Operating Instructions Part 1 Carrier

Vehicle serial number:

2 084 575 en
11.05.2000
 Important note

Duplications of any kind and excerpts

from this document are not subject to the
alterations service. Original documents of
Deutsche GROVE GmbH are marked with
the blue serial number of the truck crane
on the cover page.

Duplications and print-outs of data carriers on

which Deutsche GROVE GmbH has delivered
this document are also not subject to the
alterations service.

©
Copyright reserved by leerleerleerleerleerleer
11.05.2000

The passing on or duplication of this document as well as the use and disclosure of its contents are
prohibited unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration
of patent or utility model are reserved.
 These operating instructions consist of two parts:
– Part 1 – Carrier
– Part 2 – Superstructure

Part 1 comprises the following chapters:

1 Overview

2 Basic safety instructions

3 Information for applications engineering

4 Description of the truck crane – vehicle section

5 Vehicle engine

6 Driving the truck crane

7 Malfunctions on the carrier

8 Technical information about the carrier

9 Alphabetical index

Chapters 10 to 16 are in part 2 – Superstructure

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TABLE OF CONTENTS

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1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
1.1 Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.3 Overview and contents of truck crane user information . . . . . . 1 - 5
1.3.1 Carrier and superstructure operating manual . . . . . . . . . . . . . . . . . 1- 5
1.3.2 Lattice extension operating manual (additional equipment) . . . . . . . . . 1- 6
1.3.3 Maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6
1.3.4 Lifting capacity table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6
1.3.5 Outrigger load table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.3.6 Safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.3.7 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.3.8 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.4 Instructions for use of this document . . . . . . . . . . . . . . . . . . 1 - 8
1.4.1 How are the operating instructions laid out? . . . . . . . . . . . . . . . . . 1- 8
1.4.2 How are the pages of the operating manual formatted? . . . . . . . . . . . 1- 9
1.4.3 How can I find the necessary information quickly and easily? . . . . . . . . 1 - 10
1.4.4 Definition of direction information . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
1.4.5 Conversion table for metric measuring units . . . . . . . . . . . . . . . . . 1 - 17
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2 Fundamental safety instructions for crane operators . . . 2- 1
2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
2.2 Proper use 2 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 4
2.4 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 6
2.5 Safety instructions that apply to truck crane driving . . . . . . . . . 2- 7
2.6 Safety instructions for truck crane work . . . . . . . . . . . . . . . . . 2- 7
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3 Information for applications engineering . . . . . . . . . . . . 3- 1
3.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1.2 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1.3 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
3.2 Applications engineering . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
3.2.1 Application engineering requirements . . . . . . . . . . . . . . . . . . . . 3 - 3
3.2.2 Details about applications engineering contained in the user information . 3 - 4
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4 Description of the truck crane – vehicle section . . . . . . . 4- 1
4.1 Overview of the operating and display instruments . . . . . . . . . 4 - 1
4.1.1 Overview of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
4.1.2 Overview of driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 4
4.1.3 Front instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
4.1.4 Side instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
4.1.5 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
4.2 Functional description of the display and operating instruments 4 - 21
4.2.1 Instrument panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
4.2.2 On the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 38
4.2.3 Above the front windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 41
4.2.4 Other operating instruments in the vehicle section . . . . . . . . . . . . . . 4 - 43
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5 Vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1 Starting / turning off vehicle engine . . . . . . . . . . . . . . . . . . . 5 - 1
5.1.1 CHECKLIST: Starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1.2 CHECKLIST: In winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
5.1.3 Checks before starting up vehicle engine . . . . . . . . . . . . . . . . . . . 5- 4
5.1.4 Starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 9
5.1.5 Inspections after the engine has been started . . . . . . . . . . . . . . . . . 5 - 12
5.1.6 Turning off the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
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6 Driving the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
6.1 Checking the truck crane before driving . . . . . . . . . . . . . . . . . 6 - 1
6.1.1 CHECKLIST: Condition of the truck crane for on-road driving . . . . . . . . 6 - 1
6.1.2 Checks to be carried out before driving . . . . . . . . . . . . . . . . . . . . 6 - 9
6.2 General operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25
6.2.1 Operating the transmission with automatic gear change . . . . . . . . . . 6 - 25
6.2.2 Monitoring the control instruments while driving . . . . . . . . . . . . . . 6 - 32
6.2.3 Driving on downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36
6.2.4 Driving on uphill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 39
6.2.5 Tempomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 40
6.2.6 Temposet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 42
6.2.7 Turning off the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 43
6.3 Off-the-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 45
6.3.1 Longitudinal differential locks / drive of the 3rd axle line (drive of 3rd axle
line only with 10 x 8 x 10 additional equipment) . . . . . . . . . . . . . . . 6 - 46
6.3.2 Transverse differential locks in all driven axle lines . . . . . . . . . . . . . 6 - 48
6.3.3 Level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 49
6.3.4 Freeing a stuck truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 52
6.4 Separate steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 55
6.4.1 Unlocking the 4th axle line steering, connecting 4th and 5th axle lines . . . 6 - 56
6.4.2 Steering the 4th and 5th axle lines . . . . . . . . . . . . . . . . . . . . . . . 6 - 56
6.4.3 Separating 4th and 5th axle line, locking steering of 4th axle line . . . . . . 6 - 57
6.5 Heating and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 59
6.5.1 Driver’s cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 59
6.5.2 Roof blower (additional equipment) . . . . . . . . . . . . . . . . . . . . . . 6 - 61
6.5.3 Additional water heating system (additional equipment) . . . . . . . . . . 6 - 62
6.5.4 Additional heating system with timer (additional equipment) . . . . . . . . 6 - 64
6.6 Air-conditioning system (additional equipment) . . . . . . . . . . . 6 - 67
6.6.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 67
6.6.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 67
6.6.3 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 68
6.7 Towing a trailer (additional equipment) . . . . . . . . . . . . . . . . . 6 - 71
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7 Malfunctions on the carrier . . . . . . . . . . . . . . . . . . . . . . 7- 1
7.1 Emergency stop device on carrier . . . . . . . . . . . . . . . . . . . . . 7- 1
7.2 Breakdown in road traffic . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 3
7.3 Towing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 5
7.4 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
7.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.5.1 Plug-in modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.5.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.6 Troubleshooting and malfunction correction . . . . . . . . . . . . . . 7 - 25
7.6.1 Vehicle engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25
7.6.2 Malfunctions of the transmission with automatic gear change . . . . . . . 7 - 28
7.6.3 Differential lock malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29
7.6.4 Service brake malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30
7.6.5 Steering system malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31
7.6.6 Tachograph malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 32
7.6.7 Outrigger malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
7.6.8 Suspension locking system malfunctions . . . . . . . . . . . . . . . . . . . 7 - 33
7.6.9 Level adjustment system malfunctions . . . . . . . . . . . . . . . . . . . . 7 - 33
7.7 Procedure in the event of malfunctions . . . . . . . . . . . . . . . . . 7 - 35
7.7.1 Switching the fan thermostat to emergency operation . . . . . . . . . . . . 7 - 35
7.7.2 What to do if there is a transmission malfunction . . . . . . . . . . . . . . 7 - 36
7.7.3 Emergency operation of the solenoid valves for the outriggers . . . . . . . 7 - 43
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8 Technical specifications carrier . . . . . . . . . . . . . . . . . . . 8- 1
8.1 Technical description of the carrier . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.1 Crane carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1.2 Driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1.3 Drive units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1.4 Engine and gearbox cooling system . . . . . . . . . . . . . . . . . . . . . . 8- 2
8.1.5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2
8.1.6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2
8.1.7 Suspension system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
8.1.8 Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
8.1.9 Compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
8.1.10 Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.11 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.12 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.13 Secondary consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.14 Towing the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.15 Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.16 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.17 Slewing duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
8.2.1 Measurements and weights of the truck crane . . . . . . . . . . . . . . . . 8 - 8
8.2.2 Dimensions and weights of removable parts . . . . . . . . . . . . . . . . . 8 - 9
8.2.3 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
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9 Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1
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10 Description of the truck crane – crane section . . . . . . . 10 - 1
10.1 Overview of the operating and display instruments . . . . . . . . 10 - 1
10.1.1 Overview of crane section . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.1.2 Crane cab overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
10.1.3 Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
10.1.4 Left control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 20
10.1.5 Right control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21
10.1.6 Controls and fittings behind the crane operator’s seat . . . . . . . . . . . 10 - 22
10.1.7 Control box for operating the outriggers . . . . . . . . . . . . . . . . . . 10 - 23
10.1.8 Electronic level switch box (additional equipment) . . . . . . . . . . . . . 10 - 24
10.2 Functional description of the display and operating instruments 10 - 25
10.2.1 Crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25
10.2.2 Other operating instruments on the crane cab . . . . . . . . . . . . . . . 10 - 56
10.3 Functional description of the safety devices . . . . . . . . . . . . . 10 - 59
10.3.1 Safe load indicator (SLI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 59
10.3.2 Lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 60
10.3.3 Lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 61
10.3.4 Dead man’s switch and seat contact switch . . . . . . . . . . . . . . . . 10 - 62
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11 Crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.1 Starting/turning off the crane engine . . . . . . . . . . . . . . . . . 11 - 1
11.1.1 CHECKLIST: Starting the crane engine . . . . . . . . . . . . . . . . . . . 11 - 1
11.1.2 CHECKLIST: In winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
11.1.3 Inspections before starting the crane engine . . . . . . . . . . . . . . . . 11 - 4
11.1.4 Starting the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
11.1.5 Inspections after starting crane engine . . . . . . . . . . . . . . . . . . . 11 - 13
11.1.6 Switch off the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15
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12 Crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
12.1 Checking the truck crane before working with the crane . . . . . 12 - 1
12.1.1 CHECKLIST: When truck crane is rigged . . . . . . . . . . . . . . . . . . . 12 - 1
12.1.2 Preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5
12.1.3 Switching off the boom floating position (additional equipment) . . . . . 12 - 6
12.1.4 Switching off the slewing gear freewheel (additional equipment) . . . . . 12 - 8
12.1.5 Mechanical superstructure lock . . . . . . . . . . . . . . . . . . . . . . . 12 - 9
12.1.6 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
12.1.7 Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12
12.1.8 Check the position of the hoist ropes . . . . . . . . . . . . . . . . . . . . 12 - 12
12.1.9 Checking the reservoir of the windscreen washing system . . . . . . . . 12 - 13
12.1.10 Visual inspection of the entire crane . . . . . . . . . . . . . . . . . . . . . 12 - 13
12.1.11 Checking the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
12.2 Operating the safe load indicator . . . . . . . . . . . . . . . . . . . . 12 - 17
12.2.1 Switching on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17
12.2.2 Setting rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
12.2.3 Checks before working with the crane . . . . . . . . . . . . . . . . . . . . 12 - 27
12.2.4 During crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 29
12.3 Crane work with the main boom . . . . . . . . . . . . . . . . . . . . 12 - 35
12.3.1 External influences during crane operation . . . . . . . . . . . . . . . . . 12 - 35
12.3.2 Slewing ranges permitted for working with the crane . . . . . . . . . . . 12 - 39
12.3.3 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 41
12.3.4 Derricking gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 46
12.3.5 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 48
12.3.6 Telescoping gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 53
12.3.7 Fast speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 84
12.3.8 Menus on the crane control display . . . . . . . . . . . . . . . . . . . . . 12 - 85
12.3.9 Setting a constant engine speed . . . . . . . . . . . . . . . . . . . . . . . 12 - 95
12.3.10 Critical load control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 96
12.3.11 Incline crane cab (additional equipment) . . . . . . . . . . . . . . . . . . 12 - 96
12.3.12 Cooling the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 97
12.3.13 Movements which can be carried out simultaneously . . . . . . . . . . . 12 - 98
12.4 Driving with a rigged crane . . . . . . . . . . . . . . . . . . . . . . . . 12 - 99
12.4.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 99
12.4.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1 - 00
12.4.3 Driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . 12 1 - 02
12.5 Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1- 05
12.5.1 Short work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 05
12.5.2 Work breaks lasting more than 8 hours . . . . . . . . . . . . . . . . . . . 12 1 - 05
12.6 Crane cab heating and ventilation . . . . . . . . . . . . . . . . . . . . 12 1- 06
12.6.1 Heating the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 06
12.6.2 Additional water heating system (additional equipment) . . . . . . . . . 12 1
- 07
12.6.3 Additional heating system with timer (additional equipment) . . . . . . 12 1
- 08
12.6.4 Ventilating the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 09
12.7 Air-conditioning system (additional equipment) . . . . . . . . . . 12 1- 10
12.7.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 10
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12.7.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1- 10

12.7.3 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 11

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 ____________________________________________________________________________________ 13
13 Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1
13.1 Check lists for rigging work for crane operation with main boom 13 - 1
13.1.1 CHECKLIST: Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1
13.1.2 CHECKLIST: Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4
13.2 Choosing a suitable site . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 6
13.2.1 Load bearing capacity of the ground and the outrigger . . . . . . . . . . 13 - 6
13.2.2 Safe distance from banks and pits . . . . . . . . . . . . . . . . . . . . . . 13 - 9
13.2.3 Safe distance from electrical lines . . . . . . . . . . . . . . . . . . . . . . 13 - 9
13.2.4 Earthing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 12
13.3 Outrigger 13 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13.3.1 CHECKLIST: Extending the outriggers . . . . . . . . . . . . . . . . . . . . 13 - 13
13.4 CHECKLIST: Retracting outrigger . . . . . . . . . . . . . . . . . . . . 13 - 15
13.4.1 Outrigger span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17
13.4.2 Extending / retracting the outrigger beams . . . . . . . . . . . . . . . . . 13 - 23
13.4.3 Moving the outrigger pads into working / driving position . . . . . . . . . 13 - 28
13.4.4 Extending/retracting the support cylinders from the control box . . . . . 13 - 30
13.4.5 Extending/retracting the support cylinders from the crane cab (additional
equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 33
13.4.6 Check the alignment of the truck crane . . . . . . . . . . . . . . . . . . . 13 - 36
13.4.7 Outrigger pressure display (additional equipment) . . . . . . . . . . . . . 13 - 39
13.5 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 41
13.5.1 Counterweight sections and identification . . . . . . . . . . . . . . . . . 13 - 41
13.5.2 Counterweight versions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 42
13.5.3 Slinging points on the counterweight sections . . . . . . . . . . . . . . . 13 - 45
13.5.4 CHECKLIST: Rigging the counterweight . . . . . . . . . . . . . . . . . . . 13 - 46
13.5.5 CHECKLIST: Unrigging the counterweight . . . . . . . . . . . . . . . . . 13 - 48
13.5.6 Placing the 3 t base plate onto the counterweight platform . . . . . . . . 13 - 50
13.5.7 Assembling the counterweight version . . . . . . . . . . . . . . . . . . . 13 - 51
13.5.8 Counterweight lifting unit . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 57
13.5.9 Locking / releasing the 2 t counterweight section on the turntable . . . . 13 - 62
13.5.10 Removing or installing the 3 t counterweight section on the turntable . . 13 - 64
13.5.11 Rig the 3.5 t counterweight section (additional equipment) . . . . . . . . 13 - 66
13.5.12 Slewing with the counterweight rigged . . . . . . . . . . . . . . . . . . . 13 - 67
13.6 Rigging work on the main boom . . . . . . . . . . . . . . . . . . . . 13 - 69
13.6.1 Hook block on the bumper . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 69
13.6.2 Hook block on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . 13 - 71
13.6.3 Reeving and unreeving the hoist rope . . . . . . . . . . . . . . . . . . . . 13 - 73
13.6.4 Possible reeving methods on the main boom . . . . . . . . . . . . . . . . 13 - 80
13.6.5 Anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 84
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14 Malfunctions on the superstructure . . . . . . . . . . . . . . . 14 - 1
14.1 Superstructure emergency stop device . . . . . . . . . . . . . . . . 14 - 1
14.2 Troubleshooting for malfunctions that occur during crane
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 3
14.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 5
14.3.1 Plug-in modules and consoles . . . . . . . . . . . . . . . . . . . . . . . . 14 - 5
14.3.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 7
14.3.3 SLI fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13
14.4 Troubleshooting and malfunction correction . . . . . . . . . . . . . 14 - 15
14.4.1 Crane engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15
14.4.2 Main hoist malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 17
14.4.3 Auxiliary hoist malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
14.4.4 Derricking gear malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21
14.4.5 Telescoping gear malfunctions . . . . . . . . . . . . . . . . . . . . . . . . 14 - 22
14.4.6 Slewing gear malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 25
14.4.7 Malfunctions at the counterweight hoist unit . . . . . . . . . . . . . . . . 14 - 26
14.4.8 Crane control malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 27
14.4.9 Hydraulic system / hydraulic oil cooler malfunctions . . . . . . . . . . . . 14 - 28
14.4.10 Malfunctions on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 29
14.4.11 Retraction emergency operation . . . . . . . . . . . . . . . . . . . . . . 14 - 42
14.5 Crane control error messages . . . . . . . . . . . . . . . . . . . . . . 14 - 57
14.5.1 Error messages about control units . . . . . . . . . . . . . . . . . . . . . 14 - 57
14.5.2 Error messages about power units . . . . . . . . . . . . . . . . . . . . . . 14 - 58
14.5.3 Telescoping error messages . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 63
14.5.4 Changing the connections in the control units . . . . . . . . . . . . . . . 14 - 64
14.5.5 Control lever emergency program . . . . . . . . . . . . . . . . . . . . . . 14 - 68
14.5.6 Emergency operation submenu . . . . . . . . . . . . . . . . . . . . . . . 14 - 70
14.5.7 Entering telescope status after emergency operation menu . . . . . . . . 14 - 76
15.09.1999
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 ____________________________________________________________________________________ 15
15 Technical information for superstructure . . . . . . . . . . . 15 - 1
15.1 Technical description of the superstructure . . . . . . . . . . . . . 15 - 1
15.1.1 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 1
15.1.2 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 1
15.1.3 Crane engine and hydraulic system . . . . . . . . . . . . . . . . . . . . . 15 - 2
15.1.4 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 2
15.1.5 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 3
15.1.6 Telescoping gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 3
15.1.7 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4
15.1.8 Slewing gear units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4
15.1.9 Derricking cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4
15.1.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
15.1.11 Electrical connection to the carrier . . . . . . . . . . . . . . . . . . . . . . 15 - 5
15.1.12 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
15.1.13 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6
15.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7
15.2.1 Measurements and weights of the truck crane . . . . . . . . . . . . . . . 15 - 8
15.2.2 Dimensions and weights of removable parts . . . . . . . . . . . . . . . . 15 - 9
15.2.3 Technical data for superstructure . . . . . . . . . . . . . . . . . . . . . . 15 - 13
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16 Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1
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 Overview
1.1 Vehicle identification

1 Overview

1.1 Vehicle identification

These operating instructions are intended only for the truck crane of
which the serial number is specified on the front cover.
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Overview
1.1 Vehicle identification

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 Overview
1.1 Vehicle identification

The following plates and numbers have been fitted to the truck crane for
identification:

1 The superstructure name plate at the front of the crane operator’s cab
containing serial number and description of the crane model.

2 The CE mark on the name plate (only with truck cranes that are
delivered to member countries of the EU).

3 The chassis name plate on the passenger seat console containing the
chassis number and designation of the crane model.

4 The chassis number at the front right above the first axle line, in the
web plate of the frame.

The position of the identification numbers of detachable rigging parts (for

example counterweight, lattice extension) will be described in the corre-
sponding chapters or in their own respective operating manuals.
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Operating Instructions GMK 5100 2 084 575 en 1-3

Overview
1.2 EC declaration of conformity

1.2 EC declaration of conformity

This declaration of conformity is a supplement to the delivery protocol
given to the operator upon delivery of the truck crane (only on truck
cranes which are delivered to EC member coutries).

Industriegelände West
D-26389 Wilhelmshaven
Telefon (04421) 294-0, Telefax (04421) 294301
Deutsche GROVE GmbH – Postfach 18 53 – 26358 Wilhelmshaven
Postfach 1853 • D - 26358 Wilhelmshaven
Telex 253354
Industriegelände West • D - 26389 Wilhelmshaven
Telefon (0 44 21) 294 - 0
Telex 2 53 354 • Telefax (0 44 21) 29 43 01

EC Declaration of Conformity
as defined by the EC Machines Directive 89/392/EWG, Annex II A

We hereby declare that the machine described in the following, due to its design and
construction, and in the released version, complies with the applicable fundamental
requirements for health and safety of the EC Machines Directive.

E
Any alteration to the machine not authorized by us invalidates this declaration.

L
Designation of the machine: .......................................................

Machine type: .......................................................

Works-No./Serial-No.: .......................................................
P
Applicable
EC Directives: EC Machines Directive (89/392/EWG) as in version 93/68 EWG

Applied
M

harmonized
norms, in particular: .......................................................

.......................................................

Applied rules and regulation valid in Germany,

VBG1, VBG 8, VBG 9
A

national norms and .......................................................

technical specifications 1)
in particular: .......................................................

.......................................................
S

Date: Wilhelmshaven,
.......................................................

Manufacturer’s signature:

Information on signatory: Technical Director

.................................... Design Manager
..................................

How to fill in the form

– use block letters or typewriter – original for Deutsche Grove archive
– official language of user country – copy for customer
– legally binding manufacturer’s signature
2300200 - en /011.96

1) List of applied norms and technical specifications see company standard 2 300 198 - GN

Deutsche Grove archiving CE- ...........................................

Works-No./Serial-No.

Chairman of supervisory board: N. N.

Management: Lothar Hahn, Michael A. M. Lamb, Michael Momberg
Company Register: Amtsgericht Wilhelmshaven HRB
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 Overview
1.3 Overview and contents of truck crane user information

1.3 Overview and contents of truck crane user information

1.3.1 Carrier and superstructure operating manual

These operating instructions contain information required to operate the

truck crane.

In chapter 2 you will find Basic safety instructions. Please read and observe
these instructions, even if you are familiar with the safety manual. These
Basic safety instructions are in this chapter only; special safety instructions
which indicate concrete dangers are contained in the text. There the
action related to the danger is described.

Chapter 3 contains Information for applications engineering. It is intended pri-

marily for the truck crane operator and those responsible for applications
engineering.
This chapter contains
– the required qualifications of those involved in applications
engineering,
– special safety instructions,
– information that is relevant to applications engineering.

Chapters 4 to 6 contain information required for driving the truck crane: a

description of all structural and operational components, clearly defined
check lists for rigging modes and work and the operating instructions for
road and off-road driving.

In chapter 7 there is information on Troubleshooting for the carrier of the

truck crane.

Chapter 8 includes the Technical description of the individual parts and func-
tional elements of the carrier as well as its Technical data.

Chapter 9 contains the alphabetical index at the end of part 1 - carrier.

Chapters 10 to 12 contain information required for Operating the crane sec-

tion, i.e. work with the truck crane: a description of all components and
control elements, information about operating the crane engine as well as
the crane itself.
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Overview
1.3 Overview and contents of truck crane user information

Chapter 13 deals with rigging the truck crane. There are individual sec-
tions with information on Selecting a suitable site, rigging of support and
counterweight and Rigging work on the main boom.

Chapter 14 contains information about Troubleshooting on the superstruc-

ture of the truck crane.

The technical description of the individual components and functional parts

of the vehicle part as well as its technical data is found in chapter 15.

The alphabetical indexes in chapter 16 will help you when you are looking
for certain procedures and terms in the operating instructions.

1.3.2 Lattice extension operating manual (additional equipment)

If the truck crane has been equipped with a lattice extension, a boom ex-
tension, an auxiliary single-sheave boom top, or other additional equip-
ment, the lattice extension operating manual will be supplied. It contains
all information about combination possibilities, rigging,

1.3.3 Maintenance manual

The maintenance manual is intended for maintenance personnel.

The maintenance manual does not contain information on repair work.

The maintenance manual consists of

– instructions for cleaning the truck crane,
– run-in instructions,
– inspection and servicing intervals,
– maintenance tables,
– specifications for the required lubricants and fuels and
– a description of the maintenance work on both the vehicle section and
crane section.

1.3.4 Lifting capacity table

These tables contain data concerning the load bearing capacity, the per-
missible wind speed and the SLI code of the truck crane in various rigging
modes and boom positions.
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 Overview
1.3 Overview and contents of truck crane user information

1.3.5 Outrigger load table

These tables contain data concerning the outrigger pressure on the

pressure points of the support in relation to the load, radius, rigging
mode and boom direction.

1.3.6 Safety manual

The Safety manual is intended to warn the crane operator of the hazards
that may occur during normal operation of the truck crane. It illustrates
how to avoid these hazards from the onset and how to react should they
occur.

The Safety manual contains

– general safety instructions,
– safety instructions that apply to truck crane driving,
– safety instructions for rigging and working with truck cranes, and
– safety instructions for crane operation under specific operating conditions.
Observing the information and carrying out the measures which are given
in the Safety manual is the responsibility of the crane operator and a prereq-
uisite for the safe operation of the truck crane.

1.3.7 Spare parts list

The Spare parts list contains all available genuine spare parts and ordering
instructions.

1.3.8 Circuit diagrams

Circuit diagrams are used for troubleshooting and intended for trained
maintenance personnel and GROVE Product Support at the respective
location.

Enclosed are:
– the compressed-air circuit diagram,
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– the hydraulic circuit diagram and

– the electrical circuit diagram.

Operating Instructions GMK 5100 2 084 575 en 1-7

Overview
1.4 Instructions for use of this document

1.4 Instructions for use of this document

These operating instructions are not a training manual for prospective
crane operators! All descriptions are written explicitly for crane operators
who have been trained to operate truck cranes.
This operating manual is for reference; it contains brief or detailed ex-
planations of operating steps and procedures depending on the foreknow-
ledge of the crane operator.

1.4.1 How are the operating instructions laid out?

The Operating Instructions consist of Part 1 - Carrier and Part 2 - Super-

structure. One individual part, however, does not constitute a complete
set of Operating Instructions; both parts must be included with the truck
crane. The basic safety measures, also for crane operation, as well as
general information can be found only in Chapter 1. The individual parts
consist of
– the descriptions of the operating and control instruments their
designation, location and function,
– the check lists, which describe the respectively required crane or
rigging mode.
The individual rigging steps are listed in the correct order for extensive
rigging procedures. The accompanying handling descriptions are
referred to in the individual points. These descriptions look at the indivi-
dual rigging steps in detail and give the necessary warning and safety
instructions.

G
The check lists and the handling instructions should always be considered
as a single unit for the complete description of a rigging procedure.
The handling instructions alone always describe only one individual rig-
ging step in detail. The necessary rigging steps for the complete rigging

S
procedure and their order can only be found in the checklist.

In the check lists there are cross-references to the respective accompany-

ing sections in which the required actions are described along with the
dangers involved.
As the crane operator you are obliged to read these sections
– before using the truck crane for the first time
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– and whenever you are still unsure about operation of the truck crane.

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 Overview
1.4 Instructions for use of this document

Safe operation of the truck crane simply with the check lists is only possible
– once you have mastered the necessary activities as they are described
– in the respective sections and
– if you are aware of all dangers which could arise and know how to
– prevent them.
If in doubt always read the accompanying section which is referred to in
the check list before working with the truck crane.

1.4.2 How are the pages of the operating manual formatted?

Each page of the operating manual consists of a wide text column and a
narrow column containing several functions.

The narrow column contains as required graphic and / or text information.

This includes
– the symbols for danger, environmental protection and general
information,
– the symbols for the switches, keys and lamps required to operate the
truck crane,
– graphic illustrations of the individual functional and structural elements
of the truck crane,
– the chapter and section numbers,
– the headings of the smallest sections, in which, e. g. the course of a
single procedure is explained.

The following text passages are highlighted in italics:

– the descriptions of operating instruments such as switches, pushbut-
tons or lamps,
– cross-referenced section titles.

Text passages in which sentences are preceded by a hyphen (as in this

section) are lists. This formatting structure is used to separate the text
components for easier comprehension.

Sentences preceded by a bold dot contain specific instructions, such as

• Switch the automatic gearbox into neutral position N.
These passages require that you carry out a specific action.
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Overview
1.4 Instructions for use of this document

Switch elements and indicator lamps which have the same symbol are
only represented by one single symbol when they are mentioned in com-
mon relevance, e.g.
• Press the Suspension locking system rocker switch down.
u The Suspension locking system indicator lamp should illuminate.

1.4.3 How can I find the necessary information quickly and easily?

These operating instructions contain the following reference aids

– the table of contents at the front of the operating instructions,
– the table of contents of each chapter on the coloured sheet preceding
the respective chapter,
– the index at the back of the operating instructions, and
– cross-references in the text.
The General table of contents and the individual Chapter table of
contents provide a thematic overview of the operating instructions.

The Index (Chapter 9 and 16 of these operating instructions) lists key

words and terms alphabetically and indicates the page on which the re-
spective word is defined or the corresponding operation is described.
You will find instructions for the use of the index on page 1-16.

The text itself contains a number of cross-references to other text passa-

ges which contain additional or detailed information about a particular
term.
These cross-references are indicated by means of an arrow (➠).

Whenever you require further information on a subject, you should

always turn to the page to which the arrow refers.

Furthermore, using the cross-references you can systematically fami-

liarise yourself with general and particular information on the truck crane
or look up the function of individual elements.
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 Overview
1.4 Instructions for use of this document

Example of cross- This will be explained using the example of switching on the transverse
reference usage differential lock.

The following seven sample pages show how the cross-references guide
you through the Operating Instructions. The example starts with the over-

H
all view and goes on to the function of an individual switch.

The sample pages in this example originate from Operating Instructions

for the GMK 3050 and can deviate from the actual Operating Instructions!

9 Drivers cab ➠ p. 4 - 6

4-4 4-5

C0646

On page 4 - 4 of our example there is the overall view of the truck crane
with the position numbers 1 to 17. You will find the designation of the
truck crane part labelled with the number 9 on the opposite page 4 - 5.
There under the number 9 is Driver’s cab. The accompanying cross-
reference (➠) refers you to page 4 - 6.
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Overview
1.4 Instructions for use of this document

1 Side instrument panel ➠ p. 4 - 14

4-6

C0647

Page 4 - 6 gives an overview of the driver’s cab.

Item number 1 designates the side instrument panel. The operating
elements on the side instrument panel are given on page 4 - 14 according
to the cross-reference.

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 Overview
1.4 Instructions for use of this document

6 Rocker switch for transverse differential lock ➠ p. 4 - 22

h
6

4 - 14 4 - 15

C0648

The side instrument panel is shown on page 4 - 14. In our example the
magnifying glass is directed at the symbol designated by the item num-
ber 6. On the opposite page 4 - 15 under number 6 you will find the
designation Rocker switch for transverse differential lock. You will find infor-
mation on this switch on page 4 - 22.
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Operating Instructions GMK 5100 2 084 575 en 1 - 13
Overview
1.4 Instructions for use of this document

Rocker switch for transverse differential lock

h
Locks the transverse differentials in all driven axle lines.
May only be activated when the vehicle is stationary or is moving at
a speed of no more than 3 km/h.

To switch on: Press rocker switch down.

To switch off: Press rocker switch up;

➠ p. 6 - 34

4 - 22

C0649

On page 4 - 22 in the section functional description of the display and operating

instruments instrument panel you will find the symbol as well as the designa-
tion of the accompanying operating instrument: Rocker switch for transverse
differential lock.

Furthermore you will find a brief functional description of this switch.

You are referred to page 6 - 34 for further information.

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 Overview
1.4 Instructions for use of this document

Activating ● Stop the truck crane or allow it to roll at a speed of max. 3 km/h.
transverse
differential locks ● Straighten the steering.
● Switch on the Level adjustment system key switch.
Press the rocker switch
h ●
Press the rocker switch Transverse differential lock down.
Carefully start the truck crane and wait until the indicator lamp Transverse
differential lock illuminates. The indicator lamp will flash if one or more of
the transverse differential locks has not been activated.
It will not illuminate continuously until the transverse differential locks
of all axle lines have been activated.

6 - 34

C0650

The section Transverse differential locks in the axle lines is on page 6 - 34 of

our example. There the function and operation of the transverse differen-
tial locks is described in detail. You are also given warning information
which will help prevent you from incorrectly operating the transverse
differential locks and causing damage.
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Operating Instructions GMK 5100 2 084 575 en 1 - 15
Overview
1.4 Instructions for use of this document

Explanations of The index has the following structure:

how to use the
index The names of parts or modules for which you are looking are listed in
alphabetical order at the very left at the beginning of the line.
The following are indented under these terms:
– operations (e.g. outrigger beams / extend) or
– sub-terms (e.g. steering / display and operating elements) or

H
– sub-terms connected to operations (e.g. hydraulic system / preheat
hydraulic oil).

The first search word is always a noun which is followed by an operation

or a sub-term.

1.4.4 Definition of direction information

This section defines several terms which are used in the descriptions of
the operating elements in these operating instructions.

Basic rule Forwards always means towards the driver’s cab,

backwards always means towards the carrier rear lights.

In the driver’s cab front, rear, right and left refer to the carrier.
The driver’s cab is always at the front. This also applies when these terms
are used to describe the control levers in the driver’s cab.

In the crane cab front, rear, right and left refer to the superstructure. The
front is always in the direction of the main boom head. This also applies
when these terms are used to describe the control levers in the crane cab.

Buttons and Switches and buttons on the instrument panels are always pressed up
switches and down. In the illustrations of switches and buttons this means:

up, when pressing (1)

down, when pressing (2)
This applies whether the switch is installed horizontally, vertically or at
an angle. Up and down always refers to the way the switch or button is
illustrated in these operating instructions.
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 Overview
1.4 Instructions for use of this document

1.4.5 Conversion table for metric measuring units

These operating instructions contain measuring units partly in metric,

partly in US units. The following conversion factors apply when convert-
ing from metric to US units, and vice versa:

Convert from to Multiply by

mm inches 0.03937

inches mm 25.4

m ft 3.28084

ft m 0.30479

m2 ft2 10.76391

cm2 in2 0.155

cm3 in3 0.061

l gal (US) 0.264178

kg lbs 2.204622

lbs kg 0.45359

t lbs 2204.622

lbs t 0.0004536

kN lbf 224.809

daN/cm2 lbf/in2 14.50378

lbf/in2 daN/cm2 0.06895

bar psi 14.50378

psi bar 0.06895

m/s ft/s 3.28084

km/h or km mph or mi 0.62137

mph or mi km/h or km 1.60935

Nm lbf ft 0.7375

°C °F 1.8 x °C+32

°F °C (°F -32) / 1.8

11.05.2000

t/m2 lbs/ft2 204.8

m2/t ft2/lbs 0.004882

Operating Instructions GMK 5100 2 084 575 en 1 - 17

Overview
1.4 Instructions for use of this document

Blank page

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 Fundamental safety instructions for crane operators
2.1 Warnings and symbols

2 Fundamental safety instructions for crane

operators

2.1 Warnings and symbols

The following definitions and symbols are used in the operating instruc-
tions to highlight particularly important information:

G
This symbol indicates hazards related to the described operation that
may cause personal injury. The type of danger (e.g. risk of death, perso-
nal injury or crushing) precedes the warning sign.

S
Here dangers are referred to which could put objects at risk, e.g. damage
to the truck crane, the load or the environment.

B
This symbol alerts you to situations where you are in danger of receiving
an electric shock.

O
This symbol is to remind you that you are working with substances which
pose a risk to the environment. Take particular care. Further information
about handling substances which are harmful to the environment;
➠ Maintenance manual, chapter Safety and environmental protection.

The vertical line to the left of the text indicates: This text regardless of its
length belongs to the warning symbol.

H The hand with the pointing finger indicates passages that contain additio-
nal instructions and tips with regard to truck crane operation.
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Operating Instructions GMK 5100 2 084 575 en 2-1
Fundamental safety instructions for crane operators
2.2 Proper use

s
This symbol indicates that the topic is continued on the next page.
So turn to the next page!

Horizontal lines always point to the start or the end of an example. The text in
examples is in a different font.

2.2 Proper use

The GMK 5100 truck crane is constructed in accordance with the state of
the art and the recognised safety regulations. Nevertheless, personal
injury to the operator or a third party as well as damage to the crane and
other property may occur during use.

The truck crane may only be modified with the consent of the manufacturer.

The GMK 5100 truck crane must be in proper working condition and may
only be used for its intended purpose, while taking into account safe
operation and any possible hazards.
Malfunctions that may affect the safe operation of the unit are to be
corrected immediately.

Without the corresponding special equipment, the truck crane GMK 5100
may only be operated at an ambient temperature of –19 °F to +107 °F.

The GMK 5100 truck crane is to be used exclusively for the vertical lifting
of loads whose weight and centre of distribution are known. A hook block
must be reeved on the hoist rope and such lifting must be done only in
the permitted rigging modes. Any other use of the crane is considered
improper.

The manufacturer is not liable for damage resulting from the improper or
unauthorised use of the GMK 5100 truck crane. The user shall take on full
responsibility for any such use.

Proper use also entails

– observing all crane documentation, consisting of the operating in-
structions, the lifting capacity table, the outrigger pressure table and
the safety manual,
– following the inspection and maintenance requirements specified in the
maintenance manual.
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 Fundamental safety instructions for crane operators
2.2 Proper use

Improper use includes:

– Transporting loads on the carrier,
– Pushing, pulling or lifting loads with the level adjustment system, the
beams or the outrigger cylinders,
– Pushing, pulling or lifting loads off the ground using the slewing gear,
the derricking gear or the telescoping gear,
– Pulling off fixed objects using the crane,
– Two-hook operation with the boom extension and two-hook operation
on the main boom head without additional equipment,
– Two-hook operation,
– Operation when crane is not on outriggers (free on wheels),
– Defining SLI codes that do not correspond to the actual rigging mode,
– Working with an overridden SLI or overridden lifting limit switch,
– After SLI deactivation, the radius must be increased by pulling the rai-
sed load at an angle (e. g. with a chain hoist).
– Misuse of the outrigger pressure display as a safety function to prevent
overturning after an SLI shutdown (outrigger pressure greater than 0 t),
– Road driving in an unauthorised driving mode (axle load, dimension),
– Moving the rigged crane in an unauthorised driving mode,
– The transportation of raised loads by moving the truck crane,
– Using equipment that is not authorised for use with the crane,
– Transporting people in any way with the lifting tackle, on the load and
in the crane cab during driving.
– Carrying passengers outside the driver’s cab,
– Loading and unloading work, i.e. continuous operation without a
corresponding break,
– Usage for any kind of sport or recreation event, especially for “bungee
jumping”.
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Operating Instructions GMK 5100 2 084 575 en 2-3

Fundamental safety instructions for crane operators
2.3 Organisational measures

2.3 Organisational measures

The operating instructions and the lifting capacity table should be kept in
the truck crane for immediate access at all times and must not be remo-
ved from the truck crane. You need to have read and understood the
operation and safety instructions in these operating instructions and to
comply with them when working.
In addition to the operating instructions and the lifting capacity table, ob-
serve all general, statutory and otherwise applicable regulations concer-
ning accident prevention and environmental protection. You must have
read and understood these and work accordingly.
This includes:
– the use of hazardous materials,
– wearing personal protective equipment,
– traffic regulations or
– all regulations concerning the operation of a crane.

Ensure that those appointed to work on the truck crane are given the infor-
mation required to carry out the work before starting operations. Give
your employees (e.g. banksmen, slingers, rigging personnel) appropriate
instruction.
Ensure that the maintenance personnel possess the necessary know-how
to safely operate the crane. Ensure that the maintenance personnel have
access to the Operating Instructions.
Only properly trained or instructed personnel may carry out work on the
truck crane.
Responsibilities related to crane operation, rigging, maintenance and re-
pair work must be clearly defined.
Ensure that only the appointed employees operate the truck crane.
Do not leave long hair down or wear loose clothing or jewellery (including
rings) when working with the crane. These could cause injury by, for
example, getting caught or pulled in.
Use your personal protective equipment whenever necessary or pre-
scribed.
Observe all safety and warning signs on the truck crane.
Ensure that all safety and warning signs on the truck crane remain legible.
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 Fundamental safety instructions for crane operators
2.3 Organisational measures

Note the operational organization on the site. Report your arrival to site
management. Ask for the personnel authorized to issue instructions.

Familiarize yourself with the location and operation of the fire extin-
guishers on every site.

Note the fire alarm and fire fighting facilities on the site.

Should the operating behaviour of the truck crane change in such a man-
ner that safety is affected or if you doubt the truck cranes operating safe-
ty, stop the machine immediately and inform the appropriate responsible
persons.

Do not modify any programs in programmable control systems (e. g.

the SLI).

Do not modify or mount attachments to the truck crane without the con-
sent of the manufacturer if such changes could affect the safety of the
unit. This also applies to
– installing safety devices,
– setting safety devices and valves.
Welding work on load-bearing parts may only be conducted by properly
qualified personnel following authorisation by the manufacturer. To avoid
any damage, especially to electronic parts, there are certain steps you
must take before doing any welding work. So always consult GROVE
Product Support before doing any welding work.

Ensure that both the prescribed periods and the periods specified in the
operating and maintenance instructions for regular testing, inspection
and maintenance work are maintained.

Replace the hydraulic hose lines at the prescribed intervals or have them
replaced, even if no safety defects are noticeable.

Replacement parts must fulfil the technical requirements prescribed by

the manufacturer. Genuine spare parts always meet these requirements.

It is imperative that appropriate service equipment be used when carrying

out repair work.
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Operating Instructions GMK 5100 2 084 575 en 2-5

Fundamental safety instructions for crane operators
2.4 Personnel qualifications

2.4 Personnel qualifications

These operating instructions are not a training manual for prospective
crane operators!
All descriptions are written explicitly for crane operators who have been
trained to operate truck cranes.

Employees in training may only operate the truck crane under strict super-
vision.

Only reliable personnel may operate the truck crane.

As a truck crane operator you are obliged to fulfil a number of

requirements:
– You must possess a driving licence for this type of vehicle that is valid
in the country in which you are working.
– You must have general knowledge of crane operation and any qualifica-
tions that may be required by the country in which you are working.
– You must be familiar with and have understood the operating
instructions.
– You must be familiar with and have understood the accident prevention
regulations.
– You must fulfil all physical and mental requirements for truck crane
operation, e.g. perfect sight and hearing and the ability to react quickly.
Please refer to the section titled You as crane driver and operator in the
Safety manual.

Only experienced personnel familiar with the applicable accident

prevention regulations are authorised to sling loads and train crane
operators.

Your responsibilities as a crane operator (including those concerning

traffic regulations) must be clearly defined. You must be in a position to
refuse to carry out any instructions given to you by a third party that
violate safety regulations.

Only trained, experienced personnel with special knowledge in the fields

of hydraulics, pneumatics and electrical equipment may carry out main-
tenance work on the truck crane.

Deutsche GROVE GmbH offers general and model-related courses for

crane operators and crane technology.
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 Fundamental safety instructions for crane operators
2.5 Safety instructions that apply to truck crane driving

2.5 Safety instructions that apply to truck crane driving

Walk around the truck crane before beginning to drive. Check the con-
dition of the truck crane carefully using the check lists in the operating
instructions. Do not assume that everything is in working order simply
because it was in working order when work was last completed.

Before driving, check whether all covers and safety devices are correctly
in place and whether they are in proper working order.

Use the appropriate access aids when checking overhead crane parts.
Do not use parts of the crane to gain access to these areas.

Keep all handles, steps, step treads and ladders free of dirt, snow and ice.

Check all operating and control elements in the driver’s cab before
starting the vehicle engine.

Monitor all warning and indicator lamps as well as the control instru-
ments when the engine is started!

Lock the truck crane after operation to prevent unauthorised use.

2.6 Safety instructions for truck crane work

Carefully select a safe site for the truck crane to stand from where you can
safely work.

Walk around the truck crane before beginning crane work. Check the
condition of the truck crane carefully using the check lists in the operating
instructions. Do not assume that everything is in working order simply
because it was in working order when work was last completed.

Before commencing work with the crane, check daily that all covers and
safety devices are correctly fitted and in an acceptable condition.

Check the safety devices each day before beginning work (SLI, lifting limit
switch, dead man’s switch, emergency stop switch for crane control).
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Operating Instructions GMK 5100 2 084 575 en 2-7

Fundamental safety instructions for crane operators
2.6 Safety instructions for truck crane work

Use the appropriate access aids when carrying out overhead rigging or
maintenance work. Do not use parts of the crane to gain access to these
areas.

Only step onto machine sections which are equipped with appropriate steps
and railings and therefore guarantee safety. During rigging and maintenance
work on machine sections above body height which have no apparatus for
stepping onto them, use the extendable ladder which accompanies the
machine (e.g., when reeving the hoist cable on the boom nose.

Keep all handles, steps, step treads and ladders free of dirt, snow and ice.

Check all operating and control elements in the crane operator’s cab
before starting the crane engine.

Monitor all warning and indicator lamps as well as the control instru-
ments when the engine is started!

Make sure that there are no unauthorised people in the vicinity of or on

the truck crane when rigging. Secure the danger zone using cordons and
label them as such.

When lifting a load, raise the boom to balance out the increase in radius
caused by the boom bending so that the load is lifted up when in a verti-
cal position and does not drag, injure helpers or fall into the hoist rope
diagonally (e. g. from a vehicle or scaffold). Inform banksmen and helpers
about this as well.

Support the truck crane with the supporting span for the current rigged
counterweight before turning the superstructure.

Ensure that the truck crane is horizontally aligned before carrying out
crane work.

Only use equipment (counterweight sections, lattice extensions) that

belongs to your truck crane. The serial number of both the truck crane
and the equipment must be identical.

Simultaneously lifting loads with two cranes is particularly dangerous.

Use extreme caution when carrying out this type of work.

When work is interrupted, always put the load down and never leave the
truck crane if a load is raised.

Lock the truck crane when you leave the cab to prevent unauthorised use.
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 Fundamental safety instructions for crane operators
2.6 Safety instructions for truck crane work

Crane work carried out in the vicinity of supply lines such as oil, gas or
other supply lines is dangerous and requires that special precautionary
measures be taken. Please refer to the section titled Crane operation under
special operating conditions in the Safety manual and observe the relevant
national regulations.
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Fundamental safety instructions for crane operators
2.6 Safety instructions for truck crane work

Blank page

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 Information for applications engineering
3.1 Safety instructions

3 Information for applications engineering

3.1 Safety instructions

3.1.1 Proper use

When scheduling applications, please remember that the GMK 5100 truck
crane may only be used for applications that do not violate any laws,
regulations or the Proper use of the unit as specified by the manufacturer.
Please refer to the section titled Proper use, p. 2-2.

3.1.2 Organizational measures

The manufacturer of your truck crane has no direct influence on the way
you use, operate or maintain the crane. You are therefore responsible for
ensuring the safe operation of the crane and the fulfillment of all laws and
regulations.

Ensure that the operating instructions are supplemented with any instruc-
tions required for special operational features, such as
– organization,
– work procedures,
– personnel,
– compulsory supervision and registration.

When using oils, lubricants and other chemical substances, ensure that
the safety regulations that apply to the respective product are strictly
observed.

Ensure that process materials and replaced parts are disposed of in an

environmentally friendly manner.

Monitor the work of the employees – at least occasionally – and ensure

that they are working in accordance with the operating instructions in a
responsible, conscientious manner and are aware of the related operatio-
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nal hazards.

s
Operating Instructions GMK 5100 2 084 575 en 3-1
Information for applications engineering
3.1 Safety instructions

Use only equipment that belongs to your particular truck crane, such as
counterweight sections and lattice extensions.
The serial number of both the truck crane and the equipment must be
identical.

Observe the lifting capacity table belonging to the truck crane or included
in the Operating Instructions. If the truck crane can be operated with
different counterweight versions, the counterweight sections may only be
assembled according to the counterweight versions given in the lifting
capacity table.

When loading the truck crane, please observe the national regulations
that apply to transport. In addition, please observe the prescribed safety
measures of the shipper (e.g. the carrying agent or railway carrier).

3.1.3 Personnel qualifications

Only qualified personnel may operate the truck crane. Please refer to
page 2-6 in the section titled Personnel qualifications.

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 Information for applications engineering
3.2 Applications engineering

3.2 Applications engineering

3.2.1 Application engineering requirements

Plan each application carefully. Gather information concerning the route,

including in particular
– the distance,
– the route,
– overhead clearances and
– the load bearing capacity of bridges.

Gather information about the job including

– the load bearing capacity and stability of the ground (soil, buildings),
– the weight and dimensions of the loads to be lifted,
– the type of load (degree of risk involved),
– required stroke length and radius,
– restricted movement due to buildings etc.

Have the necessary equipment arranged, such as

– lifting gear,
– counterweight,
– blocks for support etc.

Organise transportation and obtain any necessary driving permits.

Poor planning leads to improvisation – and improvisation is the cause of

many accidents!
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Information for applications engineering
3.2 Applications engineering

3.2.2 Details about applications engineering contained in the user

information

Extensive information must be available for applications engineering in

order to guarantee the safe, trouble-free, efficient use of the truck crane:

The operating instructions contain

– dimensions and weights (➠ p. 8-8),
– driving modes permitted on public roads (➠ p. 6-4),
– dimensions and weights of detachable equipment (➠ p. 8-9, p. 16-9),
– dimensions and turning circle radii for manoeuvring (➠ p. 8-13),
– permitted span (➠ p. 13-17),
– size of outrigger pads (➠ p. 8-11).

The lifting capacity table contains

– operating areas (operating-area curve of the boom),
– load bearing capacities for the permitted rigging modes,
– load bearing capacities for the permitted spans,
– SLI coding,
– permitted wind speeds,
– load reduction in certain rigging modes.

The outrigger pressure table contains

– outrigger pressures on the ground under the outrigger for various
rigging modes and boom directions

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4 Description of the truck crane – vehicle section

4.1 Overview of the operating and display instruments

This section only contains the operating and display instruments for
driving that are located on the outside of the truck crane or in the driver’s
cab.

4.1.1 Overview of the vehicle

The figures on the following pages illustrate the location of the operating
and control instruments that are required to drive the truck crane and are
found on the outside of the vehicle.

All operating and control instruments required for crane operation are
described in Chapter 10.
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Operating Instructions GMK 5100 2 084 575 en 4-1
Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Access ladders to superstructure ➠ p. 4-44

2 Hydraulic oil tank, inspection glass ➠ p. 5-7

3 Vehicle engine dipstick and oil filler ➠ p. 5-5

4 Compressed-air system emergency filler connection ➠ p. 7-7
5 Left-hand wing mirror ➠ p. 6-19
6 Bonnet ➠ p. 4-46
7 Driver’s cab ➠ p. 4-4
8 Vehicle engine coolant reservoir ➠ p. 5-6
9 Undercarriage-hydraulic system shutoff cocks ➠ p. 5-8

10 Transmission access opening ➠ p. 7-6

11 Proximity mirror ➠ p. 6-19
12 Wide-angle mirror ➠ p. 6-19
13 Right-hand wing mirror ➠ p. 6-19
14 Vehicle engine ➠ p. 5-1
15 Holder for extendable ladder ➠ p. 4-45
16 Windscreen washing system reservoir ➠ p. 6-18
17 Battery master switch ➠ p. 5-7
18 Fuel tank filler neck ➠ p. 6-17
19 central lubrication system grease container Maintenance
instructions

20 Chocks ➠ p. 6-43
21 Hook-on ladder ➠ p. 4-45
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Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.2 Overview of driver’s cab

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Side instrument panel ➠ p. 4-16

2 Adjustable driver’s seat ➠ p. 6-18
3 Rocker switch for separate steering ➠ p. 4-29
4 Steering wheel

5 Adjustable steering column ➠ p. 4-20

6 Front instrument panel ➠ p. 4-8
7 Service brake pedal ➠ p. 6-22
8 Accelerator ➠ p. 6-22
9 Gear control lever ➠ p. 4-17
10 Parking brake lever ➠ p. 4-27
11 Fuse box (under the compartment) ➠ p. 7-19
12 Vehicle engine diagnostics plug (under the ➠ p. 4-46
compartment)

13 Fire extinguisher (additional equipment) ➠ p. 4-47

14 Glove compartment

15 Adjustable passenger’s seat ➠ p. 6-18

16 Folding berth (additional equipment) ➠ p. 4-47

17 Third seat (additional equipment)

18 Suspension operation pressure display (additional ➠ p. 4-28

equipment)
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Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 2 3 4 5

C0712

1 Sun screen

2 Loudspeaker,,

3 Cassette/radio

4 Air conditioner or roof ventilator

(both additional equipment)
air conditioner ➠ p. 4-41
roof ventilator ➠ p. 4-35
5 Cabin lighting ➠ p. 4-42

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Tachograph ➠ p. 4-10
2 Steering column lock ➠ p. 6-19
3 Release lever clutch emergency pedal ➠ p. 4-48
4 Clutch emergency pedal ➠ p. 7-37
5 Bonnet release lever ➠ p. 4-46
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Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.3 Front instrument panel

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Ventilating nozzle ➠ p. 4-35

2 Status display for supply pressure brake circuits ➠ p. 4-26
I and II

3 Status display for oil temperature in hydraulic ➠ p. 4-28

system

4 Indicator lamp for hydraulic oil return flow filter ➠ p. 4-29

5 Retarder indicator lamp (additional equipment) ➠ p. 4-28
6 ABS warning light for trailer (additional ➠ p. 4-27
equipment)

7 ABS 1 warning lamp ➠ p. 4-27

8 Warning lamp for steering circuit I ➠ p. 4-29
9 Indicator lamp for driving direction ➠ p. 4-31
10 Unlock clutch emergency pedal indicator lamp ➠ p. 4-27
11 Apply brakes warning lamp ➠ p. 4-25
12 Suspension locking system indicator lamp ➠ p. 4-28
13 ABS 2 warning lamp ➠ p. 4-27
14 Indicator lamp for steering circuit II ➠ p. 4-29
15 Indicator lamp for driving direction for trailer ➠ p. 4-31
(additional equipment)

16 Clutch overload warning lamp ➠ p. 4-25

17 Rocker switch with indicator lamp for hazard ➠ p. 4-30
warning system

18 Rocker switch for suspension locking system ➠ p. 4-28

19 Roof ventilator rocker switch (additional ➠ p. 4-35
equipment)

20 Rocker switch with indicator lamp for wing-mirror ➠ p. 4-31

heating
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Operating Instructions GMK 5100 2 084 575 en 4-9

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Tachograph display ➠ p. 6-13

2 Adjust minute key - ➠ p. 4-34
3 Adjust minute key + ➠ p. 4-34
4 Unlock drawer button ➠ p. 6-13
5 Time group button for operator 1 ➠ p. 6-13
6 Time group button for operator 2 ➠ p. 6-13
7 Time-setting menu key ➠ p. 4-33
8 Drawer ➠ p. 6-13
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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Speed display ➠ p. 4-33

2 Speed indicator display ➠ p. 4-33
3 Tachograph malfunction warning lamp ➠ p. 4-33
4 Time/day’s kilometres display push-button ➠ p. 4-33
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Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Ventilating nozzle ➠ p. 4-35

2 Speed indicator ➠ p. 4-22
3 Status display with warning lamp for vehicle engine ➠ p. 4-21
coolant temperature

4 Status display for fuel reserve ➠ p. 4-21

5 Warning lamp for supply pressure brake circuits I and II ➠ p. 4-26
6 Warning lamp for charge indicator ➠ p. 4-21
7 Indicator lamp for full-beam headlight ➠ p. 4-31
8 Indicator lamp for transverse differential lock in all ➠ p. 4-26
driven axle lines

9 Indicator lamp for vehicle engine air filter ➠ p. 4-21

10 Warning lamp for engine faults ➠ p. 4-30
11 Indicator lamp for vehicle parking brake ➠ p. 4-27
12 Boom not set down warning lamp ➠ p. 4-37
(additonal equipement)

13 Indicator lamp for longitudinal differential locks/ drive ➠ p. 4-26

of 3rd axle line (drive of 3rd axle line can only be
switched on with 10 x 8 x 10 (additional equipment)

14 Indicator lamp for vehicle engine coolant level ➠ p. 4-21

15 Indicator lamp for flame-start device ➠ p. 4-21
(additonal equipment)

16 Indicator lamp for engine electronic ➠ p. 4-22

17 Rocker switch with fog lamp and tail light indicator ➠ p. 4-30
lamp (additonal equipment)

18 Rocker switch with indicator lamp for rotating beacon ➠ p. 4-30

19 Parking light / headlight rocker switch ➠ p. 4-30
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Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Gearbox control display ➠ p. 4-22

2 Heating temperature regulator ➠ p. 4-34
3 Recirculated air / fresh air regulator ➠ p. 4-34
4 Driver’s side air distribution regulator ➠ p. 4-34
5 Passenger side air distribution regulator ➠ p. 4-34
6 Driver’s side heater fan knob ➠ p. 4-34
7 Passenger-side heater fan knob ➠ p. 4-34
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Operating Instructions GMK 5100 2 084 575 en 4 - 15

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.4 Side instrument panel

H All illustrations in this section show the views from the side instrument pa-
nel in such a way that the left edge of the illustration is always pointed for-
ward, in the truck crane’s direction of travel.

1 Rocker switch for transverse differential lock in all ➠ p. 4-26

driven axle lines

2 Indicator lamp for additional heating system ➠ p. 4-35

(additional equipment)

3 Rocker switch for longitudinal differential locks/ ➠ p. 4-26

drive of 3rd axle line (drive of 3rd axle line can
only be switched on with 10 x 8 x 10 additional
equipment)

4 Rocker switch with separate steering lock button ➠ p. 4-29

5 Unlocked steering warning lamp ➠ p. 4-29
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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Gear control lever ➠ p. 4-23

2 Gear box emergency switch (under the covering) ➠ p. 4-24
3 Automatic/manual operating mode rocker switch ➠ p. 4-23
4 Gear function switch ➠ p. 4-24
5 Two-stop rocker ➠ p. 4-24
6 Gear neutral setting N switch ➠ p. 4-23
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Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Right rocker switch for level adjustment ➠ p. 4-32

2 Key switch for level adjustment ➠ p. 4-31

3 Rocker switch for level adjustment system, front ➠ p. 4-32

4 Rocker switch for level adjustment system, rear ➠ p. 4-32

5 Rocker switch for level adjustment system, left ➠ p. 4-32

6 Indicator lamp for raising vehicle level ➠ p. 4-32

7 Indicator lamp for no on-the-road level ➠ p. 4-32

8 Rocker switch with indicator lamp for additional ➠ p. 4-35

heating system *)(additional equipment)

9 Rocker switch for raising/lowering vehicle level ➠ p. 4-32

10 Indicator lamp for lowering vehicle level ➠ p. 4-32

11 Rocker switch for raising/lowering truck crane ➠ p. 4-32

12 Rocker switch for on-the-road level ➠ p. 4-32

13 additional heating system with timer*) ➠ p. 4-36

(additional equipment)

14 Return push-button ➠ p. 4-36

15 Heating system display ➠ p. 4-36
16 Flow push-button ➠ p. 4-36
17 Heating indicator lamp turned on ➠ p. 4-37
18 Reservoir 1 push-button ➠ p. 4-36
19 Reservoir 2 push-button ➠ p. 4-36
20 Time display / set push-button ➠ p. 4-36
21 Heating system on/off push-button ➠ p. 4-36
22 Automatic heating begin indicator lamp ➠ p. 4-37

*)Either 8 or 13 possible as additional equipment

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Operating Instructions GMK 5100 2 084 575 en 4 - 19

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.5 Steering column

Setting the steering column; ➠ p. 6-19

1 Multipurpose switch, left ➠ p. 4-40

For the control of the lighting / horn / front
windscreen / windscreen wiper/washing system

2 Ignition lock ➠ p. 4-38

3 Right multipurpose switch ➠ p. 4-38
functions for standing truck crane:
– Setting idling speed ➠ p. 4-38
functions for moving truck crane:
– Tempomat ➠ p. 4-39
– Retarder ➠ p. 4-40
– Eddy current retarder (additional equipment) ➠ p. 4-40
4 Temposet button on ➠ p. 4-39
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

4.2 Functional description of the display and operating

instruments
Definition of direction information for using operating elements; ➠ p. 1-16.

4.2.1 Instrument panels

Vehicle engine

Indicator lamp for flame-start (additional equipment)

z The lamp will go on if the motor is stated when its cold.
It goes out when the motor is ready to start (waiting time can be up to
20 seconds, depending on the temperature of the motor coolant).
➠ Starting a cold vehicle engine, p. 5-10.
Warning lamp for vehicle engine oil pressure
L The oil pressure cannot fall while the vehicle is being driven.
The warning lamp for vehicle engine oil pressure goes on if the oil pressure
falls to below 0,4 bar (6 psi); ➠ p. 5-9, ➠ p. 5-12.
A warning buzzer sounds simultaneously.

Status display with warning lamp for vehicle engine coolant temperature
The temperature of the coolant may only increase to 95 °C (203 °F) on
uphill routes; ➠ p. 6-33.
If the coolant temperature exceeds the maximum temperature, a warning
buzzer will sound.

Indicator lamp for vehicle engine coolant level

t Illuminates if the coolant level is too low; ➠ p. 6-34

Indicator lamp for vehicle engine air filter

p Illuminates when the air filter is dirty.
Change the filter element ➠ Maintenance manual.

Status display for fuel reserve

Never allow the fuel tank run completely empty! ➠ p. 6-17
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Operating Instructions GMK 5100 2 084 575 en 4 - 21

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Speed indicator
This displays the current engine speed in rotations/minute.

Engine electronics warning lamp

à This lights when the motor is off and the ignition is switched on. It goes
out after the engine has been started.
It lights up when the engine is running if there is a malfunction in the en-
gine electronics; ➠ p. 7-25.

Operating instrument on the Right multipurpose switch

The multipurpose switch functions are divided into different types
(motor/brake) and are therefore described in their own section;
➠ On the steering column - tempomat, p.4-39
➠ On the steering column - temposet, p. 4-39
➠ On the steering column- idling speed, p. 4-38

Transmission
with automatic
gear change ➠ Operating the gears with automatic gear change, p.6-25
Gearbox control display
The status display always shows the current shift position:
– N for neutral position
– R for reverse gear position
– 1 to 8, depending on the gear position.
The arrow pointing up appears if the displayed gear is active as a full
gear. The arrow pointing down appears if the displayed gear is shifted
1/2 a gear down.

The display also shows various error messages, for example, the wrench,
which is the service symbol; ➠ Error messages on the display, gearbox control,
p. 7-36.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Neutral position button N

This can only be switched if the gearshift lever and the two-stop rocker
are in the central position. It switches the gears to the neutral position.

Switching on neutral position: press the button once

The neutral position is switched on when the N symbol appears on the
Gearbox control display.

Automatic/manual operating mode rocker switch

This is used to switch between the automatic and the manual operating
mode of the transmission.
The operating mode can also be switched while driving.

Switching on automatic Switch rocker switch to position A

operating mode:
Switching on manual Switch rocker switch to position M
operating mode:
The gear box automatically controls the clutch operating mechanism and
the gear change in both operating modes.
The start of the gear change and the gear selection are different in the
two operating modes.
– In the manual operating mode, changing gears can only be done with
the gearshift lever or the two-stop rocker; there is no automatic swit-
ching.
– In the automatic operating mode, the gear change and the gear selecti-
on is done using the electronic gear system.

Gearshift lever
This is used to switch gears and is sometimes also used to actuate the Ge-
ars function button. The function depends on whether the truck crane is mo-
ving or standing still.

When standing still, the gearshift lever is used to select the direction of
travel and the starting gear and is always used in combination with the
Gear function button.

Driving forwards: gearshift lever towards the front once

Driving backwards: gearshift lever towards the rear once
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Depending on the operating mode, a different starting gear will be selec-

ted and shown in the Gear display.

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Operating Instructions GMK 5100 2 084 575 en 4 - 23
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

During driving, the gearshift lever is used for upshifting or downshifting.

The function is independent on the operating mode.

Upshifting: gearshift lever towards the front once

Downshifting: gearshift lever towards the rear once
If the gearshift lever is actuated alone, the gear selection (further swit-
ching 1 gear or 1/2 gear) is done by the electronic gear system.
If the gearshift lever is used in combination with the Gear function button,
the gear will be changed by one gear directly.

The newly engaged gear will be shown in the Gear display.

Gear function button

This is used to change the function of the gearshift lever.
When standing still, the functional change for selecting the direction of
travel is needed.
While driving, the function change for the gear selection by the operator
is needed (direct further shifting by one gear).

The function is independent of the operating mode of the gears.

Changing the 1. Press Gear function button.

gearshift lever’s 2. In addition
function:

Two-stop rocker
While standing still, this is used to change the starting gear in 1/2 gear
steps. During driving, it is used to switch the gear in 1/2 gear steps.

The function is independent of the operating mode of the gears.

Upshifting 1/2 a gear: pull the two-stop rocker upwards once

Downshifting 1/2 a gear: push the two-stop rocker downwards once
The newly engaged gear will be shown in the Gear display.

Gear emergency switch

This is to switch the gear when the electronic gear system is no longer lin-
ked to the gears. The gear emergency switch is activated automatically
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and it can be used with in combination with the clutch emergency pedal
to do limited gear shifting (N, R, 2, 5). This is sometimes also possible du-
ring driving; ➠ Carrying out emergency shifts, p. 7-39.

4 - 24 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Unlocking the clutch emergency pedal

C Lights when the electronic gear system can no longer automatically clutch
because of a malfunction. If the indicator lamp , gear changes can only
be done with the help of the clutch emergency pedal; ➠ Driving with the
clutch emergency pedal, p. 7-37
This goes out when the malfunction has been corrected.

Engage brake indicator lamp

A Lights if is not possible to downshift to a lower gear because the RPM is
too high or if the speed exceeds 90 km/h (e. g. when driving downhill). A
warning buzzer sounds simultaneously.
This lamp prompts the driver to use the brakes so that the gear can be
downshifted or the speed can drop below 56mph.
The indicator lamp goes out and the warning buzzer stops sounding as
soon as a engine speed has been reached at which downshifting is possi-
ble and if the speed is under 56 mph. ➠ p. 6-30

Clutch overload warning lamp

B This lights when the permissible operating temperature for the clutch is
exceeded because of overloading during starting. A warning buzzer
sounds simultaneously.
When the warning lamp lights up, the starting procedure will be have to
be aborted. In order to prevent the clutch from overheating, it will be
automatically decoupled after a few seconds (motor will cut off or the
wheels will spin); ➠ p. 6-28
The warning lamp and the warning buzzer go out when the overload is no
longer present.

Axle drive The drive of the thirdaxle line / longitudinal differential locks and the trans-
verse differential locks can only be switched on when the key-operated
switch of the level adjustment system is pressed; ➠ p. 6-50.
Rocker switch for longitudinal differential locks / drive of 3rd axle line
c This switches on the longitudinal differential lock in the third and fourth
axle line. In the case of additional equipment with 10 x 8 x 10 drive, the
drive of the thirdaxle line is switched on as well as the drives of the 1st,
4th and 5th axle lines.
May only be activated when the vehicle is stationary or is moving at a
speed of no more than 2 mph.
To switch on: Press rocker switch down.
To switch off: Press rocker switch up.

➠ p. 6-46.
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Operating Instructions GMK 5100 2 084 575 en 4 - 25

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Indicator lamp for longitudinal differential locks / drive of 3rd axle line
c To check the switch states:
– longitudinal differential lock on/off in the third axle line,
– longitudinal differential lock on/off in the fourth axle line
– Drive of 3rd axle line on/off (only with 10 x 8 x 10 additional equipment).
Illuminates when one of the three numbered switch states is mechanically
switched on.
Goes out when all three of the numbered switch states are mechanically
switched off (if present).
➠ p. 6-46.

Transverse differential lock in all driven axle lines rocker switch

h Locks the transverse differentials in all driven axle lines.
May only be activated when the vehicle is stationary or is moving at a
speed of no more than 2 mph.
To switch on: Press rocker switch down.
To switch off: Press rocker switch up; ➠ p. 6-48.

Indicator lamp for transverse differential lock in all driven axle lines
h Illuminates if all transverse differential locks have been switched on.
Flashes if all transverse differential locks have not be switched on or off.
Goes out if all transverse differential locks have been switched off;
➠ p. 6-48.

Brakes
Status display for supply pressure brake circuits I and II
4 5
6
3 7 The operating pressure is approx. 116 psi.
2 8

1 9
The pressure in both brake circuits must be over 80 psi for driving mode;
0 bar 10 ➠ p. 6-32.
C0005

Warning lamp for supply pressure brake circuits I and II

l Goes out if the supply pressure in both brake circuits is over 80 psi.
Illuminates if the supply pressure decreases to less than approx. 73 psi;
➠ p. 6-32.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Parking brake lever

Release parking brake: Lift the locking ring on the parking brake lever and
push the parking brake lever forward as far as it will go.
Locking the parking brake: Pull the parking brake lever back until it locks
into place.
C0027
Operation as an auxiliary brake: The braking force can be continuously
regulated with the parking brake lever. The allows the parking brake to be
also used as an auxiliary brake.

