6200_1 Superstructure Malfunctions

Malfunctions on the superstructure 16.1 Superstructure emergency stop device

16 16.1

Malfunctions on the superstructure 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.

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The crane engine switches off.

s Operating Instructions GMK 5180

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Malfunctions on the superstructure 16.1 Superstructure emergency stop device

Crane control emergency stop switch

G

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.

G

Risk of accidents when the load is suspended! If a load is on the hook after the emergency stop, you must ensure that no persons are in the danger area under the suspended load. Secure the danger area if necessary if the fault cannot be rectified without delay and you leave the work site.

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

• Turn off the ignition. • Turn the Crane control emergency stop switch until it disengages. • Let go off all control levers and start the crane engine again.

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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

H

• Check if the crane movements are carried out as normal.

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Operating Instructions GMK 5180

Malfunctions on the superstructure 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.

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G

Accidents may occur due to inappropriate emergency operation! Only trained, qualified personnel may carry out an emergency operation if unrigging requires the manual operation of solenoid valves.


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Malfunctions on the superstructure 16.2 Troubleshooting for malfunctions that occur during crane operation

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Malfunctions on the superstructure 16.3 Electrical system

16.3

Electrical system

16.3.1

Plug-in modules and consoles

Pos.

1

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2

3

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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1

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

2

3

4

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Function

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Pos.

Designation of plug-in module in the electronic circuit diagram

Safe load indicator (SLI)

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16.3.2

S

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).

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Designation in circuit diagram: F1

Rating (A)

Function

1

20

Crane engine E-control

2

10

Crane engine diagnostic plug

3

10

Flame start system (additional equipment)

4

15

No function

5

10

Crane cab ceiling lamp, cigarette lighter

6

10

No function


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Function

1

10

No function

2

10

No function

3

10

No function

4

10

No function

5

10

No function

6

15

No function


Rating (A)

Function

1

10

Indicator and warning lamps for engine, hydraulic system, flame start system (additional equipment)

2

15

Window wiper/washer system

3

5

Pressure sensor/switch Crane control

4

10

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

5

10

Crane engine diagnostic plug

6

10

Flame start system (additional equipment)


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Rating (A)

Rating (A)

Function

1

5

Switches and indicator lamps

2

15

3

5

4

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

5

15

6

10

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Crane cab electronic spirit level, SLI early warning/shutdown SLI deactivation, Anchor-to-bracketswitch shutdown, Dead man’s switch, Seat contact Operating Instructions GMK 5180

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Rating (A)

Function

1

15

Crane control power supply

2

15


3

15


4

15


5

15


6

15



Rating (A)

Function

10

Shutdown of main hoist, main hoist slewing indicator

2

10

Shutdown for auxiliary hoist, auxiliary hoist slewing indicator

3

10

Shutdown for derricking gear shutdown for telescoping gear

4

10

Control lever initial position

5

10

Slewing gear

6

10

Indicator/warning lamp counterweight locked/unlocked in switch unit

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1


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Function

1

10

SLI

2

10

Proximity switch telescoping cylinder

3

5

No function

4

10

Crane control display emergency operation crane control

5

10

Crane control

6

10

Crane engine E-control


Rating (A)

Function

1

15

Crane cab heating

2

15

Radio

3

15

No function

4

5

Crane control unit 0

5

5


6

5


Rating (A)

Function

1

20

Oil cooler

2

5

Oil cooler (relay)

3

15

No function

4

10

No function

5

5

Central lubrication system

6

10

No function

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Rating (A)


H


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

• Open the lid of the battery box. The fuse groups are attached to a mounting plate. – The two fuses F 10 and F11 are in terminal box (1). – The two fuses F 12 and F13 are in terminal box (2).

Terminal box

1

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.

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2


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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

S

Risk of fire! Never repair a blown fuse with a nail, with wire, aluminium foil or other materials which conduct electricity. Always replace defective fuses only with fuses of the indicated ratings.

To change a fuse you need to remove the SLI plug-in module.

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• Remove the four retaining bolts at the corners of the front plate of the SLI plug-in module and pull out the plug-in module.

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The fuses are on the back of the plug-in module and are labelled S I 1 to S I 13. The following table shows the assignment of fuses. If a fuse is defective the relevant crane movement can not be carried out.

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Designation in circuit diagram:

H

Rating (A)

Function

SI1

5

SLI internal

SI2

5

SLI shutdown display

SI3

5

Lift main hoist shutdown

SI4

5

Shutdown lowering

SI5

5

Shutdown extending

SI6

5

Lift auxiliary hoist shutdown

SI7

5

Shutdown raising

SI8

5

Shutdown retracting

SI9

5

Lower auxiliary hoist shutdown

S I 10

5

Lowering the lattice extension

S I 11

5

SLI early warning display

S I 12

5

Raising the lattice extension

S I 13

5

SLI central unit

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


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Malfunctions on the superstructure 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

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Engine coolant temperature too high


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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

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

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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

Check fuse, replace if necessary

Dead man’s switch not activated

Press dead man’s switch



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.



