

When the main boom is fully retracted:
Vef
g
gh
g
Move the telescoping cylinder at the lowest possible speed through the
foot sections I to IV, monitor the status of the telescoping cylinder on
the position lights Telescoping cylinder in foot sections I to IV.
When the position light Telescoping cylinder in foot section V flashes, select
the locking of the telescoping cylinder immediately.
Monitor the locking process:

When the position light Telescoping cylinder in foot section V lights up,
the crane control locks the telescoping cylinder and the indicator lamp
Telescoping cylinder locked lights up.
If the indicator lamp Telescoping cylinder locked does not light up and the
indicator lamp Telescoping cylinder in foot section V flashes again, stop the
telescoping cylinder immediately.
In this case the telescoping cylinder is extended beyond the locking point
and could be extended out of its guide rails and become damaged.
When the telescoping cylinder has extended beyond the locking point:
Slowly retract the telescoping cylinder.
18.03.1999
Monitor the locking process again.
2 085 291 en
16 - 73

16.5.7
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 location 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 message EMERGENCY OPERATION in the third line.
TELESCOPING
STATUS: 0 0 1
EMERGENCY OPERATION
T: 180 s
L:8.40 ft
The remaining running time is displayed on

the left in the fourth line (e.g. 180 secs.).
When the time has run out, the display switches again to the Access emergency operation
submenu and you can re-start emergency
operation.
The three-digit number code (e. g. 001) after
the message STATUS in the second line indicates which error the crane control recognized.
TELESCOPING
STATUS: 0 0 1
EMERGENCY OPERATION
T: 180 s
L:8.40 ft
Deciphering the number code:

0 0 1:
0 1 0:
1 0 0:
16 - 74
When multiple errors occur simultaneously, all errors are displayed simultaneously 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. If this error occurs,
the main boom can only be retracted with the mechanical emergency
operation, as described in the operating instructions.
2 085 291 en
18.03.1999
Length indicator faulty

Proximity switch faulty or signals received through
locking status are unrealistic
Error recognised in a valve for the locking mechanism,

G
S

Never telescope the main boom if both the length indicator and the proximity switch have failed, i.e. with the number code 1 0 1 or 1 1 1. Otherwise 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.

Depending on which error has occurred, you can only track the telescoping 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 components 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 telescoping 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. 16-75.
If the error is due to a length indicator (number code 1 0 0), retract the
main boom as described in the following section:
Retracting with
an error on the
length indicator
If the error is on the length indicator, you can no longer read the extended
length of the telescoping cylinder on the Crane control display.
The following status display elements are still available:
Vefg
y
Check the position of the telescoping cylinder with the position lights
telescoping cylinder in foot section I to V.
You can no longer read the extended length of the telescoping cylinder in
the crane control display.
18.03.1999
ihjj
Check the position of the locking pins of the telescoping cylinder and telescope section with the red warning/green indicator lamps Telescoping cylinder unlocked and locked and Telescope section unlocked and locked.
s
2 085 291 en
16 - 75

!=
!=
no
26
!=
!=
!=
Check the extended length of the telescope

sectionson the SLI display Current telescope
status of telescope section I to V.
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
The display Information now indicates the current extended length in feet
of the telescoping cylinder.
The table on page 16-79 shows at which length the telescoping cylinder is
at the locking points of the individual telescope sections.
Before telescoping:
the telescoping cylinder must be in the foot section of the corresponding telescope section and the corresponding position light must light
up (e. g. for telescope sectionI);
h
j
.
the telescoping cylinder must be locked with the telescope section, the
indicator lamp Telescoping cylinder locked must light up;
the telescope section must be unlocked, the red warning lamp Telescope
section unlocked must light up;
the rocker switch Select locking/unlocking must be pushed in the upper
position Unlock telescope section.
Retracting the telescope section

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 immediately and they can damage or tear the electrical or hydraulic components in the main boom.
Only telescope the telescope section slowly.
Extend the locking pins on the telescope section by putting the rocker
switch Select locking/unlocking in the central position.
16 - 76
2 085 291 en
18.03.1999
Telescope in the telescope section as far as possible.

jj
.
The locking pins on the telescope section are slid out, the green indicator
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/unlocking rocker switch down.
Extending the telescoping cylinder without the telescope section

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 electrical or hydraulic components in the main boom.
Extend the telescoping cylinder slowly.
e
1&3
Extend the telescoping cylinder until it reaches the nearest foot section.
When the foot section is reached, the corresponding position light Telescoping cylinder in foot section I to V lights up (e. g. for telescope section II)
and
the Information display shows the respective extended length of the telescoping cylinder (e. g. 16.3 ft for the locking point of telescope section II
at 50%, values p. 16-79)
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 the telescoping cylinder is locked, the green indicator lamp Telescoping cylinder locked lights up.
18.03.1999
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.
s
2 085 291 en
16 - 77

If you have retracted the main boom with a defective length indicator, the
current telescope status does not correspond with the last telescope status 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. 16-80.
Retracting with
an error on the
proximity switch
If the error is on a proximity switch of the locking pins, one or more of the
following warning and indicator lamps no longer display the actual values:
Warning lamp Telescoping cylinder unlocked,
i
j
h
j
Warning lamp Telescope section unlocked,