Test position when driving with a trailer:

The parking brake lever can also be pressed in and pulled back into the
Test position of the parking brake when towing a trailer; ➠ p. 6-77.

Indicator lamp for vehicle parking brake

f Goes out if parking brake is released.

ABS 1 warning lamp

x Lights after the ignition is switched on and goes out when a driving speed
exceeding about 4 mph has been reached; ➠ p. 6-32.
Lights if a malfunction has occurred during driving in a ABS unit for the
2nd/3rd axle line.

ABS 2 warning lamp

x Lights after the ignition is switched on and goes out when a driving speed
exceeding about 4 mph has been reached; ➠ p. 6-32.
Lights if a malfunction has occurred during driving in a ABS unit for the
1st/4th/5th axle line.

ABS warning light for trailer (additional equipment)

y Goes out when driving speed exceeds about 4 mph. Lights if a malfuncti-
on occurs in the ABS unit in the trailer; ➠ p. 6-29.

Operating instrument on the Right multipurpose switch

The multipurpose switch functions are divided into different types (mo-
tor/brake) and are therefore described in their own section;
➠ On the steering column - retarder/eddy current retarder, p. 4-40.

Indicator lamp for eddy current retarder (additional equipment)

ê Goes on if the eddy current retardar is on; ➠ p. 6-38.
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Operating Instructions GMK 5100 2 084 575 en 4 - 27
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Suspension
Rocker switch for suspension locking system
u Locks all suspension cylinders in the respective position;
➠ p. 6-9,
➠ Preparing the outriggers, p. 13-19.
To switch on: Press rocker switch down.
To switch off: Press rocker switch up.

Indicator lamp for suspension locking system

u Illuminates if the suspension is locked.
Goes out if suspension locking system is released;
➠ p. 6-9.
Suspension operating pressure status display (additional equipment)

Displays the operating pressure on the indivi-

dual axle lines in the suspension groups.

1 Suspension operating pressure 1st

right axle line
2 Suspension operating pressure 2nd
and 5rd right axle lines
3 Suspension operating pressure 4th
and 5rd right axle lines
4 Suspension operating pressure 1st left
axle line
5 Suspension operating pressure 2nd
and 3rd left axle lines
6 Suspension operating pressure 4th
and 5th left axle lines

Hydraulics

Status display for hydraulic system oil temperature

The hydraulic oil temperature should not exceed 176 °F in normal driving
mode; ➠ p. 6-35.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Indicator lamp for hydraulic oil return flow filter

g Illuminates if both the filters are dirty.
Change the filter elements ➠ Maintenance Manual.

Steering Separate steering; ➠ p. 6-55.

Steering circuit warning light I
d Illuminates if the oil pressure in steering circuit I decreases while driving.
Does not go out until the truck crane is travelling at a speed of approx.
6 mph; ➠ p. 6-33.

Warning lamp for steering circuit II

e Illuminates if the oil pressure in steering circuit II decreases while driving;
➠ p. 6-33.
Separate steering rocker switch with lock button
b Is only active when the key-operated switch Level adjustment system is
pressed. By pressing the switch, the separate steering is switched on and
off. When the separate steering is switched on, the steering of the 4th axle
line is unlocked. When the separate steering is switched off, the 4th axle
line is locked in the straight position.

Switch on separate steering: Release rocker switch and press

down

Switch off separate steering: Release rocker switch and press up

➠ Switching on separate steering, p. 6-42.

Steering unlocked warning lamp
? Illuminates as soon as the steering of the 4th axle line is released.
➠ p. 6-42.
Separate steering rocker switch
b Controls the wheels of the fifth and sixth axle lines
Turn to the left: Push control lever to the left.
Turn to the right: Push control lever to the right.

➠ p. 6-43
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Operating Instructions GMK 5100 2 084 575 en 4 - 29
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Electrical
system
Ignition lock

➠ On the steering column - ignition lock, p. 4-38.

Warning lamp for charge indicator
q Lights if the ignition is switched on and the vehicle engine is switched off.
Goes out after the vehicle engine is started; ➠ p. 5-9; ➠ p. 5-12.

Rocker switch for parking light / headlight

! Turn off light: press rocker switch up
Parking light: Rocker switch in middle position
Headlight: press rocker switch down.
The headlight is switched from low-beam to high-beam by means of the
Multipurpose switch on the left. ➠ p. 4-40.
The instrument lighting is switched on with the parking light / headlight.

Rocker switch with fog lamp and tail light indicator lamp (additional
æ equipment)
The rear fog light and the fog lamps may only be switched on with low-
beam headlight.
Switch fog lamp / rear light off: Press rocker switch up:
Switch fog lamp on: Rocker switch in middle position
Switch fog lamp / tail light on: Press rocker switch down
The indicator lamp in the rocker switch lights when the rear fog light is
switched on.

Rocker switch with hazard warning system indicator lamp

k Switching on: press rocker switch down.
The indicator lamp in the rocker switch flashes.
Switching off: press rocker switch up:
Rocker switch with indicator lamp for rotating warning beacon
r Switching on: press rocker switch down.
The indicator lamp in the rocker switch lights.
Switching off: press rocker switch up.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Operating instrument on the Multipurpose switch, left

The multipurpose switch functions are divided into different types
(motor/brake) and are therefore described in their own section;
➠ On the steering column - multipurpose switch, left, p. 4-40.

Driving direction indicator lamp

i
Indicator lamp for driving direction for trailer (additional equipment).
j
@ Indicator lamp for full-beam headlight
This lights when high-beam headlight is switched on.

Rocker switch with indicator lamp for wing-mirror heating

s Switching on: press rocker switch down.
The indicator lamp in the rocker switch lights.
Switching off: press rocker switch up.

Level adjustment ➠ Level adjustment system, p. 6-49;

Key switch for level adjustment system
To switch on: Insert key into the switch. Turn the key to the right, push
in the lock cylinder and turn the key to the left. The key
cannot be pulled out.
To switch off: Turn key to right. The resiliency causes the lock cylinder
C0018 to go back to its original position. Pull out the key.
The following functions may only be used when the key switch for the
level adjustment system is activated:
– Carrier level adjustment system
– Transverse differential locks
– Drive of 3rd axle line / longitudinal differential locks
– Separate steerings
The driving speed is limited to 12 mph when the level adjustment system
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is switched on.

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Operating Instructions GMK 5100 2 084 575 en 4 - 31
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Rocker switch for raising / lowering vehicle level

: To preselect the vertical direction of movement for the Level adjustment left /
forward / backward / right rocker switch
Raising the vehicle level: Press rocker switch up.
Lowering the vehicle level: Press rocker switch down.

Indicator lamp for raising vehicle level

8 Illuminates if the Raise / lower vehicle level rocker switch has been pressed
up.

Indicator lamp for lowering vehicle level

9 Illuminates if the Raise / lower vehicle level rocker switch has been pressed
down.

Rocker switch for left / forward / backward / right level adjustment

6897 Raises or lowers the truck crane to the left, forward, backward or to the
right (depending on the position of the Raise / lower vehicle level rocker
switch).

Indicator lamp for no on-the-road level

{ Illuminates when the truck crane Level adjustment key switch is not at
on-the-road level.

Rocker switch for on-the-road level

{ To switch on: Press rocker switch down, until on-the-road level is
reached.
The No on-the-road level indicator lamp goes out when the truck crane has
reached the on-the-road level.

Rocker switch for raising / lowering truck crane

| Raising the truck crane: Press rocker switch up.
Lowering the truck crane: Press rocker switch down.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Speed indicator Speed indicator

This shows the current driving speed in km/h (outer scale) and in mph
(inner scale).

Speed indicator display

The display is only active when the ignition is switched on.
The total distanced travelled is shown in the lop line. The last line shows
the 100m distances.
In the lower line, either the day’s kilometre count or the time can be
shown. The time is kept by the tachograph.
The display in the lower line is switched over using the Display time/day’s
kilometres push-button.

Time/day’s kilometres display push-button

The push-button has two functions:

– switching the display in the Speed indicator display between time and
day’s kilometre counter
– resetting the day’s kilometre counter to zero

Switching over the dis- Depress the push-button briefly and let it go
play: again.
The display switched between time and day’s
kilometres.

Resetting the day’s kilo- 1. switch the display to day’s kilometres.

metres to zero: 2. Depress the push-button for longer than
two seconds.
The day’s kilometres display will be set to zero.
Tachograph malfunction warning lamp
Lights when a malfunction is recognised in the speed indicator/tacho-
graph system.

At the same time, an error code will be displayed on the tachograph dis-
play; ➠ Tachograph malfunctions, p. 7-33.

Tachograph Operating the tachograph; ➠ Tachograph, p. 6-20;

The following operating instruments will not be in more detail in the abo-
ve-mentioned section.

Time setting menu key

G
11.05.2000

This is used to call up the menu for setting the time;

➠ Operating manual or the tachograph manufacturer.

s
Operating Instructions GMK 5100 2 084 575 en 4 - 33
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Setting minutes + key

H To set the time forward by a maximum of two minutes;
➠ Operating manual or the tachograph manufacturer.
Setting minutes - key
I To set the time back by a maximum of two minutes;
➠ Operating manual or the tachograph manufacturer. Extensive correction of
the time setting can only be carried out by the tachograph manufacturer.

Driver’s cab Heating system regulation ➠ p. 6-59

heating system
1 Regulator for heating temperature
up: cold
down: warm
2 Regulator for recirculated air / fresh air
mode
up: fresh air mode
down: recirculated air mode
3 Regulator for air distribution on the
driver’s side
up: windscreen vents and air vent on the
instrument panel
down: cab floor
4 Regulator for air distribution on the
passenger’s side
up: windscreen vents and air vent on the
instrument panel
down: cab floor
5 Knob Passenger side heater fan
off: until it stops to the left
on: to the right, rests at three positions
6 Knob Driver’s side heater fan
off: until it stops to the left
on: to the right, rests at three positions
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Air vent with air flow regulator

1 Adjustable ventilation louvre
1 2 2 Air flow regulator

➠ p. 6-60
C0009

Roof ventilator rocker switch (additional equipment)

~ Remove air: Press rocker switch up
Off: Rocker switch in mid-position
Air in: Press rocker switch down;
➠ p. 6-61

Roof fan handwheel (additional equipment)

Closing the roof ventilator: Turn handwheel to the left
Opening roof ventilator: Turn handwheel to the right;
➠ p. 6-61

Rocker switch with indicator lamp for additional heating system

0 (additional equipment)
To switch on: Press rocker switch down.
The indicator lamp in the rocker switch only indicates that
the switch has been activated. It does not indicate
whether the heating system ignited.
To switch off: Press rocker switch up.
The indicator lamp in the rocker switch goes out;
➠ p. 6-62

Indicator lamp for additional heating system (additional equipment)

0 Illuminates when the heating system has ignited; ➠ p. 6-62.
11.05.2000

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Operating Instructions GMK 5100 2 084 575 en 4 - 35
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Additional heat- Operating the additional heating system with timer; ➠ p. 6-64.
ing system with
timer (additional
equipment)
The operating instruments in the following section are in the plug-in mo-
dule of the additional heating system with the timer and are only present
with additional equipment.

Heating system display

Serves as a display for the time and selected storage places for the auto-
matic heating start and for the input of times.

Time display / set

w This is used to activate and set the current time.
To set, also push the Forward or Reverse push-button.

Reservoir 1 push-button
M This is used to display and to switch an automatic heating start on and off
for reservoir 1.

Reservoir 2 push-button
N This is used to display and to switch an automatic heating start on and off
for reservoir 2.

Switching heating on/off push-button

L For switching the heating on and off manually.

Return push-button
J To enter the time for the automatic heating start and to set the current
time (in combination with the Display/set time push-button).

Flow push-button
K To enter the time for the automatic heating start and to set the current
time (in combination with the Display/set time push-button).
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Heating system indicator lamp switched on

This lights when the additional heating system is switched on.
It goes out when the additional heating system has been switched off.

Automatic heating start indicator lamp

This lights when an automatic heating start has been activated.
It goes out when the automatic heating start been switched off.

Other operating
instruments

Boom not set down warning lamp (additional equipment)

3 This lights when the ignition in the driver’s cab is on if the boom is not in
the boom support.
A warning buzzer sounds simultaneously. The warning lamp and buzzer
indicated that the vehicle height given in the driver’s cab is exceeded at
on-the-road level; ➠ p. 6-11
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Operating Instructions GMK 5100 2 084 575 en 4 - 37

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

4.2.2 On the steering column

Ignition lock ➠ Vehicle engine, p. 5-9

0 Ignition off, vehicle engine off, key can be removed
1 Power supply on for:
heating system, vehicle engine/transmission diagnostics,
radio/telephone (additional equipment)
2 Ignition on
3 Starting position

Right multipurpo- For carrying out the functions:

se switch
– setting the idling speed
– setting the tempomat
– setting the temposet
– switching on the retarder / eddy current retarder
Different functions are carried out with the same actuation of the multi-
purpose switch. Which function is active depends on whether the vehicle
is standing, moving or whether the retarder is switched on.

setting the idling speed

This multipurpose switch function is only
active when the vehicle is standing;
1 (upwards): increasing the idling speed
2 (downwards): decreasing the idling speed
3 (forwards) switching off the engine
push: speed adjustment
Pushing in direction 1 or 2 will produce an
engine speed change of 20 RPM.
Holding the switch down will produce conti-
nual changes in engine speed changes;;
➠ Adjusting the idling speed, p. 5-12.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Tempomat
This multipurpose switch function is only active when the vehicle is
moving at least 10 mph; ➠ Tempomat, p. 6-40.
Activating push once in direction
the tempomat: (1) or (2).
After switching on the tempomat, the current
speed will be saved and kept as the set value.

1 (upwards): increasing the set value

2 (downwards): decreasing the set value
3 (forwards) switch off tempomat
push:

Pushing in direction 1 or 2 will increase the

set value by 0.3 mph. Holding the switch
down will produce continual changes;

Temposet
This is used to limit the maximum speed after 10 mph;
➠ Temposet, p. 6-42.
4 Press Temposet on Temposet is
button once: switched on, and the
current speed is set
as the upper limit.

3 (forwards) Temposet is
push: switched off
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Operating Instructions GMK 5100 2 084 575 en 4 - 39
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Retarder / eddy current retarder (additional equipment)

➠ Retarder / eddy current retarder, p. 6-33.

Direction of switching 5.1 to 5.4 = to the rear

5.0 switched off (home position

5.1 retarder, step 1,
eddy current retarder , step 1
5.2 retarder, step 2,
eddy current retarder, step 2
5.3 retarder, step 3,
eddy current retarder, step 3
5.4 retarder, step 4,
eddy current retarder, step 4
The control steps 5.2 to 5.4 are not available
with all truck cranes which are delivered wi-
thout an eddy current retarder.

The Eddy current retarder indicator lamp lights if the retarder is switched on.
ê
Multipurpose
switch, left

1 signal horn
2 headlight flasher
3 low-beam headlight
4 high-beam headlight
5 driving direction indicator
6 driving direction indicator
7 windscreen washer
8 windscreen wiper
0 = off,
I = interval,
II = slow,
III = fast
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

4.2.3 Above the front windshield

Air conditioning The air-conditioning system is located on the roof of the driver’s cab.
system (additio- There are two different designs which are distinguished by the location of
nal equipment) the operating instruments. The function of the operating instruments is
the same with both versions; ➠ p. 6-68.

Version A
1
1 Air exit vents
2 Knob switch for fan
3 Knob switch for thermostat
4 Air exit vents, adjustable for air quantity
2 and direction

4
C0720

Version B
1 Air exit vents
2 Knob switch for thermostat
3 Knob switch for fan
4 Air exit vents
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Operating Instructions GMK 5100 2 084 575 en 4 - 41

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Fan knob
0 Fan and air-conditioning system off
1 Low output level
2 Medium output level
3 High output level

Knob switch for thermostat

Turning the knob switch to the right increases the cooling output.

Cab lighting Cab lighting is fitted on the driver’s and passenger’s side of the driver’s cab.

1 Cab light
2 Switch for cab light pressed in forward:
on by door contact
central position: off
pressed in rearward: on
3 Switch for reading lamp
4 Reading lamp

4
3
2
1

C0721
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

4.2.4 Other operating instruments in the vehicle section

Keys, doors, The following keys belong to the truck crane carrier:
windows

1 Door locks of the driver’s cab

2 Driver’s cab ignition lock
3 Key-operated switch for level adjustment
system
4 Carrier guards

The locks on the doors of the driver’s cab

may be locked from the outside using the
door key (1).

Open lock: Turn key to right.

Close lock: Turn key to left.
Open door: Press button (2).
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Operating Instructions GMK 5100 2 084 575 en 4 - 43
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

When the doors are closed, they can be locked from the inside with the
knob.

Open lock: Push button (3) up.

Close lock: Press button (3) down.
Open door: Pull (2) lever.
The sliding windows in the door may be
opened from the inside using release lever
(1) or (4).

The sliding window on the right-hand side

of the driver’s cab may also be opened using
release levers.

Access ladders Ladders and steps are fixed to the truck crane for access to the carrier.

One ladder is located on each of the both

sides between the 3rd and 4th axle lines (1).

There are two hand holes (2) above each

fixed ladder. In addition, there is a hand grip
(3) below the crane cab on the left side.

A further grip is on the right side, up on the

storage box. 11.05.2000

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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Ladders As well as the fixed access ladders you will find the following on the truck
crane:
– an extendable ladder and
– two ladders for attachment.

The extendable ladder can be transported in

a foldable holder at the front underneath the
truck crane.

At the rear of the carrier, there is a hook-on

ladder (1) on the right and on the left. The
hook-on ladders are secured on the carrier in
the holders (2).

The ladders can be attached to the bore ho-

les (3) and (4) on the right side if the carrier.

• Attach the ladder so that the plugs go as

far as possible in the bores.
• Fold out the spreader at the bottom of the
ladder so that you have a safe stopper on
the sheet metal panel or the tyres.

G
Danger from ladder falling down!
Secure the ladder in the appropriate holder after each use. In this way,
you prevent the ladder from falling down during on-road driving which
could endanger vehicles behind you or people standing at the side of the
road.
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Operating Instructions GMK 5100 2 084 575 en 4 - 45
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Diagnostics plug The diagnostics plug enables the Mercedes-Benz service to connect mea-
vehicle engine / suring devices and may only be used by service personnel.
transmission
The diagnostic plug (1) is located on the
right next to the fuses and behind the cover.

Bonnet The bonnet is equipped with two locks. For the sake of safety, one of the
two locks can only be released from the driver’s cab.

Opening the bonnet

• To release the bonnet (4), pull the Bonnet-
release lever (1) in the driver’s cab.
• Press the locking lever (5) to the right and
fold the bonnet upwards.
• Fold the support (3) upward and secure it
to the retaining sheet (2).
Closing the bonnet
• Lift the bonnet up a bit, pull the support
out of the retaining sheet and fold the
bonnet down.
• Press the bonnet against the driver’s cab
until it audibly engages.
• Check whether the bonnet is securely
engaged.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Fire extinguisher The fire extinguisher (additional equipment) is on the cab floor between
(additional the driver and passenger seat.
equipment)
• Follow the instructions for use on the fire extinguisher.
• Have the fire extinguisher serviced in good time by trained personnel
before the service interval given on the label expires.
Proper functioning of the fire extinguisher is no longer guaranteed once
the service interval given on the label has expired.

Folding bunk The folding bunk is located in the driver’s cab on the rear wall.
(additional To fold out the folding bunk you must tilt the back rest of the passenger
equipment) seat (if necessary also the middle seat) completely forward.

Folding down folding bunk

• Release the locking device by pulling on
the loop (2) and fold the bunk (3) down-
wards.
• Fasten the two securing belts into the
brackets (4) on the cab roof.
Folding away folding bunk
• Remove the two securing belts from the
brackets (4) and lay the belts on the
folding bunk.
• Fold away the folding bunk and push it
into the rear wall of the cab so that the
securing pin audibly engages behind the
mounting bracket (1).

G
Risk of accident due to bunk folding down!
Always check after folding away that the bunk sits firmly in the locking
devide and put the back rest of the passenger seat back into the upright
position. By doing this you avoid the folding bunk folding down when
braking or when emergencies provoke uncontrolled manoeuvres.

Fold away the bunk before each journey!

When the bunk is folded down, the operating instruments on the side
instrument panel which are needed for driving are hidden.
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Operating Instructions GMK 5100 2 084 575 en 4 - 47

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

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4 - 48 2 084 575 en Operating Instructions GMK 5100

 Vehicle engine
5.1 Starting / turning off vehicle engine

5 Vehicle engine

5.1 Starting / turning off vehicle engine

5.1.1 CHECKLIST: Starting vehicle engine

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Check the oil level in the vehicle engine; ➠ p. 5-4.

C0846

2 Check the coolant level of the vehicle engine; ➠ p. 5-6.

3. Check oil level in the hydraulic system; ➠ Checking hydraulic oil level,
p. 5-7.

5. Check the position of the stop cocks in the hydraulic system;

➠ Checking stop cocks in the hydraulic system, p. 5-8.
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Operating Instructions GMK 5100 2 084 575 en 5-1

Vehicle engine
5.1 Starting / turning off vehicle engine

5. Switch on the battery master switch; ➠ p. 5-7.

6. Check whether the parking brake is locked (parking brake lever points
toward the rear).

C0027

7. Turn on ignition and check instruments; ➠ p. 5-9.

8. shift the transmission to neutral position N; ➠ Shift the transmission to

neutral position p. 6-26.

9. Wait until the indicator lamp flame start system (additional equipment)
z goes out, then start the vehicle engine;
➠ Starting the vehicle engine,p. 5-10.
10. Check instruments when the vehicle engine is running;
➠ Checking the instruments, p. 5-12.

11. Also observe the In the winter check-list when the temperatures are
low; ➠ p. 5-3.
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5-2 2 084 575 en Operating Instructions GMK 5100

 Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.2 CHECKLIST: In winter

The following additional points must be observed when using the truck
crane in winter:

1. Fuel and engine oil must comply with the specifications given in the
supplied vehicle engine manufacturer’s operating manual for the
respective external temperatures.

2. The engine coolant must contain sufficient antifreeze (see supplied

vehicle engine manufacturer’s operating manual).

3. The vehicle engine can be pre-warmed by the engine-independent

additional water heating system. ➠ Additional water heating system,
p. 6-62.
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Operating Instructions GMK 5100 2 084 575 en 5-3

Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.3 Checks before starting up vehicle engine

Checking engine Check the oil level in the vehicle engine daily before commencing work.
oil level The truck crane must be on a horizontal surface when the oil is checked.

The dipstick (1) for the vehicle engine is on

the left side of the carrier (looking in the
direction of travel) behind the driver’s cab.

Prior to main check

• Check whether the oil level on the dipstick

is up to the max mark (arrow marking).
• If necessary, fill the motor oil up to the
max mark.

Check

• Start the vehicle engine and let it run in idling speed. Observe the oil
pressure display.
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 Vehicle engine
5.1 Starting / turning off vehicle engine

S
Damage may occur to the engine if the oil level is too low!
If no oil pressure is shown after 10 seconds, turn off the motor and
determine the cause; ➠ Malfunctions of the vehicle engine, p. 7-25.

• Switch off the vehicle engine after about

one minute.
• After about five minutes, check whether
the oil level on the dipstick is at the max
mark (arrow marking).
• If necessary, fill the motor oil up to the
max mark.

Topping up Data concerning the prescribed oil specification may be found in the
motor oil operating manual for the vehicle engine.

The oil filler-neck (1) for the vehicle engine is

on the left side of the carrier (looking in the
direction of travel) behind the driver’s cab,
next to the
dipstick.

• Refill the motor oil over the fillplug (1).

S
Damage may occur to the engine if the oil level is too high!
Do not fill with too much engine oil; the oil level must not be higher than
11.05.2000

the highest arrow marking (max).

Operating Instructions GMK 5100 2 084 575 en 5-5

Vehicle engine
5.1 Starting / turning off vehicle engine

Checking the The coolant reservoir is located on the left-hand side of the carrier behind
coolant level the driver’s cab.

G
Risk of burning when vehicle engine is hot!
The hot cooler is pressurised. Be careful to avoid burns from the hot
cooler, with escaping steam or any escaping coolant if you remove the lid
of the cooler when the vehicle engine is hot.
Wear suitable protective gloves and cover the lid of the cooler with a
cloth before opening it.
Turn the cooler lid slowly to the first notch in order to allow the excess
pressure to be released.

Do not open the pressure relief valve (2) on

the side of the compensation container.

• Loosen (do not open!) the cap on the fil-

ling hole (1) with the coolant at operating
temperature to release the pressure.
• Open the cap.
The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:
Top up coolant.
See the vehicle engine operating instructions
for the composition of the coolant.
• Screw on the filling hole cap until it
reaches its end position.

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 Vehicle engine
5.1 Starting / turning off vehicle engine

Switching on the
battery master
switch

The battery master switch (1) is located on

the right-hand side of the vehicle behind the
driver’s cab and is accessible through an
opening in the side plate.

• Switch on the battery master switch.

The battery master switch is activated when
the selector handle is pointing forwards and
cannot be removed.

Checking hydrau- Check the level of the hydraulic oil tank daily before commencing work.
lic oil level

This requires that:

– the truck crane be horizontally aligned,
– the support is retracted,
– the truck crane is at on-the-road level.

• Check the level of the hydraulic oil tank

through the inspection glass (1). The hy-
draulic oil should be visible in the centre
of the inspection glass when cold.
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Operating Instructions GMK 5100 2 084 575 en 5-7
Vehicle engine
5.1 Starting / turning off vehicle engine

Checking the The four stop cocks in the hydraulic system suction lines must be open
hydraulic system before the vehicle engine is started.
stop cocks

S
Damage may occur to the hydraulic pumps!
The vehicle engine may only be started if the four stop cocks in the
suction lines of the hydraulic pumps are open!
The stop cocks are open when the handles are parallel to the suction lines.

The shutoff taps are located the on the left

side of the vehicle, to the right of the hydrau-
lic oil tank.
• Check whether the shutoff taps (1) are
open.

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 Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.4 Starting vehicle engine

Activating the
ignition
• Switch on the ignition. Insert the ignition key into the ignition lock as far
as it will go and turn the key to position 2.
By internal checking in the electronic gear system, the service symbol (the
wrench) might be briefly displayed on the Gearbox control display after tur-
ning on the ignition. If the display does not go out, turn the ignition off
and on again.

S
When starting the ignition or the vehicle engine, indicator lamps which
serve as warning lamps for functions that fail during operation are tested.
Replace any defective lamps immediately!

The following indicator and warning lamps must illuminate:

Vehicle engine oil pressure
L Charge indicator lamp
q Vehicle parking brake
f Steering circuit I and steering circuit II
de ABS 1, ABS 2
xx The indicator lamp flame start system (additional equipment) (additional equip-
z ment) lights up. The temperature of the vehicle engine determines when
the lamp will go out; ➠ Starting cold vehicleengine, p. 5-10.
If the supply pressure in the brake circuits decreases to below 73 psi, the
l Supply pressure brake circuits I and II warning lamp will also illuminate.

If the Suspension locking system indicator lamp lights although the

u Suspension locking system rocker switch is pressed up (switched off), then
the air pressure in the secondary consumer circuit is too low. ➠ p. 6-9.

H
The Suspension locking system indicator lamp does not show the switching
state of the Suspension locking system rocker switch, but rather the actual
status of the suspension locking system. For this reason, check the
position of the Suspension locking system rocker switch before starting the
vehicle engine, ➠ p.6-9.
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Motor electronics
à
s
Operating Instructions GMK 5100 2 084 575 en 5-9
Vehicle engine
5.1 Starting / turning off vehicle engine

Starting the Refer to the enclosed vehicle engine manufacturer’s operating manual for
vehicle engine vehicle engine operation.

• Check whether the vehicle parking brake is locked.

If the brake is locked, the parking brake lever will point to the rear.

C0027

• Move the transmission to the neutral position N; ➠ Shift the transmission

to neutral position, p. 6-26.
The vehicle engine can be started only in this position.

Starting the vehicle engine in low temperatures can be made easier by

preheating the coolant using the additional water heating system (additio-
nal equipment); ➠ Additional water heating system, p. 6-62.

Starting a cold vehicle engine with additional equipment with flame start
system
The vehicle engine with additional equipment has a thermostat-controlled
flame start system. If the temperature of the coolant is low, the flame start
system heats the suction air of the vehicle engine by burning fuel in the
suction line.

S
Danger of explosions when using starter fuel!
The vehicle engine may never be started with the aid of starter feul (e.g.,
starter spray). Any starter fuel sprayed into the suction unit may ignite on
the flame start system.

The flame start system is activated each time the ignition is switched on.
z The vehicle engine will be ready to run in up to 20 seconds depending on
the temperature of the coolant. The engine is ready when the Flame start
system indicator lamp goes off. The vehicle engine should be started

H
within the next 30 seconds.

If the flame-start device indicator lamp does not go out after ca. 20 se-
conds, there is a malfunction of the flame-start device; ➠ Malfunctions
with the vehicle engine, p. 7-25.
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 Vehicle engine
5.1 Starting / turning off vehicle engine

H If the engine is cold and switched off but the ignition is switched on, you
must first switch off the ignition briefly and switch it back on again to
reactivate the flame start system before starting the engine.

• Check whether the flame start system indicator lamp illuminates.

z • Wait until the flame start system indicator lamp goes out.
• Leave the vehicle engine on, as with vehicles without a flame start

H
system.

You should not attempt to start the vehicle engine until after the Flame
start system indicator lamp has gone out. If you start the engine before the
lamp goes out and the temperature of the coolant is low, the vehicle engi-
ne will emit smoke for several minutes after start-up.

Starting a cold or warm vehicle engine without flame start system

• Do not press the accelerator.
• Turn the ignition key to position 3.
• Release the ignition key and the accelerator once the vehicle engine has
started running.
• Release the ignition key and the accelerator once the vehicle engine has
started running.
If the vehicle engine does not start, abort the starting procedure after
15 seconds and wait 1 minute before attempting to start the engine once
more.

Starting a warm vehicle engine

• Do not press the accelerator when starting a warm vehicle engine.

S
Danger of explosions when using starter fuel!
A warm vehicle engine must never be started using starter fuel (e.g. star-
ter spray). Any starter fuel sprayed into the suction unit may ignite on the
flame start system.

zH For additional equipment with flame start system, the indicator lamp for
the flame start system lights up shortly (2 to 3 seconds) even with a warm
vehicle engine after the ignition has been started. You do not need to wait
until the indicator lamp goes out.
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Operating Instructions GMK 5100 2 084 575 en 5 - 11
Vehicle engine
5.1 Starting / turning off vehicle engine

Setting the idling After starting the vehicle engine, the idling speed will be regulated
speed depending on the temperature of the coolant. If necessary, the idling
speed can be increased by up to about 200 RPM.

H
The idling speed is increased with the Right multipurpose switch.

This multipurpose switch function is only active when the vehicle is standing.

Increasing the idling speed:

(1) Push upwards once: The speed increases
by 20 RPM.
(1) Pull upwards and The engine speed
hold: continuously
increases.
Decreasing the idling speed:
(2) Press once down- The speed
wards: decreases by
20 RPM.
(2) Push down and The engine speed
hold: continuously
decreases.

Switch off engine speed change:

manually: push the multipurpose switch once forward (3).

automatically: start truck crane and accelerate to over 20 accelerate

12 mph.

5.1.5 Inspections after the engine has been started

Checking The following indicator and warning lamps must go out when the engine
instruments is running:
• Monitor the Vehicle engine oil pressure status display as soon as you have
L started the vehicle engine.
If the oil pressure does not increase after 10 seconds and the warning
light on the status display Vehicle engine oil pressure status display does not
go out, switch off the vehicle engine by turning the ignition key to
11.05.2000

position 0.

5 - 12 2 084 575 en Operating Instructions GMK 5100

 Vehicle engine
5.1 Starting / turning off vehicle engine

H
Charge indicator lamp
q
If the Charge indicator warning lamp does not light, the alternator will not
generate any charging current when the vehicle engine is running. Switch
the vehicle engine off and look for the cause; ➠ Malfunctions of the vehicle
engine, p. 7-25.

de
H
Steering circuit I and Steering circuit II

The warning lamp Steering circuit II goes out only when the truck crane is
moving at around 6 mph.

G
If one or both warning lights for steering circuit I or II do not go out, refer
to the notes in the section on observing control instruments when driving
➠ Vehicle engine malfunctions, p. 6-32.

Motor electronics
à If the motor electronics warning light does not go out when the crane engine
is running, there is a malfunction of the motor electronics. Switch off the ve-
hicle engine and inform GROVE Product Support or the vehicle engine ma-
nufacturer’s customer service.

Observe the following indicator lamps (also while driving):

Vehicle engine air filter

p Vehicle engine coolant level
t Hydraulic oil return flow filter
g Automatic gearbox oil filter
m ABS 1, ABS 2
xx Flame start system (additional equipment)
z If one of these indicator lamps lights up: Refer to ➠ Malfunctions on
carrier, p. 7-1.
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Operating Instructions GMK 5100 2 084 575 en 5 - 13

Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.6 Turning off the vehicle engine

G
Risk of accidents due to truck crane steering not functioning!
Only turn off the diesel engine when the truck crane is at a standstill.
When you remove the ignition key, the steering locks and you will loose
control of the truck crane if it is moving.

If the temperature of the coolant is still very high (e.g. after driving over
a pass), let the diesel engine run for another one or two minutes at in-
creased idling speed.

• Turn the ignition key to position 0 and remove the ignition key.

H If you want to shut-down the truck crane, observe the additional steps
described in Turning off truck crane, p. 6-43.

In the case of an emergency or when the

vehicle engine does not turn off after the
ignition key has been turned to position 0,
it is also possible to shut-down the vehicle
engine outside the driver’s cab.

The battery master switch (1) is located on

the right-hand side of the vehicle behind the
driver’s cab and is accessible through an
opening in the side plate.

• Switch the battery master switch off to do

this. The battery master switch is off when
the selector handle cannot be removed.
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5 - 14 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.1 Checking the truck crane before driving

6 Driving the truck crane

6.1 Checking the truck crane before driving

6.1.1 CHECKLIST: Condition of the truck crane for on-road driving

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Carry out the required checks and tasks before starting the vehicle
engine; ➠ CHECKLIST: Starting vehicle engine, p. 5-1, Items 1-7.

2. Check the tyres; ➠ Checking the tyres, p. 6-12.

3. Check the fluid level of the windscreen washing system;

➠ Checking the windscreen washing system reservoir, p. 6-18.

4. Adjust the driver’s seat; ➠ Adjusting the driver’s seat, p. 6-18.

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Operating Instructions GMK 5100 2 084 575 en 6-1
Driving the truck crane
6.1 Checking the truck crane before driving

5. Adjust the steering column; ➠ Adjusting the steering column, p. 6-19.

6. Adjusting the mirror; ➠ Adjusting the mirrors, p. 6-19.

7. Put the diagram sheet in the tachograph; ➠ Tachograph, p. 6-20.

8. Start the vehicle engine and carry out all necessary inspections;
➠ CHECK LIST: Starting vehicle engine, p. 5-1, Items 8-12.

9. Check the electrical system; ➠ Functional test of the electrical system,

!DHk p. 6-9.

10. Check the suspension locking system. The Suspension locking system
u indicator lamp must not illuminate; ➠ Checking the suspension, p. 6-9.

11. Check the on-the-road level; ➠ Checking the on-the-road level, p. 6-10.
{
12. Check the transverse differential locks in all driven axle lines;
h ➠ Transverse differential locks in the axle lines, p. 6-10.
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6-2 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.1 Checking the truck crane before driving

13. Checking longitudinal differential locks / drive of 3rd axle line;

c ➠ Longitudinal differential locks / drive of 3rd axle line, p. 6-11.
14. Check the steering locks on the axle lines; ➠ Checking the steering locks,
b? p. 6-11.

15. Check the level of the fuel tank; ➠ Refuelling, p. 6-17.

C0013

16. Check the compressed air and brake systems; ➠ Checking the
5
4 6 compressed air and brake systems, p. 6-9.
3 7
2 8

1 9
0 bar 10

C0005

17. When the boom is resting on a trailer,

– The slewing gear freewheel is switched on and the fuse box is
inserted on the superstructure lock; ➠ Switching on slewing gear
– freewheel, p. 6-16.
– Boom floating position (additional equipment) is switched on;
– ➠ Switching on boom floating position, p. 6-13
– Boom pre-tensioning (additional equipment) is switched on;
– ➠ Switching on boom pre-tensioning, p. 6-14.
– The superstructure is not locked; ➠ Hydraulic superstructure lock,
– p. 12-9.

18. When the boom is resting on the boom support:

– The boom is placed on boom supports,
– all telescopic parts are locked to each other; the telescoping
– cylinder is locked in telescope section I,
– Superstructure is locked; ➠ Hydraulic superstructure lock, p. 12-9.

19. This point does not apply to crane cabs which can be inclined (additio-
nal equipment).
The electrical connection between the superstructure and the carrier
is established; ➠ Establishing electrical connection to the superstructure,
p. 6-24.
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Operating Instructions GMK 5100 2 084 575 en 6-3
Driving the truck crane
6.1 Checking the truck crane before driving

20. All four sliding beams are retracted and secured to prevent inadver-
tent extension;
Outrigger pads are retracted and secured; ➠ Putting the outrigger pad
in driving position, p. 13-29.

21. The warning plates for designation of the vehicle width are folded
down (only for 16.00 R25 or 20.50 R25 tyres (additional equipment);
➠ Warning plates for vehicle width, p. 6-24

22. The detachable equipment parts are stripped down so that they fulfill
the regulations in the country in which you are working.
Detachable equipment parts include:
– Counterweight sections, ➠ Counterweight, p. 13-41;
– Two-stage swing-away lattice extension/boom extension,
➠ Operating manual for the lattice extension,
– hook block, ➠ Picking up the hook blocks, p. 13-69;
– Spare wheel.

To find out which equipment parts you need to take off for a driving
mode with a max. axle load of 12 t (26 600 lbs) see Driving mode table,
p. 6-5.

23. All additional parts such as blocks or lifting gear are lashed securely.

Driving mode There are driving modes for a maximum of 10 t (22 050 lbs) axle load and
table driving modes for a maximal 12 t (26 600 lbs) axle load. This section con-
tains the respective tables for the different driving modes.

How to use the table:

Select the table with the desired axle load. The driving mode of your truck
crane depends on the equipment specified under A. Determine which dri-
ving mode applies to your truck crane.
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 Driving the truck crane
6.1 Checking the truck crane before driving

Example for use of the 10 t (22 050 lbs) axle load table with 14.00 R25 tyres:

Assume your truck crane is equipped with 14.00 tyres, 10 x 6 x 10 drive and
eddy current retarder. The driving mode under A is 2 or 4.

At B you will find the accessories that you may take along during on-road
driving with a maximum of 10 t axle load.
For driving mode 2, you may take the 32 t hook block or,
for driving mode 4, you may take the 20 t hook block and the 14.00 R25 spare

H
wheel at the rear.

Observe the effects on the axle loads when towing a trailer; ➠ p. 6-71.

Table for a maximum of 10 t (22 050 lbs) axle load with 14.00 R25 tyres

Equipment Driving mode

1 2 3 4 5 6 7 8 9

14.00 R25 tyres X X X X X X X X X

drive 10 x 6 x 10 X X X X X

drive 10 x 8 x 10 X X X X
A
eddy current retarder X X X X X

trailer coupling X X

auxiliary hoist or compen- X X X X X X X X X

sation weight mounted

14.00 spare wheel at rear ● ● ●

20 t hook block ● ● ● ●

32 t hook block ● ● ●

36 ft swing-away lattice
B extension folded at the side ●

swing-away lattice
extension not installed ● ● ● ● ● ● ● ●

counterweight not installed,

up to compensations ● ● ● ● ● ● ● ● ●
weight or auxiliary hoist
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Operating Instructions GMK 5100 2 084 575 en 6-5
Driving the truck crane
6.1 Checking the truck crane before driving

Table for a maximum of 10 t (22 050 lbs) axle load with 16.00 R25 tyres

Equipment Driving mode

1 2 3 4 5 6 7

16.00 R25 tyres X X X X X X X

drive 10 x 6 x 10 X X X

drive 10 x 8 x 10 X X X X
A
eddy current retarder X X

trailer coupling X X X X

auxiliary hoist or compen- X X X X X X X

sation weight mounted

16.00 spare wheel at the

● ● ●
rear

20 t hook block ● ●

two-stage swing-away
B
lattice extension folded on ● ● ● ● ● ● ●
the side

counterweight not installed,

up to compensation- ● ● ● ● ● ● ●
weight or auxiliary hoist

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 Driving the truck crane
6.1 Checking the truck crane before driving

Table for a maximum of 12 t (26 600 lbs) axle load with 14.00 R25 tyres

Equipment Driving mode

1 2 3 4 5

14.00 R25 tyres X X X X X

drive 10 x 6 x 10 X X X

drive 10 x 8 x 10 X X
A
eddy current retarder X X X X X

trailer coupling X X X

auxiliary hoist or compen- X X X X X

sation weight installed

14.00 spare wheel at the

● ●
rear

20 t hook block ● ● ●

two-stage swing-away
lattice extension folded at ● ● ● ● ●
B the side

3 t counterweight section
● ● ● ● ●
installed on the turntable

3 t base plate and

4 t counterweight section
on the counterweight ● ● ● ● ●
platform
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Operating Instructions GMK 5100 2 084 575 en 6-7
Driving the truck crane
6.1 Checking the truck crane before driving

Table for a maximum of 12 t (26 600 lbs) axle load with 16.00 R25 tyres

Equipment Driving mode

1 2 3 4 5 6

16.00 R25 tyres X X X X X X

drive 10 x 6 x 10 X X

drive 10 x 8 x 10 X X X X
A
eddy current retarder X X X X X

trailer coupling X X X

auxiliary hoist or compen- X X X X X X

sation weight installed

16.00 spare wheel at the

● ● ●
rear

20 t hook block ● ● ● ● ● ●

two-stage swing-away
lattice extension folded to ● ● ● ●
B the side

3 t counterweight section
● ● ● ● ● ●
installed on the turntable

3 t base plate and

4 t counterweight section
on the counterweight ● ● ● ● ● ●
platform

H Note that the maximum permissible vehicle width for the country in
which you are working with 20.50 tyres; ➠ Dimensions and weights, p. 8-8.
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 Driving the truck crane
6.1 Checking the truck crane before driving

6.1.2 Checks to be carried out before driving

Functional test of
the electrical
system • Check the function of
– the lighting and signalling devices,
– the stop lights,
– the hazard warning system,
k – the windscreen wipers,
D – the windscreen washing system.
H
Check the com- • Fill the compressed-air supply in neutral gear until it reaches a cut-out
pressed air and pressure of 8.1 bar (117.5 psi).
brake systems
• The Supply pressure brake circuits I and II warning lamp will not go out
l until the pressure in the tanks has reached 5.5 bar (80 psi) (Supply pressu-
re
brake circuits I and II status display).
You may not begin driving until the air pressure in brake circuit III is
f sufficient to release the parking brake. The releasing pressure is approx.
5.4 bar (79 psi). The Vehicle parking brake indicator lamp will not go out un-
til the wheel brakes have been released.

G
Accidents may occur due to the unchecked movement of the truck crane!
If the pressure is too low the parking brake will not be released, even if
the parking brake lever is in released position.
Use the service brake to maintain the truck crane when the parking brake
is released for a functional check!
Do not refill the compressed air unless the parking brake is locked!

Checking • Check whether the suspension locking system is switched off.

suspension
The Suspension locking system indicator lamp should illuminate when
u suspension is locked.
Press the Suspension locking system rocker switch upward when the
Suspension locking system indicator lamp illuminates.

If the air pressure in the secondary consumer circuit decreases below

u
11.05.2000

5bar (73 psi), the suspension is locked even if the suspension locking
system is switched off and the Suspension locking system indicator lamp
illuminates.

s
Operating Instructions GMK 5100 2 084 575 en 6-9
Driving the truck crane
6.1 Checking the truck crane before driving

S
Damage may occur to the axle lines!
The suspension must not be locked during on-road driving! The steering
behaviour may also change when the suspension is locked.

H
Check the on-the-
The suspension is always locked when the ignition is switched off.

road level
• Insert the key into the Level adjustment system key switch. Turn the key to
the right, push it in and turn it back to the left.

C0018

The Not on-the-road level indicator lamp must not illuminate during on-road
{ driving.
If the Not on-the-road-level indicator lamp does illuminate, you must move the

H
truck crane into On-the-road-level position; ➠ Level adjustment system, p. 6-52.

Leave the key-operated switch Level adjustment system on for further checks
of transverse differential locks and the drive of the third axle line (only
with 10 x 8 x 10 additional equipment).

Checking the
transverse diffe-
rential locks
All differential locks must be switched off. Check if the Transverse differen-
h tial locks in all driven axle lines indicator lamp has gone out.
Operation of the differential locks ➠ Transverse differential locks in the axle-
lines, p. 6-48
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 Driving the truck crane
6.1 Checking the truck crane before driving

Checking longitu- The drive of the 3rd axle line can only be switched on with additional
dinal differential equipment with 10 x 8 x 10 drive.
locks / drive of
3rd axle line
The longitudinal differential locks and the drive must be switched off.
c Check whether the Longitudinal differential locks / drive of 3rd axle line indica-
tor lamp has gone out.
Operation ➠ Longitudinal differential locks / Drive of the 3rd axle line, p. 6-46.
• Once you have checked the on-the-road level, the longitudinal and trans-
verse differential locks and the drive of the third axle line / longitudinal
differential locks, switch off the Level adjustment system key switch and
pull out the key.

C0018

Checking the Operating the separate steering ➠ Separate steering, p. 6-55.

steering locks

The Separate steering rocker switch must be pressed upward.

b The warning lamp (Steering unlocked) must not light up during on-road
? driving. If the warning lamp illuminates, the steering of the 4th axle line is
not locked.

G
Risk of accidents during on-road driving with unlocked steering!
The steering of the 4th axle line must be locked during on-road driving.

Monitoring war- The warning lamp Boom not set down is additional equipment. Currently, it
ning lamp Boom is only standard equipment for those cranes in use in Great Britain.
not set down
(additional equip-
ment)
The Boom not set down warning lamp shows that the boom is not set down
3 correctly in the boom support and thus the specified vehicle height is
exceeded at on-the-road level.
The vehicle height is specified on an adhesive label in the driver’s cab.
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Operating Instructions GMK 5100 2 084 575 en 6 - 11
Driving the truck crane
6.1 Checking the truck crane before driving

S
Risk of damage to the truck crane!
If the Boom not set down warning lamp is lit, the vehicle is higher than spe-
cified. If you drive under a bridge or through low headroom (tunnel), an
accident may occur which could cause damage to the truck crane, bridge
or tunnel.
Set the boom down correctly in the boom support and ensure that on-the-
road level is set.

• Check the on-the-road level. The No on-the-road level indicator lamp must
{ not be lit; ➠ p. 6-10.
• Check whether the Boom not set down warning lamp is out. If the warning
3 lamp is lit, the boom is not set correctly in the boom support. Thus the
vehicle height specified in the driver’s cab is exceeded.
• Lower the boom until it is correctly situated in the boom support.

Checking • Check the air pressure when the tyres are cold ➠ Air pressure of the tyres,
the tyres p. 8-11.

S
Risk of damage to the tyres!
The air pressure increases when the tyres become hot during driving.
Never let out the increased air pressure of tyres that are warm from
driving!

• Check the condition of the tyres including

tread depth (1) and possible damage.

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 Driving the truck crane
6.1 Checking the truck crane before driving

Switching on the Applies only during on-road driving with the boom on the rear bed, with-
boom floating out a counterweight on the turntable or the carrier (only with additional
position equipment).

If the boom is placed on the rear bed (trailer) during on-road driving, the
trailer and boom must be able to move up and down freely, e. g. when
driving over hills. To make this “floating” of the boom possible, the pi-
ston rod side of the derricking cylinder must be hydraulically connected
with the piston head side by switching a valve.
• Support the truck crane with an outrigger span of at least 25.6 ft x
16.7 ft and enter the corresponding SLI code.
• Fully retract the main boom.
• Raise the main boom to an angle permitted within the working range.
Turn the superstructure to the 0° position to the rear and place the main
boom on a trailer.

• Remove the lever lock (padlock 1) on the

changeover valve (2).

G
Risk of accidents if the main boom falls down!
The changeover valve may be operated only when the boom has been
placed onto the trailer. Otherwise, the boom will fall down.
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Operating Instructions GMK 5100 2 084 575 en 6 - 13
Driving the truck crane
6.1 Checking the truck crane before driving

• Turn the hand lever (1) so that it is point-

ing vertically upwards.
Boom floating position is now switched on.

Switch on boom (Only applies to on-road driving with the boom on a trailer.)
initial tension
(additional When using additional equipment, you can (if the main boom is loaded
equipment) on on a trailer) use a hydraulic switching operation to reduce the axle
load on the rear axle line. The luffing cylinder piston ring is connected
with a pressure reservoir to do this.
In the hydraulic switching operation for the boom initial tension, you
will find taps I to IV. Put the taps in the following positions.
Tap I (on derricking cylinder with a padlock):
The tap I is in the proper setting when the boom floating position
is switched on; ➠ p. 6-13.
Tap IV
Tap IV (1) is directly on the derricking
cylinder.

• Switch tap IV (1) in position B for driving.

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 Driving the truck crane
6.1 Checking the truck crane before driving

Taps II and III

1
Taps II and III are located on the left side of
B the turntable behind the crane cab and
access ladder.

• Switch tap II (2) to position A (closed).

3
• Switch tap III (1) to position B (opened).
B

A
2
C0939

Tap III is now in the setting to fill the pressure reservoir.

• Start the crane engine.

• Press and hold the rocker switch crane cab incline. The pressure reservoir
§ will fill as long as the rocker switch is held.

• Fill the pressure reservoir until the

pressure on the pressure gauge (3)
doesn’t climb any more.
B
The hydraulic system is arranged so that the
pressure in the reservoir only climbs until
the required pressure for the boom
2 3 pre-tightening force has been reached.
B
• Switch tap III (1) in the A position (closed).
Now the boom intial tension is switched on.
A
• Turn off the crane engine.
1
A

H
C0938

You can find the exact value for the required pressure for the boom
pre-tightening force in the hydraulic circuit diagram.
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Operating Instructions GMK 5100 2 084 575 en 6 - 15

Driving the truck crane
6.1 Checking the truck crane before driving

Switching on the Applies only to on-road driving with the boom placed on rear bed (only
slewing gear free- with additional equipment).
wheel
If the boom is placed on the rear bed (trailer) during on-road driving, the
superstructure must be able to turn freely, e. g. when driving around cor-

H
ners. The slewing gear brake must therefore be blocked while disengaged.

The slewing gear permanent brake is only disengaged if the crane engine
is running.

• Place the boom on the trailer as described in the section Switching on

boom floating position; ➠ p. 6-13.

The slewing gear freewheel is switched on

separately on each slewing gear.
• Remove the lock (4) from the bore (2).
• Push the pin (3) inward as far as it will go.
• Guide the lock with the yoke through the
bore (1) and close it.
The slewing gear freewheel on this slewing
gear unit is now switched on and secured
against being switched off by unauthorized
persons.
• Also switch on the freewheel on the
second slewing gear unit.

Before driving with the slewing gear swit-

ched on, you have to secure the locking pin
against unintentional extension.

• Clamp the fuse box (2) onto the locking

pin´ s cylinder pipe (1).
• Push the fuse box as far as it will go onto
the cylinder pipe so that the base of the
box partially covers the locking pin.
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 Driving the truck crane
6.1 Checking the truck crane before driving

Refuelling

Monitor the fuel gauge. Refuel with diesel whenever necessary.

C0013

G
Fires may occur due to flammable gases!
Switch off the vehicle engine, driver’s cab heater and all additional
heating devices before refuelling.

The fuel tank (1) contains about 106 gal.

• Use the extendable ladder supplied (2)

when refuelling; it is attached below the
driver’s cab;
➠ Extendable ladder, p. 4-45.
To refuel, use the step up (2) on the carrier.

The prescribed fuel specification may be

found in the supplied Mercedes-Benz
operating instructions for the vehicle engine.

Close the fuel tank with the sealing cover

after each refuelling.

G
Danger of accident if the fuel tank is not closed!
Screw the sealing cover back on after each refueling. In this way, you pre-
vent vehicles behind you from being endangered by the sealing cover
falling off or fuel escaping.
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Operating Instructions GMK 5100 2 084 575 en 6 - 17
Driving the truck crane
6.1 Checking the truck crane before driving

Checking the The reservoir of the windscreen washing system is locate on the right
reservoir of the side under the driver’s cab and can be reached through an opening above
windscreen the steps.
washing system

• Pull the cover (1) from the opening.

Keep the reservoir (2) full at all times and
add a cleaning agent and, if necessary,
antifreeze to the water.

Adjusting the • Adjust the hydraulically spring-loaded seat to your height and weight.
seat The longitudinal direction, the stiffness of the suspension and angle of
the seat and back rest are adjustable.

1 Longitudinal adjustment of the entire

seat

2 Adjustment of the suspension stiffness

to your weight in kg

3 Seat height of the front edge of the seat

4 Seat height of the rear edge of the seat

5 Angle of the back rest

6 Inclination limiter of the armrest

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 Driving the truck crane
6.1 Checking the truck crane before driving

Adjusting the You can adjust the steering column for height and inclination.
steering column

Danger of accident when the steering column is unlocked!

G
Always stop the vehicle and engage the parking brake before you unlock
the steering column.
When the steering column is unlocked, you no longer properly steer
the vehicle.

• Press and hold down the lock button (1).

• Fold the release lever (2) upwards.
The steering column is now unlocked and
you can set the desired height and incli-
nation.

• Press the release lever again downwards

against the steering column until it audibly
engages.
• Check whether the steering column is
securely engaged.

Adjusting the The crane is equipped with several wing mirrors. Adjust the mirror to
mirrors your respective sitting position.

• Adjust the wide-angled wing mirror (2) on

the right-hand side of the vehicle and the
wing mirror (3) for the field of view on the
1 right-hand side of the crane.
• Adjust the proximity mirror (1) on the right-
2 hand side of the vehicle to the height of
the driver’s seat for the field of view right
next to the vehicle.
• Also adjust the wing mirror on the driver’s
door.

C0930
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Operating Instructions GMK 5100 2 084 575 en 6 - 19

Driving the truck crane
6.1 Checking the truck crane before driving

Tachograph The GMK 5100 truck crane is equipped with a tachograph (trip recorder) in
which the diagram sheets (24-hour discs) can be inserted for two drivers
at the same time.
The tachograph and the speed indicator form a unit. The Speed indicator
display and the Tachograph malfunction warning lamp are display elements
of the tachograph and are regulated directly by it.

You are obligated as a crane operator to set the respective operation on

H
the tachograph.

This section only describes the basic operation of the tachograph (in-
serting diagram sheets, setting time groups, operating errors).
Before operation, also note the information in the supplied operating in-
structions from the tachograph manufacturer.
There you will detailed information (marking the diagram sheets, malfunc-
tions, etc.).

S
Open the tachograph drawer only to insert or remove diagram sheets and
do not use the opened drawer as a shelf or surface (e.g. to mark the dia-
gram sheets). By doing this, you can prevent contamination and damage.

When there is a tachograph malfunction, the Tachograph malfunction

warning light and an error message will be shown on the display;
➠ Tachograph malfunctions, p. 7-32.

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 Driving the truck crane
6.1 Checking the truck crane before driving

Open the drawer and check the time settings

The drawer can only be opened when the following prerequisites have
been fulfilled.
– the vehicle is standing,
– the ignition is switched on,
– there are no error messages shown on the Tachograph display
(the Tachograph malfunction warning lamp is not on).
• Press the Unlock drawer button (1) once.
In the Tachograph display, the symbol (3) in the first line shows that the
unlocking has been started.
The running bar (2) in the third line shows that the unlocking has not yet
been completed.

• Wait until the drawer has been unlocked.

• Pull the drawer (2) out as far as possible.
The diagram sheet mounting (3) and an
isolating plate (1) are in the drawer.

• First check the time setting for the the

diagram sheet mounting (3); fold the
isolating plate (1) upwards to do this.
• Put a diagram sheet in the diagram sheet
mounting. Take care that the diagram
sheet is under the spring (5).
• Check whether the diagram sheet’s time
scale on the marking (4) is showing the
current time.
• If need be, correct the time with the
adjusting wheel (2) (depress and turn).
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Operating Instructions GMK 5100 2 084 575 en 6 - 21
Driving the truck crane
6.1 Checking the truck crane before driving

H
Inserting diagram sheets

Insert the diagram sheets after they have been properly marked.
The diagram sheets are always inserted with the front facing upwards.

For two-driver operation, leave the diagram sheet inserted under the
separating sheet after checking the time setting. This diagram sheet is for
the third driver. Put the diagram sheet for the first driver on the isolating
plate.
For single-driver operation, the diagram
sheet mounting under the isolating plate re-
mains empty and only the diagram sheet for
driver 1 is inserted.

• Put the isolating plate (1) back down.

• Put the diagram sheet (2) for driver 1 on
the isolating plate.
• Take care that the diagram sheet is under
the bracket (4).
• Push the drawer (3) back in until it engages.

If no malfunction is present, the Tachograph

display now shows the basic display:
– date (4) and time (5)
– driver time group (1.1)
– driver 1 diagram sheet inserted (1.2)
– total kilometres of the truck crane (3)
– driver 2 time group (2.1)
– driver 2 diagram sheet inserted (2.2) 11.05.2000

6 - 22 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.1 Checking the truck crane before driving

Setting the time group

The time group for driver 1 can be set by

repeatedly pushing the button (1).
The set time group is shown with the
symbol (1.1).
The time group for driver 2 can be set by
repeatedly pushing the button (2).
The set time group is shown with the
symbol (2.1).

The different time groups are shown with the following symbols:

Driving time: As soon as the vehicle starts to move, the tachograph auto-
matically switches to the symbol for driver 1 driving time.
If two diagram sheets are inserted, the stand-by time symbol for two-
driver operation will be automatically switched on.

Working hours: For all other work times, the same activities apply as for
stand-by time.
When setting work time and stand-by time, observe applicable local laws
and regulations.

Stand-by time: Times present at the truck crane, for example, crane opera-
tion, maintenance work, passenger time, and other times.

Pauses and times of rest: These times are prescribed by law and must be

H
observed.

If the drivers are changed during two-driver operation, the diagram

sheets in the trip recorder also have to be changed. The driving time is
always recorded on the diagram sheet which is on the isolating plate

H
(driver 1).

The symbol for resting time has to be entered for driver 2 in single- driver
operation. Otherwise an error message will appear.
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Operating Instructions GMK 5100 2 084 575 en 6 - 23
Driving the truck crane
6.1 Checking the truck crane before driving

Establishing an When driving on public roads, the superstructure lighting is supplied with
electrical connec- electrical power from the carrier. For this reason, an electrical connection

H
tion to the super- between the superstructure and the carrier has to be established.
structure

If your truck crane is equipped with an inclinable crane cab (additional

equipment), you do not have to establish any connections. In this case,
the electrical connection is made via a slip ring assembly.

• Pull off the protective cap (3) from the

socket (2) at the carrier.
• Remove the plug (4) of the connecting
cable from the dummy socket (1).
• Insert the plug of the connecting cable into
the socket (2) on the carrier.
• Close the dummy socket with protective
caps.
The electrical connection is thus made.

Warning plates For 16.00 R25 or 20.50 R25 tyres, two foldable warning signs are at the
for vehicle width front of the truck crane.
(additional
equipment)
The warning signs (1) have to be folded
down at the front on the right and left for de-
signation of the vehicle width during on-road
driving.

For off-the-road driving the warning plates

can be folded up and fastened with the
spring latch (2).
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 Driving the truck crane
6.2 General operation

6.2 General operation

G
Risk of accidents if truck crane can not be steered!
Never turn off the ignition or remove the ignition key while driving the
truck crane!
This would block the steering, thus losing control of the truck crane in
when motion.

6.2.1 Operating the transmission with automatic gear change

The GMK 5100 truck crane is equipped with a mechanical transmission

with automatic gear change. The transmission automatically controls the
clutch operating mechanism and gear changing. Despite this, a manual
change of gear can be done at any time.
A clutch emergency pedal is available in the driver’s cab for emergency
operation.

After ignition When you switch on the ignition, a warning buzzer will sound for a couple
has been seconds.
switched on

The Gearbox control display shows the current state of the transmission:
– If the parking brake was engaged the last time the ignition was
switched off, the transmission will be in the neutral position N.
– If the parking brake was released, the gear will be in the last gear
selected.
If the gearbox control recognises an error, an error message appears:
➠ Error messages on the display, gearbox control, p. 7-36.

S
The transmission can only completely shift and do a sure change of gears
if sufficient supply pressure is available in the compressed air equipment.
Check whether the Brake circuit I and II supply pressure warning lamp has
gone out.

• If need be, shift the transmission into neutral position N.

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Operating Instructions GMK 5100 2 084 575 en 6 - 25
Driving the truck crane
6.2 General operation

Shifting the You can only shift to neutral position if the gearshift lever and the two-
transmission to stop rocker are in the middle position (home position).
neutral position

• Press the Neutral position N button once.

The neutral position is activated when the N symbol appears on the Gear-
box control display.

Switch the transmission into neutral position to start the vehicle engine.
Only in this position can the vehicle engine be started.

Select the trans- You can select one of two operating modes for the transmission:
mission operat-
ing mode
– In the automatic operating mode, the gear change and the gear
selection is done using the electronic gear system.
In spite of this, you can undertake a manual change of gear at anytime.
After a manually initiated gear change, the electronic gear system be-
comes active again right away and shifts if necessary.
– In the manual operating mode, changing gears can only be done
with the gearshift lever or the two-stop rocker; there is no automatic

H
switching.

The automatic operating mode is intended for on-road driving.

The manual operating mode is primarily intended for driving on land with
rapidly changing conditions and for driving in emergency operation.

Changing the operating mode

You may switch operating modes while stationary and when driving.

• Always switch to automatic operating mode for on-road driving.

Actuate the Automatic/manual operating mode rocker switch to do this:
– To switch to the automatic operating mode, press the rocker switch
into position A.
– To switch to the manual operating mode, press the rocker switch into

H
position M.

The different functions in the two operating modes are described in more
detail in the following sections: Selecting direction of travel and starting gear,
Starting, moving, and doing a change of gear and Stopping.
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 Driving the truck crane
6.2 General operation

Display of the Example for the indication on the gearbox control display.
engaged gears

As initial position, for example, the 5th gear is engaged as a half gear.
The display now shows the engaged gear and, to the left of this, the downwards-
pointing arrow.

If you shift half a gear down, the 4th gear will be engaged as a full gear and the
display shows the engaged gear and, to the left of this, the arrow pointed up-
wards.

If you shift half a gear down again, the 4th gear will be engaged as a half gear
and the display shows the gear and, to the left of this, the arrow pointed down-
wards.
If you shift down from the initial position by a full gear, the 4th gear will be en-
gaged as a half gear directly and displayed.

Select direction The prerequisites for the information that follows are that
of travel and – the truck crane is stationary
starting gear – the parking brake is engaged
– the vehicle engine is switched on

G
– the accelerator in not actuated

Accidents may occur due to the unchecked movement of the truck crane!
When starting the truck crane, use the service brake to stop the crane
from rolling until starting gear has been engaged.

• To drive forwards with depressed Transmission function button, press the

gearshift lever one time forwards.
• To drive backwards with depressed Transmission function button, press
the gearshift lever one time rearwards.
In the automatic operating mode, a suitable starting gear between the 1st
and the 4th gear will be engaged (or reverse gear).

The 2nd gear will be engaged in manual operating mode (or reverse
gear).
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If the starting gear has been engaged, it is displayed on the Gearbox control
display.

s
Operating Instructions GMK 5100 2 084 575 en 6 - 27
Driving the truck crane
6.2 General operation

You can now change the starting gear in the following fashion:
– If you push the gearshift lever (without function button) once to the
front or the rear, the transmission will change the starting gear by
on complete gear up or down respectively.
– If you push the two-stop rocker up or down once, the transmission will
shift the starting gear by a half gear up or down, respectively.
If the starting gear has been engaged, it is displayed on the Gearbox control
display.

Starting

G
Danger from unexpected rolling!
Also engage the parking brake before starting to drive on sloped surfa-
ces. The clutching will only begin after you step on the accelerator. This
can lead to the truck starting to roll (also backwards) while you are mo-
ving your foot from the brake to the accelerator.

To start driving you have to:

– engage the parking brake (see note above)
– shift to the starting gear
– step on the accelerator (now the clutching begins)
– release the parking brake after the gear is engaged (changed engine
noise)
If, during starting, the electronic gear system recognised that the load is
B too great and the clutch will overheat (e. g. when towing free), the Clutch
overload warning lamp will light and a warning buzzer will sound.

• In this case, immediately remove your foot from the accelerator and
actuate the service brake.
• Select a lower starting gear.

H
• Start to move again.

If you do not take your foot off the accelerator, the electronics will engage
the clutch after a few seconds. This sudden load can cause the engine to
cut off or the wheels to spin.

• While driving, monitor the following transmission display and warning

instruments: ➠ Observing control instruments while driving, p. 6-32.
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 Driving the truck crane
6.2 General operation

Driving and You can always manually shift gears in either operating mode with the
changing gears gearshift lever or the two-stop rocker. The procedure is the same in either
operating mode as that described for the manual operating mode.

In automatic mode of operation

• Check whether the clutch emergency pedal is locked. The transmission
C only shifts automatically is the clutch emergency pedal is locked.
The Clutch emergency pedal unlocked indicator lamp has to be out.
In automatic operating mode, the electronic gear system shifts the gears
in the respective appropriate gear depending on the driving mode, posi-
tion of the accelerator and the operating status of the engine.

You can influence transmission upshifting with the

accelerator:
– Press accelerator a little: upshifting at low engine speed

H
– Press accelerator more: upshifting at higher engine speed

If you actuate the accelerator while the retarder is switched on, the trans-
mission will up shift by 1/2 a gear at the most.

You can influence the downshifting of the transmission with the service
brake or the retarder, as well as the position of the accelerator (e. g. kick
down).
For maximum acceleration, press the accelerator as far as possible (kick
down). The transmission will shift to a lower gear at first, depending on
the operating status. Then, to provide more power, the transmission will
shift only after a higher engine speed has been reached.

H
In manual mode of operation

In the following gear change procedures, clutching and gear shifting are
controlled by the electronic gear system. You do not need the clutch emer-
gency pedal.

The transmission only shifts in manual operating mode when the gear
change is done with the two-stop rocker or the gearshift lever. You have
three possibilities for shifting:
– 1/2 gear steps with the two-stop rocker
– electronic gear selection with the control lever
– one-gear shifting with the function button and control lever.
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Operating Instructions GMK 5100 2 084 575 en 6 - 29
Driving the truck crane

H
6.2 General operation

If you engage a lower gear during a gear change and the maximum per-
A mitted engine speed is exceeded, a warning buzzer will sound and the
Apply brakes indicator lamp lights.
In this happens, apply the brakes. The gear change will be done as soon
as a permissible engine speed has been reached.

1/2 gear steps with the two-stop rocker

• In order to upshift, pull the two-stop rocker upwards once.
The transmission will upshift by half a gear.
• In order to downshift, push the two-stop rocker downwards once.
The transmission will downshift by half a gear.
The change of gear has been completed when the newly engaged gear is
shown on the Gearbox control display.

One-gear step shifting with the function button and control lever.
• Press and hold down the Transmission function button:
– To upshift, press the control lever forwards one time.
The transmission will upshift by one gear.
– To downshift, pull the control lever rearwards one time.
The transmission will downshift by one gear.
The change of gear has been completed when the newly engaged gear is
shown on the Gearbox control display.

Electronic gear selection with the control lever (without function button)
If you do the change of gear with the control lever, you only determine
the shifting direction (up or downshifting).
The electronic gear system will determine which gear is to be engaged
based on the current driving situation.

• To upshift, press the control lever forwards one time.

The transmission will upshift by at least one gear.
• To downshift, pull the control lever rearwards one time.
The transmission will downshift by at least one gear.
The change of gear has been completed when the newly engaged gear is
shown on the Gearbox control display.