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 display’s 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


Acknowledge error message once; ➠ p. 13-89. If this happens again, note down the number codes and inform GROVE Product Support; ➠ p. 16-60.

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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 Crane control emergency stop switch; ➠ p. 16-2.

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H

If a malfunction occurs, first check whether it applies in both directions of movement. In this case also check the causes listed in the Main hoist not functioning section!

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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

Switch off rocker switch Shutdown auxiliary hoist

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

Check fuses, replace if necessary; ➠ p. 16-7.


Press dead man’s switch; ➠ p. 11-63.





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

Lowering limit switch triggered

Leave shutdown area, Lift main hoist

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


Leave shutdown area, Lower the auxiliary hoist


Leave shutdown area



Lifting, lowering or fast speed Corresponding function is do not function blocked by the crane control (error message is displayed)

18.03.1999


Acknowledge error message once; ➠ p. 13-89. If this happens again, note down the number codes and inform GROVE Product Support; ➠ p. 16-60. Switch off ignition briefly then switch on again. If this happens again, note down the status display’s stored number codes and inform GROVE Product Support; ➠ p. 13-81.


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Malfunction

Cause

Action

No lifting or lowering, or possible only at very low speed


Increase maximum speed on the display Enter power unit speed; ➠ p. 13-85.

Lowering does not function



Lifting or lowering function can not be switched off



18.03.1999

H

If a malfunction occurs, first check whether it applies in both directions of movement. In this case also check the causes listed in section Auxiliary hoist not functioning!

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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 man’s switch system not activated

Press dead man’s switch, ➠ p. 11-63.



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!)

Switch off rocker switch Shutdown derricking gear





Lifting limit switch triggered (warning light on)

Leave shutdown area, raise boom


Leave shutdown area; ➠ p. 13-16


Check fuse, replace if necessary

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




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Raising or lowering the boom do not function

Rocker switch Shutdown derricking gear switched on


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Malfunction

Cause

Action

Raising or lowering the boom does not function



No raising or lowering the boom, or possible only at very low speed



Raising or lowering the boom function can not be switched off



H

16.4.5

If a malfunction occurs, first check whether it applies in both directions of 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 man’s switch system not activated


Fuse F7/2 OW or F3/4 OW or F6/3 OW defective


Telescope section and telescoping cylinder do not lock/unlock any functions

16 - 22

Rocker switch Shutdown telescoping gear or Lattice extension incline switched on

Switch off rocker switch Shutdown telescoping gear; ➠ p. 7-36.





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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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!)


Leave shutdown area




Leave shutdown area, Lower hoist

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

Insufficient boom lubrication

Lubricate boom, ➠ 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







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


Retracting or extending function can not be switched off




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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

H

If a malfunction occurs, first check whether it applies in both directions of movement. If the malfunction occurs in both directions of movement you must also check the causes listed in the Telescoping gear not functioning section!

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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.



Fuses F6/5 OW or F3/4 OW defective










No slewing, or possible only at very low speed


Increase maximum speed on the display Enter power unit speed; ➠ p. 13-85.

Slewing can not be switched off



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Slewing to left or right not functioning


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16.4.7

Counterweight lifting gear / lock malfunctions

Malfunction

Cause

Action

Counterweight lifting gear/ lock not functioning





Counterweight lifting cylinder Hydraulic connection on the or lock not functioning 4.4 t base plate not made Corresponding function is blocked by the crane control (error message is displayed)




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.

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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.

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With error message 5.02.6 Raise the lattice extension


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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.

Fan’s thermostat valve defective

Switch fan thermostat to emergency operation; ➠ p. 16-56.

Warning lamp for feed circuit or control circuit hydraulic oil filter lights up

Hydraulic oil filter dirty

Replace hydraulic oil filter; ➠ 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


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

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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

S

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?

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6. Have the fuses been replaced?