Indicator lamp Telescoping cylinder locked,
Indicator lamp Telescope section locked.
When locking the telescoping cylinder, observe the following:
TELESCOPING
EMERGENCY OPERATION
T.
180 s
Always move the telescoping cylinder to

the correct length for the locking point before you lock it with the telescope section.
The length is indicated on the Crane control
display (e. g. 16.3 ft for the locking point of
telescope section II at 50%, values
p. 16-78)
L: 16.3 ft
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.
Some warning and indicator lamps may show correct displays of the
locking status. While locking and unlocking, you can check if individual
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 telescope section and the telescoping cylinder, but this is no longer
electronically monitored.
18.03.1999
H
H
Otherwise, you can retract the main boom exactly as with an error on a
length indicator ( p. 16-78).
16 - 78
2 085 291 en

Table for approaching the locking

points
The following table shows the extended length of the telescoping cylinder
at the locking positions of the various telescope sections.
Locking point
at fixed length
[%]
Extended length of the

telescoping
cylinder [ft]
T1
0
50
100
0.03
15.3
30.5
T2
0
50
100
1.1
16.3
31.6
T3
0
50
100
2.2
17.5
32.7
T4
0
50
100
3.2
18.5
33.7
T5
0
50
100
4.1
19.4
34.6
18.03.1999
Telescope section
s
2 085 291 en
16 - 79

16.5.8
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.
The menu is started:
If you press the Enter telescope status after emergency operation membrane
switch three times (within about 3 seconds) or
If the Different telescope status error message was confirmed and the
Display telescope status and teleautomatic menu is selected.
SET TELESCOPE STATUS

>
T1
<
T2
T3
T4
T5
>
<
In the first line there is the message SET

TELESCOPE STATUS.
In the second line there are telescope sections T1 to T5 and in the line underneath the
numerical value 0 is displayed for every telescope section.
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.
18.03.1999
+
*
16 - 80
2 085 291 en

:
<
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
50 100 >n<
For T3 : 0
50 100 >n<
For T4 : 0
50 100 >n<
For T5 : 0
50 100 >n<
n here represents the displayed numerical value of the last saved current
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
menu by pressing the Enter telescope status after emergency operation membrane switch three times quickly.
If you have entered the actual telescope status correctly, press the Enter
key once.
The message KEYCODE is in the last line
and the input prompt () flashes.
SET TELESCOPE STATUS

>
T1
<
T2
100
T3
T4
T5
KEYCODE:
To confirm the entered telescope status, you

must enter in this line the same key code
which you need to start the emergency program;
Access emergency operation menu, p. 13-88.
The crane control now saves the entered telescope status and switches to
the Display telescope status and teleautomatism menu.
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.
18.03.1999
If the crane control recognises an error in the entered telescope status,

the display shows the error message Divergent telescope status; p. 16-65.
s
2 085 291 en
16 - 81

The Enter telescope status after emergency operation menu remains switched
on until you select another menu with the respective membrane switch,
exit the menu with the membrane switch
or until an error message
occurs.
18.03.1999
>@
Risk of damage during telescoping!

Before working with the crane, check that the telescope status now indicated 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.
16 - 82
2 085 291 en

6200 - 1 Superstructure Malfunctions

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6200 - 1 Superstructure Malfunctions

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Malfunctions on the superstructure

16.1 Superstructure emergency stop device

Malfunctions on the superstructure

Switching off the

Switch off the main battery switch. Turn

The crane engine switches off.

Malfunctions on the superstructure

Risk of accidents when the load is suspended!

Releasing crane functions again

Turn off the ignition.

Check if the crane movements are carried out as normal.

Operating Instructions GMK 5180

Malfunctions on the superstructure

Troubleshooting for malfunctions that occur during

Risk of accidents when the load is suspended!

Accidents may occur due to inappropriate emergency operation!

Operating Instructions GMK 5180

Malfunctions on the superstructure

Operating Instructions GMK 5180

Malfunctions on the superstructure

Plug-in modules and consoles

Monitors crane engine and hydraulic system /

Display, Input and emergency operation crane

Malfunctions on the superstructure

Sets constant crane engine speed

Control lever for telescoping, derricking

Control lever for slewing gear, auxiliary

Safe load indicator (SLI)

Operating Instructions GMK 5180

Malfunctions on the superstructure

The fuses are divided into the groups F1 to F13.

Crane engine E-control

Crane engine diagnostic plug

Flame start system (additional

Crane cab ceiling lamp,

Malfunctions on the superstructure

Indicator and warning lamps for engine,

Window wiper/washer system

Control lever, fast speed for derricking

Crane engine diagnostic plug

Flame start system (additional

Switches and indicator lamps

Working spotlight, switches and

Crane cab electronic spirit level,

Malfunctions on the superstructure

Crane control power supply

Crane control power supply

Crane control power supply

Crane control power supply

Crane control power supply

Crane control power supply

Shutdown of main hoist,

Shutdown for auxiliary hoist,

Shutdown for derricking gear

Control lever initial position

Indicator/warning lamp counterweight

Malfunctions on the superstructure

Proximity switch telescoping cylinder

Crane control display

Crane engine E-control

Crane cab heating

Crane control unit 0

Crane control unit 1