Changing • Stop the truck crane.

between for-
• Select neutral on the transmission.
wards and
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reverse • Select the starting gear for reverse; ➠ Selecting direction of travel and
starting gear, p. 6-27.

6 - 30 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.2 General operation

If necessary, you can also do a quick change between the 1st gear and
and the reverse gear (e. g. when rocking it free). Proceed in the following
manner:
• Stop the truck crane and leave the vehicle engine running.

When the 1st gear is engaged:

• Move the control lever rearwards with the Transmission function button
depressed.
When the reverse gear is engaged, the R entry appears on Gearbox con-
trol display.
When the reverse gear is engaged:
• Move the control lever forwards with the Transmission function button
depressed.
When the 1st gear is engaged, the 1 entry appears on Gearbox control
display:

Stopping • In order to stop, remove your foot from the accelerator and actuate the
service brake.
The transmission decouples shortly before the idling speed is reached.

In automatic mode of operation:

As soon as the truck crane has stopped, the electronic gear system shifts
to a suitable starting gear.

In manual mode of operation:

H
The gear with which the truck crane stops will remain engaged.

If a gear from 5th to 8th gear is engaged after stopping, you have to select
a suitable gear for starting. The crane can only start in on of the first four
gears.

For both operating mode:

When the truck crane stops for longer than 90 seconds, the electronic
gear system automatically switches to the neutral position.
After 60 seconds, N flashes in the display. If you tap the accelerator
lightly when the display is flashing, the selected starting gear will stay
engaged for a further 90 seconds.

For longer stopping when the vehicle engine is running, you must:
– release the accelerator,
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– apply the service brake,

– lock the parking brake,
– shift the transmission to neutral position N.

Operating Instructions GMK 5100 2 084 575 en 6 - 31

Driving the truck crane
6.2 General operation

6.2.2 Monitoring the control instruments while driving

Test the service and parking brakes as soon as you begin driving.

While driving, monitor the following control and warning instruments:

Status display for supply pressure brake circuits I and II

4 5
6
3 7 The operating pressure is approx. 8 bar (116 psi).
2 8

1 9 The pressure in both brake circuits must be over 5.5 bar (80 psi) while
0 bar 10 driving.
C0005

Warning lamp for supply pressure brake circuits I and II

l A warning lamp illuminates if the pressure decreases to less than 5.5 bar
(80 psi).

G
Accidents may occur if one of the brake circuits fails!
The effectiveness of the service brake is reduced when one of the brake
circuits fails!
If the warning light illuminates, stop the truck crane immediately and
attempt to find the cause! You may only continue driving at a low travel-
ling speed until you reach the next workshop!

G
Accidents may occur if both brake circuits fail!
If the pressure in both brake circuits decreases to less than 5.5 bar
(80 psi), the truck crane can only be stopped by the parking brake.
Stop the truck crane immediately and do not drive further before the
truck crane has been repaired.

ABS 1 warning lamp

x The warning lamp lights when the vehicle is stationary. The warning light
does not go out until the truck crane is moving at walking speed.
The warning lamp does not go out or it lights when the crane is moving if
the ABS system for the 2nd/3rd axle line has malfunctioned or failed. The
ABS system is not ready for operation but the braking force of the truck
crane is fully maintained.

ABS 2 warning lamp

x The function is the same as for ABS 1 but applies to the ABS system of
the 1st/5th axle line.
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 Driving the truck crane
6.2 General operation

ABS warning light for trailer (additional equipment)

y The warning lamp only functions when a trailer equipped with an ABS
system is attached correctly to the truck crane.
The warning lamp lights up when the truck crane is still; the warning lamp
goes out only when the truck crane and trailer drive at walking speed.
The warning lamp does not go out or it lights up when the crane is being
driven if the ABS system on the trailer is malfunctioning or fails. The ABS
system on the trailer is not ready for operation but the braking force of
the truck crane and the trailer are fully maintained.

Warning lamps for steering circuits I and II

de If the oil supply has fallen in a steering circuit the relevant warning light

H
will illuminate.

The warning lamp for steering circuit I illuminates at speeds of under

d 6 mph. It must go out when the speed exceeds 6 mph!

G
Accidents may occur if both steering circuits fail!
Stop the truck crane immediately if the both warning lamps remain
illuminated at a speed of over 6 mph!
You must stop driving immediately, as the truck crane can no longer be
safely steered due to the high steering force!

G
Accidents may occur if one of the steering circuits fails!
If the one of two warning lamps remains on at a speed of over 6 mph,
slowly reduce the speed of the truck crane and stop as soon as possible
and look for the cause!
If one of the steering circuits fails, you may only continue driving at a low
travelling speed until you reach the next workshop.

Status display for vehicle engine coolant temperature

When the maximum permissible temperature of the coolant is exceeded,
a warning buzzer sounds.

The temperature of the cooling water of the coolant may only increase to
95 °C (203 °F) on uphill routes.

H Decrease the load on the engine if the temperature of the coolant exceeds
95 °C (203 °F) or the warning buzzer sounds. Continue driving at a low
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speed and high engine speed! Check whether the fan is functioning
properly!

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Operating Instructions GMK 5100 2 084 575 en 6 - 33
Driving the truck crane
6.2 General operation

S
Stop the truck crane immediately if the temperature of the coolant in-
creases to over 100 °C (212 °F) and the warning lamp illuminates!
Switch the automatic gearbox to neutral position N and let the vehicle
engine run at increased idling speed to cool it down.
If the temperature does not decrease, turn off the vehicle engine and
attempt to find the cause!

Indicator lamp for vehicle engine coolant level

t If the Coolant level indicator lamp illuminates, the coolant level is too low.
Replenish immediately to prevent the vehicle engine overheating;
➠ Checking coolant level, p. 5-6.
Vehicle engine oil pressure warning lamp
L The oil pressure may not drop while driving. The warning lamp illumina-
tes if the oil pressure falls below 0.4 bar (6 psi). A warning buzzer sounds
simultaneously.

S
Stop the truck crane immediately if the warning lamp lights and the war-
ning signal sounds.
Turn off the vehicle engine and attempt to find the cause!
Never start the vehicle engine again before you have found the cause and
eliminated the error!
➠ Vehicle engine malfunctions, p. 7-25.
Engine electronics warning lamp
à If the Engine electronics warning lamp illuminates while driving, there is a
malfunction of the engine electronics. The engine’s performance
decreases continuously but the engine does not switch off and you can
thus continue driving until you get an opportunity to stop; ➠ p. 7-25.

Unlocking the clutch emergency pedal

C If the Unlock clutch emergency pedal lights, the transmission can no longer
clutch and can therefore not shift.

• Continue to drive in the last engaged gear until the next possibility to
stop.
• Switch the transmission into neutral position shortly before coming to a
stop. In this way you prevent the motor from cutting off when you stop.
When the truck crane is stopped, you have to unlock the clutch emer-
gency pedal and use it to clutch and declutch; ➠ Driving with the clutch
emergency pedal, p. 7-37.
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 Driving the truck crane
6.2 General operation

Status display for hydraulic system oil temperature

The hydraulic oil temperature should not exceed 80 °C (176 °F) in normal
driving mode.

The radiator built into the oil circuit is switched thermostatically at

approx. 45 °C (113 °F).

S
The hydraulic system is defective if the temperature of the hydraulic oil
increases to over 80 °C (176 °F). Stop the truck crane as soon as possible
and attempt to find the cause.
Stop the truck crane immediately and turn off the vehicle engine if the
temperature of the hydraulic oil increases to over 100 °C (212 °F)!

Status display for fuel reserve

Monitor the status display Fuel reserve.
Never allow the fuel tank to run completely empty.

H
C0013

If the fuel tank is almost empty, accumulated dirt could clog the fuel filters.
The fuel system must be bled when air is taken in (refer to the Mercedes-
Benz operating manual).

If one of the following warning or indicator lamps illuminates:

Refer to ➠ Malfunctions on the carrier, p. 7-1.

Vehicle engine air filter

p Hydraulic oil return flow filter
g Flame start system (additional equipment)
z
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Operating Instructions GMK 5100 2 084 575 en 6 - 35

Driving the truck crane
6.2 General operation

6.2.3 Driving on downhill slopes

If the driving speed exceeds 90 km/h (56 mph), the Apply brakes indicator
A lamp lights and a warning buzzer sounds.
• In this case, apply the brakes to the truck crane until the speed drops
below 90 km/h (56mph).

S
Danger of damage from oscillating movements!
Always keep the speed on downhill slopes below 90 km/h (56mph). Brake
the speed of the truck crane with the avaiable means.

When driving on downhill slopes, you can also slow the truck crane with
the service brake in the following fashion:
– by selecting a lower gear
– with the retarder
– with the eddy current retarder (additional equipment).

Preselecting To increase the braking force of the vehicle engine, you can select a lower
gears gear.

• To do this, push the two-stop rocker downwards once or pull the con-

H
trol lever rearwards once.
If you engage a lower gear and the maximum permitted engine speed is
A exceeded, a warning buzzer will sound and the Apply brakes indicator lamp
lights.
If this happens, apply the brakes. The gear change will be done as soon as
a permissible engine speed has been reached.

When the maximum permissible engine speed has been reached:

– a warning buzzer sounds and the Apply brakes indicator lamp does not
light
• Apply the service brake to slow the truck crane down until the engine
speed has dropped below the maximum permissible speed and the
warning buzzer stops buzzing.

S
Danger of damage from excessive engine speed!
Be sure to slow down the truck crane if the warning buzzer sounds and
the transmission does not shift up.
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In this way, you prevent the engine from running at an excessive speed
or that the transmission will be damaged.

6 - 36 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.2 General operation

Retarder An engine flap brake with constant throttle on the truck crane serves as
the retarder. The retarder becomes active only after a engine speed of
900 rpm has been reached and can be used up to a maximum of 2300 rpm.
The braking force depends on the engine speed. The greater the engine
speed is, the higher the braking force.

Switching on the retarder

• Pull the Right multipurpose switch to the rear
into stage 5.1.
The retarder is on.
Switching further to the steps 5.2 to 5.4 has
no influence on the braking force.1)

Switching off the retarder

• Press the Right multipurpose switch forwards
into stage 5.0.
The retarder is switched off.

H As long as the retarder is in operation, the transmission will not shift

more than one gear when you use the accelerator.

1)
The control steps 5.2 to 5.4 are not available with all truck cranes
which are delivered without an eddy current retarder
(additional equipment).
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Operating Instructions GMK 5100 2 084 575 en 6 - 37
Driving the truck crane
6.2 General operation

Eddy current The eddy current retarder is switched on together with the retarder. In this

H
retarder (additio- case, the Right multipurpose switch has four switching stages (5.1 to 5.4).
nal equipment)

All stages of the eddy current retarder are switched on additionally to the
retarder.

Switching on the eddy current retarder

5.1 stage 1 on = ¼ braking power
5.2 stage 2 on = ½ braking power
5.3 stage 3 on = ¾ braking power
5.4 stage 4 on = full braking power

Switching off the eddy current retarder

• Push the Right multipurpose switch forwards
into stage 5.0.
The eddy current retarder and the retarder
are switched off.

H
The Eddy current retarder indicator lamp lights if the retarder is switched on.
ê
You cannot regulate the engine speed with the accelerator as long as the

H
eddy current retarder is in operation.

When switching over a number of levels, the switch must engage briefly
in each level in order to build up the power-supply connection of the
retarder.

The braking force of the eddy current retarder is dependent only on the
driving speed. In contrast to the retarder, the driving range engaged does
not influence the function of the eddy current retarder.
For long downhill stretches, when you have stabilised your speed, you
should use the eddy current retarder at stage 2.

G
Danger of accidents because of overheating!
As soon as the truck crane is stationary or the downhill slope has
finished, you must switch the retarder back to level 0, in order to prevent
the retarder from overheating and consequently failing without you
noticing.
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 Driving the truck crane
6.2 General operation

6.2.4 Driving on uphill slopes

Starting

G
Danger form unexpected rolling!
Also engage the parking brake before starting to drive on sloped surfa-
ces. The clutching will only begin after you step on the accelerator. This
can lead to the truck can start to roll (also backwards) while you are mo-
ving your foot from the brake to the accelerator.

To start driving you have to:

– engage the parking brake
– shift to the starting gear
– step on the accelerator (now the clutching begins)
– release the parking brake after the gear is engaged (changed engine

H
noise)

On surfaces with only a little upward inclination, it is also possible to start

driving without the parking brake by changing your foot quickly from the
brake pedal to the accelerator and pushing hard on it. Whether the vehicle
rolls backwards depends on the degree of the upward inclination.

Driving The gearbox may switch between two gears at certain gradients.
Either release the accelerator a little or select a lower gear range.

If, during starting, the electronic gear system recognised that the load is
B too great and the clutch will overheat the Clutch overload warning lamp will
light and the warning buzzer will sound.

• In this case, remove your foot from the accelerator immediately and ac-
tuate the service brake.
• Select a lower starting gear.

H
• Start to move again.

If you do not let the accelerator go, the electronics will clutch automat-
ically within a few seconds. This sudden load can cause the engine to cut

H
off or the wheels to spin.

When starting on steep gradients and when manoeuvering, it can be

advantageous to operate the service brake with the left foot in order that
11.05.2000

the brake and accelerator pedals can be operated simultaneously and

with sensitivity.

Operating Instructions GMK 5100 2 084 575 en 6 - 39

Driving the truck crane
6.2 General operation

6.2.5 Tempomat

The truck crane is equipped with speed control. This allows you to drive
at a speed which you determine.

G
Accidents may occur due to carelessness!
Always be prepared to brake even when the tempomat is activated!
Only switch the tempomat on if the traffic situation permits a constant
speed.

Activating the The tempomat is switched on and off with the Right multipurpose switch.
tempomat: This function of the multipurpose switch can only be actuated at speeds
greater than 9 mph.

• Tap the Right multipurpose switch once upwards or downwards.

The tempomat is switched on and the current speed will be saved as the
set value.

Driving with With the cruise control function switched on, you can take your foot from
tempomat the accelerator at any time without changing the set speed.
To increase speed:
• Pull the Right multipurpose switch upwards and hold it until the desired
speed has been reached.
After letting go, the current speed will be saved and kept as the set
value.
or
• Tap the Right multipurpose switch once upwards, and the speed will in-
creased by 0.3 mph and will be saved.

Decreasing the speed

• Press the Right multipurpose switch downwards and hold it until the
desired speed has been reached.
After letting go, the current speed will be saved and kept as the set
value.
or
• Tap the Right multipurpose switch once downwards, and the speed will
11.05.2000

decreased by 0.3 mph and will be saved.

6 - 40 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.2 General operation

If you want to increase the speed, e. g. in order to pass another vehicle,

you may press the accelerator and increase the speed of the vehicle
engine without erasing the predefined cruising speed. The truck crane
speed will decrease to the set speed when you release the accelerator.

G
Risk of accidents due to excessive speed!
Do not activate the tempomat control when you are driving on downhill
slopes since speed control will not have any braking effect on your truck
crane. The driving speed of your truck crane could be greater than the
speed which you have set on the speed control.

Switching off Automatic tempomat switching off

tempomat
In the following cases, the tempomat will be automatically switched off:
– if the service brake or the retarder/eddy current retarder are actuated
– if the speed falls below 6 mph.
– if the temposet function is switched on
– if the ignition is switched off
If the clutch pedal is actuated, the tempomat will only be temporarily
switched off. It will become active again when the clutch pedal is released.

Switching off the tempomat (manually)

• Tap the control lever forwards one time.
The tempomat is switched off, and you have to regulate your speed with
the accelerator again.
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Operating Instructions GMK 5100 2 084 575 en 6 - 41

Driving the truck crane
6.2 General operation

6.2.6 Temposet

The truck crane is equipped with a speed limiter function. This function
enables you to limit the truck crane to a particular speed (e. g. in areas
with speed limits). (exception ➠ Passing in this section)

H The tempomat function is switched on and off with the Right multipurpose
switch.
This function of the multipurpose switch can only be actuated at speeds
greater than 9 mph.

Switching on the • Bring the truck crane up to the speed which is not to be exceeded.
temposet
• Press the Temposet on button once.
The current speed is set as the maximum speed.

Driving with When the temposet function is switched on, you can only drive in the
temposet range under the set speed (exception ➠ Exceeding maximum speed in this
section).

Increasing the set maximum speed

• Press and hold the Temposet on button and increase the speed of the
vehicle to the desired speed.
• Release the Temposet on button. The current speed will be saved as the
upper limit.
Decreasing the set maximum speed
• Press and hold the Temposet on button and keep your foot off the accele-
rator until the desired speed has been reached (brake if necessary).
• Release the Temposet on button. The current speed will be saved as the
upper limit.
Exceeding the maximum speed
• Step on the accelerator as far as possible (kick down). The set maxi-
mum speed can now be exceeded (for example, for passing or an
evasive action).
• Release the accelerator and actuate is again and the maximum speed
will be reactivated.
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6 - 42 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.2 General operation

Switching off • Tap the Right multipurpose switch forwards one time.
temposet

6.2.7 Turning off the truck crane

Locking the • Bring the truck crane to a halt using the service brake.
parking brake
• Lock the parking brake when the truck crane is switched off.

C0027

Transmission in • Move the transmission to the neutral position N.

neutral position

Turning off the • If the temperature of the coolant is still very high (e.g. after driving over
vehicle engine a pass), let the diesel vehicle engine run for another one or two minutes
at increased idling speed.
• Turn the ignition key to position 0 and remove the ignition key in order
to turn off the engine. All indicator lamps must go out.

Securing the
truck crane from
rolling

G
Accidents may occur due to the unchecked movement of the truck crane!
The truck crane cannot be prevented from rolling by selecting a driving
range!

• Secure the truck crane on uphill and downhill slopes using both the
parking brake and chocks.
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If wheel chocks were supplied, they are above the tail lamps. The delivery
and the quantity of chocks differs depending on the country package.

s
Operating Instructions GMK 5100 2 084 575 en 6 - 43
Driving the truck crane
6.2 General operation

Switch off the Always switch off the battery master switch if the truck crane is going to
battery master be inactive for over 8 hours.
switch if the
truck crane is idle
for a longer
period of time

S
When the vehicle engine is running you must never disconnect the cable
connection to the alternator!

• Switch off all current consumers.

• Turn off the vehicle engine and remove the ignition key.
• Switch off the main battery.

H You do not need to wait for the return water of the additional water
heating system (additional equipment).
However, you should always turn off the heater to prevent it from auto-
matically activating when the main battery is switched on.

Securing the Remove the ignition key and lock the driver’s cab to prevent unauthorised
truck crane use.
against un-
authorised use

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6 - 44 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.3 Off-the-road driving

H
6.3 Off-the-road driving

If you drive on difficult ground with quickly changing loads or on slippery

ground, it can happen that the transmission shifts too late to a smaller
gear or too early in a larger gear. Should this be the case, select manual
operating mode. This gives you more control over driving and allows you
to do the respective gear changes in good time.

S
Danger of the clutch wearing out too soon!
Do not use the clutch emergency pedal for off-road driving!
You cannot clutch as gently with the clutch emergency pedal as you can
with the electronic gear system.

You may also perform the following steps in the order specified below:
– Engaging the 1st or 2nd gear
To increase the thrust of the driving gear wheel, you can select a lower
starting gear. To do this, you have to switch over to manual shifting
mode; ➠ In manual mode of operation, p. 6-29.
– Drive of the third axle line / longitudinal differential lock
For off-road driving, you can also switch on the longitudinal differential
lock in the 4th axle line and (for additional equipment with 10 x 8 drive)
the drive and the longitudinal differential lock on the 3rd axle line.
– Transverse differential locks in all driven axle lines
The transverse differential locks in the driven axle lines prevent the
spinning of individual wheels on one axle line when driving on slippery
ground. (Must not be used on firm ground and when cornering!)
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s
Operating Instructions GMK 5100 2 084 575 en 6 - 45
Driving the truck crane
6.3 Off-the-road driving

6.3.1 Longitudinal differential locks / drive of the 3rd axle line

(drive of 3rd axle line only with 10 x 8 x 10 additional
equipment)

For off-road driving, the longitudinal differential locks on the 4th axle line
can be switched on.
For additional equipment with 10 x 8 x 10 drive, the longitudinal
differential locks and the drive of the 3rd axle line are also switched on.

The drive of the 3rd axle line / longitudinal differential locks may only be
switched on if the key-operated switch Level adjustment system has been
switched on.
As long as the Level adjustment system key-operated switch is switched on,
the speed of the truck crane is limited to 12 mph and the transmission will
shift no higher than the 4th gear (full gear); ➠ Level adjustment system,
p. 6-49.

S
Switch the longitudinal differential locks / drive of the 3rd axle line on
or off only when the vehicle is stationary or moving at a maximum of
2 mph. The longitudinal differential locks / drive of the 3rd axle line may
not be switched on when driving on solid ground.
Do not leave the longitudinal differential locks / drive of the 3rd axle line
switched on for longer than is necessary and make sure you switch them
off before driving on solid ground!

Switching on • Stop the truck crane or let it move at a maximum speed of 2 mph.
drive / longitudi-
nal differential
locks
• Straighten the steering.
• Turn on the level adjustment system with the key-operated switch.
• Press the Longitudinal differential locks / drive of 3rd axle line rocker switch
c down.
• Move the truck crane carefully until the Longitudinal differential locks / drive
c
H
of 3rd axle line indicator lamp lights up.

When you turn on the Longitudinal differential locks / drive of 3rd axle line
rocker switch, you trigger the mechanical gear changes for the longitudi-
nal differential locks and the drive of the 3rd axle line. The Longitudinal
differential locks / drive of 3rd axle line indicator lamp lights up when one of
the activation processes is complete.
The indicator lamp also illuminates when a further activation process is
not carried out or completed mechanically (e.g. due to a malfunction).
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6 - 46 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.3 Off-the-road driving

Switching off
drive / longitudi-
nal differential
locks • Stop the truck crane or let it move at a maximum speed of 2 mph.
• Press the Longitudinal differential locks / drive of 3rd axle line rocker switch up.
c • Wait until the Longitudinal differential locks / drive of 3rd axle line indicator
c lamp goes out.
The indicator lamp only goes out once all deactivation procedures are

H
completed mechanically.

If the Longitudinal differential locks / drive of 3rd axle line indicator lamp does
not go out, help the deactivation procedure by slowly driving forwards
and backwards.

Once the indicator lamp has gone out, switch the level adjustment
system key-operated switch off again.

S
Gearbox damage may occur due to the transfer case not functioning
properly!
Switch off the longitudinal differential locks / drive of 3rd axle line with
the Longitudinal differential locks / drive of 3rd axle line rocker switch!
Do not use the level adjustment system key switch!
This prevents improper shifting and possible damage in the axle centre
drive and transfer case.
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Operating Instructions GMK 5100 2 084 575 en 6 - 47

Driving the truck crane
6.3 Off-the-road driving

6.3.2 Transverse differential locks in all driven axle lines

The transverse differential locks in the driven axle lines prevent the spinn-
ing of individual wheels when driving on slippery ground.

The transverse differential lock can only be switched on if the Level adjust-
ment system key-operated switch has been switched on.
As long as the Level adjustment system key-operated switch is switched on,
the speed of the truck crane is limited to 12 mph; ➠ Level adjustment
system, p. 6-49.

S
Switch the transverse differential locks on or off only when the vehicle
is stationary or moving at a maximum speed of 2 mph. The transverse dif-
ferential locks may not be switched on when driving on solid ground. Do
not leave the transverse differential locks switched on any longer than ne-
cessary. It is imperative that you switch off the transverse differential
locks when driving on firm ground!

Activating trans-
verse differential
locks • Stop the vehicle or let it move at a maximum speed of 2 mph.
• Straighten the steering.
• Turn on the level adjustment system with the key-operated switch.
• Press the rocker switch Transverse differential locks in all driven axle lines
h down.
• Carefully start the vehicle until the indicator lamp Transverse differential
h locks in all driven axle lines illuminates. The indicator lamp will flash if one
or more of the transverse differential locks has not been activated. It
will illuminate continuously only when the transverse differential locks
of all driven axle lines have been activated.

Deactivating
transverse
differential locks • Stop the vehicle or let it roll with a maximum speed of 2 mph.
• Press the rocker switch Transverse differential locks in all driven axle lines up.
h The indicator lamp will flash if one or more of the transverse differential
locks have not been deactivated. It will not go out until the transverse
differentials in all axle lines have been deactivated.
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6 - 48 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.3 Off-the-road driving

H One or more of the locks are still locked into place if the indicator lamp
flashes after the transverse differential locks have been deactivated. You
may expedite the disengaging of the locks by slowly driving forward and
backward while turning the steering slightly!

Once the indicator lamp has gone out, switch the level adjustment system
key-operated switch off again.

S
Gearbox damage may occur due to the transfer case not functioning
properly!
Always switch off the transverse differential locks with the rocker switch
Transverse differential locks in all driven axle lines!
Do not use the level adjustment system key switch!
This prevents improper shifting and possible damage in the axle central
drive.

6.3.3 Level adjustment system

You may improve the off-the-road handling of the truck crane by in-
creasing its ground clearance and chassis angle with the level adjustment
system. Operation of the level adjustment system is inhibited by a key
switch.

Leave the key switch on when the truck crane is not at on-the-road level.
After a level change, return the truck crane to on-the-road level as soon as
possible.
Turn off the key switch and remove the key.

The rocker switches for the following functions are also activated using
this key switch:
– Transverse differential locks in all driven axle lines;
– Longitudinal differential locks / drive of the 3rd axle line
(drive of 3rd axle line only with 10 x 8 x 10 additional equipment)
– Separate steering;
– Reduction of the speed to 12 mph
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s
Operating Instructions GMK 5100 2 084 575 en 6 - 49
Driving the truck crane
6.3 Off-the-road driving

Activating the
level adjustment
system

S
The suspension locking system of all axle lines must be switched off for
all level changes!
The transverse differential locks and the drive of the third axle line / longi-
tudinal differential locks must also be switched off!

• Insert the key into the Level adjustment system key-operated switch and
turn on the switch.
• Maintain the engine speed at between 1000 and 1300 rpm using the
accelerator during each level change.

C0018

Raising or lower-
ing the entire
truck crane
• Select the direction of movement of the level adjustment using the Raise /
: lower vehicle level rocker switch:
Raising the truck crane: Press rocker switch up.
Lowering the truck crane: Press rocker switch down.

The Raise vehicle level and Lower vehicle level indicator lamps show the selec-
98

H
ted direction of movement.

Applying the brakes during the level change increases tyre wear as well as
the load on the suspension cylinders. Therefore you should – if possible –
release the parking brake and allow the truck crane to roll at approx. 2 mph
during a level change.

Press the Raise / lower truck crane rocker switch down to raise or lower the
| entire truck crane.

The No on-the-road level indicator lamp will illuminate as soon as the truck
{ crane is no longer at on-the-road level.

S
Damage may occur to the suspension cylinders!
The distance the truck crane is raised or lowered changes the suspension
range accordingly. Drive carefully after changing the vehicle level in order
to prevent damage to the suspension cylinders!
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6 - 50 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.3 Off-the-road driving

Tilting the truck

crane lengthwise
or crosswise
• Select the direction of movement of the level adjustment using the
: Raise / lower vehicle level rocker switch:
Raising the truck crane: Press rocker switch up.
Lowering the truck crane: Press rocker switch down.

The Raise vehicle level and Lower vehicle level indicator lamps show the
89

H
selected direction of movement.

Applying the brakes during the level change increases tyre wear as well as
the load on the suspension cylinders. Therefore you should – if possible –
release the parking brake and allow the truck crane to roll at approx. 2 mph
during a level change.

Using the rocker switches you may tilt the truck crane
6789 – forward or backward (longitudinal tilt) or
– to one side (diagonal tilt):

raise or lower at the front,

6 raise or lower at the rear,
7 raise or lower on the right-hand side,
8 raise or lower on the left-hand side.
9 The No on-the-road level indicator lamp will illuminate as soon as the truck
{ crane is no longer at on-the-road level.

S
Damage may occur to the suspension cylinders!
The distance the truck crane is raised or lowered changes the suspension
range accordingly. Drive carefully after changing the vehicle level in order
to prevent damage to the suspension cylinders!
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Operating Instructions GMK 5100 2 084 575 en 6 - 51

Driving the truck crane
6.3 Off-the-road driving

Moving the truck • Park the truck crane on a flat, even surface.
crane into position • Straighten the steering.
On-the-road level

H Applying the brakes during the level change increases tyre wear as well as
the load on the suspension cylinders. Therefore you should – if possible –
release the parking brake and allow the truck crane to roll at approx. 2 mph
during a level change.

• Press the On-the-road level rocker switch until the No on-the-road level
{ indicator lamp goes out.

Deactivating the • Turn the Level adjustment system key-operated switch to the right until it
level adjustment engages then remove the key.

S
system
Damage may occur to the suspension cylinders!
Do not turn off the level adjustment system until the truck crane is at
on-the-road level.

6.3.4 Freeing a stuck truck crane

Freeing the truck If the crane is stuck, you can attempt to free it by changing between for-
crane by its own ward and reverse driving (rocking free):
power
When rocking the vehicle free, you should engage the transverse differen-
tial lock and the drive of the 3rd axle line.

• Press the service brake and release the accelerator.

• While the truck crane is not moving, shift into 1st gear with the two-
stop rocker or the gearshift lever.
• Release the service brake and press the accelerator until the truck crane
comes to a standstill.
• Press the service brake and release the accelerator.
• While the truck crane is not moving, shift into reverse gear with the two-
stop rocker or the gearshift lever.
• Release the service brake and press the accelerator until the truck crane
11.05.2000

comes to a standstill.
Repeat the procedure until the truck crane has been freed.

6 - 52 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.3 Off-the-road driving

Towing free in • Fasten a steel rope to one of the towing eyes on the rear chassis wall
reverse using a shackle. The towing eyes are located next to the tail lamps.
The towing eyes on the chassis rear wall are designed for a maximum
tractive force of 16 800 lbf (16 755 lbs) if:
– the pulling direction runs along the longitudinal axis rearwards, or an
angle of 90° to the right or left from the longitudinal axis and
– the pulling direction runs along the longitudinal axis rearwards without
deviation upwards or downwards

S
Damage may occur to the chassis!
Only tow the truck crane free if the you have observed the above condi-
tions for the pulling direction. Otherwise, the chassis could be damaged
or the towing eyes could bent and torn.

Towing free • Fasten a steel rope to the front towbar coupling.

S
forwards
Damage may occur to the chassis!
The tractive force on the front towbar coupling may not exceed 22 000 lbf
(22 050 lbs) going forwards or at an angle of 45° to both sides from the
longitudinal axle of the truck crane. Support the towing with the engine
power of the truck crane. Pulling jerkily or at an angle is prohibited!
Pulling out the truck crane jerkily or at an angle may damage the chassis.
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Operating Instructions GMK 5100 2 084 575 en 6 - 53

Driving the truck crane
6.3 Off-the-road driving

Blank page

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6 - 54 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.4 Separate steering

6.4 Separate steering

Manoeuvrability on the site may be increased by steering with the
4th axle line. To this end,
– the steering lock on the fourth axle line must be unlocked,
– the drag rods between the third and fifth axle lines must be separated,
– and the fourth and fifth axle line drag rods must connected with

H
each other.

Always switch on the separate steering when you drive onto small
building sites
– with a rigged truck crane or
– steer at a low speed.

The 1st, 3rd and 3rd axle lines are then connected with the steering
b wheel, the 4th and 5th lines are connected with the toggle switch separate
steering on the lower part of the left side of the driver’s seat.

Operation of the separate steering is inhibited by the Level adjustment

system key switch. Leave the key switch on when the steering on the
fourth axle line is unlocked. Relock the steering on the fourth axle line
as soon as possible. Turn off the key switch and remove the key.

H
C0018

As long as the Level adjustment system key-operated switch is switched on,

the speed of the truck crane is limited to 12 mph.; ➠ Level adjustment
system, p. 6-49.

When the steering is unlocked, you may drive in both all-wheel steering
mode and crab travel mode.

All-wheel steering:
The turning circle of the truck crane will become smaller if you turn the
wheels of the front and rear axle lines in opposite directions.

Crab travel mode:

The truck crane will move diagonally to the side if you turn the wheels of
the front and rear axle lines in the same direction.
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s
Operating Instructions GMK 5100 2 084 575 en 6 - 55
Driving the truck crane
6.4 Separate steering

6.4.1 Unlocking the 4th axle line steering, connecting 4th and 5th
axle lines

Switch on the Level adjustment system key switch.

C0018

• Press down the release separate steereing rocker switch.

b For this, you must hold down the safety button.

The release separate steereing indicator lamp goes on when the steering is
? released.

• Use the separate steereing toggle switch to steer the 4th axle line until the
b 4th and 5th axle line wheels have the same steering angle.
The connection between the 4th and 5th axle line drag rods clicks in
audibly and the 4th and 5th axle line wheels move together.
The steering system is now reconfigured for all-wheel drive.

G
Accidents may occur if the steering of the fourth axleline is unlocked
during on-road driving!
After driving in all-wheel steering mode, return the truck crane immedi-
ately to normal driving mode with the steering lock engaged at the 4th
axle line and the drag rods connected between the 3rd and 5th axle lines.
The normal driving mode is reestablished when the Separate steering release
indicator lamp is extinguished.

6.4.2 Steering the 4th and 5th axle lines

Use the separate steering toggle switch to steer the 4th and 5th axle line
b wheels:

Towards the left: Push the switch to the left.

Towards the right: Push the switch to the right.
The steering angle will change as long as you keep pressing the toggle

H
switch.
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The wheels of the first, third and third axle lines are steered with the
steering wheel.

6 - 56 2 084 575 en Operating Instructions GMK 5100

 Driving the truck crane
6.4 Separate steering

6.4.3 Separating 4th and 5th axle line, locking steering of 4th axle line

For on-road travel

– the 4th axle line steering must be locked,
– the drag rods of the 3rd and 5th axle lines must be connected to each
another.

G
Accidents may occur if the steering of the fourth axleline is unlocked
during on-road driving!
Normal steering mode with locked steering on the third axle line is not
activated until the Release separate steering indicator lamp has gone out.

• Turn the wheels of the front axle lines as far as possible to the left or

H
right using the steering wheel.

If the wheels on the front axle lines are not turned as far as they will go,
the steering lock on the 4th axle line cannot be engaged.

• Press the Release separate steering rocker switch upward.

b
The Release separate steering indicator lamp remains illuminated.
? The drag rods of the 3rd and 5th axle lines must be connected to each
other first.

• Steer the wheels of the rear axle lines with the toggle switch (Separate
b steering) into the relevant position for on-road driving corresponding to
the turned front wheels, e.g.:
front wheels are turned to the right –
rear wheels are turned to the left.
The drag rods between the 3rd and 5th axle line are connected if only the
wheels of the 4th axle move when the toggle switch is activated.

• Now engage the steering lock of the 4th axle line.

b Using the toggle switch Separate steering, turn the wheels of the 4th axle
line to the straight ahead position, so that they cannot turn any more.
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s
Operating Instructions GMK 5100 2 084 575 en 6 - 57
Driving the truck crane
6.4 Separate steering

The steering lock of the fourth axle line is locked when the warning lamp
? Release separate steering goes out.

The steering system is set to normal steering mode.

G
Accidents may occur if the steering of the fourth axleline is unlocked
during on-road driving!
If you deactivate the ignition or the Level adjustment system key-operated
switch, before the steering is locked, the magnetic valve in the separate
steering is inactive, without locking the steering of the 3rd axle line.
When the ignition is restarted, separate steering is immediately
reactivated and the Release separate steering indicator lamp illuminates.
This results in a dangerous driving mode!

• Switch off the key-operated switch Level adjustment system.

C0018

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 Driving the truck crane
6.5 Heating and ventilation

6.5 Heating and ventilation

6.5.1 Driver’s cab heating system

A heat exchanger heats the driver’s cab with the heat from the engine
coolant.

Fresh air, recirculated air or mixed air can be

used as the suction air of the heating system.
The air is controlled using the Recirculated air /
fresh air mode regulator (1):

1 Fresh air: Push regulator up.

Mixed air: Regulator in mid-position.

Recircu- Push regulator down.

lated air:

C0758

The regulator Heater temperature regulator (1)

is used to set the desired air temperature:

Warm: Push regulator down.

Cold: Push regulator up.

1 The blower is switched on with knobs (2)

and (3):

Knob (2): Driver’s side

Knob (3): Passenger side

2 3
C0759

The fans have three levels (low, medium, high).

To switch on, turn the rotary switch to the right. It engages in one level
11.05.2000

after another.
To switch off, turn the rotary switch as far as possible to the left.

s
Operating Instructions GMK 5100 2 084 575 en 6 - 59
Driving the truck crane
6.5 Heating and ventilation

Air distribution in the driver’s cab can be set

using the regulators Air distribution (1 and 2):
Regulator (1): on the driver’s side
Regulator (2): on the passenger side

12 Windscreen and
instrument panel: Push regulator up.
All vents: Regulator in
mid-position.
Cab floor: Push regulator down.

C0760

You may control the air flow of the air vents

(1) on the instrument panel using the ad-
justing knob (2). You may adjust all vents
individually using the regulator (3):

1 Vent open: Regulator pushed to the

blue area.
Vent closed: Regulator pushed to the
white area.
2
3

H
C0033

If the windscreen becomes foggy in damp weather, push the regulators

Fresh air mode / circulation air operation and Air distribution up and the regu-
lator Temperature of the heating system down.
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 Driving the truck crane
6.5 Heating and ventilation

Ventilating the
driver’s cab
• Push the regulator heater temperature (1) up
as far as it will go and turn on the blower
using the knobs (3) and (4).
• Push the regulator Circulation air operation /
2 fresh air mode (2) up.

3 4
C0761

6.5.2 Roof blower (additional equipment)

The blower used to ventilate the driver’s cab is installed in the ceiling of
the cab.
You may determine the direction of the air flow (in or out) using the
~ Roof fan rocker switch located on the front instrument panel.
Remove air: switch pressed up
Off: mid-position
Air in: switch pressed down

You may adjust the volume of air and close

the roof blower using the handwheel (1).
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Driving the truck crane
6.5 Heating and ventilation

6.5.3 Additional water heating system (additional equipment)

Preheating the The vehicle engine may be preheated using the additional heating
vehicle engine system. The regulator for the Temperature of the heating system in the

H
driver’s cab must be set to Warm and the blower should be off.

If you operate the additional heating system with the engine off, the
batteries will run down. If you use the additional heating system frequent-
ly, you must recharge the batteries in shorter intervals!

When the vehicle engine is running, the additional heating system supple-
ments the engine’s heating output when the outside temperature is low
and the engine has not sufficiently warmed up the coolant.

When the operating temperature of the vehicle engine has been reached,
a thermostat turns off the heater, while the pump of the heating system
remains on.

Once the heater has been turned off, the additional heating system should
be turned off manually to prevent it from starting up again.

Preheating the If you turn on the blower as described in the section Heating the driver’s

H
driver’s cab cab, p. 6-59, the driver’s cab will be heated simultaneously.

If you heat the driver’s cab simultaneously, the amount of time required
to preheat the vehicle engine will increase significantly.

Switching on
the additional
heating system
• Push the regulator Temperature of the heating
system (1) into the Warm position.

1
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6.5 Heating and ventilation

• Press the Additional heating system rocker switch down to turn on the
0 additional heating system. The indicator lamp in the rocker switch
illuminates.
After a preheating period of approx. 15 seconds, automatic ignition takes
place. If the heating system does not trigger after 30 seconds, ignition is

H
aborted.

The indicator lamp in the rocker switch merely indicates that the switch
has been operated and that the heating system has been switched on or
off. It does not indicate whether the heating system has been triggered.

The heating system has triggered if:

– the Additional heating system indicator lamp illuminates, and
0 – the air flowing from the blower vents is warming up (cab heating), or
– the engine temperature rises (preheating vehicle engine).
Once the heating system has triggered, a thermostat in the heater takes

H
over control of the heating system.

If a malfunction of approx. 10 seconds occurs while the heating is on, the

heating system will automatically shut down.

If you wish to restart the heating system, you must turn off the Additional
0 heating system rocker switch and turn it back on again.

Deactivating
the additional
heating system
• Press the Additional heating system rocker switch up to turn off the
0 additional heating system. The Additional heating system indicator lamp
will go out.
The heating pump will continue to run for approx. 3 minutes to cool

H
down the heater.

Turning off the battery master switch while the heater is cooling down
will not interrupt the cooling of the heater.
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Driving the truck crane
6.5 Heating and ventilation

6.5.4 Additional heating system with timer (additional equipment)

Preheating the The vehicle engine may be preheated using the additional heating
vehicle engine system. During additional heating the heating air temperature regulator in

H
the driver’s cab must be set at Warm and the fan must be switched off.

If you operate the additional heating system with the engine off, the
batteries will run down. If you use the additional heating system fre-
quently, you must recharge the batteries in shorter intervals!

When the vehicle engine is running, the additional heating system supple-
ments the engine’s heating output when the outside temperature is low
and the engine has not sufficiently warmed up the coolant.
When the operating temperature of the vehicle engine has been reached,
a thermostat turns off the heater, while the pump of the heating system
remains on.
Once the heater has been turned off, the additional heating system should
be turned off manually to prevent it from starting up again.

Preheating the If you turn on the blower as described in the section Heating the driver’s

H
driver’s cab cab, p. 6-59, the driver’s cab will be heated simultaneously.

If you heat the driver’s cab simultaneously, the amount of time required
to preheat the vehicle engine will increase significantly.

Switching the • Turn the diesel engine ignition on.

heating system
on/off
• To switch on, press the switch heating on/off pushbutton once.
L The heating switches on and the display and switch light up. The fan
starts.

The heating system switches itself on and the Heating switched on indicator
lamp illuminates.

H You can also store the switch-on point and have the heating turned on
automatically; ➠ Save automatic heating start, p. 6 - 65.
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• To switch off press the Switch heating on/off push-button once. The heat-
L ing system immediately switches itself off and the Heating switched on
indicator lamp goes out.

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6.5 Heating and ventilation

Displaying and You can set or display the current time at any time at the Heating display.
setting the
current time
• Press and hold down the Display / set time push-button.
w
As long as you press the push-button, the current time will be displayed
on the Heating display.

• To set the time, additionally press one of the two push-buttons (Return
J K or Forwards).
The longer you hold down the push-button, the faster the time will be
set backwards or forwards.
• When the right time is displayed, release all the push-buttons.
The display goes out after about 20 seconds, and the new time will be
saved.

Automatic The heating system can be set so that it switches on automatically. There
heating start are two memory positions at which you can save different heating starts
switch on and and then set any way you want.
save

Switching on automatic heating start

• To access the desired memory position, press the respective push-but-
M N ton (Memory position 1 or Memory position 2).
In the Heating system display, the called-up memory position is displayed
(e. g. 2 bottom left) along with the time of the last heating start to be
saved (e. g. 16.30).

• If the heating system is to switch on at the set time wait about 20 se-
conds until the time in the display goes out.
Now the automatic heating start is set and the Automatic heating start indi-
cator lamp illuminates.

The heating system switches on at the time which is saved at memory

position 2.
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Operating Instructions GMK 5100 2 084 575 en 6 - 65
Driving the truck crane
6.5 Heating and ventilation

Saving automatic heating start

To access the memory position at which you want to save a new time,
M N press the respective push-button (Memory position 1 or Memory position 2).

In the Heating system display, the called-up memory position is displayed

(e. g. 2 bottom left) along with the time of the last heating start to be
saved (e. g. 16.30).

• Adjust the time for the new heating start with the Reverse or Forwards
J K push-buttons (e. g. 8.00).

• The new time will be saved. After 20 seconds, the time goes out and
only the memory position will be shown.

Now the automatic heating start is set and the Automatic heating start indi-
cator lamp illuminates.

The heating switched on at the time saved at memory position 2.

Switching off The Automatic heating start indicator lamp illuminates and the active
automatic memory position is shown on the Heating system display.
heating start

• Press the respective push-button for the memory position which is dis-
M N played (Memory position 1 or Memory position 2).

The memory position will not be shown anymore and the Automatic
heating start indicator lamp goes out.

The automatic heating start is switched off.

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6.6 Air-conditioning system (additional equipment)

6.6 Air-conditioning system (additional equipment)

The air-conditioning system is located on the roof of the driver’s cab. It
only works in recirculated air mode. The refrigerant compressor is driven
via V-belts by the vehicle engine.
Further information on the crane cabin air conditioning can be found in
section Air conditioning, p. 6-68.

6.6.1 Switching on

• Turn the Blower knob to level 1, 2 or 3 depending on the output desired.

• Set the desired temperature with the thermostat knob switch.

• Adjust the air outlet jets so that the cool air is mixed well with the cabin
air.

6.6.2 Switching off

• Turn the Blower knob to the 0 position.

• Turn the Thermostat knob switch to the left as far as possible.

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Operating Instructions GMK 5100 2 084 575 en 6 - 67
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6.6 Air-conditioning system (additional equipment)

6.6.3 Air conditioning

How to ensure Avoid excessive cooling of the air in the cab.

pleasant air- For example, with an outside temperature of 104 °F the temperature
conditioning inside the cab should lie between 79 °F and 86 °C; in other words, the dif-
ference in temperature should not exceed 18 °F and 25 °C. When the exter-
nal temperature is low, you should select a correspondingly lower
temperature difference. Excessive cooling frequently results in physical
discomfort, mostly after you have left the cab.

Avoid exposing your body directly to cold air. Direct the air stream from
the nozzles in the cab floor so that the cold air mixes thoroughly with the
warm air in the cab. This produces an even temperature throughout the
cab and ensures cooling without a draught.

In the mixed air mode, operate the air-conditioning system with a low
proportion of fresh air in order to dehumidify the driver’s cab, while at the
same time ensuring a fresh supply of oxygen.

Keep adjusting the cooling system as needed:

Initially, if the truck crane has e.g. been parked in strong sunlight for a
long time, the cooling system should be operated at maximum cooling
capacity and with the blower on setting 3 with the vehicle’s engine running.
The driver’s cab doors or at least the windows should be kept open for a
time to ventilate the cab.
The cooling-down process can be accelerated by increasing the engine
speed.

If you then continue to run the air-conditioning system, close the windows
and other air vents to ensure that the driver’s cab can be cooled adequately.

Once the desired inside temperature has been reached, set the blower to
level 2 again and reduce the cooling output on the air conditioner tempe-
rature regulator correspondingly. If only a low level of cooling is required,
blower level 1 will be sufficient.
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 Driving the truck crane
6.6 Air-conditioning system (additional equipment)

Dehumidifying On humid days at the turn of the season you can dehumidify the air in the
the air in the crane operator’s cab by operating the air-conditioning system in the com-
driver’s cab bined heating and cooling mode. Operation of the heating system is

H
described in section Heating and Ventilation, p. 6-59.

As this involves the heating and air-conditioning system functioning “in

opposition to each other” dehumidifying produces little or no heat.

• Set the knob Driver / passenger side heater fan and the knob switch Thermostat
of the air-conditioning system to approximately the same output.

H
• Switch on the blower.

The air in the cab will be dehumidified more thoroughly the higher the
heating and cooling settings are set.
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6.6 Air-conditioning system (additional equipment)

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6.7 Towing a trailer (additional equipment)

6.7 Towing a trailer (additional equipment)

A towbar coupling has been installed on the rear side of the chassis to
facilitate towing a trailer.

Please observe the permissible trailer load of your truck crane.

G
Accidents may occur if the trailer rolls away!
Before coupling or uncoupling the trailer, it must be secured with the
trailer parking brake as well as chocks on the rear axle to prevent it from
rolling away. Ensure that it still possible to swivel the unbraked front axle
of the trailer.

H Before coupling the trailer, adjust the towbar to the height of the towbar
coupling.

G
Accidents may occur when coupling the trailer!
No one may stand between the truck crane and the trailer when coupling
the two vehicles.

H Please observe the professional trade association regulations regarding

the coupling and uncoupling of the trailer.

Effects on the Observe the effects on the axle loads when towing a trailer. The axle
axle loads loads of your truck crane change in the following manner when operating
with central axle trailers:

– For every 220 lbs drawbar load, the axle loads on the first and third axle
lines decreases by 55 lbs each.
– For every 220 lbs drawbar load, the axle loads on the third, fourth, fifth,
and sixth axle loads increase by 192 lbs each.
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Operating Instructions GMK 5100 2 084 575 en 6 - 71
Driving the truck crane
6.7 Towing a trailer (additional equipment)

Coupling the
trailer

G
Risk of injury if the automatic closing device is actuated!
Do not put your hand into the coupling jaw when the trailer coupling is
open. This can actuate the automatic closing device, make the cotter pin
move down with great force and seriously injure your hand.

• Open the trailer coupling.

To do this, push the hand lever (1) up. The
lever locks into the uppermost position.
• Check that the coupling jaw (2) is stable. It
must not be allowed to move to the left or
the right when the towbar coupling is open.
• Adjust the towbar of your trailer to the
height of the towbar coupling and carefully
drive the truck crane in reverse towards the
towbar.

The towbar coupling automatically locks

when the eyes of the towbar and towbar
coupling are correctly aligned. The hand
lever (1) disengages from the uppermost
position and drops down.

H Make sure that you check the prescribed condition of the coupling after
every coupling process.

The control pin (1) must not protrude from

the guide bushing after the trailer has been
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6.7 Towing a trailer (additional equipment)

G
Accidents may occur if the trailer is incorrectly coupled!
If the control pin is protruding from the guide bushing (this can also be
established in the dark by touch), the trailer is not correctly coupled and
could be disengaged from the towbar coupling when you are driving.

Connecting
supply cables

• Insert the plug of the trailer’s electrical

system into the socket (5). Also insert the
ABS connecting cable into the socket (3) if
necessary (additional equipment).
• First connect the hose of the brake cable to
the yellow coupling head (4).
• Subsequently connect the hose of the
supply cable to the red coupling head (1).
Another cable is connected to the socket (2)
(additional equipment) for special equipment
of the trailer.

G
Accidents may occur if the hoses are too short or incorrectly positioned!
The hose lines must not come off when driving around corners. When
connecting the hoses, ensure that the length is sufficient and that the
hoses have enough clearance.

• Check the function of the trailer’s direction indicators and light system.
• Test the service brake and the parking brake immediately after setting
off.
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Operating Instructions GMK 5100 2 084 575 en 6 - 73
Driving the truck crane
6.7 Towing a trailer (additional equipment)

Removing the
supply lines

G
Accidents may occur if these steps are not carried out in the proper order!
It is imperative that the hoses be disconnected in the order specified be-
low. If the hose for the brake line is disconnected first, the trailer brake
will be released and the trailer will begin to roll.

• First disconnect the hose of the supply line

from the red coupling head (1). The trailer
brakes automatically.
• Then disconnect the hose of the brake line
from the yellow coupling head (4).
• Pull the plugs of the trailer’s electrical
system out of the sockets (2), (3) and (5).
Pull the ABS connection cable (if one is at-
tached) out of the appropriate socket.

Uncoupling the
trailer

G
Risk of injury if the automatic closing device is actuated!
Do not put your hand into the coupling jaw when the trailer coupling is
open.
This can actuate the automatic closing device, make the cotter pin move
down with great force and seriously injure your hand.
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 Driving the truck crane
6.7 Towing a trailer (additional equipment)

• Use the trailer service brake and chocks as

prescribed to prevent the trailer from
rolling.
• Open the trailer coupling.
To do this, push the hand lever (1) up. The
lever locks in the uppermost position.
• Drive the truck crane carefully away from
the trailer.

G
Risk of injury when closing the trailer coupling by hand!
When closing, the hand lever moves down with great force in the direc-
tion of the coupling jaw. Therefore start the closing process only by
moving the lever briefly in the direction of the coupling jaw with the hand
balls.
If you hold the hand lever and move it down, it may carry your hand with
it and crush it.

If no trailer is connected you must close the

trailer coupling by hand. Proceed in the
following manner:

• Move the hand lever knob (1) briefly in

the direction of the coupling jaw (observe
direction of arrow).

G
Always close the coupling when no trailer is connected. This prevents
people being injured by the automatic closing device being activated un-
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Operating Instructions GMK 5100 2 084 575 en 6 - 75

Driving the truck crane
6.7 Towing a trailer (additional equipment)

Test position of When driving the truck crane with a trailer attached, you can check
the parking brake whether the braking force of the truck crane suffices to brake both the
when towing a truck crane and trailer on downhill and uphill slopes.
trailer
• When the parking brake is shut, push the parking brake lever down-
ward, pull it backward and hold it in this position.
This releases the parking brake on the trailer; the parking brake on the
truck crane remains engaged.
In this way, in the event of a defect to the trailer’s parking brake system
(e. g. a burst brake hose), you can check if the braking force of the truck
crane’s parking brake system alone is sufficient to brake the truck crane
and trailer.
• Release the parking brake lever again. The parking brake lever snaps
back into the parking brake engaged position and the trailer’s parking brake
is again engaged.

S
Accidents may occur if the truck crane is allowed to roll!
In addition to the parking brake, always secure the trailer with chocks
when parked on uphill or downhill slopes in order to prevent rolling. Do
this even if the parking brake functioned perfectly when you checked it.
Observe the corresponding regulations in your country when doing this.

H The wheel chocks are only supplied if they are apart of the country package.

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 Malfunctions on the carrier
7.1 Emergency stop device on carrier

7 Malfunctions on the carrier

7.1 Emergency stop device on carrier

With the GMK 5100, you can also turn off the vehicle engine from outside
of the crane cab in an emergency (e.g. if the truck cranes rolls unintentio-
nally or if the ignition locks malfunctions).

Turning off the You can turn off the truck crane from ouside of the driver’s cab by
vehicle engine switching off the battery master switch.

The battery master switch (1) is located on

the right-hand side of the vehicle behind the
diesel tank and is accessible through an
opening in the side plate.

• Switch off the main battery. Turn the selec-

tor handle so that it can be pulled off.
The crane engine switches off.
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Malfunctions on the carrier
7.1 Emergency stop device on carrier

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 Malfunctions on the carrier
7.2 Breakdown in road traffic

7.2 Breakdown in road traffic

Road traffic regulations require that a vehicle which has stopped in the
traffic lane, or on the verge or hard shoulder of a public highway due to a
breakdown or for any other reason be marked using the prescribed traffic
markers.

Please observe the following if a breakdown occurs:

• Keep calm!
• Brake the vehicle. Watch the traffic behind you when braking!
• Stop at a location that is safe for you, your vehicle and those behind you!

G
Risk of accidents if visibility is poor!
If possible, do not stop in a tunnel or directly after a curve.

• Secure the vehicle!

• Turn on the hazard warning lights!
• Secure the breakdown area:
– Set up a warning triangle.
– Set up a signal lamp or torch.

G
Risk of accidents if visibility is poor!
Warning triangles, signal lamps and torches must be set up in front of the
breakdown area in such a way as – to prevent rear end collisions, particu-
larly in curves!

Try to repair the damage yourself. If this is not possible, inform the local
GROVE Product Support or have the vehicle towed away; ➠ Towing the
truck crane, p. 7-5.

G
Risk of accidents when repair work is carried out in the danger area!
In danger area (e. g. tunnel, intersection, highway bridge), even repairs
which are easy to carry out are dangerous.
When in a danger area, only carry out the repair work which is required
to leave the area.
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Malfunctions on the carrier
7.2 Breakdown in road traffic

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 Malfunctions on the carrier
7.3 Towing the truck crane

7.3 Towing the truck crane

Observe the following when towing the truck crane:
– The truck crane may only be towed with a tow-rod. Attach the tow-rod
on the tow-rod coupling on the front bumper of the truck crane and the
towbar coupling of the towing vehicle.
– The statutory regulations concerning the overall length of the towing
and towed vehicle, including the tow-rod must be observed.
– If the vehicle engine, the steering and the service brake still work, you
may tow the truck crane with a truck.
– If the vehicle engine, the steering or the service brake no longer
function properly, the truck crane must be towed with a special
breakdown truck.
– The front towing coupling is for a maximum tractive force of 22 050 lbs.
The tractive force may go forwards or at an angle of 45° to both sides
from the longitudinal axle of the truck crane.

Towing away in If the truck crane has to be towed because of motor damage, just how you
case of motor should proceed depends on the length of the towing distance. The factors
damage. to consider are:
– towing out of the danger area
– towing distance up to 100 km (62 mi)
– towing distance over 100 km (62 mi)
Towing out of the danger area
The following information only applies for towing out of an immediate
area of danger (crossing, tunnel, etc.).

• To provide compressed air supply, connect the filler connection of the

truck crane to the Supply coupling head of the towing vehicle; ➠ Com-
pressed-air supply for vehicle engine breakdown, p. 7-7.
• Select neutral on the transmission; ➠ Shifting the transmission to neutral
position p. 6-26.
• Switch the transmission emergency switch to the NH position;
➠ Emergency transmission shifting, p. 7-39.
• Tow the vehicle at a maximum of 10 km/h (6 mph).
• Tow the truck crane no more than 0.6 mi; for further towing distances;
➠ Towing distance up to 100 km (62 mi), in the following section.
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Operating Instructions GMK 5100 2 084 575 en 7-5
Malfunctions on the carrier
7.3 Towing the truck crane

Towing distance up to 100 km (62mi)

• To provide compressed air supply, connect the filler connection of the
truck crane to the Supply coupling head of the towing vehicle; ➠ Com-
pressed-air supply for vehicle engine breakdown, p. 7-7.
• Select neutral on the transmission; ➠ Shifting the transmission to neutral
position, p. 6-26.
• Switch the Transmission emergency switch to the NH position; ➠ Emergency
transmission shifting, p. 7-39.

For towing distances up to a maximum of

100 km (62mi), you need the supplied
adjusting screw (2), which is marked with
“GP”.

• Loosen both clamping bolts and take off

the cover (1) from the Transmission access
opening.
• Turn and remove the plug (3) out of the
gearbox.
• Turn the adjusting screw (2) as far as possi-
ble into the gearbox and tighten it.

G
Danger of accidents if the brakes fail!
If the service brake system of the truck crane is damaged, the crane can
only be braked by the towing vehicle. You should therefore use extreme
caution when towing. Pay attention to the mass of the towed vehicle and
adjust the speed and driving style accordingly.

H
• Tow the vehicle at a maximum of 40 km/h (25mph).

The engine-dependent power steering is only supported by the emer-

gency steering pump of the transfer case during engine failure.
The emergency steering pump only pumps oil if the truck crane is rolling
at least 2 km/h (1.3 mph).

S
Steering will become difficult if the power steering is only supplied by the
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emergency steering pump.

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 Malfunctions on the carrier
7.3 Towing the truck crane

Towing distances over 100 km (62mi)

If the towing distance is more than 100 km (62 mi), you have to discon-
nect and tie up the cardan shaft between the transmission and the trans-
fer case at the transfer case.

• Observe all information which applies to towing up to 100 km (62 mi).

When the cardan shaft is disconnected and tied up, the towing speed can
be more than 40 km/h (25 mph).

Towing when the If the transmission has been damaged, you have to disconnect and tie up
transmission has the cardan shaft between the transmission and the transfer case at the
been damaged transfer case.

S
Risk of damage to the cardan shaft!
The vehicle engine must not be started while the cardan shaft is discon-
nected from the transfer case!

• Observe all information which applies to towing up to 100 km.

When the universal-joint shaft is disconnected and tied up, the towing
speed can be more than 40 km/h (25 mph).

Compressed-air
supply in the
event of engine
failure
The filler connection (1) of the truck crane
must be connected to the Supply coupling
head of the towing vehicle to supply the
truck crane with compressed air.
The filler connection (1) is located at the
front on the inside of the sheet metal
paneling between the steps and can be
reached from below.
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Malfunctions on the carrier
7.3 Towing the truck crane

Monitor the supply pressure on the Supply pressure brake circuits I and II
5
4 6 status display during towing.
3 7 The supply pressure must be at least 6 bar (87 psi) for towing!
2 8

1 9
0 bar 10

C0005

The Supply pressure brake circuits I and II warning lamp must not light up!
l
Power supply

• Switch on the battery master switch.

• Switch on the ignition.

z H For additional equipment with flame start system, the flame start system
is activated every time the ignition is started. If the vehicle engine is not
started it switches itself off after a certain interval, which depends on the
temperature of the coolant.

Axle drives • Switch all the transverse differential and longitudinal differential locks;
➠ Longitudinal differential lock / drive of the 3rd axle line, p. 6-46.
➠ Transverse differential lock, p. 6-48.

Parking brake

• Release the parking brake.

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 Malfunctions on the carrier
7.3 Towing the truck crane

H
The Parking brake indicator lamp goes out.
f
The supply pressure in brake circuit 3 is not high enough if the indicator
lamp does not go out.
Increase the supply pressure by waiting a few minutes with the vehicle
engine running or with the filling connector in place and the towing
vehicle engine running.
If the indicator lamp still does not go out, the parking brake system is
damaged and the parking brake must be mechanically released before
towing; ➠ Releasing the parking brake mechanically, p. 7-9.

Mechanically
releasing the
parking brake

S
The parking brake should only be released mechanically if it can no
longer be pneumatically released. It should only be released mechanical-
ly if the truck crane must be towed!

G
Accidents may occur due to the unchecked movement of the truck crane!
The movement of the truck crane can no longer be stopped by means of
the parking brake when the parking brake is mechanically released.
Secure the vehicle with wheel chocks before mechanically releasing the
parking brake.

Open all spring accumulators

(two each on the second to fifth axle lines)
as follows:

• Unscrew the hexagon screw (1) (spanner

size 27) until it is touching the preloaded
spring.
• Continue to unscrew the hexagon screw
(1) until the wheel brake is released
(torque 3.7 to 11 lbf ft).
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Operating Instructions GMK 5100 2 084 575 en 7-9
Malfunctions on the carrier
7.3 Towing the truck crane

G
Accidents may occur due to released parking brake!
The spring-loaded brake cylinder must be unblocked immediately after
towing. This may be carried out by trained, qualified personnel only as
the operational safety and roadworthy condition of the truck crane could
otherwise be impaired!

Towing The towing vehicle must start driving slowly.

procedure

S
Damage may occur to the chassis!
Starting to tow too quickly or in jolts can damage the chassis!

• Use chocks or corresponding aids to prevent the vehicle from rolling.

Removing the
mechanical
locking from all
spring-loaded
brake cylinders
• Fill the compressed-air supply completely (the Supply pressure brake
l circuits I and II warning lamp must not light up).
• Do not operate the service brake.

Gf
Accidents may occur if the brakes are improperly adjusted!
The removal of the mechanical locking on the brake cylinders may be
carried out by trained, qualified personnel only.

• Release the vehicle parking brake (Vehicle parking brake indicator lamp
must not be lit)

• Screw in the hexagon screw (1) completely.

• Tighten the hexagon screw with
29,5 +-07,4 lbf ft.

• Let trained personnel carry out a functio-

nal test or the service brake and the park-
ing brake.
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Tow starting

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 Malfunctions on the carrier
7.3 Towing the truck crane

• Switch on the ignition.

• Select the 3rd or 4th gear with the Transmission gearshift lever as the start-
ing gear. The selected gear has to be displayed in the Gearbox control dis-
play.
• Start towing the truck crane slowly. The towing speed may not exceed
20 km/h (12 mph).

S
When the maximum permissible engine speed is exceeded, a warning
buzzer sounds. Do not actuate the accelerator as long as the warning
buzzer is sounding. Decrease the towing speed.

• When a sufficient speed has been reached to start the motor, actuate
the accelerator.
The transmission appears to function normally.
• You can influence the clutching:
– lightly tapping the accelerator will cause slow clutching
– greater pressure on the accelerator will cause fast clutching
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Operating Instructions GMK 5100 2 084 575 en 7 - 11

Malfunctions on the carrier
7.3 Towing the truck crane

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 Malfunctions on the carrier
7.4 Wheel change

7.4 Wheel change

If a tyre puncture occurs while driving:

H
• Watch the traffic behind you and stop when it is safe.

Keep in mind that the steering wheel may jolt! Hold the steering wheel
with both hands!

• Choose the flattest possible location to change the tyres. The chosen
location should not impede traffic or pose danger to you or the vehicle!
• Protect the vehicle and the breakdown area; ➠ Breakdown in road traffic,
p. 7-3.

G
Danger of accidents from overturning wheel!
If you temporarily lean a wheel against the truck crane when changing a
wheel secure it against falling over with a rope!
Only move the outriggers if there is no wheel leaning against the truck
crane.

Removing a • Engage the vehicle parking brake.

damaged tyre
• Lock the suspension system.
• Lift the truck crane with the outrigger until the tyre that is to be changed
leaves the ground.

G
Danger of accidents from overturning wheel!
When unscrewing the last wheel nuts the wheel can slip off the hub and
tip in your direction.
Move back quickly if the wheel threatens to tip.

• Unscrew the wheel nuts.

• Pull the wheel off the wheel bolts (shake it off if necessary). Ensure that
the thread of the wheel bolts is not damaged.
• Secure the wheel against falling over if you temporarily lean it against
the vehicle.
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Operating Instructions GMK 5100 2 084 575 en 7 - 13
Malfunctions on the carrier
7.4 Wheel change

Removing the You can lift the spare wheel (additional equipment) with a chain hoist or,
wheel from the if at least the 1 t counterweight version is mounted on the turntable, also
spare wheel with the truck crane itself.
holder

G
Risk of overturning with rigged 25.6 x 8.2 ft outrigger span!
For the 25.6 x 8.2 ft outrigger span, you can only slew the super-
structure if no more than 1 t counterweight version is mounted on the
turntable. When slewing with greater counterweight versions (e. g. 4 t),
the truck crane will tip over.

G Danger of accidents from overturning wheel!

Changing the tyres without the appropriate lifting equipment for the
spare wheel is dangerous!
Have someone help you change the tyre whenever possible!

• Attach the wheel; ➠ Weight of wheels,

p. 8-9.
• Remove the four nuts (1).
• Raise the wheel from the spare wheel
holder.
• Secure the wheel against falling over by
temporarily putting it down.

Mounting a If you lift the wheel with the truck crane onto the spare wheel holder, ob-
damaged wheel serve the safety instruction Risk of overturning with a rigged outrigger span of
on the spare 25.6 x 8.2 ft! in the previous section before turning.
wheel holder
• Raise the wheel onto the spare wheel holder.
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 Malfunctions on the carrier
7.4 Wheel change

• Screw the wheel onto the spare wheel hol-

der using the four nuts (1).
Tightening torque: 370 lbf in each case.

Mounting the

G
spare wheel
Risk of accidents!
Check the wheel rim, the tyres, the wheel nuts and the wheel bolts for
damage before mounting the spare wheel.
Never mount damaged parts!
Mount only the manufacturer’s original spare wheel or a permitted wheel
of the same size and load bearing capacity!

• Check whether the surface of the wheel rim and the hub are clean
(no paint, grease or oil).
• Grease the wheel bolts slightly.
• Put the wheel on the hub vertically.
• Extend or retract the outrigger cylinders until the holes in the wheel
rims align with the wheel bolts.
• Push the wheel – shaking the wheel if necessary – onto the wheel bolts.
Ensure that the thread of the wheel bolts is not damaged.
• Screw a wheel nut hand-tight on both the upper and lower wheel bolts.
• Screw on the rest of the wheel nuts hand-tight.
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Operating Instructions GMK 5100 2 084 575 en 7 - 15
Malfunctions on the carrier
7.4 Wheel change

• Tighten the wheel nuts crosswise in

three stages in the order shown in the
diagram using a torque wrench.
First level: 150 lbf ft

Second level: 295 lbf ft

Third level: 480 lbf ft

• Tighten the wheel nuts again after driving

50 km (30 mi) and again after 150 km
(93 mi)!

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 Malfunctions on the carrier
7.5 Electrical system

7.5 Electrical system

7.5.1 Plug-in modules

Front plug-in
module

Pos. Designation of plug-in Function

module in the electronic
circuit diagram

1 1.4 D Oil temperature and pressure display,

hydraulic system, brake circuit/steering
circuit, hydraulic system, transmission,
driving direction indicator, suspension
locking system, roof ventilator, mirror
heating

2 4.3D speed indicator and tachograph

(below the plug-in module)

3 5.9D vehicle engine temperature and oil

pressure/ vehicle engine monitoring,
parking brake, coolant level, differential
locking, lighting, fuel reserve

4 Heating plug-in module Heating and ventilation on driver and

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passenger side, gearbox control display

Operating Instructions GMK 5100 2 084 575 en 7 - 17

Malfunctions on the carrier
7.5 Electrical system

Side plug-in mo-

dule

Pos. Designation of plug-in Function

module in the electronic
circuit diagram

1 6.2 D operation and monitoring

transverse differential locks, drive 3rd
axle line / longitudinal differential
locks,
separate steering, additional heating
system,
transmission,,suspension system

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 Malfunctions on the carrier
7.5 Electrical system

7.5.2 Fuses

S
Risk of fire!
Never repair a defective fuse with a nail, wire, aluminium foil or other
material which can conduct electricity.
Always replace defective safety devices with safety devices of the indi-
cated ratings.