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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

Fuse F7/1 OW or F4/6 OW defective (fuses behind the flap on the front panel of the crane cab)

Check fuses, replace if necessary; ➠ p. 16-7. Operating instructions - Part 2, Malfunctions on the superstructure

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; ➠ p. 16-38 and notify GROVE 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 chamber does not react

Check line; ➠ p. 16-41 If line is O.K., switch off pressure sensor 2; ➠ p. 16-38 and notify GROVE Product Support 18.03.1999

1. 01. 7

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

Switch off pressure sensor 2; ➠ p. 16-38 and notify GROVE Product Support

1. 02. 7


1. 02. 8

Information message; You have switched off pressure sensor 2 because of an error message


1. 03. 1

Pressure sensor upper chamber does not react

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

1. 03. 2...6 Notify GROVE Product Support 1. 04. 1

Angle sensor A, basic section does not react

1. 04. 2...6 Angle sensor A, basic section reports error

Check line; ➠ p. 16-41. 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 notify GROVE Product Support

1. 04. 7


1. 04. 8

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


1. 05. 1

Angle sensor B, basic section does not react

Check line; ➠ p. 16-41. If line is O.K., switch off angle sensor B; ➠ p. 16-38 and notify GROVE Product Support

1. 05. 2...6 Angle sensor B, basic section reports error


1. 05. 8

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


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1. 05. 7

Switch off angle sensor B, basic section; ➠ p. 16-38 and notify GROVE Product Support


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1. 06. 1

Length indicator A for telescope section V does not react

Check line; ➠ p. 16-41. If line is O.K., switch off 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 ➠ p. 16-38 and notify GROVE Product Support 1. 06. 7


1. 06. 8

Information message; 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

Check line; ➠ p. 16-41. If line is O.K., switch off length indicator B; ➠ p. 16-38 and notify GROVE Product Support

1. 07. 7


1. 07. 8

Information message; You have switched off length indicator B for telescope section V because of an error message


1. 08. 1

Length indicator A of the telescoping cylinder does not react

Check line; ➠ p. 16-41. If line is O.K., switch off length indicator A of the telescoping cylinder; ➠ p. 16-38 and notify GROVE 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; ➠ p. 16-38 and notify GROVE Product Support


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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 ➠ p. 16-38 and notify GROVE Product Support


1. 08. 8

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


1. 09. 1

Length indicator B of the telescoping cylinder does not react

Check line; ➠ p. 16-41. If the line is O.K., switch off length indicator B of the telescoping cylinder; ➠ p. 16-38 and notify GROVE Product Support

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

Switch off length indicator B of the telescoping cylinder; ➠ p. 16-38 and notify GROVE Product Support


1. 09. 8

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


1.10. 1

Angle sensor A, Lattice extension does not react

Check line; ➠ p. 16-41. If line is O.K., switch off angle sensor A, luffing jib; ➠ p. 16-38 and notify GROVE Product Support

1.10. 2...6

Angle sensor A, Switch off angle sensor A, Lattice extension reports error luffing jib; ➠ p. 16-38 and notify GROVE Product Support

1.10. 7


1.10. 8

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


1.11. 1

Difference angle sensor, lattice extension does not react

test supply line; ➠ p. 16-41. If supply line is O.K., switch off difference angle sensor; ➠p. 16-38 and notify GROVE Product Support

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1. 09. 7


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16 - 34

1.11. 2...6

Difference angle sensor, lattice extension gives error message

1.11. 7


1.11. 8

Information message; 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 Check line; ➠ p. 16-41. If necessary notify GROVE sensor lower chamber does not react Product Support

1.12. 2...6

Lattice extension pressure sensor lower chamber reports error

1.12. 7


1.13. 1

Lattice extension pressure sensor, upper chamber reacts

Check line; ➠ p. 16-41. If necessary notify GROVE Product Support

1.13. 2...6

Lattice extension pressure sensor, upper chamber reports error


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. Notify GROVE Product 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

Notify GROVE Product Support.

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Switch off difference angle sensor; ➠ p. 16-38 and notify GROVE Product Support

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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


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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

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Lower load


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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

H

Error message


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16 - 37


Switch off sensor/ indicator during malfunction

H r !0"4

no p !0"8

H

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

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Check that the remaining sensor/indicator is working

H

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

t

H

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

n°

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.

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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.


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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

r

• 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

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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

2

Lattice extension angle sensor A

3

Lattice extension difference angle sensor

4

Lattice extension pressure sensor

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1


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16 - 41


on the truck crane

Control box pressure sensors upper chamber and lower chamber

2

Plug connections under the main boom on the inner side of the turntable (connection of indicators in the main boom)

3

Derricking cylinder lower chamber pressure sensor

4

Derricking cylinder upper chamber pressure sensor

5

SLI connecting box

6

Lattice extension connection / boom extension (both additional equipment)

7

Length indicator

8

Angle sensor basic section control box A and B 18.03.1999

1

16 - 42

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16.4.12

Retraction emergency operation If the locking mechanism on the head of the telescoping cylinder does not react to the operating instruments in the crane cab any longer, 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.

H

• Lower the main boom. If it is possible to lower but there is not sufficient space, you can check whether the truck crane can be driven in the current rigging mode; ➠ Driving with the crane rigged, p. 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.


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.