The fuses are divided into 9 groups F 1 to F 9.

Groups F 1 to F 9
The groups F 1 to F 6 are located under the
cover at the right next to the front instru-
ment panel and become accessible if you
remove the covering which is shaped into a
placement surface.

Each group consists of 8 fuses.

The following tables show the designations

of the individual fuses, their strength and
function.
The designations 1 to 8 in the tables corre-
spond to the order from top to bottom
(fuse 1 is always the top fuse).

Designation in Rating Function

circuit diagram: (A)
F1

1 20 E-control for vehicle engine

2 10 engine electronics (FMR and ADM)

Mercedes Benz diagnostic plug

3 10 flame-start device (additional equipment)

4 15 hazard warning system / brake lights

5 10 ABS
6 10 ABS

7 10 driver’s cab ceiling lighting /

cigarette lighter/ 24 V/12V voltage
transformer / radio
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8 15 electronic gear system

s
Operating Instructions GMK 5100 2 084 575 en 7 - 19
Malfunctions on the carrier
7.5 Electrical system

Designation in Rating (A) Function

circuit diagram:
F2

1 10 E-control for vehicle engine

2 10 engine electronic system (FMR and

ADM),
Mercedes Benz diagnostics plug,
transmission gearshift lever and display,
bridge collision display (additional
equipment)

3 10 flame-start device
(additional equipment)
ABS

4 10 constant throttle for motor brake

5 10 level adjustment system / axle spring

accumulator

6 10 suspension locking system / steering

circuit display I + II/separate steering

7 10 differential locks / transfer case

8 10 outriggers / electronic level

(inclination indicator) / outrigger
pressure display

Designation in Rating (A) Function

circuit diagram:
F3

1 5 speed indicator
indicator lamp battery charge indicator

2 5 electronic gear system

3 15 heater fan

4 10 mirror heating

5 15 windscreen wiper and washing pump /

roof ventilator (additional equipment) /
horn

6 10 reversing light
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7 20 rotating warning lights

8 15 turn indicators

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 Malfunctions on the carrier
7.5 Electrical system

Designation in Rating (A) Function

circuit diagram:
F4

1 15 heating system

2 10 radio, telephone (additional equipment)

3 5 transmission diagnostics plug

4 10 no function

5 10 no function

6 10 no function

7 10 no function

8 10 fog lamp (additional equipment)/

rear fog light

Designation in Rating (A) Function

circuit diagram:
F5

1 5 position lamps left superstructure /

left parking light

2 10 position lamps right superstructure /

right parking light

3 10 left rear circumference lamps /

instrument lighting

4 5 right rear profile lamps

5 10 fog lamp/
left headlight - full beam

6 10 right headlight - full beams/

headlight - full beam indicator lamp

7 10 left low-beam headlight

8 10 right low-beam headlight

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Operating Instructions GMK 5100 2 084 575 en 7 - 21
Malfunctions on the carrier
7.5 Electrical system

Designation in Rating (A) Function

circuit diagram:
F6

1 20 hydraulic oil cooler

2 5 no function

3 15 retarder (additional equipment)

4 10 no function

5 5 central lubrication

6 10 no function

7 5 tachograph

8 15 additional heating system

(additional equipment)

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 Malfunctions on the carrier
7.5 Electrical system

Groups F7 to F9

G
Battery poses a danger from lead and connections containing lead!
Battery poles, clamps, and parts of the battery itself contain lead and lea-
ded connections.
Wash hands after working directly or indirectly with these parts!

The fuses F 7 to F 9 are located in the battery

box.

• Open the battery box lid and take the co-

ver off the terminal box:
fuses F 7 (1), F 8 (2) and F 9 (3).

Terminal Designation in Rating (A) Function

box circuit diagram:

1 F7 100 carrier main fuse

2 F8 50 air conditioner (additional equipment)

pre-fuse for additional heating system, voltage

transformer and tachograph /
3 F9 20 fuse for all consumer equipment, which has to
be supplied with power when the battery
master switch is switched off.
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Operating Instructions GMK 5100 2 084 575 en 7 - 23

Malfunctions on the carrier
7.5 Electrical system

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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6 Troubleshooting and malfunction correction

7.6.1 Vehicle engine malfunctions

Malfunction
H In the event of vehicle engine malfunctions also refer to the Mercedes-
Benz Instruction Manual.

Cause Action

Engine does not start Battery master switch not Switch battery master switch
(starter does not turn over) switched on on; ➠ p. 5-7.
Ignition switched off Switch on ignition;
➠ p. 5-9.
The transmission is not in Shift the transmission to N;
neutral position ➠ p. 6-26.
Parking brake not engaged Engage parking brake;
➠ p. 6-43.
Fuse F1/1 Carrier or F2/1 Check fuse, replace if
Carrier defective necessary; ➠ p. 7-19.
Engine does not start Batteries flat Charge batteries; ➠ also
(starter motor turns over) Maintenance Manual.
Fuel tank empty 1. Fill fuel tank;
➠ p. 6-17
2. Ventilate fuel system;
➠ operating manual for the
vehicle engine manufacturer
Flame-start device indicator Fuse F1/3 Carrier or F2/3 Check fuses and replace if
lamp (additional equipment) Carrier faulty necessary; ➠ p. 7-19.
does not go on during igni-
tion of the motor when cold
Vehicle engine air filter Air filter is clogged Replace dry-type air filter
warning lamp is on (➠ Maintenance manual)
Vehicle engine coolant level Coolant level too low Top up coolant;
warning lamp is on ➠ p. 5-6
The truck crane does not tra- level adjustment system Switch off level adjustment
vel at more than 12 mph switched on system; ➠ p. 6-49.
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Operating Instructions GMK 5100 2 084 575 en 7 - 25

Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Malfunction Cause Action

Engine coolant temperature Coolant level too low Fill coolant; ➠ p. 5-6.
too high (warning lamp illuminates)
Oil level in gear box too low Check oil level, top up if
necessary; ➠ p. 5-4 and
Maintenance manual
Outside of heat exchanger Clean outside of heat
dirty exchanger
V-belt of the coolant pump on Tighten V-belt;
the engine loose ➠ operating manual for the
vehicle engine manufacturer
The fan wheel on the heat Switch the fan thermostat to
exchangers does not turn emergency operation;
➠ p. 7-35
Engine oil pressure too low Engine oil level too low Check oil level, fill if
necessary; ➠ p. 5-4 and
Maintenance Manual
Motor cannot be switched off Malfunction of the electronics Switch of the engine with
with the ignition key emergency stop device;
➠ p. 7-1.
Check fuses, replace if
necessary; ➠ p. 7-19.
Motor brake (retarder) Fuse F2/4 Carrier defective Check fuses, replace if
does not switch on necessary; ➠ p. 7-19.

Vehicle engine diagnostic Fuse F2/2 Carrier or F1/2 Check fuses, replace if
plug no function Carrier faulty necessary; ➠ p. 7-19.

Power drop and abnormal If the charge air temperature ➠ Malfunctions in the
exhaust gas opacity is too high, the fault can be in operating manual of the
the charge air thermostat vehicle engine manufacturer.
(fan wheel is not turning). Function in the charge air
thermostat switch the
thermostat to Emergency
operation; ➠ p. 7-35.
The motor electronics warning In the event of engine electronics malfunctions the performan-
lamp is on during driving, the ce of the engine reduces continously. The engine does not
engine performance gets wor- switch off, however, and you can therefore continue driving
se and worse until you get an opportunity to stop.
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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Malfunction Cause Action

The motor electronics warning Cooling water level too low, Cooling water level; ➠ p. 5-6;
lamp is on during driving, the oil level too low, Oil level; ➠ p. 5-5;
engine performance gets air filter dirty. Air filter; ➠ Maintenance
worse and worse manual
V-belt too loose Check V-belt tension;
➠ Operating manual
Mercedes-Benz
Plug or cable on the control Check the plug on the control
unit loose unit (on the right next to the
fuses);
Cabling behind the Check cable, if damaged, in-
accelerator pedal is damaged form GROVE Product Support
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Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.2 Malfunctions of the transmission with automatic gear change

Malfunction Cause Action

Neutral position cannot be se- Gearshift lever or two-stop Move the gearshift lever and
lected rocker is not in the home two-stop rocker into the home
position position
Transmission does not shift Rocker switch Rocker switch Switch
automatically Automatic/manual operating automatic/manual operating mode
mode is in the position M to position A
clutch emergency pedal is Lock clutch emergency pedal;
unlocked ➠ p. 7-37
Fuse F1/8 Carrier or F 3/2 Check fuses, replace if
Carrier defective necessary; ➠ p. 7-19.
Starting gear can not be enga- Pressure of 5.5 bar has not yet Let the engine run, until the
ged and the Brake circuit I built up on the reservoirs pressure has built up.
and II supply pressure
warning lamp lights
Gear box does not switch up Level adjustment system Switch off level adjustment
to 4th gear switched on system; ➠ p. 6-49.
Transmission does not react Fuse F2/2 Carrier defective Check fuses, replace if
when the gearshift lever or necessary; ➠ p. 7-19.
the two-stop rocker is actua-
ted
Apply brakes indicator lamp Transmission can not Slow down truck crane, until
lights during driving downshift, because the indicator lamp goes out
maximum engine speed was
exceeded in a low gear.
Unlock clutch emergency pedal Automatic clutch actuation is Drive the truck crane with
indicator lamp lights no longer possible clutch emergency pedal;
➠ p. 7-37.
Gearbox control display Electronic gear system has ➠ error message on display;
shows the service symbol or recognised a malfunction p. 7-36.
another error message Clutch emergency pedal is Lock clutch emergency pedal;
unlocked ➠ p. 7-37.
Transmission does not react Electronic gear system is no Do transmission emerg.
to the gearshift lever or the longer linked to the shifting: ➠ p. 7-39.
two-stop rocker, no more dis- transmission
play on the Gearbox control
display
After the ignition has been The transmission is no longer Engage the parking brake
switched on the gear box is in the neutral position before the next time the
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nit in neutral position ignition is switched off

If the engine can not be started because a gear is engaged
and the air pressure is under 5.5 bar (80 psi), mechanically
shift the transmission into the neutral position; ➠ p. 7-41.

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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.3 Differential lock malfunctions

This section applies to malfunctions of all differential locks:

– transverse differential locks of the driven axle lines
– longitudinal differential lock in the 4th axle line and with additional
equipment with 10 x 8 drive also in the 2nd axle line

Malfunction Cause Action

Differential locks cannot be Level adjustment system not Switch on level adjustment
switched on switched on system key-operated switch
Drive train twisted Shift transmission in neutral
position
Compressed air equipment Let the engine run, until
not sufficiently filled pressure has built up. The
circuit for secondary
consumers takes a few
minutes to fill after the
indicator lamp goes out.
Fuse F2/7 Carrier defective Check fuse, replace if
necessary; ➠ S. 7-19.
Differential locks cannot be Drive train under tension Drive truck crane backwards
switched off and forwards slowly with the
steering straight.
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Operating Instructions GMK 5100 2 084 575 en 7 - 29

Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.4 Service brake malfunctions

Malfunction Cause Action

Supply pressure brake cir- Air pressure in one of the two Vehicle can be driven slowly
cuits I and II warning lamp circuits has dropped below as far as the next workshop.
lights up during driving or 5.5 bar (80 psi), check
does not go out after the pressure gauge for
engine has started compressed air supply
Air pressure in both circuits 1. Fill compressed-air supply
below 5.5 bar (80 psi), check at connection for external
pressure gauge for filling; ➠ p. 7-7.
compressed-air supply
2. Tow truck crane
using a tow-rod.
Parking brake does not disen- Air pressure in circuit 3 is too Let the engine run in neutral
gage, “Parking brake” indica- low with the parking brake
tor lamp does not go out, engaged until the air pressure
Supply pressure brake in circuit 3 is high enough.
circuits I and II warning lamp
is off
Warning lamp ABS1 lights ABS brake system in the 2nd Drive to the nearest
also at speeds over 4 mph and 3rd axle line failed workshop; Braking without
ABS support is still possible.
Warning lamp ABS2 lights ABS brake system in the 1st, Drive to the nearest
also at speeds over 4 mph 4th and 5th axle line failed workshop; Braking without
ABS support is still possible.
Eddy current retarder (additio- fuse F6/3 Carrier defective Check fuse, replace if
nal equipment) cannot be necessary; ➠ S. 7-19.
turned on

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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.5 Steering system malfunctions

Malfunction Cause Action

Steering wheel stiff, creaking Too little oil in hydraulic oil Check the level of the
noises during steering tank hydraulic oil and top up if
necessary.
Proceed afterwards at a low
rate of speed to the nearest
workshop and have the cause
of the oil loss checked.
One warning lamp for Too little oil in hydraulic oil Check the level of the
steering circuit I or II is on tank hydraulic oil and top up if
necessary.
Proceed afterwards at a low
rate of speed to the nearest
workshop and have the cause
of the oil loss checked.
Failure of steering circuit, e.g. Vehicle can be driven slowly
defective pump as far as the next workshop.
Both warning lamps for Both steering circuits have Vehicle cannot be driven, as it
steering circuits I and II are failed cannot be steered!
on
Hydraulic oil temperature too Oil level in hydraulic oil tank Check hydraulic oil level and
high too low top up if necessary
Hydraulic oil cooler does not Check fuse, replace if
switch on, fuses F 6/1 necessary; ➠ p. 7-19.
defective
Warning lamp for hydraulic Hydraulic oil return flow filter Change hydraulic oil return
oil return filter I and II lights contaminated filter I and II
up
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Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.6 Tachograph malfunctions

H When there is a tachograph malfunction, the Tachograph malfunction war-

ning light will light on the speed indicator and an error message will be
shown on the Tachograph display;

Malfunction Cause Action

! 4A050 Driving without diagram Insert diagram sheet for

sheet for driver 1 driver 1 and press any key.

! 4A051 Diagram sheet for driver 1 Insert diagram sheet for

missing driver 1 and press any key.
! 49052 Diagram sheet for driver 2 Set 1-driver-operation time
missing group for driver 2 to pause
time.
Insert a diagram sheet for
driver 2 for 2-driver operation.
Press any buttons.
! 49060 Error at the drawer Acknowledge the error
message by pressing any
! 4A400 Voltage interruption
button, until the basic display
! 4A411 Interruption of the line to the appears. If the error message
speed indicator cannot be acknowledged,
! 4A423 Error for transmitter inform service
communication
! 4900F Keyboard error

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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.7 Outrigger malfunctions

Malfunction Cause Action

Strut cylinder and outrigger Fuse F 2/8 Carrier defective Check fuse, replace if
beams cannot be extended or necessary; ➠ p. 7-19.
retracted and the electronic Solenoid valves jammed Operate solenoid valves by
level does not display hand; ➠ Emergency operation
of the solenoid valves for the
outriggers, p. 7-43.

7.6.8 Suspension locking system malfunctions

Malfunction Cause Action

Suspension lock cannot be Compressed-air system not Let engine run until pressure
switced off filled sufficiently has built up. The circuit for
secondary consumers takes a
few minutes to fill after the
indicator lamp goes out.
Fuse F2/6 Carrier defective Check fuse, replace if
necessary; ➠ p. 7-19.

7.6.9 Level adjustment system malfunctions

Malfunction Cause Action

Level adjustment system Level adjustment system key Switch on level adjustment
does not function switch switched off system key switch
The transmission is not in Shift the transmission to N;
neutral position
Suspension locking system Switch off suspension locking
switched on system
Fuse F2/5 Carrier defective Check fuse, replace if
necessary; ➠ p. 7-19.
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Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Blamk page

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

7.7 Procedure in the event of malfunctions

7.7.1 Switching the fan thermostat to emergency operation

The coolant is cooled by a heat exchanger. The speed of the fan in the
heat exchanger is regulated by a hydraulic valve with a thermostat. The
valve can be switched manually in the event of a thermostat malfunction.

G
Accidents may occur due to turning fan wheel!
Switch off the vehicle engine before switching on emergency operation.
If you switch the fan to emergency operation while the vehicle engine is
running, the fan wheel immediately begins to turn very quickly. Objects
or loose clothing can be sucked in with this.
Make sure that there are no people or objects in the vicinity of the fan
when switching to emergency operation.

The coolant water cooler is located on the

left side of the vehicle above the 1st axle line.

The tap (1) is located under the radiator and

is accessible through an opening in the side
plate.

• Close tap (1) for emergency operation. The

grip must be at right angles to the pipe
line. Close the tap slowly!

H After installing a new thermostat, the corresponding tap must be opened

again!
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Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

7.7.2 What to do if there is a transmission malfunction

If the transmission malfunctions, the electronic gear system will try to es-
tablish a secure operating condition for the transmission with the remai-
ning functions.

Error messages There are different error messages which are shown on the Gearbox control
on the Gearbox display in the event of a malfunction.
status display EE,
control display
the status display STOP and
the service symbol (the wrench).
Status display EE
If the Gearbox control display shows EE, there is a malfunction in the elec-
tronic gear system.
The status display can be shown continuously or it can flash.
The service symbol might also appear for some malfunctions.
• Proceed in the following manner to correct the malfunction:
– Turn off the ignition.
– Wait about 15 seconds.
– Switch on the ignition again.
If EE continues to be shown, and the transmission does not shift, consult
GROVE Product Support or the transmission manufacturer’s service de-
partment.

STOP status display

If the Gearbox control display shows STOP, the transmission can no longer
shift.
• Bring the truck crane to a stop as the traffic situation allows.
• Carry out the checks in the next section.

Service symbol
If the Gearbox control display shows the service symbol, the wrench,
when the ignition is turned on or when the vehicle engine is switched on;
➠ Starting the vehicle engine, p. 5-9.
If the service symbol is shown continuously, then the electronic gear
system has has recognised a malefunction or clutch emergency pedal
is folded out.
As long as the transmission continues to carry out all shifts, you can con-
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tinue to drive.
If the transmission no longer shifts:

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

• Check whether the Unlock clutch emergency pedal indicator lamp lights.
C In this case, you need the clutch emergency pedal to continue driving.
➠ Operation with the clutch emergency pedal, p. 7-37.

If the indicator lamp Release clutch emergency pedal does not light, proceed as
follows:
– Bring the truck crane to a stop as the traffic situation allows.
– Switch off the ignition and wait a few seconds.

H
– Switch on the ignition again.

If the transmission still does not shift, you can carry out an emergency
gear shift; ➠ Carring out an emergency gear shift, p. 7-39.

H If the service symbol is displayed, you should inform GROVE Product Sup-
port or the service department of the transmission manufacturer at the
next possibility. You should do this even if the transmission still shifts.
In this way you avoid that the transmission stops working entirely in case
there is a further small problem present.

Operation with If there is a malfunction in the automatic clutch operating mechanism,

the clutch emer- you can clutch with the clutch emergency pedal.
gency pedal

S
Danger of the transmission wearing out too quickly!
Only drive with the clutch emergency pedal if the Unlock clutch emergency
pedal indicator lamp is lit, and the transmission can no longer automa-
tically clutch. You cannot shift with the clutch emergency pedal as gently
as you ca with the electronic gear system.

Requirements
The Unlock clutch emergency pedal indicator lamp has to light.
C • Drive with the engaged gear to the next place where you can possibly
stop.
• Slow the truck crane down and switch into the neutral position shortly
before coming to a complete stop. In this way you prevent the motor
from cutting off.
• Engage the parking brake and turn off the vehicle engine.
• Switch on the ignition again.
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Operating Instructions GMK 5100 2 084 575 en 7 - 37
Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Unlock clutch emergency pedal

• Pull the Clutch emergency pedal release lever
(2).
The clutch emergency pedal (1) folds into the
operating position.

• Push on the clutch emergency pedal twice.

As soon as the clutch emergency pedal is

unlocked, the electronics will automatically
switch o the manual operating mode and the
Gearbox control display shows the service
symbol.

H The transmission can now only be shifted manually, regardless of the

position of the position of the Automatic/manual operating mode rocker
switch.

Driving with the clutch emergency pedal

• Select neutral on the transmission.
• Start the vehicle engine.

You have two possibilities for shifting:

– Either push the clutch emergency pedal first and start the gear change
with the gearshift lever or the two-stop rocker,
– or you select the gear first with the gearshift lever or the two-stop
rocker and start the gear change by pushing the clutch pedal.
Only let the clutch emergency pedal go when the newly engaged gear is

H
shown on the Gearbox control display.

If you let the clutch emergency pedal go too early, the transmission will
switch into neutral. The neutral position (N) will be indicated in the dis-
play by flashing and a repeating noise at the gearshift lever. In this case,
actuate the clutch emergency pedal within 2 seconds again without
actuating the gearshift lever or the two-stop rocker. The gear change will
be

H
carried out.
11.05.2000

As long as the clutch emergency pedal is actuated, the vehicle engine can-
not be turned off.

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Locking the clutch emergency pedal

When the malfunction has been corrected, you can lock the clutch emer-
gency pedal again.

• Stop the truck crane and engage the parking brake.

• Switch the vehicle engine off and turn off the ignition.

• Pull the Clutch emergency pedal release lever

(2) and hold on to it firmly.
• Push the clutch emergency pedal (1) as far
as possible and it will engage.
• Let go of the Clutch emergency pedal release
lever again.
The clutch emergency pedal is locked.

If there is no malfunction, the service symbol

in the Gearbox control display will now go out.

Carrying out an An emergency gear shift should only be carried out when:
emergency gear
shift – the transmission no longer shifts automatically,
– the Unlock clutch emergency pedal indicator lamp has gone out,
– the information in the section Error messages on the gearbox control
display (➠ p. 7-36) does not help.
In this case, the electronics can no longer direct the transmission. There
are a number of possible causes, including a pulled plug connection or a
broken cable.
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Operating Instructions GMK 5100 2 084 575 en 7 - 39
Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Emergency gear shifting when the truck crane is stationary

• Stop the truck crane and engage the parking brake.
• Allow the vehicle engine to run.
• Open the cover behind the gearshift lever.
• Press the clutch emergency pedal as far as possible.
• Press the Emergency gear shift for about a second and let it go again.
The transmission shifts to the neutral position.

The Emergency gear change has six shift positions. The positions NL and
NH are for servicing purposes.
R: in reverse gear NL: for servicing purposes1)
G: Home position NH: For service purposes 1) and
for towing
2: in 2nd gear 5: in 5th gear

You always have to shift from one shift position into a shift position
directly next to it.
• Press the Emergency gear change downwards and keep it depressed.
• Wait about 1 second, shift one shift position and wait in this position
again:
– about 1 second (for G, 2, 5, R)
– about 2 seconds (for NL and NH).
• Let the Emergency gear change go.
Now you have shifted by one shift position. To continue shifting to the
next position, you have to repeat all the steps.

1)
Are only used as intermediate steps during emergency shifting.

You can use the procedure above for a stationary truck crane to switch to
the following shift positions:

– from G to 2
– from 2 to 5 (step-by-step via NL and NH)
– from 2 to G
– from 5 to 2 (step-by-step via NL and NH)
– from G to R
– from R to G
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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Changing gears while the truck crane is moving

G
Damage to gearbox may occur!
No electronic monitoring is done during emergency operation. A gear
change will also be carried out if this leads to the maximal engine speed
being exceeded. For this reason, never engage the reverse gear or shift
from the 5th to the 2nd gear while the vehicle is in motion.

If you have started in 2, you can shift to 5 while driving:

• Press the clutch emergency pedal as far as possible.
• Proceed step-by-step, as described above, through the shifting
operations to NH - NL - 2.
• Slowly let the clutch emergency pedal go.

S
Danger of the transmission wearing out too quickly!
Have the problem with the transmission or the electronic gear system cor-
rected as soon as possible. You cannot shift with the clutch emergency
pedal as gently as you can with the electronic gear system.

Mechanical emer- When the truck crane is parked in gear and the pressure in the reservoir
gency shifting to falls below 5.5 bar (80 psi):
neutral
– the engine can not be started because the transmission is not in neutral
and
– the transmission may not be shifted to neutral because the pressure is
below 5.5 bar (80 psi) and
– the reservoir may not be filled because the engine is not running.
In this condition, the transmission can be shifted mechanically into neu-
tral in order to start the engine.

• Turn off the ignition.

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Operating Instructions GMK 5100 2 084 575 en 7 - 41
Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

For mechanical shifting, an adapter has been included on the selector

shaft. Using the adapter, the selector shaft can be turned with a wrench.

• Remove the cover plate from the transmission.

The selector shaft is located in front on the left side of the transmission,
under the hydraulic pumps.
• Place the adapter on the selector shaft (2)
such that the lugs (4) align with the
openings in the selector shaft (2).
• Slide the adapter onto the selector shaft
until it stops.
• Turn the adapter on the square neck (3)
using a wrench until one of the lugs lines
up with the marking (1).
In this position, the transmission is in neutral.
• Remove the adapter from the selector
shaft.

• Replace the cover plate and secure it.

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

7.7.3 Emergency operation of the solenoid valves for the outriggers

The truck crane has four groups of solenoid

valves for emergency operation of the out-
rigger beams and the outrigger cylinders.
A solenoid valve group (1) is located over
each outrigger beam.
Each solenoid valve group has four switches
(2). With the switches of a solenoid valve
group you can only move the outrigger
beams and outrigger cylinders on the side
opposite to them (➠ diagram p. 7-44).
The switches are only active when a second
person operates the the pressure build up
valve 47-Y9 at the same time.
You will only be able to reach the valve if
you crawl under the truck crane.

G
Risk of crushing when supporting cylinder is retracted!
When you actuate valve 47-Y9 to lower the truck crane with the support-
ing cylinders, be sure to place yourself under the crane in such a way that
you will not be crushed by the outrigger housing, the steering linkage,
the air reservoir or other parts.

Valve 47-Y9 is at the front of the forward

outrigger housing.

As long as the button (1) is pressed, the

outrigger beams and cylinders can be mo-
ved with the buttons at the solenoid valves.

The diagram on the next page shows you the position and designation of
the individual solenoid valves on the mobile crane. Which button to press
for the desired motion of the outrigger beam or supporting cylinder can
11.05.2000

be found in the accompanying table.

s
Operating Instructions GMK 5100 2 084 575 en 7 - 43
Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

G
Danger of accidents when outrigger movements are performed outside
of your field of view!
You will not be able to monitor the movement of the outrigger beams as
you are on the opposite side of the truck crane. Have a helper monitor the
movements of the outrigger beams and ensure you have visual contact
with him.

All the switches are numbered in the following diagram. Which switch
you must push for the desired motion (extending or retracting) of the
outrigger beams and the outrigger cylinders can be found in the table on
the next page.

VR HR

SR
1 2 1 2
V H
3 4 3 4

5 6 5 6
V H
7 8 7 8
SL

VL HL

C0523

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Front emergency operation Switch Valve designation in

V hydraulic circuit
diagram

left 4 44 Y 11
retract
Support cylinder right 6 44 Y 6
front
left 2 44 Y 51
extend
right 8 44 Y 2

left 1 44 Y 1
retract
Outrigger beam right 7 44 Y 61
front
left 3 44 Y 5
extend
right 5 44 Y 21

Rear emergency operation Switch Valve designation in

V hydraulic circuit
diagram

left 3 44 Y 7
retract
Support cylinder right 6 44 Y 8
rear
left 1 44 Y 3
extend
right 8 44 Y 4

left 2 44 Y 71
retract
Outrigger beam right 7 44 Y 81
rear
left 4 44 Y 31
extend
right 5 44 Y 41
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28.08.2000

Operating Instructions GMK 5100 2 084 575 en 7 - 45

Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Blank page

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7 - 46 2 084 575 en Operating Instructions GMK 5100

 Technical specifications carrier
8.1 Technical description of the carrier

8 Technical specifications carrier

8.1 Technical description of the carrier

8.1.1 Crane carrier

The following parts are screwed to the crane carrier:

– The travel drive units,
– the axle lines,
– the suspension system,
– the steering,
– the driver’s cab,
– the outriggers,
– the ball bearing connection to the crane superstructure.

8.1.2 Driver’s cab

The aluminium driver’s cab is equipped with safety glass. The operator’s
and second manïs seat are hydraulically damped. As additional equip-
ment, the driver’s cab can be equipped with a folding bed and a third seat.
All operating and control equipment for driving the truck crane is located
in the driver’s cab, which is heated by a heat exchanger with the engine
coolant.
As additional equipment, the coolant used to preheat the engine and to
heat the driver’s cab can be heated by an additional warm water heater
with a timer.

8.1.3 Drive units

The truck crane is powered by a water-cooled Mercedes-Benz diesel

engine with exhaust gas turbocharger.
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Operating Instructions GMK 5100 2 084 575 en 8-1
Technical specifications carrier
8.1 Technical description of the carrier

The axle lines are driven by a mechanical transmission with electronic

automatic gear changing and a rear-mounted transfer case.
The clutch operating mechanism and the gear changes are regulated by
the electronic gear system.
The transverse differential locks can be activated on all driven axle lines.
For driving off-the-road the following are possible:
– with 10 x 6 x 10 drive the longitudinal differential locks in the transfer
case and on the fourth axle line can also be switched on.
– with 10 x 8 x 10 drive the longitudinal differential locks in the transfer
case and on the fourth axle line can be switched on together with the
drive of the 3rd axle line.

8.1.4 Engine and gearbox cooling system

The engine is equipped with thermostat-controlled water cooling and a

charge cooling. A second radiator for transmission oil with automatic
gear change is integrated into the radiator. For cooling a viscous fan
on the diesel engine and a hydraulically driven fan on the radiator are
switched on by a thermostat.

8.1.5 Hydraulic system

The diesel engine drives a hydraulic system combination pump with three
variable displacement pumps. The hydraulic pumps are fed from the hy-
draulic tank (approx. 37 gal.) on the left side of the carrier and supply the
outrigger, the fans for engine cooling system, the suspension and both
steering circuits.
Another hydraulic pump is flanged onto the transfer case as an emer-
gency steering pump, and it supplies the steering circuit I during towing.
Two return flow filters on the hydraulic tank clean the hydraulic oil as it
flows back.

8.1.6 Steering

The steering gear is mechanically connected to the first, second, third and
fifth axle lines. The dual-circuit hydraulic steering supports the steering
movement through hydraulic cylinders on all steerable axle lines.
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 Technical specifications carrier
8.1 Technical description of the carrier

The steering is divided into two steering circuits which are supplied by
different hydraulic pumps. If steering circuit pump 1 malfunctions, an
emergency steering pump flanged onto the transfer case is switched on
automatically.

The steering system can be switched from normal steering mode to

separate steering for slow manouvering. This switches on the steering of
the 4th axle line. The wheels of the fourth and fifth axle lines are then
turned regardless of the steering direction of the front wheels.
With separate steering, the wheels of the 1st, 2nd and 3rd axle lines are
steered with the steering wheel; the fourth and fifth axle lines are steered
with the rocker switch of the separate steering at the driver’s seat.

If you switch to separate steering, you can drive with either all-wheel
steering or with crab travel mode:

– The size of the turning circle decreases with all-wheel steering.

The front and rear axle lines turn in opposite directions.
– The truck crane moves diagonally sideways in crab travel mode.
The front and rear axle lines now turn in the same direction.

8.1.7 Suspension system

All wheels are individually suspended from the crane carrier with hydro-
pneumatic suspension cylinders. The hydraulic system of the suspension
system is separated from the carrier’s hydraulic system by solenoid
valves.
The axle lines are interconnected respectively to suspension groups. The
wheel load is transferred equally between all axle lines of a suspension
group. The oil displaced when the suspension cylinders are compressed
is stored in pressure accumulators.
The suspension groups must be locked for various driving modes on the
site and during crane work. The suspension cylinders are separated from
the pressure accumulators by pneumatically operated blocking valves.
The overall level of the vehicle can be adjusted by extending and
retracting the suspension cylinders, if necessary in longitudinal and late-
ral direction. If the level of the vehicle is on-the-road level, the solenoid
valves are controlled by sensors on the suspension cylinders.
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Operating Instructions GMK 5100 2 084 575 en 8-3
Technical specifications carrier
8.1 Technical description of the carrier

8.1.8 Outrigger

The outrigger, like the suspension system, is supplied with hydraulic oil
from the carrier’s hydraulic system. The cylinders in the outrigger beams
and the outrigger cylinders are controlled separately via solenoid valves
from both sides of the carrier.

The outrigger beams can be operated from the carrier side only, from
where the movement may be observed. The outrigger cylinders can be
operated from both sides.

Each of the four outrigger beams consists of 2 beams, one of which is con-
tained in the other, which can be telescoped in and out using tackle lines.
Depending on the outrigger span, the carriers are extended one after the
other (for 25.6 x 24.6 ft span) or at the same time (for 25.6 x 16.7 ft span).

The status display for the alignment is normally done by one circular
spirit level on the right side and another on the left side of the carrier and
with another circular spirit level in the crane cab.
For additional equipment with inclinable crane cab, an electronic inclina-
tion indicator (electronic level) on the carrier detects the alignment of the
truck crane and displays it in display fields in the control boxes on each
side of the carrier. A further display is in the crane cab on the front instru-
ment panel.
Together with the inclinable crane cab and the electronic level, the sup-
port cylinders can be extended from the superstructure as additional
equipment, and, as further additional equipment, can be equipped with a
outrigger pressure indicator. With this, the hydraulic pressure is taken
directly into the individual supporting cylinders and indicated in tonnes (t)
on the display fields in control boxes on both sides of the carrier. Further
displays are located in the crane cab on the front instrument panel.

8.1.9 Compressed air system

The compressed air system comprises the air compression system,

the service brake, the parking brake and the control for the secondary
consumer.
The vehicle engine drives the compressor directly. The compressor takes
in dust-free air from the engine’s air intake system and conveys the com-
pacted air through the air drier with pressure regulator and conditioning
unit via the four-circuit protection valve in the tank.
When pumping up, the air in the air drier is conveyed by a highly porous
11.05.2000

drying agent. The dry air flows into the consumer system and into the
conditioning unit. When blowing off, the dry conditioned air flows back
through the air drier, extracts moisture from the drying agent and is
released outside.

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 Technical specifications carrier
8.1 Technical description of the carrier

A cartridge heater supports the drying process if the air temperature is

low. The compressed air system can be backfilled (e.g. when towing)
through the connection for independent ventilation. The tyres can be
filled with the compressed air system using the tyre inflation hose.

8.1.10 Service brake

The service brake (foot brake) is divided into two circuits for increased
road safety. Circuit I (brake circuit 1) effects the first and second axle line
and circuit II (brake circuit 2) effects the third to fifth axle line.
All wheels are braked pneumatically via directly controlled diaphragm
cylinders. The wheels on the first axle line have duplex wedge brakes and
the wheels on the second to fifth axle line have simplex wedge brakes.
All axle lines are equipped with automatic blocking inhibitor (ABV).
If a brake circuit should fail, a warning lamp lights up in the driver’s cab.

8.1.11 Parking brake

The parking brake (handbrake) is supplied by brake circuit 3. It has an

indirect effect on the 2nd to 6th axle lines via the spring-loaded brake
cylinder.
The parking brake can also be used as an auxiliary brake. The braking
force can be continuously adjusted with the parking brake lever.

8.1.12 Retarder

A motor flap brake is switch on as a retarder.

The truck crane can also be equipped with an eddy current retarder as
additional equipment.
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Operating Instructions GMK 5100 2 084 575 en 8-5
Technical specifications carrier
8.1 Technical description of the carrier

8.1.13 Secondary consumers

A 4th compressed-air circuit supplies all pneumatic secondary consumers of

the truck crane (e. g. activation of longitudinal and transverse differential
locks, drive of third axle line, gear change of transfer case, etc.).

8.1.14 Towing the crane

The truck crane is equipped with a towing coupling for towing operation.
The air reservoirs of all truck crane compressed-air circuits can be filled
by the towing vehicle via a filler connection.

8.1.15 Towing a trailer

The truck crane is equipped with a trailer coupling for towing a trailer
(additional equipment). The trailer brake valve is supplied by a coupling
from compressed-air circuit 3. Side lamps, stop light, driving direction in-
dicator etc. of the trailer are supplied via a plug connection from the elec-
trical system of the carrier.

8.1.16 Electrical system

The carrier’s 24 V on-board network is supplied by the alternator on the

vehicle engine and two batteries in the battery box at the left in front of
the air filter.
The electrical system includes the vehicle system of the carrier and the
limitation, position and rotating warning lights of the superstructure.

8.1.17 Slewing duct

To supply the marking lights, the position lights and the rotating warning
light with power for on-road driving, the superstructure and the carrier
are linked with a cable.
For additional equipment with inclinable crane cab, electronic level, opera-
ting the outriggers from superstructure or outrigger pressure indicator,
11.05.2000

this link is not applicable and the electrical supply is done via a slip ring
assembly.

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 Technical specifications carrier
8.2 Technical specifications

8.2 Technical specifications

GROVE truck crane GMK 5100

Permissible temperature range: –19 °F to +107 °F

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Operating Instructions GMK 5100 2 084 575 en 8-7

Technical specifications carrier
8.2 Technical specifications

8.2.1 Measurements and weights of the truck crane

Dimensions for Length: 48.16 ft (with counterweight for on-road driving)

driving on public Width: max. 9.02 ft with 14.00 R25 tyres
roads max. 9.84 ft with 16.00 R25 tyres

Height for on-the-road 12.82 ft –5.11 / +6.69 inch suspension range

level: with R 25 14.00 tyres
12.98 ft –5.11 / +6.69 inch suspension range
with 16.00 R 25 tyres
Front on-the-road ca. 20° at on-the-road level
Total weight: depending on the driving mode 110 231 lbs
or 132 277 lbs
Axle loads depending on the driving mode 22 050 lbs or
26 455 lbs
Driving modes for on-road driving ➠ section Driving mode, p. 6-5.
Dimensions and weights of the parts which must be transported on a
separate vehicle during on-road driving ➠ Dimensions and weights of remo-
vable parts, p. 8-9.
all measurements in mm

*) max.2 750 with 14.00 R25tyres

*) 3 000 with 16.00 R25 tyres

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*) more than 3 000 with 20.50 R25 tyres

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 Technical specifications carrier
8.2 Technical specifications

8.2.2 Dimensions and weights of removable parts

This section contains the transport dimensions and weights of those parts
which can be transported on separate vehicles during on-road driving.
On-the-road mode according to requirements ➠ p. 6-5.

Spare wheel
(additional
equipement)
Name Length x width x Weight
height (ft) (lbs)

Spare wheel with rim 14.00 R 25 4.92 x 4.92 x 1.31 528

Spare wheel with rim 16.00 R 25 4.92 x 4.92 x 1.47 660
(additional equipement)
Spare wheel with rim 20.50 R 25 4.92 x 4.92 x 1.96 759
(additional equipement)

Outrigger

Name Length x width x height Weight

(m) (kg)

Outrigger pad each 1.96 x 1.96 x 0.98 77

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Operating Instructions GMK 5100 2 084 575 en 8-9

Technical specifications carrier
8.2 Technical specifications

8.2.3 Carrier

Vehicle engine Make: Mercedes-Benz

Type: OM 502 LA
Power: 350 kW (476 hp) at 1800 min-1
(80/1269EWG, loose fan)

fuel tank: capacity ≈ 106 gal

Power shift DaimlerChrysler transmission G 240-16 with electronic automatic gear

transmission change, 16 forward gears, 2 reverse gears

Transfer case Kessler AD41 W2500 single stage transfer case with integrated central
gear and lockable longitudinal differential, which is pneumatically
actuated.

Axle lines Drive: 10 x 6 x 10,

1st axle line: steered axle line
2nd axle line: steered axle line
3rd axle line: steered and driven axle line
Fourth axle line: steered and driven axle line (steering can be switched on)
Fifth axle line: steered and driven axle line

Drive: 10 x 8 x 10 (additional equipement),

First axle line: steered and driven axle line
2nd axle line : steered and driven axle line
3rd axle line: steered and driven axle line (drive can be switched on)
Fourth axle line: steered and driven axle line (steering can be switched on)
Fifth axle line: steered and driven axle line

Steering Make: ZF
Type: dual-circuit hydraulic steering with emergency
steering pump
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The wheels of the 4th and 5th axle lines are steered separately when the
separate steering is switched on.

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 Technical specifications carrier
8.2 Technical specifications

Tyres 10 x 14.00 R 25, single rear wheels on disk wheels 9.50-25 / 1.7
(10 x 16.00 R 25 on disk wheels 11.00 - 25 / 1.7 as additional equipment)
(10 x 20.50 R 25 on disk wheels 17.00-25 / 1.7 as additional equipment)
Spare wheel 14.00 R-25, 16.00 R-25 or 20.50 R 25 with holder
as additional equipment)

Air pressure:

Tyres Air pressure (psi)

14.00 R 25 145

16.00 R 25 130

20.50 R 25 102
(Michelin)

20.50 R 25 116
(Bridgestone)

Outrigger Design: 4-point telescoping outrigger system, doubly telescopable

Control: Can be controlled individually from either side of the carrier.

Outrigger spans: 25.6 x 24.6 ft

25.6 x 16.7 ft
25.6 x 8.2 ft

Outrigger pad size: 23.6 x 23.6 inch

outrigger pad surface area: 557 in2

Maximum ou- Outrigger span Outrigger pressure

trigger pres-
sure:

25.6 x 24.6 ft front 113 100 lbs (ca. 113 080 lbf)
rear 141 980 lbs (ca. 142 080 lbf )

25.6 x 16.7 ft front 110 672 lbs (ca. 110 830 lbf)
rear 140 654 lbs (ca. 140 731 lbf)

Stroke of outrigger 21.65 inch backward

cylinders: 21.65 inch forward
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Operating Instructions GMK 5100 2 084 575 en 8 - 11
Technical specifications carrier
8.2 Technical specifications

Inclination indicator:, two circular spirit levels on the carrier,

a circular spirit level in the crane cab.
For additional equipment: Electronic inclination
indicator at the crane carrier (electronic level) with
displays on the carrier and in the crane cab.

Outrigger pressure Integrated in the outrigger, with digital display in

indicator: the switch box on the carrier and in the crane cab.
(additional equipment)

Vehicle’s Alternator: 28 V / 100 A

electrical
system Batteries: 2, each 12 V / 170 Ah
On-board voltage: 24 V

Tools 1 tool kit in tool box,

Wheel chocks (number according to country package)

Driving speeds Driving speed at an engine speed of 2000 rpm:

gear in the transmission with automatic gear change

1 3 5 16 16 R
Tyres
half gear half gear full gear half gear full gear

Approx. driving speeds in km/h(mph)

14.00 5,2 11,5 27,5 73,8 80,0 5,7

(3.2) (7.1) (17.1) (45.8) (49.6) (3.5)

16.00 5,7 12,5 30,0 80,2 85,0 6,2

(3.5) (7.8) (18.6) (49.7) (52.7) (3.8)

20.50 5,7 12,5 30,0 80,2 85,0 6,(3.8)

(3.5) (7.8) (18.6) (49.7) (52.7)
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 Technical specifications carrier
8.2 Technical specifications

Climbing ability Climbing ability with 132 277 lbs transport weight:

14.00 tires: 70.6%

16.00 tires: 63.0%

Driving circle radii

– for normal steering mode

– for separate steering mode

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Technical specifications carrier
8.2 Technical specifications

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8 - 14 2 084 575 en Operating Instructions GMK 5100

 9 Alphabetical index

H Explanations on how to use this index; ➠ p. 1-16.

In order to avoid unnecessary length and confusion in the alphabetical
index, not every single element of the instrument panels has been included.
These elements such as rocker switches, warning and indicator lamps as
well as status displays are described and named in detail in the overviews
of Chapter 4 and 7 Description of the truck crane.
From there you will be referred to more detailed descriptions of these
elements.
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Operating Instructions GMK 5100 2 084 575 en 9-1

 Blank page

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9-2 2 084 575 en Operating Instructions GMK 5100

 ALPHABETICAL INDEX

A Access ladders to the superstructure . . . . . . . . . . . . . . . . . . 4-44

Activating the ignition
carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Adding oil
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Additional heating system . . . . . . . . . . . . . . . . . . . . . 4-35, 6-62
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
display time, setting . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
additional heating system
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-108
Additional heating system with timer . . . . . . . . . . . . . . . . . . 6-64
automatic heating start, switch on and save . . . . . . . . . . . . 6-65
switching off automatic heating start . . . . . . . . . . . . . . . . 6-66
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
time, display/setting . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Additional water heating system
see Additional heating system
Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
on the superstructure . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Adjusting the seat
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Air-conditioning system
in the crane cab . . . . . . . . . . . . . . . . . 10-55, 12-110 to 12-112
in the driver’s cab . . . . . . . . . . . . . . . . . . . . 4-41, 6-67 to 6-70
All-wheel steering: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Anemometer
installing on the main boom . . . . . . . . . . . . . . . . . . . . 13-84
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Auxiliary hoist
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
working with the auxiliary hoist . . . . . . . . . . . . . . . . . . 12-44
Auxiliary hoist gear
display and operating instruments . . . . . . . . . . . . . . . . 10-34
axle drive
display and operating instruments in the driver’s cab . . . . . . . 4-25

B Battery master switch

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Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
bonnet
opening and closing . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Operating Instructions GMK 5100 2 084 575 en 9-3

 Boom floating position
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Boom initial tension
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Brakes
auxiliary brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
checking the brakes system . . . . . . . . . . . . . . . . . . . . . . 6-9
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
display and operating instruments in the driver’s cab . . . . . . . 4-26
eddy current retarder . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Breakdown
towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-12
Breakdown
procedure in road traffic . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4

C Carrier hydraulic system

check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
checking the position of the stop cocks . . . . . . . . . . . . . . . . 5-8
charge indicator
warning lamp, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Charge indicator lamp
after ignition has been switched on . . . . . . . . . . . . . . 5-9, 11-11
after the engine has been started . . . . . . . . . . . . . . . . . 11-13
after the vehicle engine has been started . . . . . . . . . . . . . . 5-13
CHECK LIST
retracting the outriggers . . . . . . . . . . . . . . . . . 13-15 to 13-40
rigging the counterweight . . . . . . . . . . . . . . . . . . . . . 13-46
unrigging the counterweight . . . . . . . . . . . . . . . . . . . . 13-48
Check the oil level
in the carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . 5-7
in the superstructure hydraulic system . . . . . . . . . . . . . . . 11-6
Checking the coolant level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Checking the oil level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Checking the steering lock . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Checking the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Checking the windscreen washing system
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in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
CHECKLIST
before starting crane work in winter . . . . . . . . . . . . . . . . . 11-3
condition of the truck crane for on-road driving . . . . . . . . . . . 6-1

9-4 2 084 575 en Operating Instructions GMK 5100

 extending the outriggers . . . . . . . . . . . . . . . . . . . . . . 13-13
rigging for crane operation with main boom . . . . . . . . . . . . 13-1
rigging mode when truck crane is rigged . . . . . . . . . . . . . . 12-1
starting the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-1
starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
unrigging for crane operation with main boom . . . . . . . . . . 13-4
working with the crane in winter . . . . . . . . . . . . . . . . . . . 5-3
Checks
after starting the crane engine . . . . . . . . . . . . . . . . . . . 11-13
after the engine has been started . . . . . . . . . . . . . . . . . . 5-12
before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
before starting the crane engine . . . . . . . . . . . . . . . . . . . 11-4
boom not set down warning lamp . . . . . . . . . . . . . . . . . . 6-11
of the safety equipment . . . . . . . . . . . . . . . . . . . . . . 12-14
prior to starting vehicle engine . . . . . . . . . . . . . . . . . . . . 5-4
while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Choosing the site . . . . . . . . . . . . . . . . . . . . . . . . 13-6 to 13-12
Compressed air system
see Brakes
Constant engine speed . . . . . . . . . . . . . . . . . . . . . . . . . 12-95
constant speed
see Tempostat
Control lever emergency program . . . . . . . . . . . . . . . . . . . 14-68
Conversion table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Counterweight lifting unit
current status, checking . . . . . . . . . . . . . . . . . . . . . . 13-58
2 t counterweight section on the turntable, locking / releasing . 13-62
3 t base plate, placing onto the counterweight platform . . . . . 13-50
3 t counterweight section, installing/removing . . . . . . . . . . 13-64
Extending/retracting the lifting cylinder . . . . . . . . . . . . . . 13-59
indication of a malfunction . . . . . . . . . . . . . . . . . . . . . 13-58
release/block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
unlock / lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Crab travel mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Crane cab
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53, 12-106
inclining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-109
Crane cab windscreen wipers . . . . . . . . . . . . . . . . . . . . . 10-50
Crane control
see acknowledging error messages
display and operating instruments . . . . . . . . . . . . . . . . 10-31
display of an error message . . . . . . . . . . . . . . . . . . . . 12-93
emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . 14-2
enter telescope status menu . . . . . . . . . . . . . . . . . . . . 14-76
entering power unit speeds menu . . . . . . . . . . . . . . . . . 12-89
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error memory sub-menu . . . . . . . . . . . . . . . . . . . . . . 12-86

error messages . . . . . . . . . . . . . . . . . . . . . . 14-57 to 14-78

Operating Instructions GMK 5100 2 084 575 en 9-5

 menu Display states . . . . . . . . . . . . . . . . . . . . . . . . 12-85
menu Display telescoping status . . . . . . . . . . . . . . . . . 12-88
menus on the display . . . . . . . . . . . . . . . . . . . . . . . . 12-85

Crane control emergency stop switch . . . . . . . . . . . . . . . . . . 14-2

Crane control error messages . . . . . . . . . . . . . . . . 14-57 to 14-78
Crane engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . 11-4
display and operating instruments . . . . . . . . . . . . . . . . 10-25
inspections after starting . . . . . . . . . . . . . . . . . . . . . . 11-13
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
setting a constant engine speed . . . . . . . . . . . . . . . . . . 12-95
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
starting - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
VDO electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
crane work
critical load control . . . . . . . . . . . . . . . . . . . . . . . . . 12-96
during the winter - CHECKLIST . . . . . . . . . . . . . . . . . . . . 5-3
in winter - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . 11-3
permissible slewing ranges . . . . . . . . . . . . . . . . . . . . 12-39
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
troubleshooting for malfunctions . . . . . . . . . . . . . . 14-3 to 14-4
Crane work with main boom
rigging - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
unrigging - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Critical load control . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96

D Dead man’s switch system . . . . . . . . . . . . . . . . . . . . . . . 10-62

derricking gear
display and operating instruments . . . . . . . . . . . . . . . . 10-36
lowering the main boom for maintenance . . . . . . . . . . . . 12-83
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
working with the derricking gear . . . . . . . . . . . . . . . . . 12-46
Differential locks
see Transverse differential locks
Door
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Drive of third axle line / longitudinal differential locks . . . . . . . . . . 7-8
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
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Driver’s cab
adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
adjusting the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

9-6 2 084 575 en Operating Instructions GMK 5100

 ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Driving
breakdown procedure . . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4
checks before driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
checks while driving . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
off-road . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 to 6-54
on uphill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
with a rigged crane . . . . . . . . . . . . . . . . . . . . 12-99 to 12-104
driving direction indicator . . . . . . . . . . . . . . . . . . . . . . . . 4-31
driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

E Earthing
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
electrical system
connection between the carrier and superstructure . . . . . . . . 6-24
display and operating instruments in the crane cab . . . . . . . 10-49
display and operating instruments in the driver’s cab . . . . . . . 4-30
fuses in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
fuses in the superstructure . . . . . . . . . . . . . . . . . . . . . . 14-7
plug-in modules and consoles in the crane cab . . . . . . . . . . 14-5
plug-in modules in the driver’s cab . . . . . . . . . . . . . . . . . 7-17
SLI fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Electronic level
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36
Emergency operation
solenoid valves for the outriggers . . . . . . . . . . . . . . . . . . 7-43
Emergency operation submenu on the Crane control display) . . . . 14-75
Emergency stop device
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 to 7-2
on the superstructure . . . . . . . . . . . . . . . . . . . . . 14-1 to 14-2
Enlarging the surface area of the outrigger . . . . . . . . . . . . . . . 13-8
Error messages
control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57
power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-58
SLI, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30

F Fast speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-84

Fire extinguisher
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
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Flame start system

in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel tank

Operating Instructions GMK 5100 2 084 575 en 9-7

 crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Fuses
in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
in the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
of the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13

H hazard warning system . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Heating system
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53, 12-106
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34, 6-59
Hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
checking the position . . . . . . . . . . . . . . . . . . . . . . . . 12-12
reeving on the main boom . . . . . . . . . . . . . . . . . . . . . 13-75
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-41
Hook block
on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . . . 13-71
on the bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Hydraulic system
display and control instruments . . . . . . . . . . . . . . . . . . . 4-28

I Identification
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
Instrument panels
in the crane cab - overview . . . . . . . . . . . . . . . . . . . . . . 10-6
in the driver’s cab - overview . . . . . . . . . . . . . . . . . . . . . 4-8

K Keys
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

L Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Lamp test SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
display and operating instruments . . . . . . . . . . . . . . . . . 4-31
moving the truck crane into on-road driving position . . . . . . . 6-52
raising or lowering the entire truck crane . . . . . . . . . . . . . . 6-50
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switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
tilting the truck crane lengthwise or crosswise . . . . . . . . . . . 6-51
Level of on-road driving
see On-the-road level

9-8 2 084 575 en Operating Instructions GMK 5100

 lifting limit switch
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
Lifting limit switch weight . . . . . . . . . . . . . . . . . . . . . . . 13-79
Load bearing capacity of the ground . . . . . . . . . . . . . . . . . . . 13-6
table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Locking the superstructure . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60

M Main boom
lower the boom for maintenance purposes . . . . . . . . . . . . 12-83
rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Main hoist
display and operating instruments . . . . . . . . . . . . . . . . 10-33
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
working with the main hoist . . . . . . . . . . . . . . . . . . . . 12-41
Main rope, possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-80
Malfunctions
hydraulic oil cooler for superstructure . . . . . . . . . . . . . . 14-28
counterweight lifting unit . . . . . . . . . . . . . . . . . . . . . 14-26
crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
differential locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
procedure in the event of malfunctions . . . . . . . . . . . 7-35 to 7-46
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
sevel adjustment system . . . . . . . . . . . . . . . . . . . . . . . 7-33
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
suspension locking system . . . . . . . . . . . . . . . . . . . . . . 7-33
tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
transmission with automatic gear change . . . . . . . . . . . . . 7-28
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
when working with the crane . . . . . . . . . . . . . . . . . . . . 14-3
Malfunctions on
crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
mirror heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Mounting wheel
on the spare wheel holder . . . . . . . . . . . . . . . . . . . . . . 7-14
on the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
movements which can be carried out simultaneously
for operation with the main boom . . . . . . . . . . . . . . . . . 12-98
multipurpose switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
11.05.2000

O Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 to 6-54

On-the-road level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Operating Instructions GMK 5100 2 084 575 en 9-9

 moving the crane into on-the-road level . . . . . . . . . . . . . . 6-52
Operating hour counter
see crane control, display status menu
Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-14
actuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
display and operating instruments . . . . . . . . . . . . . . . . 10-26
extending - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . 13-13
see also Level adjustment system
retracting - CHECKLIST . . . . . . . . . . . . . . . . . . 13-15 to 13-40
variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Outrigger beams
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
outrigger cylinders
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32, 13-40
Outrigger pads
moving into driving position . . . . . . . . . . . . . . . . . . . . 13-29
moving into working position . . . . . . . . . . . . . . . . . . . 13-28
Outrigger pressure displays
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-39
Outrigger spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Overview
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
crane section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
display and operating instruments . . . . . . . . . . . . . 4-1 to 4-20
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
of display and operating instruments . . . . . . . . . . . 10-1 to 10-24
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

P Parking brake
display and operating instruments . . . . . . . . . . . . . . . . . 4-27
releasing mechanically . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
removing the mechanical lock . . . . . . . . . . . . . . . . . . . . 7-10
while towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-80
Power unit speed
see crane control, entering power unit speeds

R Refuelling
11.05.2000

fuel for the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-9

fuel for the vehicle engine . . . . . . . . . . . . . . . . . . . . . . 6-17
Removing the tyre
from the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

9 - 10 2 084 575 en Operating Instructions GMK 5100

 Rigging mode
before starting work - CHECKLIST . . . . . . . . . . . . . . . . . . 12-1
setting on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20
Rigging work
main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-14
rigging for crane operation - CHECKLIST . . . . . . . . . . . . . . 13-1
unrigging after crane work - CHECKLIST . . . . . . . . . . . . . . 13-4
Roof ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Rope end clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
rotating warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

S Safe distance
from banks and pits . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
from electrical lines . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Safe load indicator
see SLI
Safety equipment
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
functional description . . . . . . . . . . . . . . . . . . 10-59 to 10-62
Sensor/indicator
releasing shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 14-38
switch off during malfunction . . . . . . . . . . . . . . . . . . . 14-38
Separate steering
checking the steering lock . . . . . . . . . . . . . . . . . . . . . . 6-11
unlocking fourth axle line steering . . . . . . . . . . . . . 6-56 to 6-57
general . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 to 6-58
steering the 4th and 5th axle lines . . . . . . . . . . . . . . . . . . 6-56
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
display and operating instruments . . . . . . . . . . . . . . . . 10-35
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
slewing gear permanent brake . . . . . . . . . . . . . . . . . . . 12-48
tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50
Slewing gear freewheel
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
SLI
display and operating instruments . . . . . . . . . . . . . . . . 10-41
during crane work . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
functional description . . . . . . . . . . . . . . . . . . . . . . . 10-59
fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
input of values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21
11.05.2000

lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
setting rigging mode . . . . . . . . . . . . . . . . . . . . . . . . 12-20
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

Operating Instructions GMK 5100 2 084 575 en 9 - 11

 SLI error message table . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
Spotlight for working area . . . . . . . . . . . . . . . . . . . . . . . 10-49
Steering
display and operating instruments in the driver’s cab . . . . . . . 4-29
steering column
operating instruments on the steering column . . . . . . . . . . . 4-20
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Stop engine cable
see emergency stop device
Superstructure hydraulic system
Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
checking the position of the stop cock . . . . . . . . . . . . . . . 11-7
cooling the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 12-97
display and control instruments . . . . . . . . . . . . . . . . . . 10-49
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
Superstructure lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Superstructure, access ladder . . . . . . . . . . . . . . . . . . . . . . 4-44
Suspension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Switching off the
crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Switching the fan thermostat to emergency operation . . . . . . . . . 7-35
Symbols in the operating instructions, explanation . . . . . . . . . . . 2-1

T Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
diagram sheets, inserting . . . . . . . . . . . . . . . . . . . . . . 6-22
open the drawer and check the time settings . . . . . . . . . . . . 6-21
time group, setting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Technical data
superstructure . . . . . . . . . . . . . . . . . . . . . . . . 15-7 to 15-16
Technical description of the carrier . . . . . . . . . . . . . . . . 8-1 to 8-6
Technical description of the truck crane
superstructure . . . . . . . . . . . . . . . . . . . . . . . . 15-1 to 15-6
Technical specifications . . . . . . . . . . . . . . . . . . . . . . 8-7 to 8-14
Telescoping gear
display and operating instruments . . . . . . . . . . . . . . . . 10-37
example of procedures when telescoping . . . . . . . . . . . . 12-62
function of the control lever . . . . . . . . . . . . . . . . . . . . 12-60
functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-54
main boom fixed length . . . . . . . . . . . . . . . . . . . . . . 12-55
main boom intermediate length . . . . . . . . . . . . . . . . . . 12-56
main boom telescoping length . . . . . . . . . . . . . . . . . . 12-56
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
11.05.2000

telescope status, status display on the SLI . . . . . . . . . . . . 12-56

telescoping sequence . . . . . . . . . . . . . . . . . . . . . . . . 12-59
telescoping, indicated on the crane control display. . . . . . . . 12-88
tempomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
driving with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

9 - 12 2 084 575 en Operating Instructions GMK 5100

 switching off: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
switching on: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
temposet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
driving with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
time
setting time in the crane cab . . . . . . . . . . . . . . . . . . . . . 4-36
topping up oil
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-12
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
in case of motor damage . . . . . . . . . . . . . . . . . . . . . . . . 7-5
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
with damaged transmission . . . . . . . . . . . . . . . . . . . . . . 7-7
Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 to 6-76
towing free
forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
transmission with automatic gear change
after ignition has been switched on . . . . . . . . . . . . . . . . . 6-25
directing of travel, changing . . . . . . . . . . . . . . . . . . . . . 6-30
direction of travel and starting gear, select . . . . . . . . . . . . . 6-27
display and operating instruments . . . . . . . . . . . . . . . . . 4-22
display and operating instruments in the driver’s cab . . . . . . . 4-22
display of the engaged gears . . . . . . . . . . . . . . . . . . . . 6-27
emergency gear shift . . . . . . . . . . . . . . . . . . . . . . . . 7-39
error messages on the gearbox control display . . . . . . . . . . 7-36
gear, changing while driving . . . . . . . . . . . . . . . . . . . . . 6-29
operating mode, select . . . . . . . . . . . . . . . . . . . . . . . . 6-26
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
operation with clutch emergency pedal . . . . . . . . . . . . . . . 7-37
procedure in the event of malfunctions . . . . . . . . . . . . . . . 7-36
shift in neutral position . . . . . . . . . . . . . . . . . . . . . . . . 6-26
starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Transverse differential locks
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Transverse differential locks in all driven axle lines . . . . . . . . . . . 6-48
Truck crane
checking horizontal alignment . . . . . . . . . . . . . . . . . . . 12-35
earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
freeing the crane by its own power . . . . . . . . . . . . . . . . . 6-52
horizontally align . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
in on-road driving position . . . . . . . . . . . . . . . . . . . . . . 6-52
11.05.2000

overview of the crane section . . . . . . . . . . . . . . . . . . . . 10-1

overview of the vehicle section . . . . . . . . . . . . . . . . . . . . 4-1
raising or lowering . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
rocking it free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

Operating Instructions GMK 5100 2 084 575 en 9 - 13

 safe distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
securing the truck crane from rolling . . . . . . . . . . . . . . . . 6-43
tilting the crane lengthwise or crosswise . . . . . . . . . . . . . . 6-51
towing free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Tyre change
see Wheel change

V Vehicle engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
diagnostics plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
display and operating instruments . . . . . . . . . . . . . . . . . 4-21
inspections after starting . . . . . . . . . . . . . . . . . . . . . . . 5-12
preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62, 6-64
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9, 11-10
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
starting - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
starting a warm engine . . . . . . . . . . . . . . . . . . . . . . . . 5-11
starting cold vehicle engine . . . . . . . . . . . . . . . . . . . . . 5-10
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Ventilation
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-109
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34, 6-61

W Warning plates for vehicle width

connection between the carrier and superstructure . . . . . . . . 6-24
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 to 7-16
wheel, removing
from the spare wheel holder . . . . . . . . . . . . . . . . . . . . . 7-14
Wind
influence of wind on crane work . . . . . . . . . . . . . . . . . . 12-36
permissible wind load . . . . . . . . . . . . . . . . . . . . . . . 12-38
wind speed table . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Wirbelstromretarder
see Bremsen
Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-105
for work breaks lasting more than 8 hours . . . . . . . . . . . . 12-105
short work break . . . . . . . . . . . . . . . . . . . . . . . . . . 12-105
11.05.2000

9 - 14 2 084 575 en Operating Instructions GMK 5100

Operating Instructions Part 2 Superstructure
Vehicle serial number: 2 084 575 en
11.05.2000
 Important note

Duplications of any kind and excerpts from this

document are not subject to the alterations
service. Original documents of Deutsche GROVE
GmbH are marked with the blue serial number of
the truck crane on the cover page.

Duplications and print-outs of data carriers on

which Deutsche GROVE GmbH has delivered this
document are also not subject to the alterations
service.

©
Copyright reserved by leerleerleerleerleerleer
11.05.2000

The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited
unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility
model are reserved.
 These operating instructions consist of two parts:
– Part 1 – Carrier
– Part 2 – Superstructure

Part 2 comprises the following chapters:

10 Description of the truck crane – crane section

11 Crane engine

12 Crane operation

13 Rigging work

14 Malfunctions on the superstructure

15 Technical information for superstructure

16 Alphabetical index

Chapters 1 to 9 are in part 1 – Carrier

This section is not equivalent to complete

operating instructions. The basic safety
information for working with the crane can be
found in Section 1, Chapter 2.
11.05.2000

Operating Instructions GMK 5100 2 084 575 en

 11.05.2000

2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10 Description of the truck crane – crane section

10.1 Overview of the operating and display instruments

This section deals only with display and operating instruments for crane
operations which are located on the outside of the mobile crane and in
the crane cab.

10.1.1 Overview of crane section

The figure on the following page shows the position of the operating and
control instruments on the outside of the truck crane which are necessary
for crane work.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 10 - 1
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

11.05.2000

10 - 2 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Main hoist ➠ p. 10-33

2 Compensation weight or ➠ p. 13-51
auxiliary hoist (additional equipment) ➠ p. 10-34
3 Counterweight ➠ p. 13-41
4 Hydraulic cooler (second cooler is additional ➠ p. 12-97
equipment)

5 Rear outrigger (outrigger beam, outrigger pad) ➠ p. 13-13

6 Hydraulic oil tank, inspection glass ➠ p. 11-6
7 Storage box and access ladder

8 Crane cab (for additional equipment inclinable) ➠ p. 10-4

➠ p. 10-20
9 Switch box for operating the outriggers and ➠ p. 10-23
switch box for electronic level (additional equipment) ➠ p. 10-24
outrigger pressure indicator (additional equipment) ➠ p. 10-24
10 Spotlight for working area (additional equipment) ➠ p. 10-49
11 Front outrigger (outrigger beam, outrigger pad) ➠ p. 13-13
12 Hook block ➠ p. 13-69
13 Data transmitter

14 Crane engine fuel tank filler pipe ➠ p. 11-9

15 Slewing gear ➠ p. 12-48
16 Central lubrication unit ➠ Mainte-
nance
manual

17 Battery master switch ➠ p. 11-7

18 Crane engine ➠ p. 11-1
19 Mirror for observing the course of the hoist rope ➠ p. 12-12
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Operating Instructions GMK 5100 2 084 575 en 10 - 3

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.2 Crane cab overview

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10 - 4 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Front instrument panel ➠ p. 10-6

2 Accelerator

3 Right control console ➠ p. 10-21

4 Crane operator’s seat with dead man’s switch ➠ p. 10-62
5 Crane control ➠ p. 10-31
6 Air-conditioning system ➠ p. 10-55
7 Crane engine diagnostic plug ➠ p. 10-58
8 Fire extinguisher (additional equipment) ➠ p. 10-57
9 Left control console ➠ p. 10-20
10 Slewing gear service brake pedal ➠ p. 10-36
11 Foot-operated switch for fast speed hoisting gear ➠ p. 10-37
➠ p. 10-41
12 Foot-operated switch for free movement of the ➠ p. 10-33
slewing gear

13 Ignition lock ➠ p. 10-49

14 Heater fan knob ➠ p. 10-53
15 Regulator for windscreen / cab floor air distribution ➠ p. 10-53
16 Recirculated air / fresh air regulator ➠ p. 10-53
17 Temperature regulator ➠ p. 10-53
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Operating Instructions GMK 5100 2 084 575 en 10 - 5

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.3 Instrument panel

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10 - 6 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Status display for oil temperature in hydraulic system ➠ p. 10-49

2 Status display for temperature of crane engine ➠ p. 10-25
coolant

3 Fuel gauge ➠ p. 10-26

4 Warning lamp for charge indicator ➠ p. 10-49
5 Indicator lamp for crane motor air filter ➠ p. 10-25
6 Warning lamp for crane engine oil pressure ➠ p. 10-26
7 Engine electronics warning lamp ➠ p. 10-26
8 Crane engine coolant level warning lamp ➠ p. 10-25
9 Flame start system indicator lamp (additional ➠ p. 10-25
equipment)

10 Hydraulic oil filter warning lamp control circuit ➠ p. 10-49

11 Hydraulic oil return filter ➠ p. 10-49
12 Rocker switch socket for left spotlight for working area ➠ p. 10-49
13 Rocker switch socket for right spotlight for working ➠ p. 10-49
areas (additional equipment)

14 Rocker switch for hoist rope control spotlight ➠ p. 10-50

(additional equipment)

15 Rocker switch with indicator lamp for additional ➠ p. 10-53

heating system *)(additional equipment)

16 Rocker switch for windscreen wiper ➠ p. 10-50

17 Rocker switch for roof window wiper ➠ p. 10-50
18 Rocker switch for intermittent front and roof wiper ➠ p. 10-50
19 Rocker switch for windscreen wiper/washing system ➠ p. 10-50
20 Additional heating system with timer*)
(additional equipment)

*)Either 15 or 20 possible as additional equipment.

The operating instruments of the additional heating system with timer 20
are identical to those for the additional heating system in the carrier;
11.05.2000

➠ p. 4-18

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Operating Instructions GMK 5100 2 084 575 en 10 - 7
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Crane control display ➠ p. 10-31

2 View and input display membrane switch ➠ p. 10-31
3 Conditions display membrane switch ➠ p. 10-32
4 Driving gear speed / limit engine speed sensing ➠ p. 10-32
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5 Control lever emergency program membrane switch ➠ p. 10-32

10 - 8 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

6 Telescoping display and teleautomatism membrane ➠ p. 10-32

switch
7 Entering telescope status for emergency operation ➠ p. 10-32
membrane switch
8 Right control lever indicator lamp in telescope function ➠ p. 10-38
9 Right control lever indicator lamp for derricking ➠ p. 10-36
function,
10 Telescoping cylinder indicator lamp on the locking ➠ p. 10-39
point
11 Telescoping cylinder position light at foot section I ➠ p. 10-38
12 Telescoping cylinder position light at foot section II ➠ p. 10-38
13 Telescoping cylinder position light at foot section III ➠ p. 10-38
14 Telescoping cylinder position light at foot section IV ➠ p. 10-38
15 Crane control emergency stop switch ➠ p. 10-33
16 Telescopic part locked indicator lamp ➠ p. 10-40
17 Telescopic part unlocked warning lamp ➠ p. 10-40
18 Telescoping cylinder locked indicator lamp ➠ p. 10-40
19 Telescoping cylinder unlocked warning lamp ➠ p. 10-40
20 Select rocker switch locking/unlocking ➠ p. 10-39
21 Counterweight lifting cylinder retracted indicator lamp ➠ p. 10-30
22 Counterweight locked indicator lamp ➠ p. 10-30
23 Rocker switch with lock button and counterweight ➠ p. 10-29
hoist unit release indicator lamp

24 Counterweight lifting cylinder extended indicator lamp ➠ p. 10-30

25 Rocker switch with lifting cylinder extend/retract ➠ p. 10-29
indicator lamp

26 Counterweight unlocked warning lamp ➠ p. 10-30

27 Rocker switch with counterweight locked/unlocked ➠ p. 10-29
indicator lamp
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Operating Instructions GMK 5100 2 084 575 en 10 - 9

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

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10 - 10 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Crane cab electronic level (additional equipment) ➠ p. 10-52

2 Anemometer ➠ p. 12-36
3 Warning lamp for lifting limit switch shutdown ➠ p. 10-34
4 Front left outrigger pressure display ➠ p. 10-54
(additional equipment)

5 Indicator lamp for slewing gear permanent brake ➠ p. 10-35

6 Slewing gear brake oil temperature warning lamp ➠ p. 10-36
7 Front right outrigger pressure display ➠ p. 10-54
(additional equipment)

8 Superstructure unlocked indicator lamp ➠ p. 10-35

9 Rear left outrigger pressure display ➠ p. 10-54
(additional equipment)

10 Indicator lamp for locked superstructure ➠ p. 10-35

11 Rear right outrigger pressure display ➠ p. 10-54
(additional equipment)

12 Rocker switch for superstructure lock ➠ p. 10-35

13 Rocker switch with indicator lamp for the measuring ➠ p. 10-52
range of the level indicator (crane cab)

14 Override key switch

– for safe load indicator (SLI) ➠ p. 10-51
– for lifting limit switch ➠ p. 10-61
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Operating Instructions GMK 5100 2 084 575 en 10 - 11

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 2 3 4

5
6
7
8

9
0

C0566
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10 - 12 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Display for current status of telescope section I ➠ p. 10-42

2 Display for current status of telescope section II ➠ p. 10-42
3 Display for current status of telescope section III ➠ p. 10-42
4 Display for current status of telescope section IV ➠ p. 10-42
5 Status display for lattice extension angle with ➠ p. 10-42
membrane switch

6 Indicator lamp for SLI shutdown ➠ p. 10-45

7 SLI early warning lamp ➠ p. 10-45
8 Status display for lattice extension length with ➠ p. 10-42
membrane switch

9 Display for maximum load ➠ p. 10-43

10 Display for degree of utilization ➠ p. 10-43
11 Display for actual load ➠ p. 10-43
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Operating Instructions GMK 5100 2 084 575 en 10 - 13
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 2 3 4
5

6 7 8 9
0 q w e

a btc d e
C0852 fghij
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10 - 14 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Membrane switch with warning lamp for error ➠ p. 10-43

information

2 Without function (in preparation)

3 Membrane switch with indicator lamp for permissible ➠ p. 10-43

slewing range

4 Membrane switch with indicator lamp for main boom ➠ p. 10-44

5 Information status display ➠ p. 10-45
6 Membrane switch with indicator lamp for main boom ➠ p. 10-44
length

7 Membrane switch with indicator lamp for height of ➠ p. 10-44

single-sheave boom top

8 Without function

9 Membrane switch with indicator lamp for degree of ➠ p. 10-44

utilization

10 Without function (in preparation) ➠ p. 10-44

11 Membrane switch with hydraulic oil pressure indicator ➠ p. 10-44
lamp for derricking cylinder lower chamber Sensor A

12 Membrane switch with hydraulic oil pressure indicator ➠ p. 10-45

lamp for derricking cylinder lower chamber Sensor B

13 Membrane switch with indicator lamp for hydraulic oil ➠ p. 10-45

pressure in derricking cylinder upper chamber

14 Outrigger span display with membrane switch ➠ p. 10-47

15 Numerical pad with membrane switches 1 to 0 ➠ p. 10-47
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Operating Instructions GMK 5100 2 084 575 en 10 - 15
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

2
1 3
4
5
6
78 9 0 ! w

C0806
e r
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10 - 16 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Counterweight display with membrane switch ➠ p. 10-45

2 Hoist display lamps ➠ p. 10-46
3 Display for current main boom angle ➠ p. 10-42
4 Reeving display with membrane switch ➠ p. 10-46
5 Rigging mode display (SLI code) with membrane ➠ p. 10-45
switch

6 Actual radius status display ➠ p. 10-42

7 Service key switch ➠ p. 10-46
8 Entry mode membrane switch ➠ p. 10-48
9 Lamp test membrane switch (2nd level assignment) ➠ p. 10-48
10 Dimmer brighter membrane switch ➠ p. 10-48
(2nd level assignment)

11 Dimmer darker membrane switch ➠ p. 10-48

(2nd level assignment)

12 Membrane switch to acknowledge ➠ p. 10-47

13 Membrane switch to switch to second level ➠ p. 10-48
14 Membrane switch to confirm entry ➠ p. 10-47
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Operating Instructions GMK 5100 2 084 575 en 10 - 17
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

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10 - 18 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Circular spirit level (does not apply for additional ➠ p. 13-36

equipment with electronic level)

2 Engine electronic system carrier warning lamp ➠ p. 10-28

3 Retract support cylinder indicator lamp 1) ➠ p. 10-28
4 Direction of movement outrigger rocker switch 1) ➠ p. 10-28
5 Extend support cylinder indicator lamp 1) ➠ p. 10-28
6 Vehicle engine cutout rocker switch 1) ➠ p. 10-28
7 Front left outrigger rocker switch 1) ➠ p. 10-28
8 Front right outrigger rocker switch 1) ➠ p. 10-28
9 Vehicle engine starter rocker switch 1) ➠ p. 10-28
10 Rear left outrigger rocker switch 1) ➠ p. 10-29
11 Rear right outrigger rocker switch 1) ➠ p. 10-28
12 Constant motor speed rocker switch ➠ p. 10-51

1)
additional equipment
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Operating Instructions GMK 5100 2 084 575 en 10 - 19

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.4 Left control console

1 Control lever for slewing gear ➠ p. 10-36

and auxiliary hoist (additional equipment) ➠ p. 10-34
2 Horn button

3 Dead man’s switch ➠ p. 10-62

4 Hoist drum synchro for auxiliary hoist ➠ p. 12-42
(additional equipment)

5 Rocker switch for slewing gear permanent brake ➠ p. 10-35

6 Rocker switch for auxiliary hoist shutdown ➠ p. 10-34
(additional equipment)

7 Rocker switch to incline crane cab (additional ➠ p. 10-51

equipment)
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 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.5 Right control console

1 Control lever for main hoist and derricking ➠ p. 10-36

gear/telescoping gear ➠ p. 10-37
2 Horn button

3 Dead man’s switch ➠ p. 10-62

4 Hoist drum synchro for main hoist ➠ p. 12-42
5 Rocker switch for main hoist shutdown ➠ p. 10-33
6 Rocker switch for shutdown derricking gear ➠ p. 10-36
7 Rocker switch for telescoping gear shutdown ➠ p. 10-37
8 Rocker switch for preselecting control lever function ➠ p. 10-36
derricking / telescoping ➠ p. 10-37
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Operating Instructions GMK 5100 2 084 575 en 10 - 21

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.6 Controls and fittings behind the crane operator’s seat

1 Loudspeaker,

2 Radio

3 Cab lighting

H The cab lighting is operated in the same way as in the driver’s cab;
➠ p.4-42.

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 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.7 Control box for operating the outriggers

2
6
3

5 4

C0117

1 Control box lighting

2 Toggle switch for preselection of outrigger cylinder / ➠ p. 10-26

outrigger beam

3 Toggle switch for front left outrigger ➠ p. 10-27

4 Toggle switch for front right outrigger ➠ p. 10-27
5 Toggle switch for rear right outrigger ➠ p. 10-27
6 Toggle switch for rear left outrigger ➠ p. 10-27
7 Toggle switch for preselection of direction of outrigger ➠ p. 10-26
movement

8 Central outrigger toggle switch with speed control ➠ p. 10-27

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Operating Instructions GMK 5100 2 084 575 en 10 - 23

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.8 Electronic level switch box (additional equipment)

1 Switch over measuring range toggle switch 1) ➠ p.10-52

2 Electronic level status display 1)
➠ p.13-36
3 Carrier outrigger pressure indicator 1) ➠ p.13-39

1)
additional equipment

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

10.2 Functional description of the display and operating

instruments
Definition of direction information for using operating elements;
➠ p. 1-16.

10.2.1 Crane work

Crane engine

Ignition lock
To switch on the ignition and to start the crane engine;
➠ Starting the crane engine, p. 11-10.

Indicator lamp for flame start system (additional equipment)

z Illuminates when the ignition is switched on and the crane engine is cold.
Goes out when the crane engine is ready to start;
➠ Starting crane engine, p. 11-11.
Warning lamp for crane engine coolant level
t Illuminates if the fluid level in the coolant water circuit of the crane engine
is too low; ➠ Checking the instruments, p. 11-13.

Status display for coolant temperature in crane engine

The temperature of the coolant should not exceed 95°C (203 °F).
If the coolant temperature exceeds the maximum temperature, a warning
buzzer will sound. ➠ Crane engine malfunctions, p. 14-15.

Indicator lamp for crane engine air filter

p Illuminates if the air filter is dirty.
Change the filter element; ➠ Maintenance manual.
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Operating Instructions GMK 5100 2 084 575 en 10 - 25
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for crane engine oil pressure

L Illuminates if the oil pressure is too low; ➠ Malfunctions in the crane engine,
p. 14-15.

Status display for fuel reserve

Never allow the fuel tank to become completely empty! ➠ p. 11-9.

C0013

Engine electronics warning lamp;

à Illuminates when the ignition is switched on.
Goes out when the engine is running and the engine’s electrical system is
functioning properly.
It lights when the engine is running and there is an engine electronic
system malfunction; ➠ p. 11-13.

Outrigger ➠ Outrigger, p. 13-13

operation

Toggle switch for preselection of direction of outrigger movement

Extending outrigger beam or cylinder: Rocker switch upwards;
➠ Extend outriggers,
p. 13-23.
Retracting outrigger beam or cylinder: Rocker switsch downwards;
C0120 ➠ Retract outrigger beam,
p. 13-26.

Toggle switch for preselection of outrigger cylinder / outrigger beam

Extend / retract outrigger beam: Rocker switch upwards;
➠ Extend outriggers,
p. 13-23.
Extending / retracting outrigger cylinder: Rocker switsch downwards;
C0121 ➠ Extend/retract outrigger
cylinders, p. 13-30.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Central toggle switch for outriggers with speed control

Moving the outrigger while the Push upwards to build up

vehicle engine is at idling speed: outrigger pressure.

Moving the outrigger while the

Push downwards to build up
vehicle engine is at increased
C0119 outrigger pressure;
engine speed:
➠ Extend outriggers, p. 13-23.

H With the following Outrigger toggle switches, only those outrigger beams
can be actuated which are on the same side of the vehicle as the toggle
switches.

Toggle switch for front right outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this

switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.
C0122

Toggle switch for front left outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this
switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.
C0123

Toggle switch for rear right outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this
switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.

C0124

Toggle switch for rear left outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this
switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.
C0125
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Operating Instructions GMK 5100 2 084 575 en 10 - 27
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Outrigging from ➠ Operating the outriggers from the crane cab, p. 13-33.
the crane cab
(additional equip-
ment)
Rocker switch for vehicle engine starter
k For starting the vehicle engine from the crane cabin.
Start vehicle engine: Press the rocker switch down.

Rocker switch for vehicle engine cutout

d For turning off the vehicle engine from the crane cabin.
Stop vehicle engine: Press the rocker switch down.

Carrier engine electronic system warning lamp

à Lights while the vehicle engine is being started from the superstructure. It
goes out while the engine is running. It lights when the vehicle engine is
running and there is an engine electronic system malfunction; ➠ p. 14-15.

Outrigger direction of movement pre-selection rocker switch

) Extending the support cylinders: Press rocker switch down.
Retracting the outrigger cylinders: Press rocker switch up.

Retract support cylinder indicator lamp

P Lights if the Outrigger direction of movement pre-selection rocker switch has
been pressed up.

Extend support cylinder indicator lamp

P Lights if the Outrigger direction of movement pre-selection rocker switch has
been pressed down.

Rocker switch for front right outrigger

/ Movement of the support cylinder or outrigger beam by simultaneously
pressing this switch and the rocker switch for Outriggers direction of move-
ment.

Rocker switch for front left outrigger

- Movement of the support cylinder by simultaneously pressing this switch
and the Outrigger central rocker switch.

Rocker switch for rear right outrigger

B Movement of the support cylinder by simultaneously pressing this switch
and the Outrigger central rocker switch.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Rocker switch for rear left outrigger

A Movement of the support cylinder or outrigger beam by simultaneously
pressing this switch and the Outriggers direction of movement rocker switch.

Counterweight  Counterweights, p. 13-41

lifting unit  Counterweight hoist unit, p. 13-57
Rocker switch with lock button and indicator lamp for release of counter-
M weight lifting unit
For turning the constant engine speed on and off. Protects against unin-
tentional actuation of the counterweight hoist unit.
The rocker switch may only be pressed down if the lock button is pushed
down simultaneously.

Switch on counterweight lifting gear: Press rocker switch down,

the indicator light lights brightly.
Switch off counterweight lifting gear: Press rocker switch down,
the indicator lamp glows.

When the counterweight hoist unit is switched on, the indicator lamps
in the Lock /unlock counterweight and Extend/retract lifting cylinder rocker
switches light.

Rocker switch with extend/retract counterweight lifting cylinder indica-

: tor lamp indicator lamp
The counterweight lifting units can only be extended or retracted when
the indicator lamp in the rocker switch is lit.

Extend counterweight lifting unit: Press rocker switch down.

Retract counterweight lifting unit: Press rocker switch up.

Rocker switch with the lock/unlock counterweight position light

R Activates the slewing movement of the counterweight lifting cylinder in
order to lock or unlock the counterweight with the counterweight lifting
cylinders.
The position light lights if the counterweight hoist unit is turned on. The
counterweight can only be locked or unlocked if the counterweight lifting
cylinders are extended fully.
Lock the counterweight: Press rocker switch up.
Unlock the counterweight: Press rocker switch down.
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Operating Instructions GMK 5100 2 084 575 en 10 - 29
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Indicator lamp for counterweight lifting cylinder extended

Q Lights when the counterweight lifting cylinder have been extended.
Alternates in flashing with the Counterweight lifting cylinder retracted indica-
tor lamp if the lifting cylinder still has not reached an end position.
Flashes at the same time as the Counterweight lifting cylinder retracted indica-
tor lamp if the crane control has recognised an error or an incorrect condi-
tion.

Indicator lamp for counterweight lifting cylinder retracted

P Lights when the counterweight lifting cylinder have been completely
retracted.
Alternates in flashing with the Counterweight lifting cylinder extended indica-
tor lamp if the lifting cylinder still has not reached an end position.
Flashes at the same time as the Counterweight lifting cylinder extended indica-
tor lamp if the crane control has recognised an error or an incorrect condi-
tion.

Indicator lamp for locked counterweight

N Lights when the lifting cylinders have been turned to Locked position.
Alternately flashes with the Counterweight unlocked warning lamp if the
lifting cylinders are in a position between Locked and Unlocked.
Flashes at the same time as the Counterweight unlocked indicator lamp if
the crane control has recognised an error or an incorrect condition.

Counterweight unlocked warning light

O Lights when the lifting cylinders have been turned to Unlocked position.
Alternately flashes with the Counterweight locked indicator lamp if the lifting
cylinders are in a position between Locked and Unlocked.
Flashes at the same time as the Counterweight locked indicator lamp if the
crane control has recognised an error or an incorrect condition.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Crane control ➠ Menus in the crane control display, p. 12-85.

Crane control display
Is switched on together with the ignition.
The readiness display SYSTEM OK! appears
******************************* after switching on.
The display shows error messages from the
ECOS
crane control system and information on the
SYSTEM OK! current conditions of different areas.
******************************* Each area has its own menu.

The various menus are selected by pressing the following membrane

switches:
– Membrane switch Display states
> – Membrane switch Power unit speeds/critical load control
@ – Membrane switch Control lever emergency program
ü – Membrane switch Display telescope status and teleautomatic
ä – Membrane switch Enter telescope status after emergency operation
Ä Error messages are displayed with priority immediately after a mal-
function occurs; ➠ Menus in the crane control display, p. 12-85.

H The text of the crane control display can be shown in German, English,
French, Dutch, Spanish, Italian, Danish, Finnish, Swedish, Portuguese,
Polish and Russian. In addition, metres or feet can be set as the unit of
measurement. The language and the unit of measurement are set at ship-
ment. If you need to change the setting, please contact GROVE Product
Support.

Membrane switch for view and entry display

The View and entry display membrane switches serve to acknowledge error
messages and to enter values in the selected range and to switch be-
tween the menu points.
The necessary membrane switches are activated if the Crane control display
indicates an error message or if settings can be carried out in the dis-
played menu.

Both left-hand membrane switches have an additional function and are al-
: ways active. They serve to switch between menu points in increasing or
decreasing order within a menu.
<
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Operating Instructions GMK 5100 2 084 575 en 10 - 31
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Display states membrane switch

> Pushing the switch selects the Display states menu. This menu shows the
current states and the operating hours of the crane engine, the hoists, the
derricking gear, the slewing gear, the telescoping gear, the control units
and the locking devices.
If a function is completely or partially blocked by the crane control
system due to a malfunction, the menu displays that a malfunction is
present; ➠ Display states menu, p. 12-85.

Power unit speeds/critical load control membrane switch

@ Pressing the switch selects the Power unit speed/Critical load control menu.
In this menu, one can enter the maximum speed for main boom and
lattice extension operation for the slewing gear, hoists, telescoping gear
and derricking gear. The critical load control can be switched on and off in
another submenu;
The critical load control can be switched on and off in another submenu;
➠ Power unit speed/critical load control menu, p. 12-89.
➠ Critical load control, p. 12-96.
Control lever emergency program membrane switch
ü Pushing the switch selects the Control lever emergency program menu. If one
control lever fails, the corresponding crane motions can be carried out in
an emergency using this menu; ➠ Control lever emergency program, p. 14-68.

Display telescope status and teleautomatic membrane switch

ä Pressing the switch selects the Display telescope status and teleautomatic
menu. This menu shows the current telescoping status of all telescope
sections as a percentage.
If all telescope sections are locked, the current extended length of the tele-
scoping cylinder is shown in feet;
➠ Telescoping gear, p. 12-53.
By pressing the switch again, the submenu Fully automatic telescope is
selected; ➠ Telescoping with fully automatic control, p. 12-79.

Entering telescope status after emergency operation membrane switch

Ä The menu Enter telescope status after emergency operation is selected with the
switch. In order to select the menu, the switch must be pressed three
times in a row within 2 seconds. This menu is required to enter the
current telescope status if the crane control system is to be suddenly cut
off from the power supply during storage of the values or if telescoping
was done in emergency mode; ➠ Enter telescope status after emergency
operation, p. 14-76.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Crane control emergency stop switch

To switch off the crane control system in an emergency. Switches off all
crane engine immediately. Crane functions are stopped suddenly.

Stop crane functions: Push in the emergency stop switch

The switch clicks in

Release crane functions again: Turn the emergency stop switch

The switch pops back out
➠ Crane control emergency stop, p. 14-2

Main hoist ➠ Main hoist, p. 12-41

Rocker switch for main hoist shutdown
ü Shuts off the main hoist to prevent inadvertent operation.
Switching off the main hoist: Press rocker switch down
Switching on the main hoist: Press rocker switch up
Righthand control lever
Lifting the main hoist: Control lever to the rear
Lowering the main hoist: Control lever forward

Foot-operated switch fast speed hoisting gear

Switches on the fast speed for the main hoisting gear and auxiliary hoist
gear (additional equipment).

Switching on fast speed: Press foot-operated switch down and hold

Switching off fast speed: Release foot-operated switch

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-30.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permissible load has
been reached (overload) or an error has occured. A continuous buzzer
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tone sounds at the same time; ➠ SLI shutdown, p. 12-31.

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Operating Instructions GMK 5100 2 084 575 en 10 - 33
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for lifting limit switch shutdown

K Illuminates when shutdown of the hoisting gear is triggered by the lifting
limit switch. The SLI displays no error messages; ➠ Lifting limit switch,
p. 10-61.

Auxiliary hoist
(additional
equipment) ➠ Auxiliary hoist, p. 12-44

Rocker switch for auxiliary hoist shutdown (additional equipment)

C Shuts down the auxiliary hoist to prevent inadvertent operation.
Switching off the auxiliary hoist: Press rocker switch down
Switching on the auxiliary hoist: Press rocker switch up
Lefthand control lever
Lifting the auxiliary hoist: Control lever to the rear
Lowering the auxiliary hoist: Control lever forward

Foot-operated switch fast speed hoisting gear

Switches on the fast speed for the main hoisting gear and auxiliary hoist
gear (additional equipment).

Switching on fast speed: Press foot-operated switch down and hold

Switching off fast speed: Release foot-operated switch

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-30.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
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tone sounds at the same time; ➠ SLI shutdown, p. 12-31.

10 - 34 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for lifting limit switch shutdown

K Illuminates when shutdown of the hoisting gear is triggered by the lifting
limit switch. The SLI displays no error messages; ➠ Lifting limit switch,
p. 10-61.

Slewing gear ➠ Slewing gear, p. 12-48

➠ Mechanical superstructure lock, p. 12-9
Rocker switch for superstructure lock
§ Locks the superstructure in 0 or 180° position to the carrier.

Lock the superstructure: Press rocker switch down

Unlock superstructure: Press rocker switch up
The appropriate indicator lamp illuminates in end position.

Indicator lamp for locked superstructure

! Illuminates when the locking pin has reached the lower end position and
the superstructure is locked.
Alternates in flashing with the Superstructure unlocked indicator lamp if the
lifting cylinder still has not reached an end position.
Flashes at the same time as the Superstructure unlocked indicator lamp if
the control system has recognised an error or an incorrect condition.

Indicator lamp for unlocked superstructure

¥ Illuminates when the locking pin has reached the upper end position and
the superstructure is unlocked.
Alternates in flashing with the Superstructure locked indicator lamp if the lif-
ting cylinder still has not reached an end position.
Flashes at the same time as the Superstructure locked indicator lamp if the
control system has recognised an error or an incorrect condition.

Rocker switch for slewing gear permanent brake

Y Closes the slewing gear permanent brake and secures the left control le-
ver for slewing crane movement against unintentional activation.
Engage the slewing gear permanent brake: Press rocker switch down
Release the slewing gear permanent brake: Press rocker switch up

Indicator lamp for slewing gear permanent brake

Y Illuminates when the slewing gear permanent brake is closed.
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Operating Instructions GMK 5100 2 084 575 en 10 - 35
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Lefthand control lever

Turn superstructure to left: Control lever to the left
Turn superstructure to right: Control lever to the right

Slewing gear service brake pedal

For applying the brakes to the slewing gear during crane operation. The
braking force ca be adjusted infinitely.

Slewing gear brake oil temperature warning lamp

a Lights when the oil temperature in the slewing gear brake is greater than
248 °F. In this case, interrupt the crane operation and wait until the war-
ning lamp goes out.

Derricking gear à Derricking gear, p. 12-46

Rocker switch for derrick/telescope control level function preselection
_ Switches the control lever function between derricking gear and telesco-
ping gear.
Derricking control lever function: Press rocker switch down.
Telescoping control lever function: Press rocker switch up.

Indicator lamp for right control lever in derricking function

U Lights when the Derricking control level function has been selected.

Rocker switch for derricking gear shutdown system

Ü For deactivating the Derricking function to prevent inadvertent activation.

Righthand control lever

Raise (= raise boom): Control lever to the left
Lower (= lower boom): Control lever to the right
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Foot-operated switch for fast speed derricking gear / telescoping gear

Switching on fast
speed mode: Push down foot-operated switch and hold it down
Switching off fast
speed mode: Release foot-operated switch

H During lowering of the boom, fast speed mode only supports the start-up
of the derricking procedure at extreme boom positions. It does not in-
crease the derricking speed; ➠ Derricking gear fast speed, p. 12-47.

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-30.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
tone sounds at the same time; ➠ SLI shutdown, p. 12-31.

Telescoping gear ➠ Telescoping gear, p. 12-53.

Rocker switch for telescoping gear shutdown

Ö Shuts off the telescoping gear to prevent inadvertent operation.

Switch off telescoping gear: Press rocker switch down.

Switching on telescoping gear: Press rocker switch up.

Rocker switch for derrick/telescope control level function preselection

_ Switches the control lever function between derricking gear and telesco-
ping gear.
Derricking control lever function: Press rocker switch down.
Telescoping control lever function: Press rocker switch up.
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Operating Instructions GMK 5100 2 084 575 en 10 - 37
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Indicator lamp for telescoping gear control lever function switched on

T Illuminates if the control lever function Telescoping gear is switched on.

Righthand control lever

Telescoping in: Control lever to the left

Telescoping out: Control lever to the right

Indicating lamp for telescoping cylinder in foot section I

V Flashes if the head of the telescoping cylinder moves into the locking ran-
ge in the foot section of telescope section I.
Lights up when the telescoping cylinder in the telescope section I foot sec-
tion is locked.
Goes out if the head of the telescoping cylinder leaves the locking range
in the foot section of telescope section I.

Indicator lamp for telescoping cylinder in foot section II

e Flashes if the head of the telescoping cylinder moves into the locking
range in the foot section of telescope section II.
Lights up when the telescoping cylinder in the telescope section II foot
section is locked.
Goes out if the head of the telescoping cylinder leaves the locking
range in the foot section of telescope section II.

Indicator lamp for telescoping cylinder in foot section III

f Flashes if the head of the telescoping cylinder moves into the locking
range in the foot section of telescope section III.
Lights up when the telescoping cylinder in the telescope section III foot
section is locked.
Goes out if the head of the telescoping cylinder leaves the locking range
in the foot section of telescope section III.

Indicator lamp for telescoping cylinder in foot section IV

g Flashes if the head of the telescoping cylinder moves into the locking
range in the foot section of telescope section IV.
Lights up when the telescoping cylinder in the telescope section IV foot
section is locked.
Goes out if the head of the telescoping cylinder leaves the locking
range in the foot section of telescope section IV.
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10 - 38 2 084 575 en Operating Instructions GMK 5100
 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Telescoping cylinder at locking point indicator lamps

9 These indicator lamps serve mainly as support during Retract emergency
8 operation and during the Emergency program submenu;
➠ Emergency program, p. 14-42.
➠ Retract emergency operation, p. 14-70.
The indicator lamps show the direction in which the telescoping cylinder
must be moved in order to be at the locking point:
If only the upper indicator lamp lights up, you reach the correct position
9 for locking by retracting the telescoping cylinder.
The upper indicator lamp flashes when the telescoping cylinder is exten-
ded or retracted at the end of the permitted range. Movement of the
telescoping cylinder is switched off.

If only the lower indicator lamp lights up, you reach the correct position
8 for locking by extending the telescoping cylinder.

If both indicator lamps light up, the telescoping cylinder is directly at the
9 locking point.

8
Rocker switch to select lock/release
. To lock or release 2 telescope sections to/from each other or a telescoping
cylinder to/from a telescope section.

Select release telescoping cylinder: Press rocker switch down

Select unlock telescope section: Press rocker switch up

Select lock telescope section/

Rocker switch in central position
telescoping cylinder:

In the central position, the crane control system automatically selects the
necessary locking procedure depending on whether one is telescoping or
moving the telescoping cylinder without a telescope section.
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Operating Instructions GMK 5100 2 084 575 en 10 - 39

Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

The selection to release is only accepted by the crane control system if

both the telescope section and the telescoping cylinder are locked.
Warning lamp for telescoping cylinder is unlocked
i Shows the position of the locking pins of the telescoping cylinder.
Flashes as soon as release is selected if the locking pins are retracted and
the end position has not been reached.
Illuminates when the locking pins are have been retracted to the end
position during release.
Goes out when the locking pins are extended to the end position during
locking.

Indicator lamp for locked telescoping cylinder

h Shows the position of the locking pins of the telescoping cylinder.
Flashes when locking is selected and keeps flashing until the locking pins
are pushed out and the locking process is finished.
Illuminates when the locking pins are pushed out to the end position
during locking and the locking process is finished.
Goes out when the locking pins are retracted to the end position during
release.

Indicator lamp for telescope section locked (green)

j Shows the position of the locking pins of the telescope section in which
the head of the telescoping cylinder is located.
Flashes when locking is selected and keeps flashing until the telescope
section is on the pushed out locking pins.
Illuminates when the locking pins are pushed out of the telescope section
into the telescope section above and the telescope section is on the pins.
Goes out if the locking pins in the telescopic section are retracted.

Warning lamp for telescope section released (red)

j Shows the position of the locking pins of the telescope section in which
the head of the telescoping cylinder is located.
Flashes as soon as relaese ist selected if the locking pins are retracted and
the end position has not been reached.
Illuminates if the locking pins in the telescopic part are retracted.
Goes out when the locking pins are extended from the telescope section
into the telescope section above it.
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10 - 40 2 084 575 en Operating Instructions GMK 5100
 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Foot-operated switch for fast speed derricking gear / telescoping gear

Switching on fast speed mode: Push down foot-operated switch and
hold it down
Switching off fast speed mode: Release foot-operated switch

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-30.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
tone sounds at the same time; ➠ SLI shutdown, p. 12-31.

Safe load
indicator Operation of safe load indicator ➠ p. 12-17

The elements in a display

1–4 Values
5 Signalling point
6 Decimal point;
in the Working position display:
Separator point between the SLI code
and supplement
7–8 Decimal points
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Operating Instructions GMK 5100 2 084 575 en 10 - 41

Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Status display, telescope status (telescope sections I - IV)

85 Displays the current telescoping status of telescope sections I to IV.
Fixed lengths are displayed as decimal values (e. g. 1.00 or 0.50); interme-
diate and telescoping lengths in percent (e. g. 100 or 50).
Structure of a status display; ➠ The elements in a display, p. 10-41

Status display for length of lattice extension with membrane switch

6)0 ft
Displays the length of lattice extension in feet. The status display is activa-
ted when an SLI code for working with the lattice extension is entered in
the Rigging mode status display. In both cases the displayed length is ob-
tained from the entered SLI code.
If the Rigging mode display of the entry mode is switched on, pressing the
membrane switch repeatedly displays other values which are permitted
according to the Lifting capacity table.
When the greatest length is reached and the membrane switch is pressed
again, the display starts again at the beginning with the lowest value.

Status display for angle of lattice extension with membrane switch

1%0 n°
Displays the inclination of lattice extension to the main boom in degrees.
The display is derived from the entered SLI code.
The status display is activated when an SLI code for working with the
lattice extension is entered in the Rigging mode status display.
If the entry mode is activated in the Rigging mode display, pressing the
membrane switch repeatedly displays other values which are permitted
according to the Lifting capacity table in increasing order.
When the greatest inclination is reached and the membrane switch is pres-
sed again, the display starts again at the beginning with the lowest value.

Status display – Current main boom angle

5&0 n°
Displays the current main boom angle to the horizontal in degrees.
For negative angles, a minus sign (–) appears to the left of the number.

Display for actual radius

4!8 ft
Displays the current radius in feet.
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10 - 42 2 084 575 en Operating Instructions GMK 5100

 klbs

max
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Status display – Maximum load

3"( klbs
max Displays the shutdown value, i.e. the maximum possible load in kilo-
pounds (1klbs = 1000 lbs).
The SLI calculates this value from
– the rigging mode set according to the Lifting capacity cable,
– the set reeving mode,
– the instantaneous length of the main boom and
– the current radius.
The signalling point shows a reduction of the load due to the reeving en-
tered. The maximum possible load (according to the Lifting capacity table,
without reduction) can be displayed in this case by pressing the Reeving
membrane switch (length of display; about three seconds).

2"% t
Status display – Actual load
Displays the actual load in tonnes.
The actual load comprises
the load to be lifted by the crane + the hook block + the lifting gear.
The signalling point displays a shutdown when overloaded.

Status display – Degree of utilization

Displays the instantaneous degree of utilization as a percentage, which
relates to the maximum and the actual loads:
– green LED display: 0 – 80 %
– yellow LED display: approx. 80 – 100 %
– red LED display: greater than 100 %

Membrane switch with warning lamp for error information

t The red warning lamp in the switch flashes if an error message occurs.
If this error leads to a shutdown, the SLI shutdown indicator lamp illumi-
nates at the same time, and a continuous buzzing tone sounds. An error
code appears in the Information display. When the Error information mem-
brane switch is pushed, other pending error messages (➠ Error messages,
p. 12-32).
The green indicator lamp in the switch has no function.

Without function.
y After pressing the switch, the value shown in the Information status
display does not change.
No lamps light up in the switch.

Membrane switch with indicator lamp for permitted slewing range

A After pressing the switch, the green indicator lamp in the switch lights up
and the permissible slewing range of the superstructure is shown in the
status display Information. The current value is derived from the set SLI
11.05.2000

code.
The red warning lamp in the switch has no function.

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Operating Instructions GMK 5100 2 084 575 en 10 - 43
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Membrane switch with indicator lamp for angle of main boom

B After pressing the switch, the green indicator lamp in the switch lights up
and the current main boom angle, in relation to the horizontal is shown in
the status display Information.
The red warning lamp in the switch has no function.

Membrane switch with indicator lamp for length of main boom

C After pressing the switch, the green indicator lamp in the switch lights up
and the current main boom length is shown in feet in the Information
status display.
No differentiation is made in the status display between fixed and interme-
diate or telescoping lengths.

Membrane switch with indicator lamp for height of single-sheave boom

G top
After pressing the switch, the green indicator lamp in the switch lights up
and the current height of the single-sheave boom top of the main boom
or the lattice extension is shown in feet in the Information status display.
The height displayed relates to the bottom axle of the boom and the
lower head sheave axle.

No function.
y After pressing the switch, the value shown in the Information status dis-
play does not change.
No lamps light in the switch.

Membrane switch with indicator lamp for degree of utilization

M After pressing the switch, the green indicator lamp in the switch lights up
and the current degree of utilization is shown in percent in the Information
status display.

Without function.
u After pressing the switch, the value shown in the Information status
display does not change.
No lamps light up in the switch.

Membrane switch with indicator lamp for hydraulic oil pressure in lower
k chamber of derricking cylinder from sensor A
After pressing the switch, the green indicator lamp in the switch lights up
and the current hydraulic oil pressure which is measured by the first
sensor on the piston surface of the derricking cylinder is shown in psi in
the status display Information.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Membrane switch with indicator lamp for hydraulic oil pressure in lower
l chamber of derricking cylinder at sensor B
After pressing the switch, the green indicator lamp in the switch lights up
and the current hydraulic oil pressure which is measured by the second
sensor on the piston surface of the derricking cylinder is shown in psi in
the status display Information.
Membrane switch with indicator lamp for hydraulic oil pressure in
m derricking cylinder upper chamber
After pressing the switch, the green indicator lamp in the switch lights up
and the current hydraulic oil pressure on the derricking cylinder surface of
the piston ring is shown in psi in the Information display.
Status display – Information
348 Displays the corresponding value when one of the following keys is pressed:
– Membrane switch Error information,
– Membrane switch Permitted slewing range,
– Membrane switch Main boom angle,
– Membrane switch Main boom length,
– membrane switch Height of the single-sheave boom top,
– membrane switch Degree of utilisation,
– membrane switch Hydraulic oil pressure derricking cylinder lower chamber
sensor A,
– membrane switch Hydraulic oil pressure derricking cylinder lower chamber
sensor B,
– membrane switch Hydraulic oil pressure derricking cylinder upper chamber,

If one of the switches without functions is pushed, the value in the display
does not change.

SLI early warning lamp

x The SLI early warning lamp illuminates when the actual load reaches 90 %
or more of the permissible load. An intermittent buzzing tone sounds at
the same time (➠ SLI early warning, p. 12-30).

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
tone sounds at the same time (➠ SLI shutdown, p. 12-31).

Status display – counterweight with membrane switch

1!0 t
Displays the counterweight which is to be used in tonnes.
The value is derived from the set SLI code.
If the Rigging mode display of the entry mode is switched on, pressing the
11.05.2000

membrane switch repeatedly displays other values which are permitted

according to the Lifting capacity table.

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Operating Instructions GMK 5100 2 084 575 en 10 - 45
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Status display, working position with membrane switch

11=0 Displays the set SLI code.

When entry mode is switched on in this display, the required SLI code can
P be entered by pressing the membrane switch Rigging mode repeatedly or
by entering on the numerical pad.
The SLI code entered appears in the first three spaces of the Rigging mode
status display, and the supplement to the SLI code in the fourth.
The SLI code and its supplement are separated by a decimal point;
➠ The elements of the display, p. 10-41.
Reeving display with membrane switch
/ n=
Displays the number of ropes reeved on the hoist indicated by the Hoist
position lights.
Main hoist: lamp I illuminates
Auxiliary hoist: lamp II illuminates

When entry mode is switched on in the display, the desired reeving can
O be entered by pressing the membrane switch Reeving repeatedly or by en-
tering on the numerical pad.

If the maximum load is reduced because of the reeving, pressing the

O membrane switch displays the maximum load (according to the Lifting ca-
pacity table) for about three seconds in the Maximum load display.

Hoist position lights

Indicates which hoist is monitored by the SLI:

Lamp I illuminates: Main hoist is switched on and the display Reeving

applies to this hoist.
Lamp II illuminates: Auxiliary hoist (additional equipment) is switched
on and the display Reeving applies to this hoist.
If a lamp flashes, the corresponding hoist is switched on and but the
display Reeving applies to the other hoist; ➠ Display lamps, p. 12-26.

Service key switch

May only be operated by GROVE Product Support. No key is delivered for
this key switch.

C0018
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10 - 46 2 084 575 en Operating Instructions GMK 5100

 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Outrigger span display panel with membrane switch

Displays the required supporting span corresponding to the SLI code
entered:

If the Rigging mode display of the entry mode is switched on, pressing the
membrane switch (1) repeatedly displays other values which are permit-
ted according to the Lifting capacity table.

The light-emitting diodes in the display show the different outrigger

spans in the following way:

Outrigger span Outrigger span Outrigger span

25.6 x 24.6 ft 25.6 x 16.7 ft 25.6 x 8.2 ft

Membrane switch acknowledge

p Used to
– confirm after changing a setting,
– switch off an acoustic warning signal.

Membrane switch confirm

v Used to confirm the entered value.

Numerical pad
abc The switches 1 to 0 are used to enter new values into the SLI. Some
switches have two assignments. The second level of the switch is acti-
vated if the membrane switch membrane Switch on 2nd level is pressed.
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Operating Instructions GMK 5100 2 084 575 en 10 - 47
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Entry mode membrane switch

n Q +
Is always used in combination with one of the two membrane switches
Reeving or Rigging mode. First the membrane switch Reeving is pushed,
then also one of the two membrane switches Reeving or Rigging mode.
Switches on the entry mode in the following way:
– The entry mode in the display Rigging mode is switched on by pressing
n P +
the Rigging mode membrane switch at the same time.
– The entry mode in the display Reeving is switched on by pressing the
n O +
Reeving membrane switch at the same time.

Membrane switch to switch on 2nd level

o Q +
Is always pressed in combination with one of the other membrane
switches. First the membrane switch Switch on 2nd level is pressed, then
also the other membrane switch. Switches to the assignment on the
2nd level if a switch is assigned two functions or if a switch is only
assigned at the second level for reasons of safety.

Membrane switch for lamp test

o a +
This function of the switch is only active if the membrane switch Switch on
2nd level is pressed. To carry out a lamp test.
All displays, warning and indicator lamps illuminate for approx. 2 seconds
with maximum brightness, then with automatically adjusted brightness.

H
Lamp test and dimmer for SLI status displays

After switching on the ignition, the basic brightness of the SLI displays,
warning and indicator lamps automatically adapt to the ambient light.
The brightness of the SLI dispaly can be adjusted with the following mem-
brane switches.

Membrane switch for brighter dimmer

o b +

This function of the switch is only active if the membrane switch Switch on
2nd level is pressed. To adjust the brightness of the LMB displays.
Every time the switch is pushed, the display becomes a step brighter until
the maximum brightness is reached.

Membrane switch for darker dimmer

o c +
This function of the switch is only active if the membrane switch Switch on
2nd level is pressed. To adjust the brightness of the LMB displays.
Every time the switch is pushed, the display becomes a step darker until
the minimum brightness is reached.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Hydraulics
Hydraulic system oil temperature display
The hydraulic oil temperature should not exceed 80 °C (176 °F) while wor-
king with crane; ➠ p. 12-97.

Warning lamp control circuit hydraulic oil filter

g Illuminates if the hydraulic oil filter in the control circuit is dirty.
Change the filter cartridge; ➠ Maintenance manual.

Warning lamp for hydraulic oil return fine filter

g Illuminates if the fine filter in the hydraulic oil return is dirty.
Change the filter element; ➠ Maintenance manual.

Electronics
Ignition lock
0 Ignition off, crane engine and crane functions off, key may be
removed.
R, 1 Ignition on, instrument lighting on.
Additional power supply on for:
Control units of the crane control, engine control, SLI 2
2 Starting position; ➠ Starting the crane engine, p. 11-10.
Warning lamp for charge indicator
q Illuminates if the ignition is switched on and the crane engine is switched
off. Goes out after the crane engine is started;
➠ Starting the crane engine, p. 11-11.
Rocker switch for socket for spotlight
G (left and center rocker switches)
The two sockets in front of the crane cab for the Crane cab working spotlights
are standard components. The working spotlights are used to illuminate
the working area in front of the crane cab.
Switching on the spotlight for
working area: Press rocker switch down.
Switching off the spotlight for
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working area: Press rocker switch up.

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Operating Instructions GMK 5100 2 084 575 en 10 - 49
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Rocker switch for hoist rope control spotlight (additional equipment)

G (Right-hand rocker switch)
A spotlight can be connected as additional equipment for illuminating the
rope drum. This enables the orderly reeling in of the hoist rope even
when it is dark.
Switching on the spotlight: Press rocker switch down.
Switching off the spotlight: Press rocker switch up.

Other operating
instruments

Rocker switch for windscreen wiper

D Used to activate the windscreen wiper on the crane cab.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.
The windscreen wiper returns to end position after switching off.
Rocker switch for roof window wiper
F Used to activate the roof window wiper on the crane cab.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.
The windscreen wiper returns to end position after switching off.

Rocker switch for intermittent wiper operation – windscreen and roof

E window
Used to activate the intermittent wiper function for the windscreen and
the roof window.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.
The windscreen wiper returns to end position after switching off.

Rocker switch for windscreen wiper/washing system

H Used to activate the wiper/washing function on the windscreen and
skylight of the crane cab. Activates the water pump and the windscreen
wiper several times.
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Switching on: Press rocker switch down.

Switching off: Release the rocker switch.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Rocker switch for constant motor speed

å To activate and adjust and deactivate a constant engine speed. To take over
the engine speed preselected with the accelerator. When the rocker switch is
pressed down once, the speed of the crane engine preselected with the accele-
rator is set as a constant engine speed.

Take over preselected Press rocker switch down

engine speed:
Increase constant Press rocker switch up
engine speed:
Switch off constant Press rocker switch down with the accelerator
engine speed released

➠ Setting constant motor speed, p. 12-95.

Rocker switch to incline crane cab (additional equipment)
: To incline the crane cab from the horizontal to the rear and back to
horizontal.

Incline crane cab to the rear: Press rocker switch down.

Incline the crane cab back to the
horizontal: Press rocker switch up.

➠ Incline crane cab, p. 12-96.

Key-operated switch for override
With the key-operated switch the shutdown of the SLI and the lifting limit
switch can be bypassed (switched off).
Override SLI shutdown: Insert the key, turn to the left
and hold
Overriding the lifting limit switch Insert the key, turn to the right
shutoff system and the SLI shutoff: and hold
Switch off override: Release the key, lock returns to its
start position, remove the key.
Observe the warnings in the appropriate sections:
➠ SLI override, p. 12-34.
➠ Override lifting limit switch shutdown, p. 10-61.
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Operating Instructions GMK 5100 2 084 575 en 10 - 51
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Electronic level in Display of the electronic level in the control box on the carrier;
crane cab ➠ Reading the electronic level display, p. 13-36.
(additional equip-
ment)
Displays the current inclination of the truck
crane in the LED display (1); ➠ Crane work
with the main boom – horizontal inclination,
p. 12-35.

The electronic spirit level in the crane cab

only displays correct values when the igniti-
on has been switched off in the driver’s cab.

Two different measurement ranges can be

set.

Switching the rocker switch with indicator lamp for measurement range
.1°
level indicator (crane cab) (additional equipment)
Changes the measurement range of the electronic level in the crane cab
between 1° and 5° angle.

Measuring range angle 0° to 1°: Press in the rocker switch at the top,
indicator lamp lights up.
1 graduated collar corrsponds to 0.2°.
Measuring range angle 0° to 5°: Push rocker switch upwards,
1 graduated collar corrsponds to 1°.

Switching over (toggle switch in the outrigger switch box)

toggle switch ➠ Align truck crane horizontally - switch over measuring range, p. 13-37.
measuring range
(additional equip-
ment)
Changes the measurement range of the electronic level on the carrier be-
tween inclination of 1° and 5°;

Measuring range inclination Press the toggle switch upwards

0° to 1°:
Measuring range inclination Press the toggle switch downwards
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0° to 5°:

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Crane cab ➠ Crane cab heating and ventilation, p. 12-106.

heating system

1 Heater fan rotary knob (3-level)

2 Regulator for recirculated air / fresh air
mode
up: fresh air mode
down: recirculated air mode
3 Air distribution regulator
up: bottom of windscreen
down: cab floor
4 Regulator to increase
temperature: cold
downwards: warm

Rocker switch with indicator lamp for additional heating system

0 (additional equipment)
Switching on: press downward
Switching off: press upward

➠ Additional water heating system (additional equipment), p. 12-107.

Additional hea- The operating instruments of the additional heating system with timer are
ting system with identical to those for the additional heating system in the carrier;
timer ➠ p. 4-18
(additional equip-
ment)
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Operating Instructions GMK 5100 2 084 575 en 10 - 53
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Anemometer An anemometer can be attached to the main boom point of your crane for
wind monitoring; ➠ p. 13-84.

The Anemometer status display in the instru-

ment panel of the superstructure displays
the wind speed in m/sec and in the Beaufort
scale.
25
20
m/sec 15 9
7
10
5 BEAUFORT

5
3

C0102

Outrigger pressu- Display of the outrigger pressure in the control boxes on the carrier;
re display (addi- ➠Outrigger pressure display for extending/retracting outrigger cylinder, p.13-39.
tional eqipment)

Front right outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the front
right outrigger cylinder.

Front left outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the front
left outrigger cylinder.

Rear right outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the rear
right outrigger cylinder.

Rear left outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the rear
left outrigger cylinder.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Air-conditioning ➠ Air-conditioning system, p. 12-111.

system (additio-
nal equipment)

The air-conditioning system is installed at the rear of the crane cab.

1 Air outlets, volume of air and direction of

air can be adjusted
2 Knob switch for thermostat
3 Knob switch for blower

Rotary knob for thermostat

Turning the rotary switch to the right increases the cooling output.

Blower knob

0 Fan and air-conditioning system off

1 Low output level
2 Medium output level
3 High output level
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Operating Instructions GMK 5100 2 084 575 en 10 - 55

Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

10.2.2 Other operating instruments on the crane cab

Doors, keys, The following keys belong to the crane cab of your truck crane:
windows

1 Crane cab door lock

2 Crane cab ignition lock
3 Key switch for override
4 Crane engine service flap

The lock on the door of the crane cab may be

locked from the outside using the door key.

Open lock: Turn key (1) to the

right
Close lock: Turn key (1) to the left
Open door: Raise grip (2)

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

A release lever is mounted on the handle bar

to open the door from the inside.

Open door: Press lever (2).

The door of the crane cab cannot be locked
from the inside.

Open sliding window

The sliding window in the door (if there is
additional equipment, also the window on
the rear wall of the cab) may be opened from
the inside using release lever (1).

The windscreen of the crane cab may be

opened.

Opening the Pull both handles (1)

windscreen: outwards and press down the
brake lever (2). Push the
windscreen forwards, until
the desired position of the
2
windscreen is reached, then
release the brake lever.
Closing the Pull both handles (1)
1 windscreen: outwards and press down the
brake lever (2). Pull wind-
screen back, until it latches in.

Fire extinguisher The fire extinguisher (additional equipment) is located in a holder behind
(additional the crane cab’s crane operator’s seat.
equipment)
• Follow the instructions for use on the fire extinguisher.
• Have the fire extinguisher serviced in good time by trained personnel
before the service interval given on the label expires.
11.05.2000

Proper functioning of the fire extinguisher is no longer guaranteed once

the service interval on the sign has expired.

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Operating Instructions GMK 5100 2 084 575 en 10 - 57
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Seat adjustment You may adjust the hydraulically spring-mounted seat in the crane cab to
your respective height and weight.
1 Unlocking and adjusting height of the
left armrest
2 Backward/forward adjustment of the
entire seat including the control consoles
3 Adjusting the suspension stiffness to
your weight in kg
4 Backward/forward adjustment of the
seat and the back rest without the
control consoles
5 inclination of the front seat
6 inclination of the rear seat
7 Unlocking and adjusting height of the
right armrest
8 Angle of the back rest

VDO electronics
crane engine

The VDO electronics provide the service

personnel with the opportunity of connect-
ing measuring devices and may only be
operated by the service personnel.

There is a cover in the side panelling at the

rear right of the crane cab.

The VDO electronics (1) can be accessed

once the cover has been removed.
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 Description of the truck crane – crane section
10.3 Functional description of the safety devices

10.3 Functional description of the safety devices

10.3.1 Safe load indicator (SLI)

To increase operational safety, the GMK 5100 truck crane is equipped with
a safe load indicator (SLI) as overload protection.

The SLI covers operation with one hook only.

G
Danger of overturning with two-hook operation!
The safe load indicator covers operation with one hook only!
Two-hook operation is not allowed and is not covered by the SLI.

The safe load indicator serves to prevent the permissible load bearing
capacity of the truck crane from being exceeded at a particular radius.
The load bearing limit can be exceeded, for example, during crane opera-
tion when the main boom is telescoped out or lowered further than is allo-
wed.

The safe load indicator is an electronic unit.

It is used to set the truck cranes rigging mode.

The SLI automatically registers These factors must be set according

the following factors: to the current rigging mode:
– Length of the main boom – supporting span
– counterweight mass
– Angle of main boom
– length of the lattice extension
– Actual load (from the pressure (additional equipment)
load on the derricking cylinder) – number of reevings of the
hoist rope
– Angle of the luffing jib Setting either by entry of the
– (additional equipment) individual components or by
SLI code.

G
Danger of overturning if wrong settings are entered into the SLI!
The SLI does not automatically assimilate all information in crane
operation required to calculate the load limit.
You must therefore enter the rigging mode (SLI code) and the reeving
mode at the SLI control unit manually.
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Operating Instructions GMK 5100 2 084 575 en 10 - 59
Description of the truck crane – crane section
10.3 Functional description of the safety devices

Transducers (sensors) are attached to the truck crane which supply the
SLI derrick extension with current load values. The current and maximum
load values are continuously displayed on the SLI control unit in the crane
cab. Before reaching the load limit, the SLI signals that the warning limit
has been reached by giving a visual and an acoustic (intermittent buzzing
tone) signal. The acoustic signal can be switched off.

If the load moment continues to increase, the SLI shuts down all move-
ments which increase the load moment when the load limit is exceeded
and signals that the shut-down limit has been reached with a visual and
acoustic (continuous buzzing tone) signal. The acoustic signal can be
switched off.

The values necessary for the operation are constantly displayed on the
SLI (e.g. reach, actual load, main boom length, maximum load).

G
Risk of accidents if SLI is incorrectly set!
If the actual rigging mode is not set, the maximum load calculated by the
SLI will not correspond with the actual permissible load capacity!
An incorrectly set safe load indicator only gives you a false sense of
security. Overloading of the truck crane will most certainly result in an
accident!

10.3.2 Lowering limit switch

The lowering limit switch prevents the hoist rope from being reeled off
the drum completely. It deactivates the Lower hoist movement when five
turns of rope are left on the hoist drum.
The switching point must be reset when the hoist rope is replaced;
➠ Maintenance manual.
Activating the lowering limit switch during operation is not permitted.

G
Risk of accidents if the lowering limit switch is incorrectly set or defective!
Reset the lowering limit switch after every hoist rope change and do not
do any crane work if the lowering limit switch is damaged, incorrectly set
or disabled. This avoids damage to the hoist rope after it is completely
unreeled which can lead to the load falling.

If the unreeved hoist rope is completely reeled up (e. g. when rigging the
auxiliary hoist) and the hoist rope is unrolled from the stationary rope
drum, the lowering limit switch must be reset.
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 Description of the truck crane – crane section
10.3 Functional description of the safety devices

G
Risk of accidents from incorrect setting of the lowering limit switch!
Only unreel the hoist rope with Lower hoist. If you unreel the hoist rope
from the stationary rope drum, the lowering limit switch does not detect
the number of winds and you must reset the lowering limit switch before
starting crane work. This keeps the lowering limit switch from switching
off too late or not at all, which causes the load to crash to the ground.

10.3.3 Lifting limit switch

The lifting limit switch reacts as soon as it is no longer under the load of
the lifting limit switch weight. This is the case if:

– during crane work, the hook block lifts the lifting limit switch weight or
if one derricks so far that the lifting limit switch weight is lying on the
ground,
– or if during rigging the lifting limit switch weight is still not attached or
is lying on the ground.
In these cases, the lifting limit switch activates and switches off all load
moment increasing motions. Load moment increasing motions are lifting,
lowering the boom and telescoping out.

The Lifting limit switch shutdown warning lamp illuminates when the lifting
K limit switch is deactivated.

If there is a shutdown, one must leave the shutdown area with a different
motion or by setting down the load.

The lifting limit switch must not be activated during normal operation.

Overriding the The shutoff system of the lifting limit switch can be overridden from the
lifting limit crane cab together with the SLI, and the lifting limit switch can be blocked
switch shutdown mechanically on the main boom.

G
Risk of accidents from overridden safety devices!
When overriding the lifting limit switch with the key switch Override,
crane operation is no longer monitored by the SLI! The lifting limit switch
therefore may not be overridden while the cane is being operated. It is
not permitted to work with an overridden or defective lifting limit switch!
Before beginning crane work, check whether the locking system of the
lifting limit switch on the main boom is deactivated and deactivate it if
necessary; ➠ Check and if necessary deactivate the lifting limit switch on the
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main boom, p. 13-78.

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Operating Instructions GMK 5100 2 084 575 en 10 - 61
Description of the truck crane – crane section
10.3 Functional description of the safety devices

S
You may only override the lifting limit switch when carrying out main-
tenance or rigging work in accordance with the Operating Instructions.
In these cases, the lifting limit switch may only be overridden when there
is no load on the hook. On operate at minimum hoist speed with an over-
ridden lifting limit switch.

The shutoff system of the lifting limit switch can be overridden (switched
off) together with the SLI with the key switch Override.

• Insert the key into the key-operated switch.

• Turn the key to the right.
• Hold the key in this position.
The lifting limit switch is overridden as long as you hold the key in this
position.

S
Always pull the key out of the Override key switch after overriding!
The key must not be left in the key-operated switch while the crane is in
operation!

H The key switch has another position which only overides the SLI;
➠ SLI override, p. 12-34.

10.3.4 Dead man’s switch and seat contact switch

All crane functions are protected by a dead

man’s switch system. This system includes
one Dead man’s switch (1) on each of the two
control levers and a seat contact switch in
the crane cab seat.

Crane movements may only be controlled

when you are sitting on the seat inside the
crane cab or are pressing at least one of the
two dead man’s switches. If you leave the
seat and neither of the dead man’s switches
are being pressed, all crane movement will
stop within approx. 1 second.
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 Crane engine
11.1 Starting/turning off the crane engine

11 Crane engine

11.1 Starting/turning off the crane engine

11.1.1 CHECKLIST: Starting the crane engine

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Checking the oil level in the crane engine; ➠ Checking the oil level in the
crane engine, p. 11-4.

2. Check the coolant level of the crane engine; ➠ Checking coolant level,
p. 11-8.

3. Check oil level in the hydraulic system; ➠ Checking hydraulic oil level,
p. 11-6.

4. Checking the setting of the stop cock of the hydraulic system;

➠ Checking the stop cock in the hydraulics system, p. 11-7.
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Operating Instructions GMK 5100 2 084 575 en 11 - 1
Crane engine
11.1 Starting/turning off the crane engine

5. Switching on the battery master switch; ➠ Switching on battery master

switch, p. 11-7.

6. Check the level of the fuel tank; ➠ Refuel, p.11-9.

C0013

7. Turn on ignition and check instruments; ➠ Turning on ignition, p. 11-

10.

8. Start the crane engine; ➠ Starting crane engine, p. 11-11.

9. Check the instruments with the engine running; ➠ Checking the

instruments, p. 11-13.

10. Also observe the In winter check-list when the temperatures are low;
➠ p. 11-3.
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 Crane engine
11.1 Starting/turning off the crane engine

11.1.2 CHECKLIST: In winter

The following additional points must be observed when using the truck
crane in winter:

1. Fuel and engine oil must comply with the specifications given in the
supplied crane operating manual for the respective external tempera-
tures.

2. The engine coolant must contain sufficient antifreeze (see supplied

crane engine operating manual).

3. The crane engine can be preheated by the engine-independent additio-

nal water heating system (additional equipment); ➠ Additional water
heating system, p. 12-107.

4. The hydraulic oil must be preheated; ➠ Preheating the hydraulic oil,

p. 12-5.
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Operating Instructions GMK 5100 2 084 575 en 11 - 3

Crane engine
11.1 Starting/turning off the crane engine

11.1.3 Inspections before starting the crane engine

Checking the oil Check the oil level in the crane engine daily before commencing work.
level in the crane The dipstick has been marked to check crane engine when it is not run-
engine ning.
• The dipstick (1) is located at the front of
the crane engine and can be reached
through an opening in the panelling.

Prior to main check

• Check the oil level. The oil level has to be

at the max.-mark (arrow marks).
• Top up with oil if necessary.

Pre-check

• Check whether the oil level on the dip stick

is up to the max mark (arrow marking).
• If necessary, fill the motor oil up to the
max mark.

Inspection
11.05.2000

Start the vehicle engine and let it run at idling speed. Pay attention to the
oil pressure gauge.

11 - 4 2 084 575 en Operating Instructions GMK 5100

 Crane engine
11.1 Starting/turning off the crane engine

S
Danger of damage to the motor caused by the oil pressure being too low!
If no oil pressure is shown after 10 seconds, turn off the crane engine and
look for the reason. ➠ Crane engine malfunction, p.14-15.

• Turn off the crane engine after about

1 minute.
• After about five minutes, check whether
the oil level on the dipstick is at the max
mark (arrow marking).
• If necessary, fill the motor oil up to the
max mark.

Adding engine oil Data concerning the prescribed oil specification may be found in the
Mercedes-Benz operating manual.

G
Risk of burning when the crane engine is hot!
During operation, the crane engine and add-on parts can reach tempera-
tures of up to 750 °F. Wear appropriate protective gloves and be careful
not to touch hot parts when filling a hot crane engine.

The oil filler neck is located at the top of the

crane engine and can be reached through an
opening in the panelling.

• Fill the engine oil through the filler neck (1).

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Operating Instructions GMK 5100 2 084 575 en 11 - 5
Crane engine
11.1 Starting/turning off the crane engine

S
Damage may occur to the engine if the oil level is too high!
Do not put in too much oil. The oil level may not exceed the upper arrow
mark (max).

Check hydraulic Check the level of the hydraulic oil tank daily before commencing work.
oil level
The truck crane must be on a horizontal surface when the oil level is
checked.

Requirements:
– The telescope section of the main boom
– must be fully retracted and
– the main boom must be resting on the
– boom support.

• Check the level of the hydraulic oil tank

through the inspection glass (1). The
hydraulic oil should be visible in the centre
of the inspection glass when cold.

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 Crane engine
11.1 Starting/turning off the crane engine

Check the stop To start the crane engine, the stop cock in the suction line of the hydraulic
cock of the system must be open.
hydraulics system

S
Damage may occur to the hydraulic pumps!
The crane engine may only be started if the stop cock in the suction line
of the hydraulic pumps is open!
The stop cock is open when the handle is parallel to the suction line.

The stop cock (2) is located on the inner side

wall of the hydraulic oil tank (1) for the super-
structure behind the cover plate in the suction
line of the hydraulic pump.

• Check that the stop cock (2) is open.

Switching on 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 on the battery master switch.

The battery master switch is switched on if
the selector handle cannot be pulled off.
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Operating Instructions GMK 5100 2 084 575 en 11 - 7
Crane engine
11.1 Starting/turning off the crane engine

Checking the Information concerning the prescribed coolant agents may be found in
coolant level the supplied Maintenance Manual.

G
Risk of burning when the crane engine is hot!
The hot cooler is pressurized. Be careful to avoid burning on the hot
cooler, with escaping steam or any escaping coolant if you remove the lid
of the cooler when the crane engine is hot.
Wear suitable protective gloves and cover the lid of the cooler with a
cloth before opening it.
Turn the cooler lid slowly to the first notch in order to allow the excess
pressure to be released.

Do not open the pressure relief valve (2) on

the side of the compensation container.

• Loosen (do not open!) the cap on the fil-

ling hole (1) with the coolant at operating
temperature to release the pressure.
• Remove the cap.
The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:
Top up coolant.
See the crane engine operating manual for
the composition of the coolant.

• Screw the filling hole cap on until it

reaches end position.

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 Crane engine
11.1 Starting/turning off the crane engine

Refuelling

Monitor the Fuel supply status display, even when working with the crane.
Refuel with diesel whenever necessary.

C0013

S
Fires may occur due to flammable gases!
Switch off the crane engine, crane cab heater and all additional heating
devices before refuelling.

The diesel tank is located at the rear on the

right side of the superstructure. The filler
neck (1) is run upwards through the sheet
metal.

Always use a funnel and filter when

refuelling.

The fuel tank holds approx. 53 gal.

You can find information about the prescri-

bed fuel specifications in the supplied crane
engine operating manual.

G
Danger of accident if the fuel tank is not closed!
Screw the sealing cover back on after each refueling. In this way you
prevent vehicles behind you from being endangered by the sealing cover
falling off or fuel escaping.
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Operating Instructions GMK 5100 2 084 575 en 11 - 9

Crane engine
11.1 Starting/turning off the crane engine

11.1.4 Starting the crane engine

Activating the
ignition

• Switch on the ignition. Insert the ignition key into the ignition lock as far
as it will go and turn the key to position 1.

Lamp test by crane control system

After switching on the ignition the crane control system carries out a lamp
test with the most important warning, indicator and display lamps.

• Check that, after switching on the ignition, the following warning,

indicator and display lamps illuminate for approx. 2 seconds.
If necessary switch on the ignition several times until you have checked
all lamps.
Under the display Crane control system:
– the four indicator lamps (1),
– the two warning lamps (2) and
– the two indicator lamps (3),
must illuminate for approx. 2 seconds.

• Replace any defective lamps immediately!

S
When starting the ignition or the crane engine, indicator lamps which
serve as warning lamps for functions that fail during operation are tested.
Replace any defective lamps immediately!
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 Crane engine
11.1 Starting/turning off the crane engine

The following indicator and warning lamps must illuminate:

Crane engine oil pressure

L Charge indicator lamp
q The indicator lamp Flame start system (additional equipment) lights up.
z The time it takes to go out depends on the temperature of the crane
engine; ➠ Start cold crane engine, p. 11-11.

Motor electronics
à
Starting the Refer to the supplied operating manual for the crane engine for infor-
crane engine mation about operating the crane engine.

Starting the crane engine in low temperatures can be made easier by pre-
heating the coolant using the additional water heating system (additional
equipment); ➠ Additional water heating system, p. 12-107.

Starting a cold crane engine with additional equipment with flame start
system
With additional equipment, the crane engine is equipped with a thermo-
stat-controlled flame start system. If the temperature of the coolant is low,
the flame start system heats the suction air of the crane engine by bur-
ning fuel in the suction line.

G
Risk of explosion!
Do not use volatile cold start assisting agents underground or in a tunnel.
The cold start assisting agent can ignite from contact with other ignition
sources. Ask for details in your local mining authority office.

The flame start system is activated every time the ignition is started.
z Depending on the temperature of the coolant, it can take up to 20 seconds
until the crane engine is ready to start. The engine is ready when the
Flame start system indicator lamp goes off. The crane engine should be star-

H
ted up within the next 30 seconds.

If the flame-start device indicator lamp does not go out after approx.
20 seconds, there is a malfunction of the flame-start device; ➠ Problems
with the cranemotor, p. 14-15.
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Operating Instructions GMK 5100 2 084 575 en 11 - 11
Crane engine
11.1 Starting/turning off the crane engine

H If you already had the ignition switched on for some time with a cold, sta-
tionary crane engine, you must switch the ignition off and back on again
to activate the flame start system before starting.

• Check whether the flame start system indicator lamp illuminates.

z

H
• Wait until the flame start system indicator lamp goes out.

• You should not start the crane engine until the indicator lamp for the
flame start system has gone out. If you start the crane engine before
the lamp goes out and the temperature of the coolant is low, the crane
engine will emit smoke for several minutes after start-up.

Starting a cold or warm crane engine without flame start system

• Press the accelerator down approx. 1/4 of the pedal distance.
• Turn the ignition key to position 2 and hold it there until the crane engi-
ne starts up.
• Release the ignition key after the crane engine starts up.
If the engine does not start, abort the starting procedure after approx.
15 seconds and wait one minute before reattempting to start the engine.

Starting a warm crane engine

S
Danger of explosions when using starter fuel!
The warm crane engine may never be started with the aid of starter fuel
(e.g. starter spray). Starter fuel sprayed into the suction unit can ignite.

zH For additional equipment with flame start system, the indicator lamp for
the flame start system lights up shortly (2 to 3 seconds) even with a warm
crane engine after the ignition has been started. You do not need to wait
until the indicator lamp goes out.

Do not operate the accelerator pedal when starting a warm crane engine.
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11 - 12 2 084 575 en Operating Instructions GMK 5100

 Crane engine
11.1 Starting/turning off the crane engine

• Turn the ignition key to position 2 and hold it there until the crane engine
starts up.
• Release the ignition key after the crane engine starts up.