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Mechanical emergency operation

H

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

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Telescope section I


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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.

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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


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16 - 47


S

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

Check if length data can be read You may only carry out hydraulic emergency operation if the extended length of the telescoping cylinder is still shown.

• Check if the current extended length of the bottom right telescoping cylinder is shown in the Crane control display (e. g. 30.5 ft). TELESCOPING –

100

– 100

–

0

–

0

–

0

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 derricking cylinder lower chamber sensor B membrane switch. • 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

S

Risk of damage to the main boom! Never carry out hydraulic emergency operation if no display is available. Otherwise you no longer have any possibility to monitor and can damage components in the boom or put the boom in a condition in which it can no longer be extended or retracted.

16 - 48

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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.

G

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

• Put down the load. • Override the SLI. To do this turn the Override key-operated switch to the right.

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.


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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.

H

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



S

Risk of damaging the hydraulic hoses! Always guide the hydraulic hoses through the rear opening in the basic section. If you guide the hydraulic hoses through the manhole at the top of the basic section the hydraulic hoses will be cut during retracting.

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.

G

Risk of crushing from unintentional retraction! Secure the main boom against unintentional retraction before you reach into or enter the manhole in order to connect the hydraulic hoses. During retraction, the telescope sections move into the area of the manhole and can crush you or your limbs.

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).


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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.

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G

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).

H

A hydraulic/mechanical safety circuit blocks the simultaneous unlocking of the telescope section and the telescoping cylinder. You can only unlock the telescoping cylinder if the telescope section is locked. The telescope section can only be unlocked when it is locked with the telescoping cylinder. • Attach the appropriate hose for the required locking/unlocking. – To lock/unlock the telescoping cylinder, the left connection (3) on the telescoping cylinder must be connected with the emergency supply.

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– To lock/unlock the telescope section, the right connection (2) on the telescoping cylinder must be connected with the emergency supply.


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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.

H

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.

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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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16 - 55


H

• 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.

H

If the telescoping cylinder at locking point indicator lamps are not activated, you can check as follows if the telescoping cylinder is locked: At the locking point at 0% in the basic section you can see the locking pins of 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).

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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

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Malfunctions on the superstructure 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 connection 2 defective, slewing gear and fast speeds blocked.

18.03.1999

UNIT 0:

Control unit on connection 0 defective, function of the crane control, main hoist and auxiliary hoist blocked.


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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.

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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

3

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.

H

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

Ö

– locate more precisely the cause of the error; ➠ Error causes and effects, p. 16-63.

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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:

3

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

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STATUS: 0 0 0 0 0 1 0 0


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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

3

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.

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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


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


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

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Digital input

Effect/ Remedy


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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


Effect/ Remedy



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

3

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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

Ö

• 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

–

●

–

0

– T4–

T5

–

–

0

0

0–

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 ).

ä

Ä

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H

– T3


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16.5.4 Connections and control units

S

Changing the connections in the control units The control units are behind the crane operator’s 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

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H


At least two control units must be still intact to unrig the truck crane. If two control units fail you will need at least one new control unit to be able to unrig the truck crane. It is possible to put down a load without a control unit, however. 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.

H

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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To drive the slewing gear, for example, remove connection 1 from the control unit and insert connection 2 into this control unit.

H

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

H

0 and 2

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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.

S

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.


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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

ü

• 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

ü

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.

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Carrying out emergency program

To carry out the emergency program you must extend the defective control lever and also press a membrane switch.

ü

• 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. In addition, press the membrane switch when you have extended the control lever to the left. In addition, press the membrane switch when you have extended the 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

H

• Let go of the switch or the control lever to stop the crane movement.


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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.

S

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.

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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.


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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.

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18.03.1999

H

– 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

Risk of damage to the main boom! 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.

Risk of damage to the main boom! 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.


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16 - 75


!=

!=

H

no 2§6

!=

!=

!=

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 derricking cylinder lower chamber sensor B membrane switch. 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:

V

– 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

S

Risk of damage to the main boom! 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.

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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

S

Risk of damage to the main boom! 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

S

• 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).

h

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.


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H

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 –

0

–

0

–

0

–

0

–

0

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).

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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

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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

Ä Ö

– 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

>

●

<

0

–

0

–

0

–

0

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.

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: <

H ö Ö

• 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

–

0

– T3

– T4–

T5

–

–

0

0

KEYCODE:

0–

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.

H

The crane control accepts the newly set telescope status only when you store the new values with the ENTER key and enter the appropriate key code after making your selection.

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Ö

If the crane control recognises an error in the entered telescope status, the display shows the error message Divergent telescope status; ➠ p. 16-65.


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S

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.

ö

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>@üä ö

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.

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6200_1 Superstructure Malfunctions

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