11.1.5 Inspections after starting crane engine

Checking The following indicator lamps and warning lights must go out when the
instruments crane engine is running:

• Monitor the Crane engine oil pressure status display as soon as you have
L started the crane engine.
If the oil pressure does not increase after approx. 10 seconds and the
warning lamp in the crane engine oil pressure display does not go out,
switch off the crane engine by turning the ignition key to the 0 position.

H
Charge indicator lamp
q
If the Charge indicator warning lamp illuminates when the charge engine is
running, switch off the vehicle engine and attempt to find the cause of the
problem; ➠ Malfunctions in the crane engine, p. 14-15.

Motor electronics
à If the Engine electronics warning lamp lights while the engine is running,
there is a malfunction of the engine electronics. Switch off the crane mo-
tor and inform GROVE product support or the service department of the
crane engine manufacturer.

• The following indicator lamps should also be monitored – during crane

work:
Crane engine air filter
p Hydraulic oil filter for control circuit
g Hydraulic oil return flow filter
g
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Flame start system (additioaal equipment)

z
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Operating Instructions GMK 5100 2 084 575 en 11 - 13
Crane engine
11.1 Starting/turning off the crane engine

If one of the indicator lamps illuminates: Refer to ➠ Malfunctions in the

superstructure, p. 14-1.

If the warning lamp Crane engine coolant level illuminates, the coolant level
t has decreased too much.
Switch the crane engine off and add coolant;
➠ Checking coolant level, p. 11-8.
If the coolant temperature exceeds the maximum temperature, a warning
buzzer will sound. ➠ Crane engine malfunctions, p. 14-15.

H You can display the current speed of the crane engine in the Crane control
display; ➠ Display to display conditions, p. 12-87.

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 Crane engine
11.1 Starting/turning off the crane engine

11.1.6 Switch off the crane engine

G
Risk of accidents when the load is suspended!
Never turn the crane engine off while a load is suspended on the hook.
Never leave the crane cab while a load is suspended on the hook block.
Always keep your hand close to the control levers while a load is suspen-
ded on the hook so that you are able to react correspondingly at all times.
Always put down the load before you stop work!

• To turn off the crane engine, turn the ignition key to the 0 position and
pull the ignition key out.

In an emergency or if the crane engine does

not stop after you have turned the ignition
key to the 0 position, you can also turn the
crane engine off from outside of the crane
cab.

The battery master (1) switch is located at

the right-hand side of the superstructure un-
der the battery box behind the panel and is
acessible from below.

• To do so, switch the battery master switch

off. The battery master switch is off when
the selector handle cannot be removed.

H If there has been an emergency stop of the crane control, the crane en-
gine will also be shut off right away; be sure to note the information in
the section Crane control emergency stop; ➠ p. 14-2
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Operating Instructions GMK 5100 2 084 575 en 11 - 15

Crane engine
11.1 Starting/turning off the crane engine

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11 - 16 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.1 Checking the truck crane before working with the crane

12 Crane operation

12.1 Checking the truck crane before working with the crane

12.1.1 CHECKLIST: When truck crane is rigged

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-

H
references. Observe the warning and safety information given there!

This check list only applies if the truck crane has been rigged and is on
the site.
If the truck crane is not yet rigged, you must proceed according to the
CHECKLIST: Rigging; ➠ p. 13-1.

1. For truck cranes with inclinable crane cab (additional equipment), this
point does not apply. The electrical connection between the super-
structure and the carrier is not made; ➠ Disconnect the electrical
connection to the superstructure, p. 12-11.

2. Carry out the activities and checks for starting the crane engine;
➠ CHECKLIST: Starting the crane engine, p. 11-1, Points 1–6.
Check also the relevant lamps with the lamp test crane control
system; ➠ Switching on the ignition, p. 11-10.

3. The suspension system is locked; ➠ Locking the suspension, p. 13-19.

u
4. Boom floating position is switched off; ➠ Switching off boom floating
position, p. 12-6.
Boom pre-tensioning (additional equipment) is switched off;
➠ Switching off boom pre-tensioning, p. 12-6.
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s
Operating Instructions GMK 5100 2 084 575 en 12 - 1
Crane operation
12.1 Checking the truck crane before working with the crane

5. Slewing gear freewheel is switched off; ➠ Switching off slewing gear

freewheel, p. 12-8.

6. All four outrigger beams on the outrigger are extended to the

necessary span and locked; ➠ Support variants, p. 13-17.

7. The outrigger pads are propped in such a way that the outrigger
pressures that occur during crane work cannot exceed the load
bearing capacity of the ground under any circumstances;
➠ Load bearing capacity of the ground and the outrigger, p. 13-6.

8. No wheels now touch the ground;

➠ Extending / retracting the outrigger cylinders, p. 13-30.

9. The truck crane is aligned horizontally ➠ Check the alignment of the

truck crane, p. 13-36.

10. While inspecting the truck crane look out in particular for any
escaping fluids (oil, fuel or water).
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 Crane operation
12.1 Checking the truck crane before working with the crane

11. The safety devices have been checked for perfect working order:
– SLI
– Lifting limit switch
– Dead man’s switch system
– Crane control emergency stop switch
➠ Monitoring the safety equipment, p. 12-14.

12. The required counterweight combination is rigged;

➠ Counterweight, p. 13-41.

13. The position of the hoist ropes on the hoist drums have been checked;
➠ Checking the position of the hoist ropes p. 12-12.

14. The truck crane is earthed accordingly;

➠ Earthing the truck crane, p. 13-12.

15. The key from the key-operated switch Override for SLI and lifting limit
switch has been removed; ➠ SLI override, p. 12-34.

16. The current rigging mode is set on the SLI and the accompanying SLI
11== code is displayed according to the Lifting capacity table; ➠ Entering
values, p. 12-23.

17. The number of the reeved rope lines for the corresponding hoist has
2 n=
been entered with the membrane switch or via the numerical pad and
appears in the display Reeving; ➠ Setting rigging mode, p. 12-20.

18. The telescope status has been checked; ➠ Check before telescoping for the
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first time, p. 12-59.

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Operating Instructions GMK 5100 2 084 575 en 12 - 3
Crane operation
12.1 Checking the truck crane before working with the crane

19. The maximum permitted slewing speed for the current rigging mode
is set; ➠ Maximum permitted slewing speeds, p. 12-51.
SPEEDS
SLEW
NORMAL : ❙
POINT :

20. The lamp test has been performed on the SLI and the brightness of
oa +
the SLI status display has been set in such a way that all of the
displays are easily read; ➠ p. 12-19.
o bc +
,
21. The level of the windscreen washing system is regulated;
➠ Checking the windscreen washing system reservoir, p. 12-13.

22. The superstructure lock is released;

¥ ➠ Mechanical superstructure lock, p. 12-9.
23. The crane operator’s seat has been suitably adjusted;
➠ Adjusting the seat, p. 10-58.

24. The mirrors for monitoring the hoisting gear have been correctly
adjusted; ➠ Adjusting the mirrors, p. 12-12.

25. The electrical system (spotlight for working area, windscreen wiper/
washing system, horn) has been checked to ensure perfect working
order; ➠ Electrical system, p. 12-11.

26. Check the temperature of the hydraulic oil; preheat the hydraulic oil if
necessary; ➠ Preheating the hydraulic oil, p. 12-5.
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12 - 4 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.1 Checking the truck crane before working with the crane

12.1.2 Preheating the hydraulic oil

The hydraulic oil must be preheated before beginning crane work if

the truck crane is operated at a temperature of under 0 °C (32 °F).
The Hydraulic system oil temperature status display in the crane cab is
definitive.

For oil tempe- You may carry out crane movements without loads at an average engine
ratures between speed and average operating speed in normal gear.
–15 °C and 0 °C
(5 °F and 32 °F):
• Do not increase the engine speed and operating speed until the Hydrau-
lic system oil temperature status display shows an oil temperature of at
least 10 °C (50 °F).

For oil tempera- Let the crane engine run at intermediate speed and raise the main boom
turesbelow to the steepest position. Move the crane function Raise against the end
–15 °C (5 °F): position until the status display Hydraulic system oil temperature displays an
oil temperature of at least 10 °C (50 °F).
The preheating procedure may take up to 20 minutes depending on the
initial temperature of the oil.

• Carry out all crane functions at least twice once the oil is heated in

H
order to displace the cold oil in all sections of the hydraulic system.

Cold oil can cause the switching of the solenoid valves to be delayed or
the rough start-up of the driving gears.
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Operating Instructions GMK 5100 2 084 575 en 12 - 5

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.3 Switching off the boom floating position

(additional equipment)
(Applies only after on-road driving with boom resting on trailer.)

The boom floating position may be switched on only for transporting the
boom on the rear bed (trailer). The boom floating position must be swit-
ched off before raising the boom from the trailer.
• Turn the hand lever (2) to the horizontal po-
sition.
• Secure the hand lever in horizontal positi-
on with the padlock (1) and remove the key.

G
Risk of accidents if the main boom falls down!
The hand lever must be secured in horizontal position using a padlock.
The boom will fall down if the hand lever is accidentally operated when
the boom is raised.

Switch off boom If the boom initial tension is switched on for on-road driving, you must
initial tension switch it off again before you take the boom off the trailer.
(additional
equipment) • Put taps I to IV in the following positions.

Tap I (at the derricking cylinder with the padlock)

Tap I is in the proper setting when the boom floating position is switched
off.
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12 - 6 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.1 Checking the truck crane before working with the crane

Tap IV
• Switch tap IV (1) in the A position for
crane operation.

S
Overheating danger for the hydraulic oil!
Always close tap IV before using the crane. If the tap is left open, the
pressure in the hydaulic circuit will increase greatly, and all the hydraulic
oil can be heated to above the allowed temperature of 80 °C.

Taps II and III

The pressure accumulator is drained with
B tap II.

• Switch tap II (2) in the B position (opened).

The pressure on the pressure gauge (3)
2 3 must drop to 0 bar.
B
Tap III (1) is not operated. To operate the
crane, the valve must be switched into
position A (closed).
A

1
A
C0938
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Operating Instructions GMK 5100 2 084 575 en 12 - 7

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.4 Switching off the slewing gear freewheel (additional equipment)

(Applies only after on-road driving with the boom resting on a trailer.)

The slewing gear freewheel is switched on if the boom has been set onto
the trailer for on-road driving. The slewing gear freewheel must be swit-
ched off again before working with the crane. For this, the block on the sle-
wing gear brake must be removed.

S
The superstructure can be damaged when working with the crane while
the slewing gear freewheel is switched on!
When the slewing gear freewheel is switched on, the turning superstruc-
ture cannot be braked with the slewing gear service brake or the slewing
gear permanent brake. Switch off the slewing gear freewheel when wor-
king with the crane. This prevents the superstructure from colliding with
obstacles as it turns.

H Switch off the slewing gear freewheel when the crane motor is running,
because the pin can be moved more easily.

• Remove the lock (4) from the bore (1).

• Pull the pins (3) out as far as possible.
• Guide the lock with the yoke through the
bore (2).
• Close the lock.
The slewing gear freewheel is now switched
off and secured against being switched on
by unauthorized persons.

• Also switch off the freewheel on the se-

cond slewing gear unit.

• After switching off the slewing gear freewheel, remove the fuse box
from the superstructure lock; ➠ p. 6-15.

Before slewing • Support the truck crane with an outrigger span of at least 25.6 ft x 16.7 ft
and enter the corresponding SLI code.
• Raise the main boom to an angle permitted within the working range.
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12 - 8 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.1 Checking the truck crane before working with the crane

12.1.5 Mechanical superstructure lock

The superstructure may be locked in 0° position facing backward or

180° position facing forward with a locking pin to prevent it from turning.
The locking pin is hydraulically retracted and extended and can be control-
led from the crane cab.

Always lock the superstructure when:

– you work with the truck crane in the 0° position to the rear,
– you have set down the boom for on-road driving to the front in the 180°
position,
– slewing is not allowed with the current rigged counterweight because
the outrigger span is too small.
A table in section Slewing with rigged counterweight, p. 13-67 shows you for
which combinations of counterweight and outrigger span slewing is not
allowed.
Also refer to the section Permissible slewing ranges for working with the crane,
➠ p. 12-39.

G
The crane can overturn when the superstructure lock is released!
Always lock the superstructure when one of the points indicated above
applies. This prevents the superstructure from coming out of the 0° posi-
tion due to unfavourable conditions (e. g., inadvertent actuation of the
slewing gear or swinging loads), which could cause the truck crane to
overturn or, because of too great a counterweight mass, to tip to the rear.

Disengaging the
lock
If the Superstructure locked indicator lamp illuminates, the lock is in place.
!
• Press the Superstructure lock rocker switch upward.
§
As soon locking pins leave the lower end position, both the Superstructure
!¥ locked and Superstructure unlocked indicator lamps will flash alternately.

The Superstructure unlocked illuminates when the locking pin has reached
¥

H
the upper end position. The Superstructure locked indicator lamp goes out.

The superstructure is not properly unlocked if the Superstructure unlocked

indicator lamp does not illuminate. In this case turn it slightly from side to
side until the indicator lamp illuminates.
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Operating Instructions GMK 5100 2 084 575 en 12 - 9

Crane operation
12.1 Checking the truck crane before working with the crane

H If both the Superstructure locked and Superstructure unlocked indicator

lamps flash at the same time, the electronic system has recognised an
error.
Press the Superstructure lock rocker switch once:
The electronic system will show which status has been determined with
the indicator lamps.
If, for example, both indicator lamps light at the same time while the lok-
king pin is in the upper end position, then the lower proximity switch is
defective.

Engaging the lock • If necessary, remove the fuse box from the superstructure lock;
➠ p. 6-15.
You can only engage the lock when the superstructure is in the 0° or 180°
position.

• Slew the superstructure to the 0° or the

180° position.
If the superstructure is in the 0° or 180°
position, the arrow (1) on the turntable
points to the respective marked screw (2)
of the roller slewing ring.

If the Superstructure unlocked indicator lamp lights, the lock is released.

¥ • Press the Superstructure lock rocker switch downward.
§ As soon locking pins leave the upper end position, both the Superstructure
!¥ locked and Superstructure unlocked indicator lamps will flash alternately.

• The Superstructure locked indicator lamp illuminates when the locking pin
¥ has reached the lower end position.

H
The Superstructure unlocked indicator lamp goes out.

If the locking pin does not exactly engage with the bore in the carrier, the
11.05.2000

Superstructure locked indicator lamp does not illuminate. In this case turn it
slightly from side to side until the indicator lamp Superstructure locked
illuminates.

12 - 10 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.1 Checking the truck crane before working with the crane

12.1.6 Electrical system

Check that the following parts of the components of the electrical system
are functioning perfectly:
– horn,
– spotlight for working area,
– instrument lighting,
– control and warming indicators,
– windscreen wipers and
– windscreen washing system.

Disconnect the When driving on public roads, the superstructure lighting is supplied with
electrical connec- electrical power from the carrier. When working with the crane you have
tion to the super- to disconnect the electrical connection between the carrier and superstruc-

H
structure ture.

If your truck crane is equipped with an inclinable crane cab (additional

equipment), you do not have to disconnect any connections.

• Pull the cap off the dummy socket (1).

• Remove the plug (4) of the connecting cab-
le from the socket (2) at the carrier.
• Insert the plug of the connecting cable into
the dummy socket (1) at the superstructure.
• Close the socket with the cap (3) so that it
is protected against contamination.
The electrical connection is thus broken.
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Operating Instructions GMK 5100 2 084 575 en 12 - 11

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.7 Adjusting the mirrors

• Adjust the mirrors (1) on the crane cab and

the hoist so that you have a clear view of
the rope running on the hoist.
If your truck crane is equipped with an
auxiliary hoist (additional equipment), also
adjust the mirror on the auxiliary hoist.

12.1.8 Check the position of the hoist ropes

G
Risk of accidents with turning rope drum!
Keep yourself and other people away from the turning rope drum. If you
take hold of the turning rope drum, your fingers and hands could be
crushed between the rope drum and hoisting gear frame or get caught
and drawn in by the turning drum.

Check the position of the hoist ropes (1) on

the rope drums of the hoists.

• Slowly turn the rope drum at least one

turn in the lowering direction. At the same
time, watch the unreeled rope.
– The rope must be wound evenly on the
drum.
– The turns on the drum must all be at an
equal distance of 0 to 0.07 inch.
– The cross-over points must be at an angle
of approx. 180° to each other.
(The upper layer of rope lies over the
lower layer at the cross-over points.)
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 Crane operation
12.1 Checking the truck crane before working with the crane

12.1.9 Checking the reservoir of the windscreen washing system

The windscreen washing system reservoir is located beside the crane

operator’s seat.

Remove the cap of the reservoir to check its

contents.

Keep the reservoir (1) full at all times and

add a cleaning agent and, if necessary,
antifreeze to the water.

12.1.10 Visual inspection of the entire crane

Walk around the truck crane before beginning crane work.

Check in particular for any escaping fluids such as oil, fuel or water.

G
Remember that loss of oil can mean that crane movements can not be car-
ried out (even in emergency situations, e.g. when raising in emergency
operation).

O
Immediately repair any oil, fuel or coolant leaks or have them taken care
of so that no oil, fuel or coolant seeps into the ground or ends up in bo-
dies of water while working with the crane.
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Operating Instructions GMK 5100 2 084 575 en 12 - 13

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.11 Checking the safety devices

G
Accidents may occur when working with defective safety devices!
It is strictly prohibited to operate the crane with non-operational or
overridden safety devices!
Defective safety devices are to be repaired immediately by GROVE
Product Support only.

Safe Load • Switch on the safe load indicator;

Indicator ➠ Switching on the SLI, p. 12-17.
• After the test program has run check if:
– an error message is displayed,
– the SLI early warning and SLI shutdown warning lamps light up,
xw – a continuous buzzer tone sounds.
• Carry out a test of the lamps; ➠ p. 12-19.
All display, warning and indicator lamps on the SLI must light up at
maximum brightness.

The SLI will now function properly if:

– no error messages are displayed,
– both warning lamps illuminate,
– the continuous buzzer tone sounds and
– the lamp test resulted in no failures of lamps and lights.
If the SLI is not functioning correctly, do not start crane work. Notify the
responsible GROVE Product Support and have them repair the SLI.

Lifting limit • Raise the main boom.

switch
• Slowly raise the hook block until the hook block has been lifted away
from the lifting limit switch weight.
• Check whether the warning lamp Lifting limit switch shutdown illuminates.
K • Check whether the crane movements that increase the load moment are
deactivated. Check the crane movements of all crane movements which
increase the load moment!
Movements which increase the load moment are: lifting loads, lowering
the main boom and extending the main boom.
The lifting limit switch now functions properly if the warning lamp Lifting
limit switch shutdown illuminates and the movements which increase the
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load moment have been shut down.

12 - 14 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.1 Checking the truck crane before working with the crane

If the lifting limit switch is not functioning correctly, do not start crane
work. Notify the appropriate GROVE Product Support and have them
repair the anchor-to-bracket switch.

Seat contact
switch and dead
man’s switch
system

G
A defective seat contact switch poses a risk of accidents!
Do not stand beside the crane cabin on the carrier during this check. If the
dead man’s switch is defective, the superstructure can turn and knock you
off the crane. Get inside the crane cab!

Monitoring the seat contact switch in the crane operator’s seat

• Do not sit on the crane driver’s seat.
• Do not press either of the dead man’s switches on the control levers.
• Check that no crane movement can be carried out.

Monitoring the dead man’s switch system on the control levers

• Slowly raise the hook block. At the same time press the dead man’s
switch on a control lever.
• Release the dead man’s switch. After approx. 1 second the crane move-
ment must be shut down.
• Repeat the check. Press the dead man’s switch on the other control
lever.
The seat contact switch and dead man’s switch are functioning properly if
crane movement is not allowed when the crane operator’s seat is unoccu-
pied and the dead man’s switch has not been pushed; and if crane motion
stops upon release of the dead man’s switch.

If the dead man’s switch is not functioning correctly, do not start crane
work. Inform the appropriate GROVE Product Support and have them
repair the dead man’s switch.
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Operating Instructions GMK 5100 2 084 575 en 12 - 15
Crane operation
12.1 Checking the truck crane before working with the crane

Crane control • Set down the load and release both control levers.
emergency stop
• Press the Crane control emergency stop switch so that it snaps in.
switch
The Crane control emergency stop switch is working correctly up to this point
if the crane engine stalls.

If the crane control emergency stop switch does not function correctly, do
not start crane work. Notify the responsible GROVE Product Support and
have them repair the crane control emergency stop switch.

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12 - 16 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

12.2 Operating the safe load indicator

12.2.1 Switching on the SLI

Switching on
The SLI is switched on with the ignition.

A test programme is run in the SLI in the first 5 seconds. During this time
– the SLI early warning and SLI shutdown warning lamps illuminate,
xw – the numbers in the displays constantly change or flash and
– an acoustic signal sounds (continuous buzzer tone).

H
The test programme also runs after every voltage drop

If, when restarting the motor, you do not turn the ignition key to position
0, but to position R instead, the SLI will not be turned off and you will not

H
have to acknowledge the settings again.

After completion of the test program

– the SLI shutdown warning lamp lights up,
– the SLI early warning warning lamp lights up,
– the continuous buzzer tone continues to sound.
Depending on how long the SLI was switched off, the displays Rigging
mode and Reeving are activated differently.
Status displays after a short period of standstill:
If the SLI was switched off only briefly (less than 24 hours), the last setting
is shown on the displays.
If then displayed values do not correspond to the current rigging mode of
the truck crane, you must set the current rigging mode;
➠ Setting rigging mode, p. 12-20.
The signalling point Reeving appears on the status display in order to
" n= remind you that the value for the reeving must be transferred to the SLI
before operating the crane.
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If the value displayed coincides with the current reeving, you can transfer
the value; ➠ Transferring values, p. 12-25.

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Operating Instructions GMK 5100 2 084 575 en 12 - 17
Crane operation
12.2 Operating the safe load indicator

The signalling point now changes to the display Rigging mode. If the value
10== appearing on this display also corresponds to the current rigging mode,
you can transfer the value; ➠ p. 12-25.

Status displays after a long period of standstill:

If the SLI was switched off for longer than 24 hours, the digit zero and the
== n= signalling point appear in both the Reeving and Rigging mode status
displays.
All other status displays with membrane switches are not activated.
00==
The SLI switches on the entry mode on the display Reeving.
The display flashes and thus requests that you enter the value for the
current reeving.

• Enter the current reeving; ➠ Entering values, confirming entry, transferring

values, p. 12-23 to p. 12-25.
After you have transferred the value on the display Reeving, the entry
mode changes to the display Rigging mode. The display flashes and thus
requests that you enter the current rigging mode of the truck crane;
➠ Setting rigging mode, p. 12-20.
When the current values have been entered and transferred on the
displays Reeving and Rigging mode, you can confirm the SLI shutdown.

• Press the Acknowledge membrane switch.

p The continuous buzzer tone is switched off.
The SLI-early warning and SLI-shutdown warning lamps go out.
w If the SLI is defective, the red warning lamp in the Error information mem-
t brane switch illuminates (Error display ➠ Error message in section ‘While
working with the crane‘, p. 12-32).

G
Accidents may occur when working with defective SLI!
It is prohibited to work with the SLI when it is overridden, out of
operation or defective!

If no error message is displayed, the SLI is now set for the crane
operation.
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12 - 18 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

Lamp test on the You should carry out a lamp test before you set the rigging mode.
SLI
• Keep the membrane switch Switch on second level pressed and, in
o a +
addition, briefly press the membrane switch Lamp test.
All display, warning and indicator lamps in the SLI must illuminate with
maximum brightness.
After approx. two seconds, the normal display reappears with the
brightness automatically set.
If the lamp test shows a display, warning or indicator lamp to be
defective, or if no continuous buzzer tone sounds after switching on;
➠ Malfunctions on the SLI, p. 14-29.

G
Risk of accidents when the SLI is defective!
The SLI is faulty if display, warning or indicator lamps fail to light up or
the buzzer fails to sound.
You must never work with a defective SLI!

If you cannot see the SLI status displays due to unfavourable lighting
conditions, you can adjust the brightness of the displays using the dim-
mer.

Dimmers for the After switching on the ignition, the basic brightness of the all status
SLI status displays and warning and indicator lamps in the SLI automatically adapt
displays to the ambient light. If necessary, you can readjust the brightness of the
status display.

• Keep the membrane switch Switch on second level pressed and, in

o b +
addition, press the membrane switch Dimmer brighter.
The status display gets brighter by one level every time the mem-
brane switch is pressed until the maximum brightness has been
reached.
• Keep the membrane switch Switch on second level pressed and, in
o c +
addition, press the membrane switch Dimmer darker.
The status display gets darker by one level every time the membrane
switch is pressed until the minimum brightness has been reached.
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Operating Instructions GMK 5100 2 084 575 en 12 - 19

Crane operation
12.2 Operating the safe load indicator

12.2.2 Setting rigging mode

There are two ways of setting the rigging mode on the SLI:
– via the SLI code,
– via individual components.

Setting using the When setting the rigging mode using the SLI code, the SLI code for the
SLI code rigging mode is entered according to the Lifting capacity table. The SLI code
is entered in the Rigging mode status display. After entry the SLI indicates
the required rigging mode on the various status displays.
You must additionally enter the reeving on the status display Reeving.

G
Risk of accidents when the rigging mode is set incorrectly!
The actual rigging mode must coincide with the rigging mode displayed
on the SLI. Compare the displayed rigging mode with the actual rigging
mode; ➠ Checks before working with the crane, p. 12-27.
In addition to the SLI code, enter the current reeving on the Reeving display.
In this way you prevent the SLI from incorrectly calculating the permissible
load and that the truck crane becomes overloaded when in use, thus
causing it to overturn.

Setting using The individual components for the current rigging mode are:
individual – the supporting span,
components – the counterweight,
– the reeving
– the length of lattice extension (only with additional equipment)
– the angle of the lattice extension (only for additional equipment),
– the slewing range and
– if necessary, the hoist indicator lamp (only with additional equipment
with auxiliary hoist)

You can set the values for the individual components directly using the
membrane switches on the corresponding status display. Here you can
select the respective values which are permitted according to the Lifting
capacity table.
After setting, the SLI code for the recently set rigging mode is displayed in
the Rigging mode display (not with changes on the display Reeving).
Setting the hoist display lights; ➠ Switching over hoist display lights, p. 12-26.
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 Crane operation
12.2 Operating the safe load indicator

G
Danger of overturning due to incorrectly set rigging mode!
When the individual components are selected, values which have already
been set can change again. After selecting always compare the SLI code
which appears in the Rigging mode status display with the SLI code which
is provided in the Lifting capacity table for the actual rigging mode. If the
SLI changes the components which have already been set, the SLI codes
do not coincide and the settings must be corrected.
In this way you prevent the SLI from calculating with the incorrectly set
components and the truck crane becoming overloaded and overturning
when in operation, ➠ Checks before working with the crane, p. 12-27.

General An error code appears in the status display Information when there is an
instructions error message. This status display automatically switches over if you
enter values on the status display Rigging mode.

In this case the Information status display automatically switches to the dis-
] play of the permitted slewing range and the green indicator lamp in the
Permitted slewing range membrane switch illuminates.

If error messages now occur, you will be able to recognize this by the
t acoustic signal and the red warning lamp in the Error information mem-
brane switch. You can see these error messages in the Information status
display by pressing this membrane switch; ➠ Error messages, p. 12-32.

After you have read the error message, you can cancel the acoustic signal
p by pressing the Acknowledge membrane switch. You can cancel the error
message and warning lamp only after the cause of the error has been
eliminated; ➠ Error messages, p. 12-32.

Sequence during The setting sequence is the same for all status displays. There are only

H
setting differences when the values are entered directly.

If the flashing status display requests that you enter values after having
switched on the SLI, the SLI is already in entry mode and you can directly
enter values; ➠ Entering values, p. 12-23.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 12 - 21
Crane operation
12.2 Operating the safe load indicator

1. Switch the SLI to entry mode; ➠ Switching on entry mode, p. 12-22.

2. Enter new value; ➠ Entering values, p. 12-23.
3. Confirm entry; ➠ p. 12-25.
4. Transfer the new value to the LMB processor; ➠ Transferring values,
p. 12-25.

Switching on If you have switched on the SLI with the ignition, you can switch on the
entry mode entry mode. When doing this you must consider whether:
– you want to change the values on the status display Reeving or
– you want to change the values on another status display.

Changing values on the status display Reeving

• Keep the Entry mode membrane switch pressed and briefly press the Ree-
n O +
ving membrane switch and then let go of both switches again.

The status display flashes and the signalling point is displayed.

! n= Thus the entry mode on the status display Reeving is switched on.
You can now change the value for the reeving.

Changing the values on another status display

• Enter an SLI code for the main boom or the lattice extension in the sta-
00=0 tus display Rigging mode, depending on the intended job.

• Press the membrane switch Confirm entry once.

v • Keep the membrane switch Entry mode pressed and in addition to this
n P +
briefly press the membrane switch Rigging mode and then let go of both
switches.
The SLI code in the display flashes and the signalling point is displayed.
00== This switches on the entry mode for the display Rigging mode.
All the displays of the individual components which are associated with
the flashing SLI code are now activated.
You can now enter the values on the status displays of the individual com-
ponents (except for reeving) or you can enter the SLI code directly on this
status display.
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12 - 22 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

Entering values You can only enter values when the SLI is in entry mode. Depending on
the status display you have two possibilities of entering the desired value.
On the status display you can
– select the desired value in single steps, or
– enter the values directly via the numerical pad.
The following table shows which displays are activated depending on the
flashing SLI code and assigns the entry options to the various displays.

Display
indivi- with
activated with SLI code for
dual numerical
Main Lattice steps pad
boom extension
Supporting span X X X

Counterweight X X X

Rigging mode X X X X

Reeving X X X X

Length of lattice
extension
X X
(additional
equipment)

Angle of the lattice

extension
(additional X X
equipment)

H In the detailed descriptions of the entry options in this section the Counter-
weight status display is for the most part given as an example.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 12 - 23
Crane operation
12.2 Operating the safe load indicator

Selecting the desired value in single steps

You can only enter values when the SLI is in entry mode. The SLI is in
entry mode if the status display Rigging mode or (if you want to change the
reeving) Reeving flashes; ➠ Switching on entry mode, p. 12-22.

• Press the membrane switch next to the desired status display (e.g. on
Q the display Counterweight).
The next possible value appears in the status display.
2=0 t

If you press the membrane switch again, the status display jumps to the
2$0 t next highest possible value.

• Continue pressing the membrane switch until the desired value appears
in the status display.
Every time a new value is displayed on the status screen, the status

H
display Rigging mode switches to the corresponding SLI code.

If you have inadvertently skipped the desired value, run through all
possible values until the status display begins again with the initial value.

Entering the values directly via the numerical pad

This entry option is only available for the Reeving and Rigging mode status
displays.
You can only enter values when the SLI is in entry mode. The SLI is in
entry mode if the status display Rigging mode or (if you want to change the
reeving) Reeving flashes; ➠ Switching on entry mode, p. 12-22.

• Enter the desired value; to do this press the corresponding membrane

abc switches on the numerical pad one after the other.
The entered value flashes in the selected status display.
" n=

H If you have inadvertently entered the incorrect value, repeat the entry.
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12 - 24 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

After entering the values

When you have selected all necessary values on the displays or have
entered them via the numerical pad, you must confirm the entry and
transfer the values to the SLI.

Confirming
entry
• Press the membrane switch Confirm entry once.
v The numerical value on the status display Rigging mode or Reeving does
11== not flash any more (depending on on which status display the entry mode
was switched on). The signalling point at the right edge of the respective
status display illuminates.
The entry is now confirmed and the SLI is ready to transfer the entered

H
value.

If you have entered a value which is not allowed according to the Lifting
capacity table, the value is not transferred and the status display continues
to flash after pressing the membrane switch Confirm entry; furthermore an
error message is displayed; ➠ Error messages, p. 12-32.

Transferring For the transfer of newly entered values, you must transfer the value on
values the status display at which the signalling point is displayed:

– A newly entered value for reeving is transferred on the status display

Reeving.
– All other newly entered values are transferred on the status display
Rigging mode.

Press the membrane switch next to the corresponding status display

P (here Rigging mode is used as an example).

The signalling point goes out; the value displayed has been accepted by
11=0

H
the SLI.

If you have changed several rigging components (e.g. the outrigger span
and the length of lattice extension as well), then these values are trans-
11.05.2000

ferred at the same time as the new SLI code.

In addition you must confirm and transfer the current reeving on the
display Reeving.

s
Operating Instructions GMK 5100 2 084 575 en 12 - 25
Crane operation
12.2 Operating the safe load indicator

Once there are no more error messages and you have already acknow-
wx ledged all of the error messages which were issued, both warning lamps
SLI shutdown and SLI early warning go out after pressing the membrane
switch for transferring and you can work with the truck crane.

Switching over Only for additional equipment with auxiliary hoist.

hoist position The lamp for the hoist with which the load is to be lifted must light at the
lights Hoisting gear indicator lamps. The SLI always uses the displayed reeving
for calculations.

Lamp I: Main hoist

Lamp II: Auxiliary hoist
The corresponding lamp is activated as soon as the hoist is switched on.
If a hoist is switched on and you additionally switch on the second hoist,
the lamp for the second hoist flashes.
The lamp for the hoist with which the load is to be lifted must always
illuminate.

If the load is to be lifted with the hoisting gear whose indicator lamp is
flashing, then switch over the display in the following way.

Example: Switching over status display

For this example the load is to be lifted with the main hoist. But of the display
lamps Hoists, lamp II for the auxiliary hoist illuminates and lamp I for the main
hoist flashes.

Switch over the status display in the following manner:

• Switch off both hoists; to do this, press both rocker switches Main hoist shut-
üC down and Auxiliary hoist shutdown downward.
• Switch on the main hoist; to do this, press the rocker switch Main hoist shut-
ü down upward.

Now the I lamp lights at the Hoisting gear indicator lamps for the main hoist
" n= and the last reeving entered for the main hoist reeving is shown on the Reeving
display.

G
Risk of accidents if SLI is incorrectly set!
After switching over the hoisting gear, always check whether the dis-
played reeving agrees with the current reeving of the indicated hoisting
gear and, if necessary, enter the current reeving.
In this way you prevent the SLI from making calculations based on an
incorrect reeving, which can lead to the truck crane overloading or over-
11.05.2000

turning.

12 - 26 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

12.2.3 Checks before working with the crane

G
Risk of accidents if SLI is incorrectly set!
If the actual rigging mode and the rigging mode indicated by the SLI are
not the same, the permissible load calculated by the SLI is not the actual
permissible load. The consequences are sure to be overloading and an
accident!
The valid SLI codes can be found in the Lifting capacity table.

• Check whether the rigging mode displayed by the SLI is the same as the
actual rigging mode.
• Check
– the reeving of the hook block,
– the mounted counterweight mass,
– the span
– the length of lattice extension (for additional equipment)
– the angle of the lattice extension (for additional equipment) and
– which hoist is switched on (only with auxiliary hoist additional
equipment)
• Check the functioning of all SLI displays, warning lamps and indicator
o a +
lamps by keeping membrane switch Switch on second level pressed and, in
addition, by pressing the membrane switch Lamp test once.
The rigging mode displayed by the SLI and the actual rigging mode must
11== always be the same. If not, the SLI is set incorrectly.

Of the display lamps Hoists, the lamp for the hoist with which the load is
to be lifted illuminates:
Lamp I: Main hoist
Lamp II: Auxiliary hoist

• Switch over the status display if necessary; ➠ Switching over hoist display
lights, p. 12-26.

The number of reeved rope lines for the hoist indicated by the display
2 n=
lamps Hoists is shown in the Reeving status display.

• If necessary, correct the value for the reeving.

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Operating Instructions GMK 5100 2 084 575 en 12 - 27
Crane operation
12.2 Operating the safe load indicator

The mass of the required counterweight is shown in the Counterweight dis-

2!5 t
play. The value is derived from the set SLI code.

The required outrigger span is shown in the Outrigger span display. The
light-emitting diodes in the display show the different outrigger spans in
the following way:

Outrigger span Outrigger span Outrigger span

25.6 x 24.6 ft 25.6 x 16.7 ft 25.6 x 8.7 ft

The length of lattice extension required is shown in the Length of lattice

69 ft
extension status display.

The required angle of the lattice extension is indicated in the Angle of the
20 n° lattice extension display.

H If no lattice extension may be mounted in accordance with the SLI code

set, both of these status displays remains dark. 11.05.2000

12 - 28 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

12.2.4 During crane work

Continuous Apart from the displays listed in section 12.2.3 the following information
displays is constantly displayed by the SLI:
The radius of the boom in the Radius status display.
When the lattice extension is mounted, the information refers to the
1"7 ft
lattice extension.
The main boom angle in the Boom angle status display.
3&4 n°
When the boom is lowered to below the horizontal, a minus sign (–)
appears in the display at the left.
The telescope status of the main boom in the Current telescope status
displays.

– Fixed lengths are displayed as decimal values,

=5
– Intermediate lengths and telescoping lengths are displayed as
89 percentages.

The shutdown value, i.e. the maximum possible load in tonnes, is shown
7/0 klbs
max
in the Maximum load status display.
The SLI calculates this value from
– the rigging mode set,
– the reeving setting,
– the current length of the main boom and

H
– the current boom angle.

If the load is reduced because of reeving, the signalling point is indicated.

The maximum possible load can be displayed for about three seconds by
depressing the Reeving membrane switch.

The load, comprising the load on the hook + the lifting gear + the hook
6"0 klbs block, in the Actual load status display.
The relationship of the actual load and maximum load in the Degree of
utilization status display.

Optional status The information listed in the following section can be shown in the
displays Information status display.
• To do this, press the appropriate membrane switch.
11.05.2000

The green indicator lamp in the membrane switch lights up and the
current value appears in the Information status display.

s
Operating Instructions GMK 5100 2 084 575 en 12 - 29
Crane operation
12.2 Operating the safe load indicator

If a different membrane switch was pressed before the selection was

made, the green indicator lamp in the membrane switch goes out and the
displayed value changes.
– Permissible slewing range in degrees with the
A Permissible slewing range membrane switch
– Current main boom angle in degrees
B using the Main boom angle membrane switch
– Current main boom length in feet
C with the Main boom length membrane switch
– Current height of the single-sheave boom top in feet
G with the Height of the single-sheave boom topmembrane switch
– Current degree of utilization
M with the Degree of utilization membrane switch
– Current hydraulic oil pressure in the lower chamber of the derricking
k cylinder in psi with the Hydraulic oil pressure in the derricking cylinder-lower
chamber sensor A membrane switch.
– Current hydraulic oil pressure in the lower chamber of the derricking
l cylinder in psi with the Hydraulic oil pressure in the derricking cylinder-lower
chamber sensor B membrane switch.
– Current hydraulic oil pressure in the upper chamber of the derricking
m cylinder in psi with the Hydraulic oil pressure in the derricking cylinder-up-
per chamber sensor A membrane switch.
More detailed information on the respective status displays ➠ Chapter
10.2.1 Description of the functions of the display and operating display and operating ele-

H
ments.

If a selector key which has no function assigned to it is pressed, the value

in the Information status display does not change and the green indicator
lamp in the key does not light up.

If the maximum load is reduced because of the reeving, the maximum

O load can be displayed according to the Lifting capacity table (without reduc-
tion because of the reeving) on the Maximum load display by pressing the
Reeving membrane switch. The value is shown for about three seconds.
The display then changes back to the reduced value.

SLI early warning

The SLI early warning lamp will illuminate when the actual load reaches
x 90 % (depending upon the regulations of the respective country) or more
of the maximum permissible load. The intermittent buzzer tone sounds
11.05.2000

at the same time.

• Press the membrane switch Acknowledge to switch off the buzzer tone.
p
12 - 30 2 084 575 en Operating Instructions GMK 5100
 Crane operation
12.2 Operating the safe load indicator

The load is shown in the Degree of utilization status display. The green and
yellow LEDs illuminate.

SLI shutdown There are two types of shut down:

– The shutdown due to overload, when approx. 100 % of the maximum
permissible load is exceeded.
– Shutdown resulting from error messages; ➠ Error message in this
section, p. 12-32.

For both types of shutdown

– all crane movements which increase the load moment are shut down,
– the SLI shutdown warning lamp lights up,
w – the continuous buzzer tone sounds.
A shutdown resulting from overloading can be recognised by the fact that
in addition to the messages mentioned above:
– the signalling point lights up in the Actual load status display and
2$$ klbs
– the red LEDs light up in the Degree of utilization status display.

If the SLI shuts down due to an error, the red warning lamp in the
t membrane switch Error information also lights up (➠ Error messages in this
section, p. 12-32).

If you would like to switch off the continuous buzzer tone:

• Press the Acknowledge membrane switch.
p For shutdowns caused by overloading, you can cancel the shutdown by
leaving the shutdown area. You may then only perform the crane opera-
tions listed in the following table.

Crane movements switched off Crane movements allowed

Lift load Lower load
Lower main boom Raise main boom
Extend main boom Retract main boom*)

H *)
With certain telescoping states the SLI also shuts down the retraction of
the telescoping for safety reasons. In this case leave the shutdown area
11.05.2000

by raising the boom or, if this is not possible, set the load down, tele-
scope to the next fixed length and lift the load again.

s
Operating Instructions GMK 5100 2 084 575 en 12 - 31
Crane operation
12.2 Operating the safe load indicator

If you have not already switched off the buzzer tone, you must press the
p Acknowledge membrane switch after leaving the shutdown area in order to
cancel the shutdown.

The SLI shutdown warning lamp goes out after you leave the shutdown
w area.

Error messages Shutdown due to an error is indicated by the red warning lamp in the
Error information membrane switch.
The code for the error is indicated in the status display Information after
you have pressed the membrane switch Error information. Error codes for
which there are no technical malfunctions are listed along with their
possible countermeasures in a table at the end of this section.

Gt
Risk of accidents!
You must stop crane operation as soon as an error message occurs!
Repairs to the SLI may only be carried out by properly qualified personnel.

• Press the Error information membrane switch.

An error code appears in the Information display. If there are several

errors, you can have all of the error codes displayed one after the other

H
by repeatedly pressing the membrane switch Error information.

If the Error information membrane switch is pressed without there being an

error message, a minus sign appears in the Information status display in all
positions.
----

Example of an error display:

An error message comprises three different numbers, which are separated by pe-
!1§8 riods on the status display. The numbers stand for (from left to right):
the error group: e.g. 1
the components in
this error group e.g. 13
the type of error e.g. 8

Table of error messages with possible causes and remedies;

➠ Malfunctions of the SLI, p. 14-29.
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12 - 32 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.2 Operating the safe load indicator

Error messages Some error messages are indicated by the respective display flashing, in
with additional addition to SLI deactivations. The follow displays blink:
optical displays

Either:
– the indicators Current length of telescope
section I to IV (1)
or
– the display Actual load (2) and
– the display Current radius (3)
or
– the indicators Current length of telescope
section I to V (1) and
– the display Actual load (2) and
– the display Current radius (3).

H Flashing values mean that the SLI can no longer safely calculate these
values. The error message occurs if the SLI recognises differences between
the measured and calculated values which are too large, or if the values
from the SLI and the crane control do not agree (e.g., after manually enter-
ing a telescope status on the display Crane control). Countermeasure;
➠ Malfunctions of the SLI, Error message 1.19.1 and 3.06.3, in the error
messages table beginning on page 14-30.
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Operating Instructions GMK 5100 2 084 575 en 12 - 33
Crane operation
12.2 Operating the safe load indicator

SLI override

G
Risk of accidents if SLI is overridden!
The SLI may not be overridden while the crane is being operated.
It is prohibited to operate the crane if the safe load indicator is switched
off, overridden, out of operation or defective!

S
You may only override the SLI when carrying out maintenance or rigging
work in accordance with the Operating Instructions.
In such cases, the SLI may only be overridden when there is no load on
the hook.

G
Risk of accidents when the SLI is defective!
You may override the SLI if it is defective.
Always put down the load immediately if the SLI is defective!
If there is still a suspended load, do not make any more movements
which increase the load moment (extending the telescope, lowering the
boom).

The SLI shutdown system can be bypassed (deactivated) using the key-
operated switch Override.

• Insert the key into the key-operated switch.

• Turn the key to the right.
• Hold the key in this position.
The SLI is overridden as long as you hold the key in this position.

If the SLI is overridden, the Information display shows error message

)0§6 9.03.06.
After overriding you must acknowledge the error message.

S
Always remove the key from the Override key switch after override!
The key must not be left in the key-operated switch while the crane is in
operation!

H The SLI can also be overridden together with the lifting limit switch.
See the instructions in the chapter Overriding the lifting limit switch shutoff
system; ➠ p. 10-61.
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12 - 34 2 084 575 en Operating Instructions GMK 5100

 Crane operation
12.3 Crane work with the main boom

H
12.3 Crane work with the main boom

If a swing-away lattice extension is reeved during operation with the main

boom, the loads given in the Lifting capacity tables decrease. The values
which have to be taken of the loads are given in the Lifting capacity tables in
their own table.

12.3.1 External influences during crane operation

Horizontal The horizontal alignment of the truck crane may change due to the
alignment varying load on the ground during crane work.

G
Risk of accidents if the truck crane is not horizontally aligned!
The SLI calculates the radius using the length and angle of the main
boom. If the truck crane is not horizontal the actual radius will change
and the crane may overturn!

• Check the horizontal alignment of the truck crane before beginning

crane work in the crane cab:
– at the circular spirit level or
– the electronic level (additional equipment).
➠ Check the alignment of the truck crane, p. 13-36.
Also check the horizontal alignment during crane work. Due to deforma-
tion of the frame, the horizontal alignment can change up to 2° when the
superstructure is turned from the 0° or 180° position.
If the truck crane does not return to the horizontal position after turning
back to the 0° or 180° position, you must immediately determine the
cause and eliminate it and realign the crane if neccessary. Check the posi-
tion ofv the superstructure when doing so; ➠ p. 13-36.

Safe distances When working with the crane, maintain adequate distance between all
parts of the truck crane including the load and objects on the site as well
as all persons on the site.
Keep a particularly close watch on objects that pose a direct risk
(for example, scaffolding or gas containers).
Keep a safe distance away from electrical lines;
➠ Safe distance from electrical lines, p. 13-9.
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Operating Instructions GMK 5100 2 084 575 en 12 - 35
Crane operation
12.3 Crane work with the main boom

Effect of wind on Strong winds can overstrain the truck crane.

crane operations Monitor the wind speed on the Anemometer continuously during crane
operation.
If your truck crane is not equipped with an anemometer, enquire about
the expected wind speed at the local meteorological office. The per-
missible wind speed for a fully loaded truck crane may be found in the
Lifting capacity table.

Anemometer An anemometer is installed on the tip of the main boom to monitor the

H
wind.

When the lattice extension (additional equipment) is being used, the ane-
mometer must be plugged into the lattice extension.

Wind strength Wind speed Effect of wind

inland
Beaufort Name m/s km/h
scale (ft/s) (mph)
0 to 0.2 Calm, smoke rises vertically.
0 Calm 1
(0 to 0.7)
Direction of wind shown by
Light 0.3 to 1.5 1 to 5 smoke but not by wind
1
draught (1.0 to 4.9) (0.6 to 3.1) vanes.
Wind felt on face, leaves
Light 1.6 to 3.3 6 to 11 rustle, weather vane moved
2
breeze 5.3 to 10.8) (3.7 to 6.8) by wind.
Leaves and small twigs in
Gentle 3.4 to 5.4 12 to 19 constant motion, wind
3
breeze (11.2 to 17.7) (7.5 to 11.8) extends light flag.
Wind raises dust and loose
Moderate 5.5 to 7.9 20 to 28 paper, twigs and small
4
breeze (18.0 to 25.9) (12.4 to 17.4) branches are moved.
Small deciduous trees begin
Fresh 8.0 to 10.7 29 to 38 to sway. Crested wavelets
5
breeze (26.2 to 35.1) (18.0 to 23.6) form on inland waters.
Large branches in motion,
Strong 10.8 to 13.8 39 to 49 telegraph lines whistle,
6
breeze (35.4 to 45.3) (24.2 to 30.5) umbrellas used with difficulty.
Whole trees in motion,
Moderate 13.9 to 17.1 50 to 61 inconvenience in walking
7
gale (45.6 to 56.1) (31.1 to 37.9) against wind.
11.05.2000

17.2 to 20.7 62 to 74 Breaks twigs off trees,

8 Fresh gale generally impedes progress.
(56.4 to 67.9) (38.5 to 46.0)

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 Crane operation
12.3 Crane work with the main boom

Slight structural damage

20.8 to 24.4 75 to 88 occurs (chimney pots and
9 Strong gale
(68.2 to 80.0) (38.5 to 46.0) slates removed).

24.5 to 28.4 89 to 102 Trees uprooted, considerable

10 Full gale structural damage occurs.
(80.4 to 93.2) (55.3 to 63.4)

G
Risk of accidents with too high wind speeds!
If the wind speed exceeds the maximum permissible values according to
the Lifting capacity table, you must adjust the crane operation and set the
truck crane to the rigging mode prescribed by the following table.
This applies also when the wind surfaces of the load is smaller than the
permissible specific wind surfaces Aper; ➠ Permissible wind load in the
following section.
There is no automatic shutdown.

If the maximum permissible wind speed is exceeded (according to the

lifting capacity table), proceed in the following way:

for wind speeds or wind speeds over 20 m/s

up to 20 m/s (65 ft/sec) (65 ft/sec)
Put down the load. Put down the load.

Turn the superstructure in such a Completely retract the main boom.

way that the main boom provides
the wind with as little working Turn superstructure to the front
surface as possible. (180° position) or rear (0° position)
of the truck crane and lock the
superstructure.

Set the main boom – if possible –

H
on the main boom support.

Procedure when exceeding the permissible wind speed during operation

with the lattice extension or boom extension; ➠ Lattice extension operating
manual.
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Operating Instructions GMK 5100 2 084 575 en 12 - 37
Crane operation
12.3 Crane work with the main boom

Permissible The permissible specific wind surface of the load (Aperm) during crane
wind load operation is Aperm = 4.8 ft2 per 1000 lbs of lifting capacity.
The wind surface depends on the aerodynamic power correction value c f
of the load. The wind surface of the load must be reduced proportionally
in consultation with the supervisor for c f -values (c f-values in accordance
with DIN 1055 Part 4) greater than 1.2 and wind surfaces greater than the
permissible wind surface (Aperm).
Formula:


√
1,2 ⋅ Aperm
vred = v ⋅
cf ⋅ A'

vred reduced permissible wind speed in m/sec

v permissible wind speed according to lifting capacity table in m/sec

cf actual aerodynamic power correction value

A’ actual wind surface of the load in ft2/1000lbs
Aperm permissible wind surface of the load in ft2/1000 lbs

B
Risk of accidents due to electrical shock!
Earth the load before crane operation
– near strong transmitters (radio/television transmitters, radio/television
stations, etc.),
– near high-frequency switchgears and
– in potentially stormy weather.

The load can become electrostatically charged even if the truck crane is
earthed; ➠ Earthing the truck crane, p. 13-12. This applies especially when
a hook block is used with sheaves made of synthetic material and non-
conductive load handling gear (e.g. plastic or manila ropes).
To prevent the electrostatic charging of the load, you will need:
– an electrically conductive metal rod inserted in the ground
( length, ca.5 ft),
– an electrically conductive cable (minimum cross section 10.016 inch2),
– an electrically conductive metal rod with insulated handle used to touch
the load.

B
11.05.2000

Risk of accidents due to electrical shock!

Ensure that the connection between the load and the ground is a faultless
electrically conductive connection!

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 Crane operation
12.3 Crane work with the main boom

• Connect one end of the cable to the metal rod that is to be inserted into
the ground. Hammer the metal rod at least 3.3 ft into the ground.
Moisten the soil around the metal rod for better conductivity.
• Connect the other end of the cable to the metal rod with the insulated
handle.

B
Risk of accidents due to electrical shock!
The metal rod is to be held by the insulated handle only!

• Hold the metal rod by the insulated handle. Use the metal rod to touch
the load before touching the load with your hand.

12.3.2 Slewing ranges permitted for working with the crane

According to the lifting capacity table there are two permitted ranges for
crane work:
– the 360° slewing range and
– the 0° working position rearwards and
– for rigging work, the 180° position forwards.

360 slewing • Support the truck crane with the outrigger span required according to
range the Lifting capacity table.
• Select the 360° slewing range using the Permissable slewing range mem-
brane switch on the SLI or enter the required SLI code in accordance

H
with the Lifting capacity table; ➠ Entering values, p. 12-23.

The required outrigger span for the 360° slewing range depends on the
rigged counterweight. A table in section Slewing with rigged counterweight,
p. 13-67 shows the necessary outrigger spans.

Working position The superstructure must be locked before the crane is operated in the
0° to the rear working position 0° to the rear. Observe the maximum permitted tele-
scope status and outrigger span given in the Lifting capacity table.

• Support the truck crane.

• Turn the truck crane to the rear in the 0° position.
• Lock the superstructure; ➠ Mechanical superstructure lock, p. 12-9.
11.05.2000

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Operating Instructions GMK 5100 2 084 575 en 12 - 39
Crane operation
12.3 Crane work with the main boom

Select the 0° slewing range using the Permissable slewing range membrane
switch on the SLI or enter the required SLI code in accordance with the
Lifting capacity table; ➠ Entering values, p. 12-23.

G
The crane can overturn when the superstructure lock is released!
The superstructure must always be locked when you work with the crane
in the 0° position to the rear. This prevents the superstructure from over-
turning due to unfavorable effects (for example, inadvertent actuation of
the slewing gear or swinging loads) out of the 0° position which would
cause the truck crane to overturn or parts of the truck crane to be over-
strained. Before leaving the 0° to the rear working position you must
change the SLI code.

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 Crane operation
12.3 Crane work with the main boom

12.3.3 Hoists

Main hoist You may work with the main boom or the lattice extension using the hoist
rope on the main hoist.

G
Risk of accidents due to inadvertent operation of a hoist!
Always switch off the hoist that is not in use!
You may not turn the drum if the hook block is unreeved and you have
completely reeled in the hoist rope.
– If the hoist rope is inadvertently turned in the lowering direction,
the switching point of the lowering limit switch is displaced, resulting in
slack rope. This causes rope loops to form on the hoist drum which can
lead to load slipping and destruction of the hoist rope.
– If the hoist rope is inadvertently turned in the raising direction,
the switching point of the lowering limit switch changes, leaving less
than the required number of safety windings on the drum.

G
Accidents may occur if the load is lifted at a slant!
With a load the main boom bends and the hoist rope is no longer aligned
in a vertical position pointing upwards. Balance out the deflection by rai-
sing so that the load is lifted vertically upwards. In this way you prevent
the load dragging and injuring helpers or falling into the hoist rope at an
angle. Inform all helpers about this as well.

• Check whether the auxiliary hoist (additional equipment) is switched off.

C The Auxiliary hoist shutdown rocker switch on the left-hand control lever
must be pressed downward to prevent inadvertent actuation of the
auxiliary hoist.
• Switch on the main hoist.
ü Press the Deactivate main hoist rocker switch on the right-hand control
lever upward.
Lamp I of the display lamps Hoists is activated upon switching the main
hoist on.
If you want to lift the load with the main hoist, the I lamp for the main
hoist must light.

• If the I lamp flashes, switch over the indicator lamps; ➠Switching over
hoist position lights, p. 12-26.
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Operating Instructions GMK 5100 2 084 575 en 12 - 41
Crane operation
12.3 Crane work with the main boom

The value on the display Reeving is always valid only for the hoist of
/ n= which the lamp illuminates among the display lamps Hoists. When
switching on a hoisting gear, a value will be shown which was last
entered for this hoisting gear.

Lifting: Pull the right-hand control lever back.

Lowering: Push the right-hand control lever forward.
You may regulate the speed of the main hoist by moving the control lever
and changing the engine speed using the accelerator.

You can set the maximum speed of the hoist gear on the Crane control dis-
@ play; ➠ Power unit speeds/critical load control menu, p. 12-89.

You can set a constant engine speed with the rocker switch Constant engine
å speed; ➠ p. 12-95.

With a degree of utilization of up to 50 % (lifted load maximum of 50 % of

the load bearing capacity according to the Lifting capacity table) you may
move the hoists also in fast speed.
Activate a higher speed with the Hoists fast speed foot-operated switch. The
fast speed for the main and auxiliary hoists (additional equipment) is acti-
vated at the same time with the foot-operated switch; ➠ p. 12-84.

H The speed of the hoists is clearly increased by switching to fast speed

only if you have extended the control lever more than approx. 70 %.

A hoist drum synchro (1) is installed in the

manual control lever. You will notice an
impulse on the hoist drum synchro when
the hoist drum rotates.
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 Crane operation
12.3 Crane work with the main boom

You can monitor the rope running on the drum using the mirror over the
hoist.

G
Risk of accidents when the load is suspended!
Never leave the crane cab while a load is suspended on the hook block.
Never turn the crane engine off while a load is suspended on the hook.
Always keep your hand close to the control levers while a load is suspen-
ded on the hook so that you are able to react correspondingly at all times.
Always put down the load before you stop work!

A lifting limit switch on the boom head deactivates the Raise main hoist,
K Raise auxiliary hoist and Lower the boom and Telescoping out movements. The
Lifting limit switch shutdown warning lamp lights up when the switching
point is reached.
Leave the shutdown area by carrying out the movements Lower or Retract
telescoping.

G
Risk of accidents with overridden lifting limit switch!
Always leave the shutdown area after a lifting limit switch shutdown.
The shutdown must absolutely not be overridden during crane operation
and as long as a load is suspended on the hook. If you move the hook
block further against the boom with an overridden shutdown, the hoist
rope can tear and the load will uncontrollably fall to the ground.

Further information about shutdown of the lifting limit switch; ➠ Lifting

limit switch, p. 10-61.

A lowering limit switch on the hoist prevents the hoist rope from being
completely reeled off. It deactivates the Lower movement when five turns
are left on the drum. For safety reasons, these five turns must remain
reeled on the drum.
Drive out of the shutdown area by performing the Lift movement.

G
Risk of accidents if the lowering limit switch is defective!
Do not carry out any crane work if the lowering limit switch is
– damaged,
– out of operation or
– improperly set.
Too much hoist rope would be reeled off and the required safety turns
would no longer be there.

H The switching point of the lowering limit switch must be checked if the
11.05.2000

hoist rope is replaced. Five turns must remain on the rope drum if the
hoist rope is reeled off to the switching point, ➠ Maintenance Manual.

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Operating Instructions GMK 5100 2 084 575 en 12 - 43
Crane operation
12.3 Crane work with the main boom

H The hoist rope is stiff in low temperatures. A weight must be added if the
reeved hook block repeatedly cannot be lowered.
You must operate the hoist slowly when reeling in the rope, as stiff rope
is difficult to wind.

You may use the Main hoist shutdown rocker switch on the right control
ü lever to prevent inadvertent actuation of the main hoist.
To do this, press the rocker switch downward.

You can display the operating hours and possibly the blocked functions of
> the hoist on the crane control display with the membrane switch Display sta-
tus; ➠ Menu Display status, p. 12-85.

Auxiliary hoist You may work with the main boom or the lattice extension using the hoist
(additional rope on the main hoist.
equipment)

Risk of accidents when working with auxiliary hoist!

G
Before working with the auxiliary hoist, read and follow all the safety in-
structions in the Main hoist section; ➠ p. 12-41.
When working with the auxiliary hoist, all the safety instructions for wor-
king with the main hoist also apply, along with the information in this
section.

H If you run the auxiliary hoist rope over the left head sheave (additional
equipment), you must extend the main boom to a total length of at least
65 ft before lifting a load.
Otherwise the rope angle exceeds the maximum permitted value.

• Check whether the main hoist is switched off to prevent unintentional

ü actuation.
The Main hoist shutdown rocker switch must be pressed down.
• Switch on the auxiliary hoist.
C Press the Auxiliary hoist shutdown rocker switch on the left-hand control
lever upward.
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 Crane operation
12.3 Crane work with the main boom

Lamp II of the display lamps Hoists is activated upon switching the

auxiliary hoist on.
If you want to lift the load with the auxiliary hoist, the II lamp for the auxi-
liary hoist must light.

• If the II lamp flashes, switch over the indicator lamps; ➠Switching over
hoist position lights, p. 12-26.

The value on the display Reeving is always valid only for the hoist of
/ n= which the lamp illuminates among the display lamps Hoists.

Lifting: Pull the left-hand control lever rearward.

Lowering: Push the left-hand control lever forward.
You may regulate the auxiliary hoist speed by moving the control lever
and by changing the engine speed using the accelerator.

H Work with the auxiliary hoist is carried out in the same way as for the
main hoist (high-speed, set driving gear speed, etc.)

Use the Auxiliary hoist shutdown rocker switch on the left-hand control
C lever to deactivate the auxiliary hoist to prevent inadvertent operation.
To do this, press the rocker switch downward.
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Operating Instructions GMK 5100 2 084 575 en 12 - 45

Crane operation
12.3 Crane work with the main boom

12.3.4 Derricking gear

The main boom can be inclined between –3° and + 83°. The angle of the
main boom in relation to the horizontal position can be set by raising and
lowering the main boom.
The SLI switches off lowering of the boom, depending on the load size
and main boom length according to the Lifting capacity table.

Raising the boom out of a horizontal position and lowering it to the hori-
zontal with the completely retracted main boom is automatically cleared
by the SLI if it is permitted by the SLI rigging programs (Rigging pro-
grams ➠ Lifting capacity tables)

H
With other telescope statuses a rigging code must be entered.

For the outrigger span 25.6 x 8.2 ft, a rigging code must also be entered
when the boom is retracted and raising and placing is only permitted in
the positions 0° to the rear or 180° to the front.

G
The truck crane may overturn when lifting loads!
Lifting loads by raising the boom is strictly prohibited as the SLI does not
function when this is carried out!

H Raising the boom is a movement which decreases the load moment; it is

not deactivated by the SLI. However, if excessively heavy loads are lifted
by raising the boom, the truck crane can overturn.

• Switch the derricking gear on.

Ü Push the Derricking gear shutdown rocker switch on the right-hand control
lever upward.
• Switch the right-hand control lever to the Derricking function.
_ Push the Derricking / telescoping preselection control lever function rocker
switch downward.
The Derricking control lever function indicator lamp illuminates.
U
Lowering: (= lower boom) Push the right control lever to the right.
Raising: (= raise boom) Push the right control lever to the left.
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 Crane operation
12.3 Crane work with the main boom

You may regulate the speed of the derricking gear by moving the control
lever and changing the engine speed using the accelerator.

You can set the maximum speed of the derricking gear for working with
@ the main boom and lattice extension on the Crane control display; ➠ Power
unit speeds/critical load control menu, p. 12-89.

You can set a constant engine speed with the rocker switch Constant engine
å speed; ➠ p. 12-95.

You can switch to fast speed with the Fast speed derricking gear/telescoping
gear (arrow) foot-operated switch; ➠ p. 12-84.

When the two-stage swing-away lattice extension or boom extension

(both additional equipment) are being operated, the fast speed for the
raising is blocked.

H When the boom is completely extended and in the steepest position and
you wish to lower the boom without a load, you must switch on the fast
speed to lower the boom so that the derricking gear can come out of the
dead centre position.

You can press the Derricking gear shutdown rocker switch downward to
Ü prevent unintentional actuation of the auxiliary hoist.

You can display the operating hours and possibly the blocked functions of
> the derricking gear on the Crane control display with the membrane switch
Display status; ➠ Menu Display status, p. 12-85.
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Operating Instructions GMK 5100 2 084 575 en 12 - 47

Crane operation
12.3 Crane work with the main boom

12.3.5 Slewing gear

You can display the operating hours and possibly the blocked functions of
> the slewing gear on the Crane control display with the membrane switch
Display status; ➠ Menu Display status, p. 12-85.

Slewing gear If the crane engine is not running, slewing gear brake is automatically
permanent brake applied.

Apply the slewing gear permanent brake when the crane engine is run-
Y ning with the Slewing gear permanent brake rocker switch on the left control
lever. To do this, press the rocker switch downward.
The Slewing gear permanent brake indicator lamp illuminates when the
Y slewing gear permanent brake is applied.

S
The boom may buckle!
The slewing gear permanent brake should never be used to brake
slewing movement!
Do not apply the slewing gear permanent brake until the superstructure is
no longer slewing.

G
The crane can overturn when the superstructure lock is released!
The superstructure must always be locked when you work with the crane
in the 0° position to the rear. This prevents the superstructure from over-
turning due to unfavorable effects (for example, inadvertent actuation of
the slewing gear or swinging loads) out of the 0° position which could
cause the truck crane to overturn.

Slewing

G
Risk of accidents due to slewing superstructure!
There is a risk of crushing due to slewing machine sections.
Actuate the horn before slewing the superstructure and make sure that
nobody is standing in the slewing range of the superstructure.
In this way you prevent people getting crushed between the slewing
superstructure and fixed objects or between the superstructure and the
carrier.
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 Crane operation
12.3 Crane work with the main boom

G
Risk of overturning with insufficient support!
Always support the truck crane on outriggers before rotating the super-
structure. When the counterweight is rigged, the truck crane can overturn
rearward if the outrigger span is to small.

• Check whether a sufficient outrigger span with which the superstructure

may be slewed is set for the rigged counterweight with the table in
section Slewing with rigged counterweight, p. 13-67.
• Set the maximum permissible slewing speed for the current rigging
mode; ➠ Maximum permitted slewing speed, p. 12-51.
• Release the mechanical superstructure lock before you slew the super-
structure; ➠ Mechanical superstructure lock, p. 12-9.

Slewing to the left: Push the left-hand control lever to the left.
Slewing to the right: Push the left-hand control lever to the right.

Slewing speed The further you move the control lever to the right or left, the more
quickly the slewing gear slews.

S
The boom may buckle!
Accelerate and brake slewing speed only to such a degree that the load
does not sway!

If you release the control lever or move it to the middle position, the sle-
wing movement will slowly run down.

Furthermore, you can change the slewing speed by:

– changing the engine speed with the accelerator
– setting a constant engine speed; ➠ p. 12-95.
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Operating Instructions GMK 5100 2 084 575 en 12 - 49
Crane operation
12.3 Crane work with the main boom

Braking slewing
movement

S
The boom may buckle!
Accelerate and brake slewing speed only to such a degree that the load
does not sway.

You can brake the slewing movement of the superstructure by actuating

the Slewing gear service brake pedal.

You can regulate the braking force to any level. The further the pedal is
depressed, the greater the braking force.

H Only depress the service brake pedal fully in case of danger (to make an
emergency stop).

If the Slewing gear brake temperature warning lamp lights up, interrupt the
a crane operation at the next opportunity and allow the slewing gear brake
to cool down.

G
Risk of accidents from overheating slewing gear brake!
The warning lamp lights up when the oil temperature in the slewing gear
brake gets too high. Stop crane operation at the next opportunity. This
prevents the slewing gear brake from overheating and causing the brake
plates to be damaged. When the slewing gear brake has overheated, its
braking power is reduced.
Only restart working with the crane when the warning lamp is extinguished.

Tracking the When the slewing gear is tracked, the superstructure can adjust itself to
slewing gear outside forces (e. g. wind or when working with a second crane).

• Release the slewing gear permanent brake.

• Move the left-hand control lever to the central position.
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 Crane operation
12.3 Crane work with the main boom

Maximum per- You must set the maximum permitted slewing speed before each job.
mitted slewing The maximum permitted slewing speed depends on:
speed – the working radius and
– the degree of utilization, i.e. the percentage of the permitted load
according to the Lifting capacity table which is lifted.

Determine the maximum permitted slewing speed for your special job
from the following tables for the main boom, the boom extension and the
luffing jib.

Table for main boom

Degree of utilisation for the load bearing capacity

Radius
[ ft ] 25% 50% 75% 100%

Adjustable, maximum slewing speed in %

0 to 33 100 50 40 30
33 to 66 50 40 30 25
66 to 98 30 25 20 20
98 to 131 15 15 15 15
131 to max 10 10 10 10

Table for two-stage swing-away lattice extension and boom extension

Degree of utilisation for the load bearing capacity

Radius Degree of util. Degree of util. Degree of util. Degree of util.

[ ft ] 25% 50% 75% 100%

Adjustable, maximum slewing speed in %

0 to 33 70 50 40 30
33 to 66 40 40 30 25
66 to 98 25 25 20 20
98 to 131 15 15 15 15
131 to 164 10 10 10 10
164 to max 10 10 10 10
Set this slewing speed by calling up the menu Power unit/critical load
@ control in the Crane control display; ➠ p. 12-89.
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Crane operation
12.3 Crane work with the main boom

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 Crane operation
12.3 Crane work with the main boom

12.3.6 Telescoping gear

Structure of the Most procedures which you initiate for the operation of the telescoping
chapter gear are afterwards carried out by the crane control and monitored. In the
process you receive acknowledgements, you can follow the procedure
and, at the right time, initiate further procedures.
For this it is important that you are not only familiar with the operation,
display, and control instruments of the telescoping gear, but also its
functioning. Then you can comprehend the procedures which the crane
control carries out in the boom while you move the control lever; you will
become familiar with the status displays and crane control more quickly.
Therefore the chapter is organized in the following sections:

– Description of functioning,
– Main boom fixed lengths, intermediate lengths, telescoping lengths,
– Telescope status,
– Notes on telescope-sequence,
– Function of the control lever,

– Example of procedures when telescoping

(further sections are refered to in this section).

H The last section and the sections following it belong together and
describe the actual telescoping procedure. Before you proceed according
to this section for the first time, you must know the basic information
from the previous sections. Only in this manner is a safe operation of the
telescoping gear possible.
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Operating Instructions GMK 5100 2 084 575 en 12 - 53
Crane operation
12.3 Crane work with the main boom

Description of The main boom consists of the non-telescoping section, four telescope
functioning sections and a single-level telescoping cylinder. The following diagram
shows the main boom in section with the telescoping cylinder.

In the diagram the main boom is completely retracted and the telescoping
cylinder is located in the foot section of telescope section I.

All telescope sections (I to IV) are rigged on the outside with locking pins
(1) which are pushed out of the telescope sections with springs (9). If a
bore (2) of the telescope section above it aligns with the corresponding
locking pin, the spring pushes the locking pin in at that point and the
telescope section is locked. All telescope sections can be locked at three
different points (on the fixed lengths) in the corresponding bores (2).

Levers are fixed to the locking pins of all telescope sections of which the
brackets (6) reach inward into the foot sections of the telescope section.
The brackets reach in all telescope sections the same distance into the
foot sections.
The piston rod (7) of the telescoping cylinder is fastened to the main
boom basic section. If the telescoping cylinder is telescoped, its head runs
(8) through the foot sections of telescope sections (I to IV). If the head (8)
is situated at a locking point (the head is situated at the locking point of
telescope section I), the mechanism (3) on the telescope cylinder snaps
into the bracket (6).

If the telescoping cylinder is located on the locking point, the bores (4)
also align on the inner sides of the telescope sections with the locking
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pins (5) of the telescoping cylinder.

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 Crane operation
12.3 Crane work with the main boom

Telescoping cylinders and telescope sections can be locked and unlocked

at all locking points. In order to telescope, the telescoping cylinder must
be locked with the corresponding telescope section and the telescope
section must be unlocked.

To lock the telescoping cylinder, the locking

pins are (5) pushed into the bores (4) of the
telescope section by spring force.

In order to unlock the telescope section, a

hydraulic cylinder (2) is extended. The me-
chanism (3) transfers this movement to the
brackets (6) and retracts the locking pins (1)
against the spring force.

The telescope section is locked again after

telescoping, the procedure takes place in the
reversed sequence (as with unlocking).
When the telescoping cylinder is unlocked,
the locking pins are hydraulically retracted
against the spring force.

H The locking pin of the telescoping cylinder and the mechanism are moved
hydraulically. The necessary pressure for this is comes from a reservoir
which must be first be filled. Because of this, retardations of 2 to

H
3 seconds may occur.

A hydraulic/mechanical switch and the crane control prevent a telescope

section and the telescoping cylinder from being unlocked simultaneously.
A telescope section can be unlocked only when the telescoping cylinder is
locked and vice versa.

Main boom Main boom fixed length

fixed length,
All telescoping statuses where all telescope sections are locked are usual-
intermediate
ly called main boom fixed lengths. Higher load bearing capacities are per-
length,
mitted only when all telescope sections are locked.
telescoping
In the case of the GMK 5100, only those telescoping status with the
length
highest lifting capacities are permitted as main boom fixed lengths
because of the large number of possible locked telescoping statuses for
the same boom length.
There are thus a total of 25 main boom fixed lengths (➠ Lifting capacity
table). The lifting capacity values for the fixed lengths of the main boom
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Main boom intermediate length

All telescoping statuses where all telescope sections are unlocked are
usually called main boom intermediate lengths.
In an unlocked telescoping status the whole load affects the telescoping
cylinder. This means that the permitted lifting capacitues are sometimes
considerably less than with main boom fixed lengths.
In the case of the GMK 5100, all locked telescoping statuses which do not
have the highest load bearing capacity with their main boom length are
also treated as main boom intermediate lengths. No higher loads are
therefore permitted for these locked telescoping statuses.

The lifting capacity values for the intermediate lengths of the main boom
are automatically monitored by the SLI.
Telescope the main boom to the required length before lifting the load!
With the lifting capacities which are given in the lifting capacity table for
main boom intermediate lengths, telescoping with a load is not possible!

Main boom telescoping length

There is a main boom telescoping length when the main boom is at a
main boom intermediate length and is also telescoped with a load.
The lifting capacity values for the telescoping length of the main boom
are in the same range as the lifting capacity values for the main boom in-
termediate lengths which are monitored by the SLI.
The telescopic load is restricted by:
– the angle of the boom and
– the lubrication of the sliding wear pad between the telescope sections.

S
The main boom should only be telescoped with a load if the job cannot
be done otherwise.

Telescope status The position of the telescope sections, i.e. which telescope section has
been telescoped how far, is called the telescope status.

The current telescope status is displayed:

– on the SLI and
– on the Crane control display.
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This section deals with the status display of the telescope status on the
SLI, the status display of the telescope status on the Crane control display is
described starting at the section Example of procedures when telescoping.

If a telescope section is retracted or extended, both the length of the main

boom and the length of the respective telescope section change on the
display.

The main boom fixed length is displayed in decimals (e. g. 0.5) and the
main boom intermediate length and main boom telescoping length are
displayed as two-digit percent values (e. g. 47).

Example: Telescope status display for main boom fixed lengths

1 2 3 4
!00 =50 =50 =50 C0645

Telescope section I 100 % extended (fixed length)

Telescope section II 50 % extended (fixed length)

Telescope section III 50 % extended (fixed length)

Telescope section IV 50 % extended (fixed length)

The following percent values represent main boom fixed lengths:

Telescope section I 0 / 50 / 100 [%]

Telescope section II 0 / 50 / 100 [%]

Telescope section III 0 / 50 / 100 [%]

H
Telescope section IV 0 / 50 / 100 [%]

Not all locked telescope statuses are permitted as main boom fixed
lengths; ➠ p. 12-55.
The fixed lengths can be found in the Lifting capacity table.
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The decimal display (e.g. 1.00) follows only if all telescope sections are
telescoped to a fixed length. As soon as one or more telescope sections
are telescoped to a different length, all lengths count as main boom inter-
mediate lengths or main boom telescoping lengths.

The status display changes accordingly, as the following example demon-

strates.

Example: Telescope status display for main boom intermediate lengths

and main boom telescoping lengths.

1 2 3 4
067 050 050 050 C0645

Telescope section I 67 % extended (intermediate length)

Telescope section II 50 % extended (fixed length)

Telescope section III 50 % extended (fixed length)

Telescope section IV 50 % extended (fixed length)

The following percentage values represent main boom intermediate

lengths and main boom telescoping lengths:

Telescope section I 0 - 100

Telescope section II 0 - 100

Telescope section III 0 - 100

H
Telescope section IV 0 - 100

There can only ever be one telescope section at an intermediate length

(because only one telescope section can be unlocked).

H
The useful intermediate lengths can be found in the Lifting capacity table.

The maximum permissible lifting capacity also changes constantly in the

Maximum load status display.
Whenever the extending of a telescope section would lead to a telescope
status which is not permissible according to the Lifting capacity table, the
SLI switches this extending off as soon as the telescope section moves.
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Notes on The telescope sections can only be telescoped individually one after the
telescope- other.
sequence
When extending you must always extend the telescope section with the
highest numbering first, then the telescope section with the second
highest numbering, etc. (e. g. IV, III, II, I).
Retracting always takes place in the reversed sequence as extending.

Check before tele- The crane control calculates the displayed telescope status from the
scoping for the current status of the telescoping gear and the locking and unlocking
first time processes which have occurred and been saved.

Normally, the crane control recognises differences between current

and displayed telescope statuses and displays a corresponding error
message; ➠ Telescoping error message, p. 14-63.

If the values are deleted because of an accident (e.g. lightning strike), the
crane control can no longer calculate the current telescoping status and
an error message occurs.

S
Risk of damaging the telescoping gear!
After switching on the ignition before the first telescoping, always check
that the current telescope status is displayed in the Crane control display.
After an accident, if the crane control is unable to correctly calculate the
current telescope status and no error message occurs, telescoping can
cause damage to the telescoping gear.

After switching on the ignition, always check before the first telescoping
that the telescope status displayed in the Crane control display matches the
current telecope status.

If the current telescope status is not correctly displayed, enter the current
telescope status; ➠ Entering telescope status after emergency operation, p. 14-76.
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Function of the This section only describes the functioning of the control lever and has
control lever general notes for telescoping. Before you telescope, you must fulfill cer-
tain requirements. Read the section Example of procedures when telescoping
for this; ➠ p. 12-62.

The SLI deactivates telescoping extension depending on the size of the

load and length of the main boom (angle between the main boom and the
horizontal position). Ensure that the boom has been sufficiently raised
before the main boom telescoping is extended.

• Switch on the telescoping gear.

Ö Push the Auxiliary hoist shutdown rocker switch upward.

• Switch the right hand control lever to the telescopic function.

_ Press the Derrick / telescope control level function rocker switch upward.
The indicator lamp Telescoping gear switched on illuminates.
T

G
Risk of accidents from unexpected crane movement!
Make sure that the indicator lamp Telescoping gear switched on illuminates
before you move the control lever for telescoping.
This prevents accidents from the unexpected derricking of the main
boom and lattice extension.

Extend: Push the right-hand control lever to the right.

Retract: Push the right-hand control lever to the left.

H With certain telescoping states the SLI also shuts down the retraction of
the telescoping for safety reasons. In this case leave the shutdown area
by raising the boom or, if this is not possible, set the load down, tele-
scope to the next fixed length and lift the load again.

You may regulate the telescoping speed by moving the control lever and
changing the engine speed using the accelerator.
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You can set the maximum speed of the telescoping gear for working with
the main boom and lattice extension on the Crane control display; ➠ Power
unit speeds/critical load control menu, p. 12-89.

In addition you can set a higher speed when extending by using the foot-
operated switch Fast speed derricking gear/telescoping gear (arrow).

You may set a constant engine speed using the rocker switch Constant
å engine speed.

The telescoping gear can be switched off by rocker switch (Telescoping gear
Ö shutdown) to prevent it from being operated accidentally.

H
To do this, press the rocker switch downward.

The distance between the hook block and the boom head also changes
during telescoping. Reel off the hoist rope when retracting and reel it on
when extending the telescoping.

S
Be careful not to damage the hoist rope!
Slack rope will occur if the hook block is allowed to touch the ground
while the boom is being retracted. This causes rope loops to form on the
hoist drum which can lead to load slipping and damage to the hoist rope.

H The telescoping movement is shut off if the hook block reaches the lifting
limit switch during extension of the main boom telescoping.

You can display the operating hours and possibly the blocked functions of
> the telescoping gear on the Crane control display with the membrane
switch Display status; ➠ Display status menu, p. 12-85.
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Example of The procedures for telescoping with semi-automatic control are described
procedures when in the following sections.
telescoping You can also telescope to fixed lengths with the fully automatic control;
in the course of this the crane control regulates the procedures described
here automatically; ➠ Telescoping with fully automatic control, p. 12-79.
This section shows you the sequence of an entire telescoping procedure

H
for a better overview at the outset.

This section and the sections refered to here presuppose that you are
familiar with the functioning of the telescope system;
➠ Description of the functioning, p. 12-54.
The entire example cannot apply to all telescoping procedures, since the
start and end position of the telescoping gear is different for every proce-
dure. Nevertheless a part of the sequence of the telescoping procedure
described here applies to all telescoping procedures.

Read the sequence for this example and follow the cross-references in the
sections with the descriptions of what to do. These sections always take
up the following example at the end. You thus get an overview of all
necessary steps and can implement these for your special telescoping
procedure.

The following start and end states apply to this example:

– All telescopic sections are retracted and locked.
– The telescoping cylinder is locked to telescope section IV.
– The telescope sections II and III should be extended to 50 %.
– Telescope section I should be extended to an intermediate length
of 37 %.

Sequence of the exemplary telescoping procedure

1. Check the telescope status, the position of the telescoping cylinder
and the locking pin; ➠ Check the initial position, p. 12-63.

2. Unlock telescoping cylinder; ➠ p. 12-66.

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3. Move telescoping cylinder into the telescope section, the telescope

section which needs to be telescoped and lock it there (in our example
telescope section III); ➠ Extending / retracting telescoping cylinders,
p. 12-68.

4. Unlock telescope section for telescoping; ➠ Unlocking telescopic section,

p. 12-71.

5. Telescope telescope section to fixed length and lock; ➠ p. 12-73.

6. To telescope other telescope sections (in our example telescope sec-

tion II would be the next one) repeat Points 2 to 5 until all required
telescope sections have been telescoped to the required length.

7. If necessary, extend the last telescope section (in our example tele-
scope section I) to the necessary intermediate length;
➠ Telescoping telescope section to intermediate length, p. 12-77.

Check initial Before you telescope the main boom, you must check the following states:
position
– the current telescope status
(how far the telescope sections are telescoped),
– the position of the telescoping cylinder
(in which foot section the telescoping cylinder is located),
– the position of the locking pins
(whether telescope sections and cylinders are locked or unlocked).
Various displays on the front instrument panel define the current status of
the main boom.
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Check current telescope status

• Switch on the menu Display telescoping and teleautomatism. Press the
ä Display telescope status and teleautomatism membrane switch.
The entry TELESCOPE STATUS is in the first line of the menu, and the
entry SEMI-AUTOMATIC CONTROL in the third line. These two entries do
not change.
The current telescope status for telescope sections I to IV is indicated in
percentages in the second line from left to right.

As long as all , the numerical values are sepa-

rated by a dash, and below, next to the entry
TELE, there are also two dashes.
The current extended length of the telescop-
TELESCOPE STATUS
ing cylinder is indicated to the right in me-
– 0 – 0 – 0 – 0 – tres. e.g., L: 2.88 ft).
SEMI-AUTOMATIC CONTROL
TELE: – – L: 2.88 ft

If a telescope section is unlocked (e.g., Tele-

scope section III), the respective numerical
value is in brackets in the second line.
Below, next to the entry TELE, the unlocked
TELESCOPE STATUS
telescope section is displayed (T1 to T4 for
– 0 – 0 > 0 < 0 – telescope sections I to IV).
SEMI-AUTOMATIC CONTROL To the right is the current telescope status as
a percentage (e.g., 0 %).
TELE: T3 L: 0%

In our example, the display would indicate the start position as it appears in the
first illustration. The main boom is completely retracted; therefore the display
shows 0 (%) for all telescope sections.
At the bottom left there are two dashes, and the current extended length of the
telescoping cylinder is L: approx. 2.88 ft, since the head of the telescoping
cylinder is extended into the foot section of telescope section IV.
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Checking the position of the telescoping cylinder

The current telescope status is now known; the next thing you should do
is check in which telescope section the head of the telescoping cylinder is
located.

One of the display lamps Telescoping cylinder in foot section I, II, III, or IV
Vefg displays the position of the telescoping cylinder.
The corresponding display lamp illuminates when the head of the tele-
scoping cylinder is at the locking point in the foot section of the respective

H
telescope section.

Definition: When the statement “The telescoping cylinder is in foot

section II” appears in the following chapters, this means that “the head”
of the telescoping cylinder is in the foot section.

In our example “Initial position” is defined as the following: The telescoping

g cylinder in telescope section IV is locked, thus the head of the telescoping
cylinder is there. The display lamp Telescoping cylinder in foot section IV would
illuminate accordingly.

Checking the position of the locking pins

If you know in which telescope section the telescoping cylinder is located,
check the positions of the locking pins as the last initial position.

Both indicator lamps Telescope section unlocked and Telescope section locked
jj display the position of the locking pins in the telescope section in which
the telescoping cylinder is located.

The red indicator lamp Telescope section unlocked illuminates when the tele-
j scope section is not locked to the telescope section above it.

The green indicator lamp Telescope section unlocked illuminates when the
j telescope section is locked to the telescope section above it.

Both indicator lamps Telescoping cylinder unlocked and Telescoping cylinder

ih locked display the position of the locking pins on the telescoping cylinder.

The red indicator lamp lights up when the telescoping cylinder is not
i locked.

The green indicator lamp illuminates when telescope cylinder is locked to

h the telescope section in which it is located.
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In our example the green indicator lamp telescope section locked would illumi-
jh nate and thus display that telescope section IV is locked to telescope section III
(it was presupposed that all telescope sections are locked to one another).
The green indicator lamp Telescoping cylinder locked would in addition illumi-
nate (it was presupposed that the telescoping cylinder is locked to IV).
Present state: – telescoping cylinder is locked in foot section IV –
The next objective: – Unlock telescoping cylinder –

Unlocking tele- Before you can move the telescoping cylinder from one telescope section
scoping cylinder into another telescope section, you must unlock the telescoping cylinder.
The locking pins on the telescoping cylinder retract when unlocking.
Prerequisites for the unlocking of the telescoping cylinder:
– The telescope section is locked; the green indicator lamp Telescope
j section locked illuminates.
– The telescoping cylinder is locked to the telescope section; the green
h
H
indicator lamp Telescoping cylinder locked illuminates.

If these prerequisites are not fulfilled, the unlocking procedure is on the

one hand blocked by a hydraulic/mechanical switch for safety reasons
and is on the other hand not released by the crane control.

Unlocking telescoping cylinder

• Select the unlocking of the telescoping cylinder; to do this, press the
. rocker switch Select locking/unlocking downward.

Now the red indicator lamp Telescoping cylinder unlocked flashes; the crane
i control thus confirms the selection.

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the right control lever toward retract or extend to unlock.
As soon as the locking pins move, the green indicator lamp Telescoping
h cylinder locked flashes in addition.

As soon as the locking pins are completely retracted, the red indicator
i lamp Telescoping cylinder unlocked illuminates.
The green indicator lamp Telescoping cylinder locked goes out.

If you continue to move the right control lever after the Telescoping cylin-
der unlocked warning lamp lights up, the telescoping cylinder moves in the
corresponding direction immediately.
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H If the locking process is not finished after about 10 seconds (warning

lamp Telescoping cylinder unlocked is not on), you can not retract the locking
pins because they are under load.
With the Telescoping cylinder at locking point indicator lamps you can see if
you need to retract or extend the telescoping cylinder to relieve the load.
If only the bottom indicator lamp lights up, you must extend the telesco-
8 ping cylinder.

8 If both indicator lamps or only the top indicator lamp light up, you must
retract the telescoping cylinder.
9

S
Risk of damaging the boom system!
If extending and retracting the telescoping cylinder several times does
not cause unlocking, you must not move the telescoping cylinder any
further against the stop.

If extending and retracting several times does not unlock the telescoping
cylinder:
– Lock the telescoping cylinder by pressing the Select locking/unlocking
rocker switch up and moving the control lever.
– Start the locking process again by pressing the Select locking/unlocking
rocker switch down and moving the control lever.

The process of unlocking applies to all telescoping procedures; thus the red
i indicator lamp Telescoping cylinder unlocked would also now illuminate in our
example. The display would display the length L = 2.88 ft.
Current end state: – telescoping cylinder is locked in telescope section IV –
The next target: – Moving telescoping cylinder in foot section III –
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Extending/ In order to telescope a telescope section you must first move the tele-
retracting tele- scoping cylinder into the foot section of the corresponding telescope
scoping cylinder section and lock it there.
and locking
You can select the locking before the telescoping cylinder has reached the
corresponding foot section. The crane control then locks the telescoping
cylinder in the first foot section which is reached when extending/
retracting.
That is why the exact time of the selection depends on whether the tele-
scoping cylinder:
– is to be moved and locked with an extended main boom
– or is to be moved and locked with a fully retracted main boom.

Before you telescope the telescoping cylinder with the selection, the
following prerequisites must be fulfilled:

– The telescope section in which the telescoping cylinder is located is

j locked, the green indicator lamp Telescope section locked illuminates.
– The lock between the telescoping cylinder and telescope section has
i been released, the red indicator lamp Telescoping cylinder unlocked illumi-
nates.

Moving and locking the telescoping cylinder with the main boom extended

This case applies when you move the telescoping cylinder back after
extending or retracting in order to telescope the next possible section.

Before you extend or retract the telescoping cylinder, the prerequisites at

the beginning of this chapter must be fulfilled.

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the telescoping cylinder; to do this, move the control lever in the
corresponding direction.
If the telescoping cylinder is moved without the telescope section, the

H
crane control always switches automatically to fast speed.

The following actions run parallel; you do not need to interrupt the
extending/retracting of the telescoping cylinder.

The telescope section begins to extend and the corresponding display

g lamp (e.g. Telescoping cylinder in foot section IV) flashes for the time being.
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As soon as this display lamp goes out, you can select the locking of the
telescoping cylinder.

• Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescoping cylinder locked flashes; the crane
h control thus confirms the selection.

While you are moving the telescoping

cylinder, the lower right status display for
the current extended length of the teles-
coping cylinder continuously changes
TELESCOPE STATUS (e.g. L: 25.02 ft).
– 0 – 0 – 0 – 0 – In this way you can directly follow the
SEMI-AUTOMATIC CONTROL extending/retracting on the status display.

TELE: – – L: 25.02 ft

When the telescoping cylinder retracts into a foot section, the corres-
f ponding display lamp flashes (in the example Telescope cylinder in foot
section III).

The crane control now reduces the telescoping speed specified by the
control lever and initiates the locking process owing to the selection made:

1. Once the locking point has been reached, the corresponding display
f lamp (e.g. Telescoping cylinder in foot section III) lights up.

2. The locking pins are extended, and the red indicator lamp Telescoping
i cylinder unlocked flashes as long as the locking pins are moving.

3. As soon as the telescoping cylinder is locked, the green indicator lamp

h Telescoping cylinder locked lights up.
The red warning lamp Telescoping cylinder unlocked goes out.

• Bring the telescoping process to an end, and move the control lever to
the central position.
The retracting/extending of the telescoping cylinder with the main boom
extended has thus been finished.

Moving and locking the telescoping cylinder with the main boom fully

H
retracted

As long as the unlocked telescoping cylinder is situated in a foot section,

the crane control reduces telescoping speed specified by the control lever.
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• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the telescoping cylinder; to do this, move the control lever in the

H
corresponding direction.

The following actions run parallel; you do not need to interrupt the
extending/retracting of the telescoping cylinder.

As long as the telescoping cylinder is situated in a foot section, the corre-

g sponding display lamp (e.g. Telescoping cylinder in foot section IV) flashes.
If the telescoping cylinder leaves this foot section, the display lamp goes
out and the display lamp of the next foot section flashes simultaneously
(e.g. Telescoping cylinder in foot section III).

If the display lamp of the foot section in which you would like to lock the
f telescoping cylinder (e.g. Telescoping cylinder in foot section III) is flashing,
you must select the locking within 3 seconds.

• Switch the rocker switch Select locking/unlocking to the central position to

.
H
do this.

Once you have waited longer than 3 seconds before you select the
locking, the telescoping cylinder has moved past the locking point. In this
case stop the extending/retracting (move control lever into the central po-
sition) and move the telescoping cylinder in the opposite direction until
the display lamp of the corresponding telescope section flashes again.
Now select the locking within 3 seconds.

The green indicator lamp Telescoping cylinder locked flashes; the crane
h control thus confirms the selection and initiates the locking process:

1. Once the telescoping cylinder has reached the locking point, the corre-
f sponding display lamp (e.g. Telescoping cylinder in foot section III) lights up.

2. The locking pins are extended, and the red indicator lamp Telescoping
i cylinder unlocked flashes as long as the locking pins are moving.

3. As soon as the telescoping cylinder is locked, the green indicator lamp

h Telescoping cylinder locked lights up.
The red indicator lamp Telescoping cylinder unlocked goes out.

• Bring the telescoping process to an end, and move the control lever to
the central position.
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The retracting/extending of the telescoping cylinder with the main boom

fully retracted has thus been finished.

The section “Moving and locking telescoping cylinder with completely retracted
main boom” applies for our example. All telescope sections are fully retracted,
thus the telescoping cylinder is situated in adjacent foot sections.
The telescope cylinder should be moved from foot section IV directly to foot
section III.
The display lamps in this section conform to actuality in our example. You can
accept this section as an example.
New end state: – Telescoping cylinder is locked in foot section III –
The next objective: – Unlock telescope section III –

Unlock Before you can telescope a telescopic section, you have to unlock it. You
telescope section can only unlock the telescope section in which the telescoping cylinder is
situated. The locking pins of this telescope section are retracted by the
mechanism on the telescoping cylinder when unlocking.

Prerequisites for the unlocking of the telescope section:

– The telescoping cylinder is locked to the telescope section; the green
h indicator lamp Telescoping cylinder locked illuminates.
– The telescope section is locked; the green indicator lamp Telescope
j
H
section locked illuminates.

If these prerequisites are not fulfilled, the unlocking procedure is on the

one hand blocked by a hydraulic/mechanical switch for safety reasons
and is on the other hand not released by the crane control.

Unlocking telescope section

• Select the unlocking of the telescopic section; to do this, press the
. rocker switch Select locking/unlocking upward.

Now the red indicator lamp Telescope section unlocked flashes; the crane
j control thus confirms the selection.

As soon as the locking pins move, the green indicator lamp Telescope
j section locked flashes in addition.
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When the locking pins are retracted, the red indicator lamp Telescope
j section unlocked lights up.
The green indicator lamp Telescope section locked goes out.

As soon as the telescope section is unlocked,

the status display on the Crane control display
changes; the numerical value for the unlok-
ked telescope section is now in brackets.
TELESCOPE STATUS
The unlocked telescope section (e.g. T3) is
– 0 – 0 > 0 < 0 – displayed at the lower left.
SEMI-AUTOMATIC CONTROL To the right, its current telescope status in
percent (e.g. L: 0 %).
TELE: T3 L: 0 %

H
Now the telescope section is unlocked and can be telescoped.

If the locking process is not finished after about 10 seconds (warning

lamp Telescoping cylinder unlocked is not on), you can not retract the locking
pins because they are under load.
Relieve the locking pins by slowly retracting or extending the main boom
until the green indicator lamp Telescope section locked also flashes.

S
Risk of damaging the boom system!
If extending and retracting several times does not cause unlocking, you
must not move the telescoping cylinder any further against the stop.

If extending and retracting several times does not unlock the telescoping
cylinder:
– Lock the telescope section by pressing the Select locking/unlocking rocker
switch up and moving the control lever.
– Start the locking process again by pressing the Select locking/unlocking
rocker switch down and moving the control lever.
The process of unlocking applies to all telescoping procedures; thus the red indi-
j cator lamp Telescope section unlocked would also now illuminate in our example.
Telescope section III is unlocked; the numerical value for telescope section III
would correspondingly appear on the display in brackets.
The unlocked telescope section III would be displayed as T3 in the lower line
and the current telescoping of 0 % next to it.
Present end state: – Telescope section III unlocked –
The next objective: – Extend telescope section III to 100 % –
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Telescoping tele-
scope section to

H
fixed length and
lock

Read the sections concerning the fixed, intermediate, and telescoping

lengths, the telescoping sequence and the functioning of the control lever
at the beginning of this chapter and observe the notes for telescoping;
➠ p. 12-53.
If you extend several telescope sections or want to work on a fixed length,
you must extend the telescope section to a fixed length and lock it there.
You can select the locking before the telescope section has reached the
fixed length. The crane control then locks the telescope section at the first
fixed length which is reached. Since every telescope section has three
fixed lengths, the point in time of the selection depends on whether the
telescope section:

– is to be locked at the fixed length reached first

– or is to be locked at the fixed length after the next.
Before you telescope the telescope section with the selection, the fol-
lowing prerequisites must be fulfilled:

– The telescoping cylinder is situated in the foot section of the telescope

f section which is to be telescoped. The corresponding display lamp
(e.g. Telescoping cylinder in foot section III) illuminates.
– The telescoping cylinder is locked to the telescope section which is to
h be telescoped; the green indicator lamp Telescoping cylinder locked illumi-
nates.
– The telescope section in which the telescoping cylinder is located is
j unlocked, the red indicator lamp Telescope section unlocked illuminates.

Locking the telescope section at the first fixed length reached

This case applies if you for example extend a fully retracted telescope
section to the middle fixed length and want to lock it there.

Before you telescope a telescope section, the prerequisites at the

beginning of this chapter must be fulfilled.

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the telescoping cylinder; to do this, move the control lever in the
corresponding direction.
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Operating Instructions GMK 5100 2 084 575 en 12 - 73
Crane operation
12.3 Crane work with the main boom

H The following actions for telescoping run parallel; you do not need to
interrupt the telescoping.

While you are telescoping the telescopic

section, the numerical value in brackets and
the value at the lower right on the display
continuously change.
TELESCOPE STATUS
– 0 – 0 > 20 < 0 –
SEMI-AUTOMATIC CONTROL In this way you can directly follow the tele-
scope status of the telescope section
TELE: T3 L: 20,3%
(e.g. T3) on the status display.

If the initial position was an intermediate length before telescoping, you

can immediately select the locking of the telescope section.

If the initial position was a fixed length before telescoping, you must wait
until the percent value for the telescope status has risen by 2 % before
selecting.

• Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescope section locked flashes; the crane control
j thus confirms the selection.

When the telescoping cylinder reaches the next fixed length, the crane
control reduces the telescoping speed specified by the control lever and
initiates the locking process owing to the selection made:

1. Shortly before reaching the locking point, the locking pins are pushed
j out and the red indicator lamp Telescope section unlocked also flashes.

2. The locking pins are pushed out at the locking point and the telescopic
j section is set down on the locking pin.
The green indicator lamp Telescope section locked first switches from flash-
ing to illuminating when this process has been completed.
The red indicator lamp Telescope section unlocked goes out.
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 Crane operation
12.3 Crane work with the main boom

S
Be careful not to damage the telescoping cylinder!
Move the control lever until the green indicator lamp Telescope section lok-
ked is no longer flashing and is on. If necessary, move the telescope secti-
on from side to side somewhat until the indicator lamp illuminates.
Only then is the locking process completed and the telescope section is
joined in a power dozing manner with the telescope section above it.
In this way you prevent the load from affecting the telescoping cylinder
when the crane is in operation and enable the release of a load for fixed
lengths.

• Bring the telescoping process to an end, and move the control lever to
the central position.
As soon as the telescope section is locked,
the numerical value for the telescope section
is no longer in brackets.
Both dashes are displayed again on the left
TELESCOPE STATUS
side of the lower line.
– 0 – 0 – 50 – 0 – The display to the lower right again changes
SEMI-AUTOMATIC CONTROL to the current extended length of the tele-
scoping cylinder (in the example L: 17.61 ft).
TELE: – – L: 17.61 ft

Locking the telescope section at the next fixed length

This case applies when you want to telescope a telescope section from
e.g. 0 % to 100 % or vice versa.
Before you telescope a telescope section, the prerequisites at the
beginning of this chapter must be fulfilled.
• Check if the Telescoping gear switched on indicator lamp is on and tele-

H
T scope the telescope section.

The following actions for telescoping run parallel; you do not need to
interrupt the telescoping.

While you are telescoping the telescopic

section (e.g. telescope section III), the nume-
rical value in brackets and the value at the
lower right on the display continuously
TELESCOPE STATUS
change.
– 0 – 0 > 55 < 0 – 0
• Follow the telescoping process on the
SEMI-AUTOMATIC CONTROL status display (e.g. L: 55 %).
TELE: T3 L: 55.3%
• Wait until the first fixed length for this tele-
scope section is exceeded (e.g. up to 55 %,
11.05.2000

the first fixed length for T3 is at 50 %).

s
Operating Instructions GMK 5100 2 084 575 en 12 - 75
Crane operation
12.3 Crane work with the main boom

• Now you can select the locking.

Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescope section locked flashes; the crane control
j thus confirms the selection.

When the telescoping cylinder reaches the next fixed length, the crane
control reduces the telescoping speed specified by the control lever and
initiates the locking process owing to the selection made:

1. Shortly before reaching the locking point, the locking pins are pushed
j out and the red indicator lamp Telescope section unlocked also flashes.

2. The locking pins are pushed out at the locking point and the telescopic
j section is set down on the locking pin.
The green indicator lamp Telescope section locked first switches from flash-
ing to illuminating when this process has been completed.
The red indicator lamp Telescope section unlocked goes out.

S
Be careful not to damage the telescoping cylinder!
Move the control lever until the green indicator lamp Telescope section
locked does not flash any more. If necessary, move the telescope section
from side to side somewhat until the indicator lamp illuminates.
Only then is the locking process completed and the telescope section is
joined in a power dozing manner with the telescope section above it.
In this way you prevent the load from affecting the telescoping cylinder
when the crane is in operation and enable the release of a load for fixed
lengths.

• Bring the telescoping process to an end, and move the control lever to
the central position.
As soon as the telescope section is locked,
the numerical value for the telescope section
is no longer in brackets.
Both dashes are displayed again on the left
TELESCOPE STATUS side of the lower line.
– 0 – 0 – 100 – 0 – The display to the lower right again changes
SEMI-AUTOMATIC CONTROL to the current extended length of the tele-
scoping cylinder (e.g. L: 33.25 ft).
TELE: – – L: 33.25 ft
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 Crane operation
12.3 Crane work with the main boom

In our example, the section “Locking the telescope section at the fixed length
reached first” applies. Telescope section III should be extended to 50 %, so you
can select locking as soon as the telescope section has been telescoped approx. 2
% from initial state. The values in this section are suited to the example. You
can accept this section directly as an example.
Present end state: – Telescope section III extended to 50 % –
New objective: – Extend telescope section II –

In order to reach the end position of the example from page 12-62, you would
have to now extend telescope section II first. You would have to repeat the secti-
ons which are refered to in items 2 to 5 of the example on page 12-62. The steps
are the same as with extending telescope section III. The initial and end positions
would simply have to be changed for telescope section II and the status displays
would change accordingly. This is the case for every other telescoping process.

You can also telescope a telescope section without selecting the lock,
as described in the next section.

Telescoping tele- Before you telescope a telescope section to an intermediate length,

scope section to the following prerequisites must be fulfilled:
intermediate
length
– The telescoping cylinder is situated in the foot section of the telescope
V section which is to be telescoped. The corresponding display lamp
(e.g. Telescoping cylinder in foot section I) illuminates; ➠ Extending/
retracting telescoping cylinders and locking them, p. 12-68.
– The telescope section in which the telescoping cylinder is located is
j unlocked, the red indicator lamp Telescope section unlocked illuminates;
➠ Unlocking telescopic section, p. 12-71.
– The telescoping cylinder is locked to the telescope section; the green
h indicator lamp Telescoping cylinder locked illuminates.
• Check if the Telescoping gear switched on indicator lamp is on and tele-
T scope the telescope section.

While you are telescoping the telescope

section, the status display on the Crane
control display changes for the current tele-
scope status (e.g. for telescope section I).
TELESCOPE STATUS
> 37 < 50 – 50 – 0 – Extend the telescope section until the status
SEMI-AUTOMATIC CONTROL display shows the desired intermediate
length in percent (e.g. L. 37 %).
TELE: T1 L: 37%
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Operating Instructions GMK 5100 2 084 575 en 12 - 77
Crane operation
12.3 Crane work with the main boom

The telescope status given in our example is therefore reached. The main boom
is now at the intermediate length (37 / 50 / 50 / 0 ) and you can lift according to
the corresponding capacity chart.

To reach the on-the-road mode, you have to proceed in the reverse sequence;
retract telescopic parts I, II III and IV one after the other and lock the telesco-
ping cylinder in telescopic part I.

Locking tele- If you retract the main boom fully without having selected the locking du-
scope section ring the last telescoped telescope section, you must lock this telescope
section before on-road driving.

• Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescope section locked flashes; the crane control
j thus confirms the selection.

As soon as the locking pins move, the red indicator lamp Telescope section
j unlocked flashes.

When the locking pins have reached the end point, the green indicator
j lamp Telescope section locked illuminates.
The red warning lamp Telescope section unlocked goes out.

When all telescope sections are locked, the

two dashes are displayed on the bottom left.

The display to the lower right again changes

TELESCOPE STATUS
to the current extended length of the te-
– 0 – 0 – 0 – 0 – lescoping cylinder (e.g. 0.00 ft when the te-
SEMI-AUTOMATIC CONTROL lescoping cylinder is in the foot section of
telescope section I).
TELE: – – L: 0.00 ft

H If you have retracted the main boom for on-road driving, you must now
lock the telescoping cylinder in telescope section I so that the axle loads
are in accordance with the values in the Driving mode table.
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 Crane operation
12.3 Crane work with the main boom

Telescoping with To telescope to fixed lengths you can also use the fully automatic control
fully automatic (teleautomatic control). To do this enter the desired telescope status in
control a submenu on the display Crane control system and then steer the control
lever out in the direction in which the telescoping should go. The locking
and unlocking processes are carried out automatically by the crane con-

H
trol system.

Before you use the fully automatic telescoping, you must have read the
entire telescoping gear section so that you can comprehend the locking
and unlocking processes that the crane control carriers out. With the fully
automatic control you can telescope the individual telescope sections
only to the 0 %, 50 % and 100 % lengths.
If you want to telescope one of the telescope sections to another length
(e.g. 70 %), you can telescope with the fully automatic control at first to
the next locking point (e.g. 50 %) and then telescope the last telescope sec-
tion further with the semi-automatic control (e.g. to 70 %).

You can only activate the submenu for entering the desired telescope
status if
– the Crane control display is in the Display telescope status and teleautomatism
menu and
– the telescoping gear is activated.
You can start the sub-menu independent of the current telescope status.

• Switch on the menu Display telescope status on the display if necessary.

• Switch the rocker switch Select locking/unlocking to the central position.
. • If necessary switch on the telescoping gear. The Telescoping gear switched
T on indicator lamp must light up.
Press the membrane switch Display telescope status and teleautomatic.
ä Now the sub-menu for the entry of the desired telescope status appears
on the Crane control display.

The entry SET TELEAUTOMATIC is in the

first line.
Telescope sections T1 to T4 are in the
second line, and in the line below this, the
SET TELEAUTOMATIC
numerical value 0 is displayed for every tele-
> T1 < T2 – T3 – T4 – scope section.
– ● – 0 – 0 – 0 – 0 In addition, the entry request (●) flashes on
the numerical value for T1.
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Operating Instructions GMK 5100 2 084 575 en 12 - 79
Crane operation
12.3 Crane work with the main boom

You can enter the desired telescope status for every telescope section
with the membrane switches Entry and view, located to the right, next to
the display.

You can only enter the value on which the entry request flashes anew.

• 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.
* • You can select a higher or lower fixed length with these two membrane
: switches. The following values are available:
For T1 : 0 50 100
< For T2 : 0
For T3 : 0
50 100
50 100
For T4 : 0 50 100

• Press this membrane switch in order to switch off the menu.

ö The display switches to the Display telescope status and teleautomatism menu.
• Once you have entered the desired value, you have to start the teleauto-
Ö
H
matic. Press this membrane switch to do this.

If the four green light diodes above the first line flash three times after the
teleautomatic has been started, you have entered a telescoping which is
not permissible according to the Lifting capacity table. Furthermore, the
display shows the submenu for entering and you can enter a new per-
missible telescoping.

If you have entered a permissible telescope status, the teleautomatic is

started and the display changes to sub-menu Teleautomatic.

The menu shows the entry TELESCOPING in

the first line.
The current telescope status is displayed in
the second line.
TELESCOPING
The third line shows the telescope status
– 100 – 0 – 0 – 0 – which you entered before. This telescope
– 50 – 100 – 100 – 100 – status now sets the crane control as the
objective.
TELE: – – L: 31.32 ft
The last line of the display is exactly as in
the Display telescope status and teleautomatism
menu.
11.05.2000

The crane control now calculates the necessary telescoping sequence.

In order to start the telescoping, you must move the control lever in the
corresponding direction and hold it fast:

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 Crane operation
12.3 Crane work with the main boom

• If you want to extend first, move the right control lever to the right.
• If you want to retract first, move the right control lever to the left.
The crane control telescopes fully automatically only until a change of
direction is necessary; then the telescoping is interrupted and you must

H
move the control lever in a different direction.

The other extension of the control lever for changing the direction is only
necessary for extending a telescopic part. The telescoping cylinder moves
automatically in both directions between the telescopic parts when chang-
ing, irrespective of the direction steered by the control lever.
You can regulate the speed for telescoping just as for the semi-automatic
control.
You can leave the menu at any time by pressing the rocker switch Select
. locking/unlocking either upward or downward.

You can change from the menu Display telescope status and teleautomatism
ä back to the submenu for entering the desired telescope status at any time.
To do this press the membrane switch Display telescope status and teleautoma-

H
tism once.

You can also change to the submenu for entering the telescope status and
enter a new telescope status whilst the crane control carries out the fully-
automatic telescoping when, e.g. you have entered an incorrect telescope
profile.

Example of telescoping with teleautomatic

Assuming the current telescope status is

100 / 0 / 0 / 0, the desired telescope status should
be 50 / 100 / 100 / 100 and the telescoping cylin-
TELESCOPING der is locked in foot section I.
The status display would then correspond to the
– 100 – 0 – 0 – 0 –
illustration to the left and the following tele-
– 50 – 100 – 100 – 100 –
scoping sequence is yielded:
TELE: – – L: 31.32 ft
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Operating Instructions GMK 5100 2 084 575 en 12 - 81
Crane operation
12.3 Crane work with the main boom

– T1 retract to 0 %
– T4 extend to 100 %
– T3 extend to 100 %
– T2 extend to 100 %
– T1 extend to 50 %

• Move the right control lever to the left in order to retract and hold it fast.

While you are holding the control lever, the crane control automatically carries
out the necessary locking and unlocking processes and fully retracts telescope
section I.

You can follow the process on the display and

the indicator and display lamps.

When the telescopic part is retracted (Value in

TELESCOPING
brackets = 0), the crane control system moves
– 0 – 0 – 0 – 0 – the telescoping cylinder into the next telescopic
– 60 – 100 – 100 – 100 – part to be extended (telescopic part IV) and
TELE: – – L: 2.88 ft locks the telescoping cylinder into it.

When the display lamp for the telescoping cylinder in the foot section IV and the
gh indicator lamp Telescoping cylinder locked illuminates, the crane control system
stops all processes, as a change of direction in the telescoping is necessary.

• Move the right control lever to the right in order to extend and hold it fast.

While you are holding the control lever, the crane control automatically carries
out the necessary locking and unlocking processes and fully extends telescope
section IV to II and telescope section I to 60 %.

When the specified telescope status has been re-

ached, the display changes to the menu Display
telescope status and teleautomatism and displays
TELESCOPING the current telescope status.
> 50 < 100 – 100 – 100 –
SEMI-AUTOMATIC CONTROL
TELE: – – L: 15.67 ft

H
The telescoping with fully automatic control is thus completed.

If you want to extend telescope section I to 70 %, for example, you can now
extend this telescope section further with the semi-automatic control.
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 Crane operation
12.3 Crane work with the main boom

Lowering the In order to lower the partly extended boom to an angle smaller than that
main boom for permitted in the operating area, you must enter an SLI rigging code. You
maintenance can find the rigging codes in the respective rigging graph from the lifting

H
capacity table.

If the main boom is fully retracted and no load is raised, the SLI switches
automatically to the rigging code when the working range is left.

• Put down the load.

• If the main boom is not fully retracted, enter the appropriate SLI code
for the current rigging mode of the truck crane according to the Lifting
capacity table.
• Turn the superstructure in the necessary direction;
➠ Slewing with rigged counterweight, p. 13-67.

G
Risk of overturning with an outrigger span of 25.6 x 8.2 ft!
With an outrigger span of 25.6 x 8.2 ft the main boom may be set down
only in the 0° forwards or 180° to the rear positions.
If you place the boom to the side with this outrigger span, the truck crane
tips over even with the boom retracted.

G
Risk of overturning if SLI is overridden!
If the SLI switches off the lowering of the boom, the truck crane is in a
status in which the main boom can not be placed in a horizontal position
(e.g. a raised load or extended too far).
Do not override the SLI, put down the load if necessary and retract the
main boom.

• Lower the main boom to the horizontal position.

Telescoping the • Enter the corresponding SLI rigging code for the current rigging mode
main boom in of the truck crane according to the Lifting capacity table.
the horizontal
The maximum permitted telescope status for the current rigging mode
position
(counterweight, outrigger span, direction of rotation) is determined by the
SLI rigging code. If this telescope status is exceeded, the SLI switches off
the extending function.
• Put down the load.
• Extend the main boom only so far that the SLI switches off the exten-

H
ding function.
11.05.2000

If you continue to extend the main boom after an SLI shutdown, you can
get into areas in which you can not retract or raise.

Operating Instructions GMK 5100 2 084 575 en 12 - 83

Crane operation
12.3 Crane work with the main boom

12.3.7 Fast speed

G
Accidents may occur if movements are suddenly accelerated!
Reduce the engine speed before switching on fast speed so that the mo-
vements are not accelerated too intensely. The truck crane could start to
rock and then overturn.

You can switch to fast speed for some crane movements in order to reach
a faster working speed. Depending on the crane movement, the fast
speed is switched to in different ways:
– with the foot-operated switch Fast speed derricking gear/telescoping gear or
– the foot-operated switch Fast speed hoisting gear.
The fast speed derricking gear/telescoping gear foot pedal (arrow) is used to
switch to fast speed for the crane movements telescoping and raising the
boom.

H During lowering of the boom, fast speed mode only supports the start-up
of the derricking procedure from extreme boom positions; it does not in-
crease the derricking speed.

S
Make sure that the lifted load is no more than 50 % of the maximum load
according to the. Lifting capacity table (degree of utilization maximum
50 %) before you move the hoists with fast speed!

With the foot-operated switch Fast speed hoisting gear you activate the fast
speed for the crane movement Raising/lowering main hoisting gear and
raising/lowering auxiliary hoist gear (additional equipment).

S
Danger of build-up of slack rope!
Take care that slack does not form when the hoist is lowered!

H
11.05.2000

The slewing gear cannot be driven in fast speed.

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 Crane operation
12.3 Crane work with the main boom

12.3.8 Menus on the crane control display

You can call up various menus on the Crane control display. You receive
information about the power units from and can sometimes enter values
in these menus; error messages are also displayed here. You can select
five different menus directly:
– the menu Display states,
– the menu Power unit speeds/critical load control,
– the menu Control lever emergency operation,
– the menu Display telescope status and teleautomatism,
– the menu Enter telescope status after emergency operation.

Error messages and a sub-menu Emergency operation are displayed auto-

matically and with priority; ➠ Display of an error message, p. 12-93.
Whenever further sub-menus are arranged under a menu, you can call
these up from the open menu.

Not all menus are described in this section:

Menu Control lever emergency operation; ➠ p. 14-68.
Menu Enter telescope status after emergency operation; ➠ p. 14-76.
Sub-menu Emergency operation; ➠ p. 14-70.

Menu Display In this menu you can display the operating hours of all power units and
states possibly read off existing malfunctions. The operating hours of the crane
engine correspond to the superstructure operating hours, which are
specified in the maintenance manual.

• Select the menu; press the membrane switch Display states once to do so.
> The crane control display now switches to the
menu Display states and in the uppermost line
the message STATUS REPORT appears.
STATUS REPORT
The most recently selected menu item (here
DERRICKING GEAR derricking gear) appears in the second line.
STATUS : O.K
TIME : 3.27 h

You can call up different menu items after each other by repeatedly pres-
> sing the membrane switch Display status or

you can use both these membrane switches to switch between menu
:
11.05.2000

items in increasing or decreasing order.

<
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Operating Instructions GMK 5100 2 084 575 en 12 - 85
Crane operation
12.3 Crane work with the main boom

The following menu items are available:

– Engine (crane engine)
– System (for the crane control)
– Main hoist
– Auxiliary hoist (only with additional equipment)
– Derricking gear
– Telescoping gear
– Locking system (locking pins in the telescoping gear)
– Slewing gear
– Secondary power units (counterweight lifting gear/locking pins,
superstructure lock, incline crane cab)
– Critical load control

• Select the desired menu item (e.g., main hoist).

:
< The total operating hours of the selected
power unit are displayed in the last line.
In this example the total operating time of
the main hoist amounts to 168 hours and
STATUS REPORT
27 minutes.
MAIN HOIST
STATUS : O.K The third line displays the status of the
selected power unit. There are two different
TIME : 168.27 h
status displays:

Status Significance
display

There are not malfunctions, the power unit is released by

O.K
the crane control without restrictions.

One or more error messages have been acknowledged for

ERROR this power unit and stored in the sub-menu Memory error.

Memory error sub-menu

You can call up the sub-menu memory error from this status display in
order to see already acknowledged error messages again.

Press this membrane switch next to the status display to do so.

+
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 Crane operation
12.3 Crane work with the main boom

The display now changes to the sub-menu Memory error.

The entry MEMORY ERROR is in the top line;

to the right of it is the number of the error
which was acknowledged (e.g. 1).
The second line shows the power unit
MEMORY ERROR 1
concerned (e.g. main hoist).
MAIN HOIST
J3502 : 01000000 Both lower lines display the error exactly like
the corresponding error message which was
STATUS : 01000001
acknowledged; ➠ Display of an error message,
p. 12-93.

You can call up further existing errors with both of these membrane
: switches next to the display. The errors are numbered consecutively and
the corresponding number of the error is displayed at the top right.
< Once the error with the number 1 has been reached and you press the
upper membrane switch again, the display changes back to the menu
Display states.

*öÖ To leave the Memory error submenu you can press one of the adjacent
membrane switches.

Menu items with special displays

In the Engine menu item, the current engine
speed of the crane engine is displayed in the
third line. In this example the current engine
speed is 1000 revolutions per minute.
STATUS REPORT
MOTOR The speed display is updated when the
STATUS : 1000 UPM speed of the crane engine changes.
TIME : 227.35 h

If there is an error, the message ERROR appears as with the other menu

H
items in the third line.

You can switch on this display when setting a constant engine speed if
you would like to set the constant engine speed to a certain value
(e.g. 1300 rpm); ➠ Setting constant motor speed, p. 12-95.
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Operating Instructions GMK 5100 2 084 575 en 12 - 87
Crane operation
12.3 Crane work with the main boom

The menu item Locking system gives informa-

tion on the mechanism on the head of the
telescoping cylinder and its locking pins.
STATUS REPORT
In this menu item the last line shows how
LOCKING SYSTEM frequently the mechanism has controlled the
STATUS : O.K cycle Unlock telescope section.
CYCLES : 1727

The intervention of the critical load control

is displayed directly under the menu item
Critical load control (primarily for servvice
purposes).
STATUS REPORT
CRITICAL LOAD CONTROL In the third line there are three different entries:
STATUS : ON ON critical load control switched on
OFF critical load control switched off
❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ERROR error has occured

The bar graph in the last line shows to which percentage the performance
of the hydraulic pumps is throttled to (1 box is approx. 5 %; the diagram
shows approx. 40 %). The display is updated constantly. The bar display
shows 100 % if the critical load control CLC is switched off.
After STATUS the message ERROR appears if there is an error message.
The menu Display states remains switched on until you select another
menu with the corresponding membrane switch or until there is an error
message.

Menu Display In this menu you can see the current telescope status and the extended
telescoping status length of the telescoping cylinder.

and teleautomatic
• Select the menu. Press the membrane switch Display telescope status and
ä teleautomatic.
The display Crane control now changes in
the menu Display telescope status and teleauto-
matic; in the top line the message TELESCO-
PING appears.
TELESCOPING
The display changes depending on the tele-
– 0 – 0 > 20 < 0 –
scoping status; this is described in more
SEMI AUTOMATIC CONTROL detail in the section Telescoping gear;
TELE: T3 L: 20:3% ➠ Example of procedures when telescoping,
p. 12-62.
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 Crane operation
12.3 Crane work with the main boom

The menu Display telescoping status and teleautomatic remains switched on

@üäÄ until you select another menu with the corresponding membrane switch
or until there is an error message.

Power unit In this menu, you can enter the maximum speed of all power units.
speeds/critical
load control menu

• Select the menu; press the membrane switch Power unit speeds/critical
@ load control once to do this.
The crane control display now switches to the
menu Power unit speeds/critical load control; the
entry SPEED appears in the uppermost line.

SPEEDS
The most recently selected menu item (here
SLEWING GEAR slewing gear) appears in the second line.
NORMAL : 95 % ←

POINT : 45 %

You can call up different menu items after each other by repeatedly pres-
@ sing the membrane switch Display status or

You can use both these membrane switches to switch between menu
: items in increasing or decreasing order.

< You can call up the following menu items:

– Main hoist
– Auxiliary hoist (additional equipment)
– Derricking gear
– Telescoping gear
– Slewing gear
– Critical load control; ➠ p. 12-91

: • Select the desired menu point (e.g., Telescoping gear).

<
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Operating Instructions GMK 5100 2 084 575 en 12 - 89
Crane operation
12.3 Crane work with the main boom

Displaying entered speeds

The menu displays what percent of the

maximum speed is set as maximum speed.
The displayed value behind the following
applies here:
SPEEDS
– NORMAL for operation with main boom
TELESCOPING GEAR
– POINT for operation with the two-stage
NORMAL : 95 % ←
swing-away lattice extension or boom ex-
POINT : 40 % tension (both additional equipment).

H The arrow to the right always refers to the value with which the crane
control calculates at the moment.

The arrow switches to the value for TOP

SECTION as soon as the lattice extension is
electrically connected.

SPEEDS
TELESCOPING GEAR
NORMAL : 95 %
POINT : 40 % ←

Entering the maximum speed

Before you can enter the new value for the maximum speed, you must
switch to entry mode.

• Press the Entry mode membrane switch to switch on the entry mode for
+ NORMAL.
• Press this membrane switch to switch on the entry mode for POINT.
* The entry request flashes in front of the two
numerical values (● e.g. with NORMAL, in
front of 95 %).
You can only newly enter the value which has
SPEEDS
the entry request in front of it.
SLEWING GEAR
NORMAL : ● 95 % ← You can enter values from 10 % to 100 % for
NORMAL.
POINT : 53 %
The values for POINT are limited.
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 Crane operation
12.3 Crane work with the main boom

• Press this membrane switch if you want to increase the value.

: Every time the button is pressed, the value increases by 5 %.
• Press this membrane switch if you want to decrease the value.
<
H
Every time the button is pressed, the value decreases by 5 %.

When you hold down the membrane switch, the value continuously
changes by 5 % intervals.

• Press this membrane switch if you want to set the value back to the
ö initial state.
Once you have entered the desired value, you have to save it.

H
• Press this membrane switch to save the new maximum speed.
Ö
The newly set speed is accepted by the crane control only if you have
saved it.
You can also enter both values (NORMAL and TOP SECTION) anew and
then save them together with enter.
You can no longer set the entry back with ESC after saving.

Switching on/off critical load control

Press the membrane switch Power unit

speeds/critical load control until the entry
CRITICAL LOAD CONTROL appears in
the second line.
SPEEDS
CRITICAL LOAD CONTROL Whether the critical load control is switched
STATUS : ON on (ON) or off (OFF) is displayed in the third
line behind STATUS.

Before you can change the setting, you have to change to the entry mode.

• To do this press one of the two right membrane switches Entry and view,
+ Display and hold it down briefly.
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Operating Instructions GMK 5100 2 084 575 en 12 - 91
Crane operation
12.3 Crane work with the main boom

Now the entry request flashes in front of the

entry in the third line (●).

Now you can change the entry.

SPEEDS
CRITICAL LOAD CONTROL
STATUS : ● ON

• Press this membrane switch in order to switch off the critical load
< control; the entry OFF appears in the third line.
• Press this membrane switch in order to switch on the critical load
: control; the entry ON appears in the third line.
Press this membrane switch to save the changed entry.
Ö The menu Power unit speeds/critical load control stays on until you select
>üäÄ another menu with the corresponding membrane switch or until there is
an error message.

Access emergency If the crane control no longer receives signals from a length indicator or
operation menu proximity switch, if the received signals from the locking pin statuses are
unrealistic, or if the crane control recognizes an error in a valve for the
locking mechanism, the following crane movements are switched off:
– retracting and extending,
– locking and unlocking telescoping cylinders,
– locking and unlocking telescope sections.

Furthermore, the following lamps have no function:

– Telescoping cylinder at locking point,
89 – Telescoping cylinder in foot section I to IV;
Vefg – Telescopic part locked, Telescopic part unlocked,
jj – Telescoping cylinder locked, Telescoping cylinder unlocked.
hi The display Crane control switches to the Error message displays.

• Acknowledge the error message.

Ö
If the Display telescope status and teleautomatism menu was selected before
the error message occurred, the crane control switches directly to the
Access emergency operation menu.
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 Crane operation
12.3 Crane work with the main boom

The menu can be recognised by the messa-

ge ACCESS EMERGENCY OPERATION in the
third line.
The three-digit numeric code in the second
TELESCOPING GEAR
line displays which type of error has occurred;
STATUS :001 ➠ Deciphering the numeric code, p. 14-70.
ACCESS EMERGENY OPERATION
In the last line there is the message
KEYCODE : —
KEYCODE and the entry request (—) flashes.

To start the emergency program, a key code must be entered in this line:

• Press the following membrane switches next to the display one after
the other:

Ö : < Ö

H
Each correct entry is confirmed on the display with a star (*).

If you press the wrong membrane switch more than once, the entries
which have already been confirmed (*) will also be erased and the key
combination must be entered again.

When the key combination has been correctly entered, the crane control
commences emergency operation and the following lamps are reacti-
vated;
– Telescoping cylinder at locking point,
89 – Telescopic part locked, Telescopic part unlocked,
jj – Telescoping cylinder locked Telescoping cylinder unlocked.
hi
Display of an The crane control shows current errors with priority on the display Crane
error message control. As soon as there is an error, the display switches to the Error
message display.
The message ERROR MESSAGE appears in
the top line.
The power unit concerned is displayed in the
second line (e.g. the telescoping gear).
ERROR MESSAGE
The third line shows the designation of the
TELESCOPING GEAR part on which a malfunction occurred. Be-
J3502 : 00000010 hind that is a numerical code which descri-
bes the cause of the error.
STATUS : 00000001
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The numerical code in the last line describes the area in which the error

s
occurred.

Operating Instructions GMK 5100 2 084 575 en 12 - 93

Crane operation
12.3 Crane work with the main boom

Further information on the numerical code; ➠ Crane control error messages,

p. 14-57.

Acknowledging error messages

You can acknowledge an error message and thus return to the menu
which was selected before the error message occurred.

• Press the membrane switch Enter once to acknowledge; there are three
Ö possible reactions:
– If no further error message is in the queue, the display switches to the
menu which was selected before the error message occurred.
– If further error messages are in queue, the next error message appears
on the display. You can acknowledge all error messages one after the
other.
– If the error message was displayed because the crane control cannot
detect any lengths and positions (proximity switch or length indicator is
faulty or the line has been cut), the crane control switches to the sub-
menu Emergency operation after the acknowledgement; ➠ p. 14-70.

Calling up error messages again after acknowledging

All acknowledged error messages are saved in the sub-menu Error
memory. As long as the ignition remains switched on, you can call up the
acknowledged error messages again:

• To do this, switch to the menu Display states.

>
: • Call up the menu item for the power unit for which the error message

< appeared.

Switch to submenu Error memory. Here you can see the acknowledged
+

H
error messages again.

The error memory is deleted each time the ignition is switch off. As long
as the cause of error is not eliminated, the error message appears after
switching on the ignition and is again stored in the error memory after
acknowledging. In this way you can also note the error messages later if
you have switched off the ignition, e.g. to contact GROVE Product
Support.
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 Crane operation
12.3 Crane work with the main boom

12.3.9 Setting a constant engine speed

You can set a constant engine speed for the crane engine from the crane
å cab using the rocker switch Constant engine speed.

You can read off the current engine speed of the crane engine from the
@ Crane control display on the status display Display states while setting;
➠ p. 12-87.
• Use the gas pedal to reach the desired rpm.
• Press the rocker switch Constant engine speed once downward to set the
å Constant engine speed.
Now this rpm is set as the constant speed, and it will be maintained after
you remove your foot from the gas pedal.

If you wish to increase the constant engine speed, press the rocker switch
å constant engine speed upwards and hold it until you have reached ther desi-
red speed.

If you wish to increase the engine speed, depress the gas pedal.
The preset engine speed will increase. When you take your foot off the
gas pedal, the rpm will sink again to the preset speed.

• In order to turn off the constant engine speed, remove your foot from
å the pedal and press the rocker switch Constant engine speed once down-
ward.
The motor speed will drop idling speed, and you can regulate speed with
the gas pedal again.
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Operating Instructions GMK 5100 2 084 575 en 12 - 95

Crane operation
12.3 Crane work with the main boom

12.3.10 Critical load control

The truck crane is equipped (standard) with a critical load control. The
critical load control system ensures that the crane engine does not stall
when more hydraulic power is demanded of it. You do not have to take
over any steering tasks with the accelerator here.

The critical load control takes into account the available engine power at
the set crane engine speed. It reduces the performance of the hydraulic
pumps automatically, when the hydraulic power demanded is greater
than the power of the crane engine at the time (e.g. when another crane
movement is switched on).

If the hydraulic power demanded exceeds the engine power, the critical
load control system reduces the performance of all variable displacement
pumps, in the correct relationship to the degree of deflection of the
respective control levers. The relationship of the working speeds remains
identical. It is not necessary to correct the movements of the control
levers.

If overloading occurs, the critical load control system ensures that the you
do not have to adjust the working speeds of several simultaneous crane
movements using the control levers to stop the crane engine from stalling.

If the critical load control does not work faultlessly owing to a defect and
the crane engine stalls because of this, or if individual power units can no
longer be controlled, you can switch off the critical load control; ➠ Power

H
unit speeds/critical load control menu, p. 12-89.

The slewing gear is not influenced by the critical load control.

12.3.11 Incline crane cab (additional equipment)

In order to attain a more favourable sitting position while working at grea-

ter heights, you can incline the crane cab by up to 20° toward the rear.

G
Risk of accidents caused by falling objects in the crane cab!
Remove all loose objects (e.g. bags, bottles, etc.) from the crane cab so
that they cannot fall when inclining the crane cab. And close the door to
the crane cab before inclining.
11.05.2000

In this way you prevent fluids from reaching the plug-in modules, that the
crane cab door opens by itself, or that unwanted operating errors caused
by fright occur.

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 Crane operation
12.3 Crane work with the main boom

Inclining crane cab to the rear

• Close the crane cab door.

• Press the rocker switch Incline crane cab downward.
: The crane cab inclines rearward as long as you hold the rocker switch
down until the end position of 20°.

Incline the crane cab back to the horizontal

• Press the rocker switch Incline crane cab upward.

: The crane cab inclines forward as long as you hold the rocker switch
down until the horizontal end position.

12.3.12 Cooling the hydraulic oil

Standard The truck crane is equipped with a hydraulically driven oil cooler which is
oil cooler controlled via a thermostat. When the hydraulic oil reaches a temperature
of 55 °C (131 °F), the oil cooler is switched on.

During normal crane operation the temperature of the oil must not exceed
80 °C (176 °F).

• Monitor the Hydraulic system oil temperature status display during crane
operation.

If the hydraulic oil reaches a temperature of 80 °C (176 °F), you must stop
crane operation and allow the oil to cool down with the crane engine
running.

Additional The truck crane can be equipped with a second oil cooler as additional
oil cooler equipment.
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Operating Instructions GMK 5100 2 084 575 en 12 - 97

Crane operation
12.3 Crane work with the main boom

12.3.13 Movements which can be carried out simultaneously

All listed driving gears can be moved in all combinations, so:

– Main hoist
– Telescoping gear or derricking gear 1)
– Slewing gear
– Auxiliary hoist (additional equipment)
– Auxiliary drive gears (superstructure lock, incline crane cab or counter-
weight hoist unit) 2)

1)
Moving the derricking gear and the telescoping gear at the same time
is not possible because of the common control lever allocation.

2)
Moving the auxiliary drive gears in combination with other driving
gears can lead to speed loses. For this reason, you should only use
these combinations if it is absolutely necessary (for example, when
locking the superstructure, simultaneously moving the slewing gear

H
with the superstructure lock).

Some of the movement combinations which can be carried out simul-

taneously can reduce the speed in fast-speed mode.

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 Crane operation
12.4 Driving with a rigged crane

12.4 Driving with a rigged crane

This section describes moving the truck crane with an installed counter-
weight but without a rigged lattice extension.

G
Risk of accidents!
It is forbidden to move the truck crane with a load on the hook.
Put the load down before you move the truck crane.
Secure the hook block so that it cannot swing.

G
Risk of overturning!
Before a rigged crane can be driven the superstructure must be locked
and the slewing gear permanent brake must be engaged.

G
Risk of accident if the truck crane is not completely visible!
While driving the equipped truck crane, always stay in visual or radio con-
tact with a banksman who additionally observes the parts which you can-
not see (e.g. the raised boom when the superstructure is rotated to the
rear).
This prevent accidents resulting from collisions with persons, other con-
struction equipment, ledges of buildings, cables or other objects.

12.4.1 Driving route

The route must be a flat, even surface. The level adjustment system can-
not compensate for uneven surfaces. If the surface pressure of the tyres
exceeds the permissible load on the ground, the surface pressure must be
increased using packing made of durable material (e.g. wooden planks).

S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ p. 6-12.
Do not reduce the tyre pressure!
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Operating Instructions GMK 5100 2 084 575 en 12 - 99

Crane operation
12.4 Driving with a rigged crane

12.4.2 Position of the boom

The vehicle may only be moved if certain conditions are met. The boom
may have to be moved to a specified position, depending on the installed
counterweight.

S
Damage may occur to the axle lines!
Always move the boom to the prescribed position before you move the
rigged truck crane. The permitted load on the axle lines will be exceeded
if the boom is in a position which deviates from the prescribed position.

• Set the appropriate SLI code for the rigging mode on the safe load indi-
11== cator. The SLI codes are found in the Lifting capacity table.
• Move the boom into the prescribed position. The prescribed boom posi-

H
tion is found in the following table.

If the SLI shuts down the lowering of the boom before the boom has
reached the prescribed position, you must adjust on the SLI the current
SLI rigging code for the actual rigging mode of the truck crane according
to the Lifting capacity table.

G
Risk of accidents if SLI is overridden!
Always set the SLI rigging code when you want to lower the partially
extended main boom below an angle permitted in the operating area.
Do not override the SLI; if the SLI is overridden, the truck crane works
without overload protection!

H
Boom
positions

You will find the table with the prescribed boom positions for driving with
a rigged truck crane with mounted lattice extension in the sections Driving
with rigged crane and rigged lattice extension or rigged boom extension;
➠ Operating instructions for lattice extension.
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 Crane operation
12.4 Driving with a rigged crane

Boom positions without lattice extension:

Counter- Telescope status Boom Boom Axle load2) in lbs

weight (Tel I/II/III/IV) angle in position1) front rear
in t °

0 front 23 150 19 840

1.0 0/0/0/0
80 rear 20 940 23 150

0 front 20 940 28 660

7.0 0/0/0/0
80 rear 24 250 24 250

0.5 / 0 / 0 / 0 0 front 27 560 25 350

11.0
0/0/0/0 80 rear 27 560 24 250

0.5 / 0.5 / 0 / 0 15 front 27 560 34 170

20.0
0/0/0/0 70 rear 30 860 28 660

0.5 / 0.5 / 0.5 / 0 16 front 29 760

24.0
0/0/0/0 60 rear 31 970 33 070

1.0 / 0.5 / 0.5 / 0.5 15 front 36 380 34 170

31.0
0/0/0/0 55 rear 35 270 35 270

1)
Boom position at rear = 0° position, boom over
truck crane rear edge
Boom position at front = 180° position, boom over
driver’s cab
2)
Axle load front: on 1st to 3rd axle lines
rear: on 4th and 5th axle lines

H The axle loads specified refer to a driving mode with the basic unit inclu-
ding the 50 t (110 200 lbs) hook block.
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Operating Instructions GMK 5100 2 084 575 en 12 - 101

Crane operation
12.4 Driving with a rigged crane

12.4.3 Driving the rigged truck crane

Locking the Before the truck crane is moved, the superstructure must be locked to the
superstructure carrier; ➠ Mechanical superstructure lock, p. 12-9.
and engaging the
slewing gear
permanent brake
• Lock the superstructure; the indicator lamp Superstructure locked must
! illuminate.
• Apply the slewing gear permanent brake and hence switch off the
Y slewing gear Slewing function to prevent inadvertent operation.
To do this, push down the Slewing gear permanent brake rocker switch.
The Slewing gear permanent brake indicator lamp lights up when the

H
slewing gear permanent brake is applied.

If the crane engine stops the slewing gear permanent brake is auto-
matically applied.

Retracting the • Retract the outrigger cylinders until the wheels are just above the ground.

G
outriggers
Risk of overturning!
Take care that the truck crane does not overturn when the outriggers are
being retracted!
Retract all the outrigger cylinders as uniformly as possible!

Switching over
the suspension
locking system
• Switch the suspension locking system off. Push up the Suspension locking
u system rocker switch. The Suspension locking system indicator lamp must
go out.
• Retract the outrigger cylinders until the truck crane is approximately at
on-the-road level.
• Activate the suspension locking system again. To do this push down
u the Suspension locking system rocker switch. The Suspension locking system
indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.

G
Risk of overturning!
To reduce the risk of the crane overturning do not raise the outrigger pads
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more than 2 to 4 inch off the ground. Leave the outrigger beams extended.

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 Crane operation
12.4 Driving with a rigged crane

Switching on se- Before driving with the rigged crane you must switch on separate steering:
parate steering

• Switch on the Level adjustment system key switch.

C0018

• Switch on separate steering by releasing the Separate steering rocker

a switch and pressing it down.

S
Damage may occur to steering linkage!
Before driving with the rigged crane always switch on separate steering
and steer the truck crane only when the vehicle is moving.
If separate steering is switched off or if you steer with the vehicle stationa-
ry the steering linkage may become damaged.

Driving

S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ p. 6-12.
Do not reduce the tyre pressure!

S
Damage may occur to steering linkage!
Steer only when the vehicle is moving. The steering linkage can be dama-
ged if the steering is turned when the vehicle is stationary.

H The wind speed must be checked before the rigged truck crane is moved!
The same maximum permissible wind speeds apply as when working
with the crane; ➠ Effect of wind on crane operation, p. 12-36.

• Select a low gear on the transmission. ➠ Select driving direction and star-
ting gear, p. 6-27.
• Drive at only a very low speed!
• The turning radius should be as large as possible when turning corners!
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Operating Instructions GMK 5100 2 084 575 en 12 - 103
Crane operation
12.4 Driving with a rigged crane

• Steer the truck crane only when it is moving and avoid sudden steering
movements!
When the surface is uneven the truck crane must be raised with the outrig-
ger cylinders, horizontally aligned and then re-lowered; ➠ Retracting out-
riggers, p. 12-102 and Switching over suspension locking system, p. 12-102.

Extending the The truck crane must be on outriggers before beginning work with the
outriggers crane; ➠ Outriggers, p. 13-13.

G
Risk of overturning!
The truck crane must be raised until no wheels touch the ground!

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 Crane operation
12.5 Work break

12.5 Work break

12.5.1 Short work break

G
Risk of accidents when the load is suspended!
Never leave the crane cab while a load is suspended on the hook block.
Never turn the crane engine off while a load is suspended on the hook.
Always keep your hand close to the control levers while a load is suspen-
ded on the hook so that you are able to react correspondingly at all times.
Always put down the load before you stop work!

• Lock the slewing gear permanent brake by pushing down the Slewing
Y gear permanent brake rocker switch.
• Switch the crane engine off, turn the ignition key to the 0 position and
remove it.
• Ensure that no unauthorized persons can operate the truck crane.

12.5.2 Work breaks lasting more than 8 hours

• Retract all telescope sections.

• Lower the boom onto the boom support.
• Lock the slewing gear permanent brake by pushing down the Slewing
Y gear permanent brake rocker switch.
• Switch the crane engine off, turn the ignition key to the 0 position and
remove the ignition key.
• Switch off all current consumers.
• Switch off the main battery switch.

H You may switch off the battery master switch even if the heater is still
running down. This does not interrupt the run-down period of the heater.

• Ensure that no unauthorized persons can operate the truck crane.

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Operating Instructions GMK 5100 2 084 575 en 12 - 105

Crane operation
12.6 Crane cab heating and ventilation

12.6 Crane cab heating and ventilation

12.6.1 Heating the crane cab

A heat exchanger provides warmth for the crane cab using heat from the
engine coolant. Suction air for the heating system can be fresh air, recir-
culated air or mixed air with any desired amount of fresh air.

The suction air for the heating system is set

with the regulator Recirculated air / fresh air
mode (3):
Fresh air mode: regulator downward
Recirculated air: regulator upward
Mixed air: regulator in the inter-
mediate position
The air distribution in the crane cab is set
with the regulator Air distribution front
windshield / cab floor (2):
To the windscreen: regulator upward
To the cab floor: regulator downward
All nozzles: regulator in the
middle

The infinitely variable Temperature regulator (4) is used to set the desired
hot air temperature.
Cooler: Regulator upward
Warmer: Regulator downward
The knob Heater fan (1) is used to activate the fan.
The fan has the settings 0 (off), 1, 2 and 3 (maximum output).

S
In recirculated air mode, the heating system sucks in air through the black
grille below, behind the crane operator’s seat. Never cover the grille,
e.g. with items of clothing or bags!
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 Crane operation
12.6 Crane cab heating and ventilation

12.6.2 Additional water heating system (additional equipment)

The engine-independent additional water heating system heats up the

crane engine’s coolant. The heat is generated by burning fuel from the
tank in the superstructure. The heating system is operated by onboard
electrics in the superstructure. The additional heating system may be
operated when the engine is stationary or running.

In the case of a stationary and cold engine, this can be preheated using
the additional heating system. The heating pump circulates the coolant
within the engine. The Temperature regulator in the crane operator’s cab
should be set up to the setting “Cold”.
If you set the regulator Temperature to “Warm” and turn on the fan as
described in section Heating the crane cab, p. 12-106, the crane cab will

H
heated at the same time.

If you operate the additional heating system while the crane engine is
switched off, the batteries will run down. The batteries must then be
recharged after shorter periods of time!

When the engine is running, the additional heating system supports the
preheating of the engine until the engine operating temperature is
reached.
The heat supply will be interrupted when the engine operating tempe-
rature is reached. The heating pump continues to run until, using the

H
rocker switch, the additional heating system is switched off.

When the engine operating temperature is reached, the additional heating

system should be switched off to prevent uncontrolled starting when the
engine temperature drops.

Switching on the
additional
heating system
To activate push down the Additional heating system rocker switch. The indi-
0 cator lamp in the rocker switch illuminates.

After a preheating period of approx. 15 seconds, automatic ignition takes

place. If the heating system does not trigger after 30 seconds, ignition is

H
aborted.

The indicator lamp in the rocker switch merely indicates that the switch has
been operated and that the heating system has been switched on or off.
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It does not indicate whether the heating system has been triggered.

Operating Instructions GMK 5100 2 084 575 en 12 - 107

Crane operation
12.6 Crane cab heating and ventilation

The heating system has ignited if:

– the air flowing from the fan vents is warming up (cab heating system) or
– the engine temperature rises (preheating the crane engine).

Once the heating system has triggered, a thermostat in the heater takes

H
over control of the heating system.

If a malfunction of approx. 10 seconds occurs while the heating is on, the

heating system will automatically shut down.

If you wish to restart the heating system, you must turn off the Additional
0 heating system rocker switch and turn it back on again.

Switching off the

additional
heating system
• To deactivate push up the Additional heating system rocker switch.
0 The indicator lamp goes out.
The heating pump will continue to run for approx. 3 minutes to cool

H
down the heater.

Turning off the battery master switch while the heater is cooling down
will not interrupt the cooling of the heater.

12.6.3 Additional heating system with timer (additional equipment)

The additional heating system with timer is operated in the same way as
the carrier; ➠ p. 6-64.

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 Crane operation
12.6 Crane cab heating and ventilation

12.6.4 Ventilating the crane cab

• Push the regulator Temperature (4) as far

upward as possible (cold position).
• Push the regulator Recirculated air / fresh air
mode (3) as far upward as possible (fresh
air position).
• Push the regulator Air distribution wind-
screen / cab floor (2) to the central position
(all nozzles).
• Switch the heater fan knob (1) to level 3.

Various windows in the crane cab can also be opened for ventilation;
➠ Doors, keys, windows, p. 10-56.
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Operating Instructions GMK 5100 2 084 575 en 12 - 109

Crane operation
12.7 Air-conditioning system (additional equipment)

12.7 Air-conditioning system (additional equipment)

The air-conditioning system is installed behind the crane operator’s seat.
It only works in recirculated air mode. The refrigerating agent compressor

H
is driven by the crane engine.

The air-conditioning system sucks the cabin air in through grilles.

Therefore do not cover the grilles with bags or items of clothing.

Notes for air conditioning the crane cab can be found in the section
Air conditioning, p. 12-111.

12.7.1 Switching on

• Turn the Fan knob to level 1, 2 or 3, depending on the output desired.

• Set the desired temperature with the Thermostat knob switch.

• Adjust the air outlet jets so that the cool air is mixed well with the cabin
air.

12.7.2 Switching off

• Turn the knob Fan to the 0 position.

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 Crane operation
12.7 Air-conditioning system (additional equipment)

• Turn the Thermostat knob to the left as far as possible.

12.7.3 Air conditioning

How to ensure Avoid excessive cooling of the air in the cab.

pleasant air- For example, with an outside temperature of 104 °F the temperature insi-
conditioning de the cab should lie between 79 °F and 86 °F; in other words, the diffe-
rence in temperature should not exceed 18 °F to 25 °F. When the outside
temperature is lower, you should select a correspondingly lower tempera-
ture difference. Excessive cooling frequently results in physical discom-
fort, usually only after you have left the cab.

Avoid exposing your body directly to cold air. Direct the air stream from
the nozzles in the cab floor so that the cold air mixes thoroughly with the
warm air in the cab. This produces an even temperature throughout the
cab and ensures cooling without a draught.

In the mixed air mode, operate the air-conditioning system with a low
proportion of fresh air in order to dehumidify the driver’s cab, while at the
same time ensuring a fresh supply of oxygen.

Keep adjusting the cooling system as needed. Initially, if the truck

crane has e.g. been parked in strong sunlight for a long time, the cooling
system should be operated at maximum cooling capacity and with the fan
on setting 3 with the crane engine running.
The crane cab door or at least the windows should be left open for a short
while to air thoroughly.
The process can be accelerated by increasing the engine speed of the
crane engine.

If you then continue to run the air conditioner, close the windows and
other air vents to ensure that the crane cab can be cooled adequately.

Once the desired inside temperature has been reached, set the fan to
level 2 again and reduce the cooling output with the knob Thermostat
accordingly. If only a low level of cooling is required, fan level 1 will
be sufficient.
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Operating Instructions GMK 5100 2 084 575 en 12 - 111
Crane operation
12.7 Air-conditioning system (additional equipment)

Dehumidifying On humid days at the turn of the season you can dehumidify the air in the
crane cab air driver’s cab by operating the air-conditioning system in a combined
heating and cooling mode. Operation of the heating system is described

H
in section Crane cab heating and ventilation, p. 12-106.

As this involves the heating and air-conditioning system functioning

“in opposition to each other”, dehumidifying produces little or no heat.

• Set the Temperature regulator of the crane cab heating system and the
Thermostat knob on the air-conditioning system to approximately the
same output.

H
• Switch on the fan.

The higher the level of heating and cooling selected the more efficiently
cab air becomes dehumidified.

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 Rigging work
13.1 Check lists for rigging work for crane operation with main boom

13 Rigging work
Once you have reached the site, you must carry out numerous rigging
tasks before you can begin crane work. Follow the instructions contained
in this check list!

If the truck crane has already been rigged on the site, proceed according
to the CHECKLIST: With rigged truck crane, p. 12-1.

13.1 Check lists for rigging work for crane operation with

H
main boom

This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

13.1.1 CHECKLIST: Rigging

1. Choose a suitable site; ➠ p. 13-6

2. Check whether the parking brake is locked (parking brake lever points
toward the rear).

C0027

3. Lower the truck crane as far as possible and align horizontally using the
level adjustment system; Switch on level adjustment system; ➠ p. 6-50.

4. Activate the suspension locking system; ➠ p. 13-19.

u
5. Support truck crane and align horizontally; ➠ CHECKLIST: Extending
the outrigger, p. 13-13.
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Operating Instructions GMK 5100 2 084 575 en 13 - 1
Rigging work
13.1 Check lists for rigging work for crane operation with main boom

6. Inspect the truck crane looking out in particular for any escaping fluids
(oil, fuel or water).

7. Check the position of the hoist ropes; ➠ p. 12-12.

8. Starting the crane engine; ➠ CHECK LIST: Starting the crane engine,
p. 11-1.

9. Releasing the superstructure lock; ➠ p. 12-9.

¥
10. Pick up hook block
– from accompanying vehicle; ➠ p. 13-71,
– from the stop rod; ➠ p. 13-69.

11. Install the lifting limit switch, connect and check whether the locking
has been cancelled; ➠ Lifting limit switch on the main boom – installing
the lifting limit switch, p. 13-77.

12. Attach lifting limit switch weight and fasten to hoist rope;
➠ Lifting limit switch on the main boom - lifting limit switch weight, p. 13-79.
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 Rigging work
13.1 Check lists for rigging work for crane operation with main boom

13. Mount the anemometer (additional equipment); ➠ p. 13-84.

14. Rig the counterweight version according to the Lifting capacity table;
➠ CHECK LIST: Rigging the counterweight, p. 13-46.

15. Adjusting the mirrors; ➠ p. 12-12.

16. Set the SLI code specified in the Lifting capacity table for the respective
00== rigging mode on the SLI. If the rigging mode was entered for indivi-
dual components: compare the displayed rigging mode with the
actual one; ➠ p. 12-20.

17. Set the number of reeved ropes on the SLI; ➠ p. 12-20.

2 n=
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Operating Instructions GMK 5100 2 084 575 en 13 - 3

Rigging work
13.1 Check lists for rigging work for crane operation with main boom

13.1.2 CHECKLIST: Unrigging

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Unrigging the counterweight; ➠ CHECK LIST: Unrigging the counter-

weight, p. 13-48.

2. Depending on the transportation of the hook block place this

– on a separate vehicle; ➠ p. 13-71
– attach to the bumper; ➠ p. 13-69.

3. Turn the boom in the direction of driving.

4. Lock the superstructure.

!
5. Retract and set down boom.
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 Rigging work
13.1 Check lists for rigging work for crane operation with main boom

6. All telescope sections are locked and the telescoping cylinder is

locked for on-road driving with telescope section I; ➠ Locking telescope
section, p. 12-78.
– 0 – 0
HALF
TELE: – –

7. Switch off the crane engine; ➠ Crane engine, p. 11-15.

8. Switch off the battery master switch when the truck crane is no longer
being used; ➠ Switch on battery master switch, p. 11-7.

9. Remove the anemometer; ➠ p. 13-84.

10. Retract the outrigger; ➠ CHECKLIST : Retracting outrigger, p. 13-15.

11. Switch off the suspension locking system; ➠ Check the suspension, p. 6-9.
u
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Operating Instructions GMK 5100 2 084 575 en 13 - 5

Rigging work
13.2 Choosing a suitable site

13.2 Choosing a suitable site

The stability of the truck crane primarily depends on the condition of the
ground at the site. Please read the following section Load bearing capacity of
the ground and the outrigger carefully.

Use the Outrigger pressure table to determine the pressure that will be
applied to the ground by the outrigger pads for the intended work with
the crane.

Examine the actual load bearing capacity of the ground on the site. If
necessary, enlarge the surface area of the outrigger pads using suitable
packing material (➠ Enlarging the outrigger surface area, p. 13-8 in this
section). The permissible pressure on the ground under the outrigger
must not be exceeded.

The outrigger cylinders can only be used to compensate for a specific off-
road angle. It is therefore necessary to note the structure of the terrain.
Maximum possible levelling by lifting with outrigger cylinders;
➠ Technical data - supporting equipment, p. 15-19.
When choosing a site, ensure that there is sufficient distance between the
truck crane and banks, pits and electrical lines.
Refer to section Safe distance to banks and pits, p. 13-9, and section Safe
distance to electrical lines, p. 13-9.

13.2.1 Load bearing capacity of the ground and the outrigger

Choose the on-site location for your truck crane with care. In particular,
ensure that the ground can withstand the resulting outrigger pressure.
Choose a location that will facilitate the smallest possible radius and
ensure that no obstacles are within the slewing range of the crane.

Always extend all four outrigger beams to the width specified in the lifting
capacity table. Never move the superstructure out of transport position
without first locking the suspension and supporting the truck crane.

The outrigger pads transmit the supporting force to the ground. If the sur-
face pressure of the outrigger pads exceeds the permissible load bearing
capacity of the ground, you must enlarge the surface area of the outrigger
with packing made of durable material (e. g. wooden planks or steel
plates) (➠ Enlarging the surface area of the outrigger, p. 13-8 in this section).
Arrange the packing under each outrigger so that the outrigger pad
touches down in the centre of the outrigger surface area.
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 Rigging work
13.2 Choosing a suitable site

The required surface area is calculated using the outrigger pressure and
the load bearing capacity of the ground.
The outrigger pressure for the intended use of the crane may be found in
the outrigger pressure table. Maximum outrigger pressure and size of the
outrigger pad; ➠ Technical data - supporting equipment, p. 8-11.
The following table contains approximate values for the load bearing

H
capacity of the ground.

Have the ground tested (e.g. using a ram probe) if you are unsure of the
load bearing capacity of the ground at the site.

Load bearing
APPROXIMATE VALUES FOR THE LOAD BEARING capacity
CAPACITY OF THE GROUND (lbs/ft2)

Backfilled ground, not artificially compacted ground: 0 to 2 050

Vegetated, apparently untouched soil:

Mud, peat, marsh 0

Non-cohesive ground which fine to 3 070

is sufficiently firm: medium sand

coarse sand to 5 000

gravel

Cohesive ground: mushy 0

soft 820

stiff 2 050

semi-solid 5 000

hard 8 200

Rock with minimal fissures in in closed 30 700

sound, unweathered condi- succession of
tion and with favourable beds
strata:
massive or 61 400
columnar
formation

Calculate the required supporting surface area:

outriggerpressure (lbs)
surface area (ft 2 ) =
 lbs 
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loadbearing capacity of the ground  2 

 ft 

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Operating Instructions GMK 5100 2 084 575 en 13 - 7
Rigging work
13.2 Choosing a suitable site

Always align the packing horizontally. Always align the truck crane
horizontally with the outrigger cylinders.

G
Risk of overturning when substructure or truck crane is at an angle!
Align the packing horizontally and align the truck crane horizontally with
the outrigger cylinders. In this way you prevent the outrigger pads slip-
ping from the angled substructure or the truck crane from having an unfa-
vourable centre of gravity owing to an incline and overturning when sub-
ject to a load.

Enlarging the Only use durable materials for the packing, such as
surface area of
the outrigger
– thick wooden planks or square timber made of hardwood (such as
bongossi, etc.)
– thick steel plates with soldered webs that prevent the outrigger pads
from slipping or
– wide steel profiles soldered together (girders) with soldered webs to
prevent the outrigger pads from slipping.

G
Accidents may occur if the crane overturns due to weak packing!
Thin boards or planks made of pine wood or bricks are not made to
withstand the resulting pressure and divert it into the ground.

Wooden planks and square timber must be at least 80 mm high.

They must be knotless and free of fractures.

Please note the illustration to the left when

constructing the packing.

The materials used must have the same

height in every layer.

The layers must be offset from the following

layer by 90°.

Consult your supervisor if you are in doubt.

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 Rigging work
13.2 Choosing a suitable site

13.2.2 Safe distance from banks and pits

Set the crane a safe distance away from banks and pits. The distance also
depends on the type of soil, if the banks and pits are not supported.

As a rule of thumb:

If the soil is loose or backfilled, the distance

(a) must be twice as large as the depth of the
pit (b).

a=2xb

If the soil is vegetated or not loose, the

distance (a) must be as large as the depth of
the pit (b).

a=1xb

The safe distance is measured from the base

of the pit (c).

13.2.3 Safe distance from electrical lines

B
This truck crane is not insulated. Contact between overhead power lines
and the boom, the hoist rope, the lifting tackle, the load itself or the guide
lines can result in serious, possibly fatal injuries.
Have the current in the power lines switched off or keep the truck crane,
its equipment, lifting tackles and the load a safe distance of at least 20 ft
away from power lines and their associated equipment.

• Contact the responsible electrical utility and have them switch off the
current.
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Operating Instructions GMK 5100 2 084 575 en 13 - 9
Rigging work
13.2 Choosing a suitable site

If it is not possible to switch off the current:

Risk of accidents due to electrical shock!

B
This truck crane is not insulated. Contact between overhead power lines
and the boom, the hoist rope, the lifting tackle, the load itself or the guide
lines can result in serious, possibly fatal injuries.
Keep the truck crane, its attachments, lifting tackles and the load at a safe
distance of at least 20 ft away from the power lines and their associated
equipment.

H
The US Department of Labor “Occupational Safety and Health Administra-
tion” (OSHA) forbids working with the crane within a distance of less than
10 ft when sources of voltage up to 50 000 volts are involved; higher volta-
ges require a greater distance. The manufacturer recommends a mini-
mum safe distance of 20 ft.

20 ft

20 ft

20 ft

20 ft

20 ft
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 Rigging work
13.2 Choosing a suitable site

• If it is not possible to switch off the current, always maintain a mini-

mum safe distance with the truck crane, its attachments, lifting tackle,
the load and the guide lines.
• Set up an obstacle at the minimum safe distance which keeps the truck
crane and its attachments away from the power line. The obstacle must
be erected so that the effect of wind on the cable is taken into account.
• In addition, block off the area determined by the minimum
safe distance around the truck crane (safety area).
• One signal man, more than one if necessary, must monitor compliance
to the minimum safe distance and warn the crane driver immediately if
it is necessary to stop crane movements. The signal man and crane ope-
rator must be in communication via radio.
• The signal man must also ensure that nobody is present in the
safety area when work is being carried out near power lines.

If the crane should come into contact with the cable despite all precauti-
ons:
• Keep calm!
• Do not jump down from the crane and do not leave the crane cab!
• Inform the signal man so that he can ensure that nobody enters the
safety area that has been cordoned off.
• Move the truck crane out of the danger zone by moving it normally!
• Inform the appropriate GROVE Product Support unit of the incident and
have the truck crane inspected for possible damage.
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Operating Instructions GMK 5100 2 084 575 en 13 - 11

Rigging work
13.2 Choosing a suitable site

13.2.4 Earthing the truck crane

B
Risk of accidents due to electrical shock!
Earth the truck crane before operation
– near strong transmitters (radio/television transmitters, radio stations, etc.),
– near high-frequency switchgears,
– in potentially stormy weather.

The truck crane can become electrostatically charged. This applies in

particular if the truck crane is equipped with synthetic outrigger pads or
the outrigger pads are packed with insulated material (e.g. wooden
planks).

Earthing the To prevent the electrostatic charging of the truck crane, you will need:
truck crane
– an electrically conductive metal rod inserted in the ground
(approx. 5 ft in length),
– an electrically conductive cable (minimum cross section 0:16 inch2),
– a screw clamp for welding work.

B
Risk of accidents due to electrical shock!
Ensure that the connection between the truck crane and the ground is a
faultless, electrically conductive connection!

• Connect one end of the cable to the metal rod that is to be inserted into
the ground. Hammer the metal rod at least 3.3 ft into the ground.
Moisten the soil around the metal rod for better conductivity.

B
Risk of accidents due to electrical shock!
Fasten the screw clamp for welding work on soldered parts of the main
boom or the superstructure only. Do not fasten the clamp to screwed on
parts such as valves, cover plates, engines, gear units, etc.!

• Connect the other end of the cable to the screw clamp for welding work
and fasten the clamp to the main boom or the superstructure.
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 Rigging work
13.3 Outrigger

13.3 Outrigger

G
Risk of crushing due to extended outrigger!
You may actuate the outriggers only if you yourself or a banksman with
whom you are in visual contact have an unobstructed view of their
movements.

13.3.1 CHECKLIST: Extending the outriggers

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Align the truck crane horizontally with the level adjustment system;
➠ Preparing the truck crane for outrigger, p. 13-19.

2. Activate the suspension locking system; ➠ p. 13-19.

u
3. Pull all four locking pins; ➠ Safety during crane operation - releasing out-
rigger; p. 13-20.

4. Move the outrigger pads into working position and lock them into
place; ➠ p. 13-28.

5. Extend all outrigger beams to the necessary width of the desired

outrigger span;
➠ Outrigger span, p. 13-17,
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➠ Extending the outrigger beams, p. 13-23.

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Operating Instructions GMK 5100 2 084 575 en 13 - 13
Rigging work
13.3 Outrigger

6. Secure all outrigger beams against independent extension with the

locking pins; ➠ Safety for on-road driving, p. 13-20.

7. Enlarge the surface area of the outrigger if necessary; ➠ p. 13-8.

8. Extend outrigger cylinders until no wheels are touching the ground;

➠ p. 13-30.

9. Align the truck crane horizontally with the outrigger; ➠ p. 13-36.

G
The truck crane may overturn if improperly supported!
When working with the crane
– Extend the outrigger beams only to the permitted spans of 8.2 ft,
16.7 ft, or 24.6 ft;
– Secure the outrigger beam with locking pins;
– Enlarge the surface area of the outrigger if necessary;
– Raise truck crane until no wheels are touching the ground;
– Align the truck crane horizontally.

10. Before operating the crane, remove the ignition key from the driver’s
cabin and lock the driver’s cabin to prevent unauthorized use.
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 Rigging work
13.4 CHECKLIST: Retracting outrigger

H
13.4 CHECKLIST: Retracting outrigger

This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Depending on the transportation of the hook block place this

– on a separate vehicle; ➠ p. 13-71.
– attach to the bumper; ➠ p. 13-69.

2. Retract the outrigger cylinders completely; ➠ p. 13-32.

3. Pull all locking pins and, if necessary, insert them in the holdings;➠
Safety during crane operation - releasing outrigger; p. 13-20.

4. Retract outrigger beam; ➠ p. 13-26.

5. Secure all outrigger beams against independent extension with the

locking pins / safety hoops; ➠ Safety for on-road driving, p. 13-20.
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Operating Instructions GMK 5100 2 084 575 en 13 - 15
Rigging work
13.4 CHECKLIST: Retracting outrigger

6. Move the outrigger pads into driving position and lock them into
place; ➠ p. 13-29.

7. Store the packing securely on the truck crane or on a separate vehicle.

G
Accidents may occur during on-road driving!
For on-road driving
– all outrigger beams and cylinders must be completely retracted,
– all outrigger pads must be retracted and secured and
– all outrigger beams must be secured with the pins.
The outrigger must not protrude from the outer limits of the vehicle.

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 Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.1 Outrigger span

You can set various outrigger spans with the outrigger. The outrigger
spans are given in feet x feet (e. g. 25.6 x 24.6 ft). The first value stands for
the outrigger length between the front and rear outrigger beams. It is
always 25.6 ft for the GMK 5100 truck crane.
The second value indicates the necessary width to which you must extend
the outrigger beams. The widths for the following outrigger spans are
permissible:
– Outrigger span 25.6 x 24.6 ft
– Outrigger span 25.6 x 16.7 ft
– Outrigger span 25.6 x 8.2 ft
The prescribed width can be found in the lifting capacity table. An outrigger
cylinder is mounted to the end of every outrigger beam. The outrigger
cylinders are used to raise, lower and horizontally align the truck crane.

G
The truck crane may overturn if it is not properly supported!
Before the superstructure can be slewed, the truck crane must be
supported on all four outriggers with extended outrigger beams and the
outrigger beams must be secured against independent extension with the
locking pins! The wheels must not touch the ground!

Outrigger span Front span 24.6 ft

25.6 x 24.6 ft Rear span 24.6 ft
25.6 ft

Display on the SLI

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Operating Instructions GMK 5100 2 084 575 en 13 - 17
Rigging work
13.4 CHECKLIST: Retracting outrigger

Outrigger span Front span 16.7 ft

25.6 x 16.7 ft Rear span 16.7 ft

25.6 ft
Display on the SLI

Outrigger span Front span 8.2 ft

25.6 x 8.2 ft Rear span 8.2 ft
25.6 ft

Display on the SLI

Risk of overturning during slewing with a rigged outrigger span of

G
2.6 x 8.2 ft!
At this outrigger span, the superstructure may only be slewed if 1 t coun-
terweight version (at the most) has been rigged. Slewing with heavier
11.05.2000

counterweight versions will lead to truck crane tipping over.

13 - 18 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

Before supporting the truck crane it should be aligned horizontally and

lowered as far as possible.

• Align the truck crane horizontally in longitudinal and lateral directions

using the level adjustment system; ➠ Switch on level adjustment system,

H
p. 6-37.

If the truck crane is situated on a low level, the distance of the outrigger
pads to the ground is small. If necessary, uniformly lift the truck crane
with the level adjustment system if you have to pack the outrigger pad or,
owing to the condition of the terrain, you extend a support against a hill.

Locking the The suspension must be locked in all axle lines when the truck crane is
suspension supported.

• Press down the Suspension locking system rocker switch in the driver’s cab
u to lock the suspension. The indicator lamp lights up when the sus-
pension is locked.
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Operating Instructions GMK 5100 2 084 575 en 13 - 19
Rigging work
13.4 CHECKLIST: Retracting outrigger

Safety for on- All four outrigger beams must be secured with locking pins/safety hoops
road driving for on-road driving.

• Retract all four outrigger beams com-

pletely.
• Insert the locking pins (1) on all four out-
rigger beams in the bores in the outrigger
beam box and the outrigger beam.
• Turn the locking pins so that it can not
come out (handle must point down).
• Secure all inner and outer outrigger beams
one beneath the other with the safety
hoops (2).

G
Risk of accidents if outrigger beams slip out!
Always secure all of the outrigger beams with the locking pins and safety
hoops for on-road driving. This prevents the outrigger beams from falling
out while driving around corners, which could cause serious accidents.

Safety during During crane operation, the outrigger beams must be secured with a pin
crane operation at all outrigger spans.
– Supporting span 25.6 x 24.6 ft with 2 locking pins
– Supporting span 25.6 x 16.7 ft with 1 locking pin and safety hoop
– Supporting span 25.6 x 8.2 ft with 1 locking pin and safety hoop
To extend and retract, the outrigger beams must be released.

S
Risk of accidents if outrigger beams are not secured!
The outrigger beams may move on their own due to the changing load
conditions when working with the crane. Secure the outrigger beams
against this by inserting locking pins into all four beams.

H The locking pins always have to be inserted in the same place at all the
outrigger spans at the outrigger housing.
For the 25.6 x 24.6 outrigger span, the outrigger beams are additionally
secured one beneath the other by further locking pins.
On the right side, the locking pins are inserted from the front; on the left
side, the locking pins are inserted from the rear.
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 Rigging work
13.4 CHECKLIST: Retracting outrigger

Securing the outrigger beams

• Insert the locking pin (1) for all spans in the
bores in the outrigger beam box and ou-
trigger beam.
• Turn the locking pins so that it can not
come out (handle must point down).

For the 25.6 x 24.6 outrigger span, the inner

and outer outrigger beams are secured with
an additional locking pin, one beneath the
other.

• Remove the locking pin (2) from the holder

(1) and insert it through the bore and the
outrigger beam.
• Turn the locking pins so that it can not
come out (handle must point down).

The outrigger beam is now secured against independent extension.

• Also secure the other outrigger beams.

H The safety hoop also remains inserted for the 8.2 ft and 16.7 ft spans.
➠ p. 13-25.
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Operating Instructions GMK 5100 2 084 575 en 13 - 21
Rigging work
13.4 CHECKLIST: Retracting outrigger

Releasing the outrigger beams

• Rotate the locking pin (1) to a position at

which you can pull it out (handle must be
pointed to the side).
• Pull the locking pin out of the bores (2) in
the outrigger beam box and the outrigger
beam.

For the 25.6 x 24.6 ft outrigger span you also

have to release the locking pins for the inner
and outer outrigger beams.

• Rotate the locking pin (1) to a position at

which you can pull it out (handle must be
pointed to the carrier).
• Remove the locking pin from the bores (2)
on the outrigger beam and insert them in
the holders (1).

This outrigger beam is now released and can be extended or retracted.

• Also release the other outrigger beams.

H The safety hoop also remains inserted for the 8.2 ft and 16.7 ft spans.
➠ p. 13-25.
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 Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.2 Extending / retracting the outrigger beams

Extending the The outrigger beams can be extended/retracted individually or in pairs.

outrigger beams The outrigger beams of one side of the vehicle can be actuated only by
means of the control box on the same side of the vehicle.

The control box for outrigger actuation (1) is

located on both sides of the carrier, behind
the steps.

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

S
The truck crane may overturn if improperly supported!
Always extend the outrigger beams only to the span of a permitted out-
rigger span (24.6 ft, 167 ft) or retract them completely (8.2 ft.) and secure
the outrigger beams against independent retraction with the locking pin
provided that it is possible.

H Before you can extend the outrigger beams, you must release them;
➠ Securing / releasing the outrigger beams, p. 13-20.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 13 - 23
Rigging work
13.4 CHECKLIST: Retracting outrigger

• Press up the Preselection of direction of outrigger movement toggle switch.

C0120

• Press up the Preselection of outrigger cylinder / outrigger beam toggle switch.

C0121

Two speeds are available for extending the outrigger beams:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.
Slow outrigger movements:
C0119

• Press the Outrigger central toggle switch upward. The diesel engine
continues to run at idling speed.

• In addition, press the toggle switch for the desired outrigger beam
(e.g. front right).
• Extend all four outrigger beams to the necessary width of the desired
outrigger span; ➠ Outrigger span, p. 13-17.

H
C0122

You may also retract or extend the outrigger beams in pairs on the side
where you are positioned by pressing two respective toggle switches
simultaneously (e.g. the two toggle switches for front right and rear right).
11.05.2000

13 - 24 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

Outrigger span 25.6 x 24.6 ft

For the 24.6 ft span, the safety hoops are to
be removed and the outrigger beams fully
extended to the marking (3).

The locking pins (1) can be completely inser-

ted in the bores in the outrigger housing and
the outrigger beams. The locking pins (2) can
be completely inserted in the bores in the in-
ner and outer outrigger beams.

25.6 x 16.7 ft span

For the 16.7ft span, the support beams are
connected with the safety hoop (2) and are
extended to the marking (3).

The locking pins (1) can be completely inser-

ted in the bores in the outrigger housing and
the outrigger beams.

25.6 x 8.2 ft span

For the 8.2 ft span, the outrigger beams are
to be fully retracted and can be connected
with the safety hoop (2).

The locking pins (1) can be completely inser-

ted in the bores in the outrigger housing and
the outrigger beams.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 13 - 25
Rigging work
13.4 CHECKLIST: Retracting outrigger

G
Risk of overturning when the outrigger beams are not extended uniformly!
All outrigger beams must always be extended to the same extent.
Check whether all outrigger beams are extended to the necessary width
and secure all outrigger beams with the locking pins.

Retracting the
outrigger beams

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

H Before you can retract the outrigger beams, you must release them;
➠ Securing / releasing the outrigger beams, p. 13-20.
• Press down the Preselection of direction of outrigger movement toggle
switch.

C0120

• Press up the Preselection of outrigger cylinder / outrigger beam toggle switch.

C0121

Two speeds are available for retracting the outrigger beams:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.
Slow outrigger movements:
C0119
11.05.2000

• Press the Outrigger central toggle switch upward. The diesel engine
continues to run at idling speed.

13 - 26 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

• In addition, press the toggle switch for the desired outrigger beam
(e.g. front right).
• Retract all four outrigger beams completely.

H
C0122

You may also retract or extend the outrigger beams in pairs on the side
where you are positioned by pressing two respective toggle switches
simultaneously (e.g. the two toggle switches for front right and rear right).
11.05.2000

Operating Instructions GMK 5100 2 084 575 en 13 - 27

Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.3 Moving the outrigger pads into working / driving position

Moving the
outrigger pads
into working
position

• Loosen the retaining pins (1) and remove

the pins (3) from the bore holes on the out-
rigger pad (2).
• Pull the outrigger pad outward as far as
possible.

• Insert the pin (2) through the two bores at

the rear of the outrigger pad.
• Secure the pin using the retaining pin (1).
• Also extend the other three outrigger
pads. Secure every outrigger pad with
a yoke and retaining pin.

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13 - 28 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

Moving the
outrigger pads
into driving
position

• Release the retaining pin (1) and pull the

yoke (2) out of the bores in the outrigger
pad.

• Push the outrigger pad (2) right up to the

holding rod (4).
• Push the pin (3) through the front bore ho-
les on the outrigger pad.
• Secure the pin with the retaining pin (1).
• Push also the other three outrigger pads
up to the holding rods. Secure every out-
rigger pad with a pin and retaining pin.
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Operating Instructions GMK 5100 2 084 575 en 13 - 29

Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.4 Extending/retracting the support cylinders from the control

box

Extending the The outrigger cylinders can be operated individually, in pairs or all toge-
outrigger cylinders ther.

With additional equipment, you can also retract and extend the support
cylinders from the crane cab in order to correct the horizontal alignment.
➠ Extending/retracting the support cylinders from the crane cab, p. 13-33.

S
Danger of overturning if the load bearing capacity of the ground is too low!
Monitor the outrigger pressure and keep the load bearing capacity of the
ground in mind during crane work. If the ground does not have sufficient
load bearing capacity, you must support the outrigger pads with a sui-
table material.
In this way you prevent the ground under the outrigger pads from collaps-
ing, causing the truck crane to incline and overturn; ➠ Enlarging the sur-
face area of the outrigger, p. 13-8.

• Ensure that the packing of the outrigger pad is horizontally aligned.

Choose packing that will provide the outrigger cylinders with enough stroke

H
to align the truck crane horizontally and lift all wheels off of the ground.

The outrigger cylinders must have a remaining stroke of at least 1 inch in

order to carry out alignment corrections. The outrigger cylinders may not
be completely extended.

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

• Press up the Preselection of direction of outrigger movement toggle switch.

11.05.2000

C0120

s
13 - 30 2 084 575 en Operating Instructions GMK 5100
 Rigging work
13.4 CHECKLIST: Retracting outrigger

• Press down the Preselection of outrigger cylinder / outrigger beam toggle

switch.

C0121

Two speeds are available for extending the outrigger cylinder:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.
Slow outrigger movements:
C0119

• Press the Outrigger central toggle switch upward. The vehicle engine
continues running at idling speed.

• In addition, press the toggle switch for the desired outrigger cylinder
(e.g. front right).
Extend all four outrigger cylinders one after the other until the outrigger
pads touch the ground.

C0122

• Continue to extend the outrigger cylinders in pairs, in order to raise the

H
truck crane until none of the wheels touches the ground.

You may also retract or extend the outrigger cylinders in pairs or together
by pressing two or all four respective toggle switches simultaneously
(e. g. front left and front right, to lower the truck crane forward).

S
Be careful not to damage the outrigger cylinder!
Move the outriggers as uniformly as possible on all four support points.
This prevents the outrigger cylinders from buckling due to one-sided
pressure.

• Align the truck crane horizontally; ➠ p. 13-36.

11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 13 - 31
Rigging work
13.4 CHECKLIST: Retracting outrigger

Retracting the
outrigger cylinders

S
Risk of damage to the tyres!
Before retracting the outrigger cylinders walk around the crane and remove
all sharp and pointed materials which are under the tyres in this area.
This keeps the tyres from being punctured or damaged when the truck
crane is lowered.

• Press down the Preselection of direction of outrigger movement toggle switch.

C0120

• Press down the Preselection of outrigger cylinder / outrigger beam toggle

switch.

C0121

Two speeds are available for retracting the outrigger cylinders:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.
Slow outrigger movements:
C0119

• Press the Outrigger central toggle switch upward. The diesel engine
continues to run at idling speed.

In addition, press the toggle switch for the desired outrigger cylinder
(e.g. front right).

Before working with the crane you must horizontally align the truck crane
with the support cylinders.

C0122
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13 - 32 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.5 Extending/retracting the support cylinders from the crane cab

(additional equipment)

If the ground beneath the support cylinder pads should give way while
the crane is in operation and the truck crane is no longer in the horizontal
position, the support cylinders can also be activated from the crane cab
(additional equipment) to bring the truck crane back into the horizontal po-
sition.
Observe the information in the section on load bearing capacity of the
ground and the outriggers; ➠ p. 13-6.

G
Risk of overturning!
It is not allowed to readjust the outrigger with a load on the hook.
Always set the load down on the ground before activating the outrigger.

G
Danger of overturning by unauthorised operation of the outrigger from
the crane cab
The vehicle engine may only be started immediately before operating the
outrigger because when the vehicle engine is running, the outrigger can
also be operated without authorisation by both of the control boxes on
the carrier. Simultaneous operation from multiple control boxes can lead
to malfunctions! Because of this, switch off the vehicle engine again im-

H
mediately after readjustment!

The electronic spirit level in the crane cab only displays correct values
when the ignition has been switched off in the carrier.
If the crane engine is started from the superstructure, the display functi-
ons properly.

Extending / The working speed depends on the idling speed of the vehicle engine; ➠
retracting the Adjusting the idling speed, p. 5-12.
support cylinder

Danger of accidents when outrigger movements are performed outside

Gk
of your field of view!
Monitor the every movement of the support cylinders closely or have a
banksman monitor the movements during operation.

• Start the vehicle engine by pressing the Vehicle engine starter rocker
switch.
During the starting procedure, the Carrier engine electronics warning lamp
à
11.05.2000

lights up. The warning lamp goes out, as soon as the vehicle engine is
running.

s
Operating Instructions GMK 5100 2 084 575 en 13 - 33
Rigging work
13.4 CHECKLIST: Retracting outrigger

• Let go of the Vehicle engine starter rocker switch as soon as the vehicle en-
gine is running and the Carrier engine electronic system warning lamp

H
goes out.

If the warning lamp does not go out after the engine has started, there is a
malfunction; ➠ p. 7-23.

Extending the support cylinders

• Press up the Outrigger direction of movement pre-selection rocker switch
) down and hold it down.
The Extend support cylinder indicator lamp lights.
P
• Additionally, press the rocker switch for the desired outrigger cylinder
OA (e. g. rear left).

Retracting the outrigger cylinders

• Press up the Outrigger direction of movement pre-selection rocker switch
) down and hold it down.

The Retract support cylinder indicator lamp lights.

O
• Additionally, press the rocker switch for the desired outrigger cylinder
OA (e. g. rear left).

After ex-
tend/retract
Turn off the vehicle engine when the truck crane is back in the horizontal
d position. To do this, press the Vehicle engine cutout button.

Risk of overturning!

G
After adjusting the truck crane, check the condition and position of the
packing material for the outrigger pads. Wooden beams may have slip-
ped or been pushed out of position. Rotate the truck crane by 360° and
check every individual outrigger.
Do not rely on a visual inspection using the mirror.

If you notice a change and the packing on the ground under the outrigger
is no longer safe, stop working with the crane and rig the truck crane
11.05.2000

again as prescribed.

13 - 34 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

G
Risk of accidents!
Do not forget that if the ground already gives way at several points under
the outrigger before or while readjustments are being made, the wheels
of the truck crane may touch the ground again. This would cause the sta-
bility of the truck crane to change and thus increase the danger of overtur-
ning. If you are not absolutely certain that the truck crane’s wheels do not
touch the ground, you must get out and ensure that he truck crane is still
on outriggers, as called for in the regulations.
If the wheels of the truck crane are touching the ground: Stop working
with the crane immediately and rig it again as prescribed.
11.05.2000

Operating Instructions GMK 5100 2 084 575 en 13 - 35

Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.6 Check the alignment of the truck crane

• Check the horizontal alignment of the truck crane:

– at the circular spirit level or
– the electronic level (additional equipment)

Checking the The current alignment of the truck crane is displayed by two circular spirit
alignment with levels on the carrier. A further circular spirit level is in the crane cab.
the circular spirit
level
• Check the horizontal position of the truck crane using the circular spirit
level. The truck crane is horizontally aligned when the air bubble is in
the centre of the middle circle.

Alignment with The current alignment of the truck crane is displayed by two electronic
the electronic levels on the carrier. A further electronic level is in the crane cab.
level (additional
equipment)

The electronic level (1) is located on both si-

des of the carrier in a switch box behind the
steps.
1

The status display is activated in both con-

trol boxes as soon as you open the door of
one control box.

888 888
888 888

C0801

Reading the status display

Whenever the truck crane is higher on one side, the diodes in the
11.05.2000

cruciform arranged girders (1 to 4) illuminate. Every girder stands for one

certain direction.

13 - 36 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

(1) The side of the truck crane opposite

1
you is higher than the side where you
5 are.

(2) The truck crane is higher to the right of

2 the status display than it is left of it.

(3) The side of the truck crane where you

are is higher than the side opposite
3
you.
4
(4) The truck crane is higher to the left of

888
the status display than it is right of it.

888 (5) The truck crane is horizontal.

888 888 C0802

H Diagonal inclines are displayed; the diodes on two girders next to each
other light up simultaneously.

Switching over the measuring range

You may select one of two measuring ranges with the luminous diode
display:

Measuring range angle 0° to 5°

• Press the toggle switch Switch over measuring
range (2) downward.
A graduated collar (1) corresponds to a
1° inclination.
1

Measuring range angle 0° to 1°

2 • Press the toggle switch Switch over measuring
range (2) upward.
A graduated collar (1) corresponds to a

888 888 0.2° inclination.

888 888 C0803

Measuring range angle 0° to 1° reacts very
sensitively. If the diodes on the girders illumi-
nate as much as possible, switch over to
measuring range angle 0° to 5° so that you
11.05.2000

can follow the alignment with the outrigger

cylinders.

s
Operating Instructions GMK 5100 2 084 575 en 13 - 37
Rigging work
13.4 CHECKLIST: Retracting outrigger

Aligning the
truck crane
horizontally • If the boom is in the boom support, align the truck crane horizontally
with the support cylinders:
– until the air bubble is in the centre of the middle circle in the circular
spirit level
– until the square lights up in the middle of the display on the electronic
level in the 0° to 1° inclination measuring range.

• If the boom is retracted, rotate the superstructure into the

0° or the 180° position and align the truck crane horizontally with the
support cylinders:
– until the air bubble is in the centre of the middle circle in the circular
spirit level
– until the square lights up in the middle of the display on the electronic
level (in the 0° to 1° inclination measuring range).

G
Danger of overloading the boom!
Always slew the superstructure to the 0° or 180° position before aligning
the truck crane horizontally with the boom raised. If the superstructure is
in another position, the electronic level detects the deformation of the frame
as an additional angle and the displayed value can deviate from the ac-
tual value by up to 2°, and the truck crane is at an incline. The side load of
the boom increases when working at this incline and the boom can
become overloaded.

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13 - 38 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.4 CHECKLIST: Retracting outrigger

13.4.7 Outrigger pressure display (additional equipment)

The outrigger pressure display is located on both sides in the control

boxes, under the status display of the electronic level.
The status display is activated in both control boxes as soon as you open

H
the door of one control box.

When the support cylinder is retracted as far as it will go, the values of
the outrigger pressure display do not correspond to the actual outrigger
pressure. An optimal display can be obtained when the movement
“Retract support cylinder” has last been driven (not to its limits).

There are four digital displays which display the outrigger pressure in
pounds (klbs); the following illustration shows the displays in the left con-
trol box.

Reading the status displays

Status displays (1, 4) in the upper row
display the outrigger pressures in the out-
1 rigger cylinders on the side opposite you.
4
Status displays (2, 3) in the lower row

888 888 display the outrigger pressures in the out-

rigger cylinders on the side where you are.

888 888 Both of the status displays on the right (1, 2)

display the outrigger pressure in the out-
rigger cylinders to your right.

Both of the status displays on the left (3, 4)

2 display the outrigger pressure in the out-
3 rigger cylinders to your left.
C0807

If you, for example, are before the status displays on the left side, as the
illustration shows. The following arrangement applies:
Display (1): Outrigger pressure right rear
Display (2): Outrigger pressure left rear
Display (3): Outrigger pressure left front
Display (4): Outrigger pressure right front.

H The crane is well aligned when the outrigger pressures in both of the
front outrigger cylinders are about the same and when the outrigger
11.05.2000

pressures in both of the rear outrigger cylinders are about the same.
But the horizontal alignment with the electronic level is definitive for the
correct state for working with the crane.

Operating Instructions GMK 5100 2 084 575 en 13 - 39

Rigging work
13.4 CHECKLIST: Retracting outrigger

Blank page

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13 - 40 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

13.5 Counterweight

13.5.1 Counterweight sections and identification

Counterweight For the GMK 5100 truck crane, the counterweight versions are assembled
sections from eight counterweight sections, these being
– the 1 t compensation weight or
the auxiliary hoist (additional equipment)
– a 3 t counterweight section screwed onto the turntable
– a 3 t base plate
– one 4 t counterweight section
and, with additional equipment,
– a 4 t counterweight section with lateral recesses
– a 7 t counterweight section or two 3.5 t counterweight sections
– a 2 t counterweight section as well as
– two 3.5 t counterweight blocks

Identification The truck crane and the accompanying counterweight parts are labelled
with the same serial number.

S
Interchanging counterweight parts is dangerous!
Operate the truck crane using only counterweight sections belonging to
the truck crane. The truck crane and the counterweight parts are labelled
with the same serial number.
Other or additional counterweight sections may not be installed.

Counterweight sections
The serial number (1) is located on all
counterweight sections and counterweight
blocks which are over the weight indication.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 13 - 41
Rigging work
13.5 Counterweight

13.5.2 Counterweight versions

G
Risk of accidents!
Combine the counterweights with each other only in the way prescribed
in this chapter and in the Lifting capacity table. Other variations are not
permitted.
If other versions are used, the truck crane is no longer protected against
overloading by the SLI.

G
Risk of overturning when slewing with rigged counterweight!
You may only slew the superstructure with rigged counterweight if a suffi-
ciently large outrigger span is rigged. Take the required outrigger span
from the table in the section Slewing with rigged counterweight, slewing
p. 13-67 and stabilize the truck crane accordingly before slewing the super-
structure. In this way you can aviod the truck crane overturning to the rear.

For counterweight versions, the GMK 5100 truck crane either has the auxi-
liary hoist (additional equipment) or the 1 t compensation weight.
If an auxiliary hoist is not installed on the truck crane, the dead weight of
the auxiliary hoist will not be included in the total counterweight. This mis-

G
sing weight is compensated for by the 1t compensation weight.

Risk of accidents due to incompletely rigged counterweight!

Only operate the truck crane when either the 1 t compensation weight is
rigged or an auxiliary hoist is installed. Only then is the counterweight
completely rigged. In this way you prevent the SLI using an incorrect
value for calculations and the truck crane overturning during work.

The counterweight sections of the GMK 5100 can be assembled into

H
seven different counterweight versions.

In the following illustrations, a 3 t counterweight section is mounted on

the turntable. If the 3 t counterweight section is removed, place it on the
other counterweights.

1t
1 t - compensation weight or
11.05.2000

auxiliary hoist (additional equip-

ment)

13 - 42 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

4t (after driving with 12 t axle load)

1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight

4t (after driving with 10 t axle load)

1 t - compensation weight or auxiliary
hoist (additional equipment)

3 t - base plate

7t
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section

3 t - base plate

11 t
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section
11.05.2000

4 t - base plate
3 t - base plate

Operating Instructions GMK 5100 2 084 575 en 13 - 43

Rigging work
13.5 Counterweight

20 t (additional equipment)
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section

2 t - counterweight section

7 t - counterweight section
(or as additional equipment 2 x 3.5t)
4 t - counterweight section
3 t - base plate

24 t (additional equipment)
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section
2 t - counterweight section
4 t - counterweight section

7 t - counterweight section
(or as additional equipment 2 x 3.5 t)
4 t - counterweight section
3 t - base plate

31 t (additional equipment)
1 t - compensation weight or
auxiliary hoist (additional equipment)
3 t - counterweight section
2 t - counterweight section
4 t - counterweight section

7 t counterweight section
(or as additional equipment 2 x 3.5 t)
4 t - counterweight section
3 t - base plate
11.05.2000

2 x 3.5 t - counterweight block

13 - 44 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

13.5.3 Slinging points on the counterweight sections

Four slinging points are inserted in each of

the cast counterweight sections.

There are four slinging mushrooms welded

onto the following counterweight sections:
– 3 t base plate
– 2 t counterweight section
– 3 t counterweight section

There are three slinging points inserted into

both 3.5 t counterweight sections (additional
equipment); ➠ 3.5 t Rigging counterweight sec-
tions, p. 13-66.

Each of the 3.5 t counterweight blocks is

equipped with two slinging points (additio-
nal equipment).

G
Risk of accidents if used incorrectly!
Only attach the various counterweight sections to the appropriate
slinging point and use lifting gear with sufficient lifting capacity.
Only lift the counterweight sections individually. The slinging points are
not designed for lifting counterweight sections placed on top of each
other.
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Operating Instructions GMK 5100 2 084 575 en 13 - 45

Rigging work
13.5 Counterweight

13.5.4 CHECKLIST: Rigging the counterweight

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

Rig counter- Requirements:

weight
– The truck crane is stabilized with the outrigger span required for crane
work according to the Load capacity chart; ➠ Outrigger span, p. 13-17.
– SLI is set to actual rigging mode with the currently rigged counter-
weight. ➠Entering values, p. 12-23.
– The 1 t compensation weight or the auxiliary hoist is rigged.

1. Lift 3 t base plate from the separate vehicle and place it onto the coun-
terweight platform; ➠Placing 3 t base plate onto counterweight platform,
p. 13-50.

2. Depending on the desired counterweight version, lift the required

counterweight sections one after another onto the 3 t base plate;
➠Assembling the counterweight version, p. 13-51.

3. If the 31 t counterweight is to be rigged:

lift the two 3.5 t counterweight blocks one after the other from the se-
parate vehicle with the truck crane and attach them in the holdings of
the upper 4 t counterweight section; Assembling the counterweight versi-
on, p. 13-51.

4. Turn the superstructure to the rear.

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 Rigging work
13.5 Counterweight

5. Lock the superstructure; ➠Mechanically locking the superstructure,

! p. 12-9.

6. If 24 t or 31 t of counterweight is to be rigged:
Check whether all pins on the 3 t counterweight section are in position
and released; ➠ Check the position of the locking pins, p. 13-57.

7. If necessary, rotate the lifting cylinder to the Unlocked position; the

O Counterweight unlocked warning lamp must light up;
➠ Unlocking, p. 13-60.

8. Lower the lifting cylinder into the 3 t base plate until the Extend counter-
:Q weight lifting cylinder indicator lamp lights. ➠ Extend/retract lifting cylin-
der, p. 13-59.

9. Lock counterweight lifting cylinder; the Counterweight locked indicator

RN lamp has to light; ➠Locking, p. 13-58.

10. Retract lifting cylinder with counterweight section until the Counter-
:P weight lifting cylinder retracted indicator lamp lights; ➠Extending / retrac-
ting the lifting cylinders, p. 13-57.

11. Select the current rigging mode with the newly rigged counterweight
00== version or enter the corresponding SLI code; ➠ Entering values,
p. 12-23.

12. Only unlock the superstructure if the truck crane is supported with the
¥ outrigger span required for the rigged counterweight;
➠ Mechanically locking the superstructure, p. 12-9.
➠ Slewing with the counterweight rigged, p. 13-67.
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Operating Instructions GMK 5100 2 084 575 en 13 - 47

Rigging work
13.5 Counterweight

13.5.5 CHECKLIST: Unrigging the counterweight

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

Unrig Requirements:
counterweight
– The truck crane is stabilized with the outrigger span required for crane
work according to the Load capacity chart; ➠ Outrigger span, p. 13-17.
– The SLI is set to the current rigging mode with the currently rigged
counterweight; ➠ Entering values, p. 12-23.

1. Turn the superstructure to the rear; ➠ Slewing with the counterweight

rigged, p. 13-67.

2. Lock the superstructure; ➠ Mechanical superstructure lock, p. 12-9.

!
3. If the 2 t counterweight section is to remain rigged:
lock the 2 t counterweight section to the turntable (only possible if the
3 t counterweight section is mounted on the turntable); ➠Locking the 2
t counterweight section, p. 13-62.

4. Extend the lifting cylinder until the counterweight section is on the

:Q counterweight platform; the Counterweight lifting cylinder extended indi-
cator lamp must light; ➠ Extending/retracting the lifting cylinders,
p. 13-56.

5. Unlock the lifting cylinder; the Counterweight unlocked warning lamp

RO must light ; ➠ Unlocking, p. 13-60.

6. Retract lifting cylinder with until the Counterweight lifting cylinder retrac-
:P ted indicator lamp lights; ➠ Extending/retracting the lifting cylinders, p.
11.05.2000

13-56.

13 - 48 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

7. Select the current rigging mode with 4 t counterweight on the SLI

00== (even if the 2 t counterweight section remains rigged) or enter the re-
spective SLI code; ➠Entering values, p. 12-23.

8. Unlock superstructure; ➠Mechanically locking the superstructure, p. 12-9.

¥
9. If 31 t counterweight is rigged:
Lift each of the two 3.5 t counterweight blocks from the 4 t counter-
weight section holders with the truck crane and place them onto the
separate vehicle. ➠ Slinging points on counterweight sections p.13-45.

10. Depending on the driving mode, lift the required individual counter-
weight sections from the 3 t base plate and place them on the separa-
te vehicle.
If need be, place the 3 t base plate on the separate vehicle;
➠ Slinging points on counterweight sections, p. 13-45,
➠ Driving mode table, p. 6-5.
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Operating Instructions GMK 5100 2 084 575 en 13 - 49

Rigging work
13.5 Counterweight

13.5.6 Placing the 3 t base plate onto the counterweight platform

The 3 t base plate is placed on the counterweight platform with the truck
crane either for on-road driving or for rigging. Depending on the counter-
weight version or the driving mode (➠ p. 6-5) further counterweight sec-
tions can be placed on the 3 t base plate;

Select the current rigging mode with the rigged counterweight

00== (1 t or 4 t) on the SLI or enter the corresponding SLI code.

G
Danger – free-standing truck crane may overturn!
Stabilize the truck crane before lifting the counterweight section onto the
carrier.

G
Risk of crushing when placing the counterweight sections!
Ensure that helpers maintain sufficient clearance from the 4.4 t counter-
weight section with all parts of their bodies during placement.
Remove all objects which could become clamped or crushed from the
counterweight platform!

G
Risk of crushing when rotating the superstructure!
Anyone who climbs onto the carrier using the access ladder is in the sle-
wing range of the superstructure.
Make sure that nobody uses this access ladder (e. g. a helper) while you
are lifting a counterweight section from the separate vehicle onto the car-
rier.

There are four retaining sheets (1) welded

onto the counterweight platform. The retai-
ning sheets bring the counterweight section
into the proper position for rigging and secu-
re them during driving.
• Sling the 3 t base plate on the intended
slinging points and lift them onto the coun-
terweight platform; ➠Slinging points on the
counterweight sections, p. 13-45.
• Position the 3 t base plate in such a way
that the retaining sheets (1) grip in the re-
cesses (2) of the counterweight section.
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 Rigging work
13.5 Counterweight

13.5.7 Assembling the counterweight version

The 1 t and 4 t counterweight versions are mounted on the turntable.

Additionaly, for the 7 t, 11 t, 20 t and 24 t counterweight versions, the ne-

cessary counterweight sections are stacked on the 3 t base plate with the
truck crane on the counterweight platform.
For the 31 t counterweight version, two additional 3.5 t counterweight
blocks are attached.

G
Risk of crushing when rotating the superstructure!
Anyone who climbs onto the carrier using the access ladder is in the sle-
wing range of the superstructure.
Make sure that nobody uses the access ladder (e. g. a helper) while you
are lifting a counterweight section from the separate vehicle onto the car-
rier.

G
Danger – free-standing truck crane may overturn!
Stabilize the truck crane with the outrigger span required for working
with the crane, before you slew the superstructure and lift the counter-
weight sections; ➠ Outrigger span, p. 13-17.

G
Accidents may occur due to falling counterweight parts!
Hoist the counterweight sections and counterweight blocks only indi-
vidually. The holders for the lifting gear are not designed for hoisting
sections/blocks placed on top of each other; ➠ Slinging points on the
counterweight sections, p. 13-45.
Always attach the counterweight blocks slowly and only vertically from
above. This prevents overloading and the possibility of the attachment
plates breaking off. When attaching the counterweight blocks, ensure that
no persons are located under the counterweight.

Counterweights The following counterweight versions can be assembled with weights

mounted on the which are mounted on the turntable.
turntable
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 13 - 51
Rigging work
13.5 Counterweight

1 t counterweight

With th 1 t counterweight, only the 1 t com-

pensation weight or the auxiliary hoist (addi-
tional equipment) is mounted on the
turntable.

The 3 t counterweight section is removed.;

➠ Mounting or removing the 3 t counterweight
section at the turntable, p. 13-64.

4 t counterweight version
(at 12 t axle load)

With th 4 t counterweight, the 1 t compensati-

on weight or the auxiliary hoist (additional
equipment) is mounted on the turntable.
Additionally, the 3 t counterweight section is
mounted on the turntable; ➠ Mounting or
removing the 3 t counterweight section at the turn-
table, p. 13-64.

Assembling further combinations; ➠ Coun-

terweights on the counterweight platform,
4 t at the turntable, p. 13-53.

4 t counterweight version
(at 10 t axle load)
The 4 t counterweight version can also be as-
sembled with the 3 t counterweight section
removed:
The 1 t compensation weight or the auxiliary
hoist (additional equipment) is mounted on
the turntable.

• Hoist the 3 t base plate onto the counter-

weight platform; ➠ p. 13-50.
Assembling further combinations; ➠ Coun-
11.05.2000

terweights on the counterweight platform,

1 t at the turntable, p. 13-55.

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 Rigging work
13.5 Counterweight

Counterweight This section applies for the assembly of counterweight versions after a
on the counter- drive with a maximum of 12 t axle load (3 t counterweight section moun-
weight platform , ted on the turntable).
4 t at the turn-
table Requirements:
– The 4 t counterweight version is mounted on the turntable.
– The current rigging mode with 4 t counterweight is set at the SLI.
– For rigging from 7 t to 20 t counterweight, the 2 t counterweight section
is not to be locked together with the 3 t counterweight section at the
turntable;
➠ Locking / releasing the 2 t counterweight section at the turntable, p. 13-62.

7 t counterweight version

When driving with an axle load of 12 t, the

counterweight for the 11 t combination can
already be on the counterweight platform.
If only the 7 t counterweight is permitted to
be rigged, you have to hoist the 4 t counter-
weight section from the 3 t base plate.

• If the counterweight was transported on a

separate vehicle, hoist the 3 t base plate
onto the counterweight platform;
➠ p. 13-50.

11 t counterweight version

When driving with an axle load of 12 t, the

counterweight for the 11 t combination is
already on the counterweight platform.

• If the counterweight was transported on

a separate vehicle, hoist the 4 t counter-
weight section without recesses onto the
3 t base plate.
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Operating Instructions GMK 5100 2 084 575 en 13 - 53
Rigging work
13.5 Counterweight

20 t counterweight version

• Hoist
– the 4 t counterweight section without
– recesses,
– the 7 t counterweight section
– and the 2 t counterweight section
one after the other onto the 3 t base plate.

24 t counterweight version

• Hoist
– the 4 t counterweight section without
– recesses
– the 7 t counterweight section
– the 4 t counterweight section with
– recesses and
– the 2 t counterweight section
one after the other onto the 3 t base plate.

31 t counterweight version

• Rig the 24 t counterweight version

• Hoist each of the 3.5 t counterweight
blocks above the upper 4 t counterweight
section in such a way that the attachment
plates are located vertically above the re-
cesses.
• Place the counterweight blocks slowly into
the recesses.
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 Rigging work
13.5 Counterweight

Counterweight This section applies for the assembly of counterweight versions after a
on the counter- drive with a maximum of 10 t axle load (3 t counterweight section not
weight platform , mounted on the turntable).
1 t at the turn-
table Requirements:
– The 1 t counterweight version is mounted on the turntable.
– The current rigging mode with 1 t counterweight is set at the SLI.
– The supplied centering rings are ready.

7 t counterweight version

• Hoist the 3 t base plate onto the counter-

weight platform; ➠ p. 13-50.
• Fit both centering rings (1) over the grips
of the 3 t base plate.
• Hoist the 3 t counterweight section onto
the 3 t base plate; ➠ p. 13-50.

11 t counterweight version

• Hoist the 3 t base plate onto the counter-

weight platform; ➠ p. 13-50.
• Hoist the 4 t counterweight section onto
the 3 t base plate;
• Fit both of the centering rings (1) over the
ends of the grips of the 3 t base plate.
• Hoist the 3 t counterweight section onto
the 4 t counterweight section.
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Operating Instructions GMK 5100 2 084 575 en 13 - 55

Rigging work
13.5 Counterweight

20 t counterweight version
For this you do not need centering rings.
You can, however, place the centering rings
between the 4 t and 7 t counterweight secti-
ons.
• Hoist
– the 4 t counterweight section without
– recesses,
– the 7 t counterweight section
– the 2 t counterweight section and
– the 3 t counterweight section
one after the other onto the 3 t base plate.
For additional equipment with 2 x 3.5 t coun-
terweight; ➠ 3.5 t Rigging counterweight sec-
tions, p. 13-66.
24 t counterweight version
For this combination, you do not need cente-
ring rings. You can, however, place the cente-
ring rings between the 4 t and 7 t
counterweight sections.

• Hoist
– the 4 t counterweight section without
– recesses
– the 7 t counterweight section
– the 4 t counterweight section with
– recesses
– the 2 t counterweight section and
– the 3 t counterweight section
onto the 3 t base plate.

31 t counterweight version

• Rig the 24 t counterweight version.

• Hoist each of the 3.5 t counterweight
blocks above the upper 4 t counterweight
section in such a way that the attachment
plates are located vertically above the
recesses.
• Place the counterweight blocks slowly into
the recesses.
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 Rigging work
13.5 Counterweight

13.5.8 Counterweight lifting unit

The counterweight hoist unit consists of two rotatable arranged lifting

cylinders which are attached to the turntable and two swivel cylinders
which are rotated by the lifting cylinder for unlocking and locking the
counterweight.
The lifting cylinders are used to lift the 3 t base plate with the assembled
counterweight from the counterweight platform onto the turntable (du-
ring rigging) and to lower it back onto the counterweight platform (during
unrigging).

G
Risk of crushing during lifting and lowering of the counterweight!
Before lifting the 3 t base plate, remove all objects from the top counter-
weight section which could become clamped or crushed.
Be sure that no person is on the counterweight platform while the coun-
terweight is being lifted or lowered.

Check the positi- Before hoisting the 24 t and 31 t counterweight versions, all the locking
on of the locking pins on the 3 t counterweight section at the turntable have to be in the
pins Unlocked position. This will prevent that the retaining plates of the 2 t coun-
terweight section are pressed against the locking pins during hoisting.

G
Risk of crushing for fingers!
When pushing the locking pins, do not touch the locking pin on their stop
pegs. The pins can suddenly swing and crush your fingers between the
stop peg and the stop plate.

The locking pins (3) are in the Unlocked posi-

tion if these are pushed as far as possible
against the plate (2) and the linchpins are in-
serted in position (1).

• Check whether the locking pins are in the

Unlocked position. Reposition if necessary;
• The drawing only shows the pins on the
left side. Also check the positions of the
other two locking pins (at the rear and on
the right side) and, if necessary, correct
them.
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Operating Instructions GMK 5100 2 084 575 en 13 - 57
Rigging work
13.5 Counterweight

Release/disable
counterweight
hoist unit
• To release the counterweight hoist unit, unlock the Counterweight hoist
M unit release rocker switch and press it down.
When the counterweight hoist unit is released, the indicator lamp in the
M:R rocker switch lights, along with the indicator lamps in the Extend/retract
lifting cylinders and the Lock/unlock counterweight rocker switches.

• To block the counterweight hoist unit, press the Counterweight hoist unit
release rocker switch up.
When the counterweight hoist unit is blocked, the indicator lamp in the
M:R rocker switch goes out, along with the indicator lamps in the Extend/retract
lifting cylinders and the Lock/unlock counterweight rocker switches.

Checking the The current locking status and the current position of the lifting cylinder is
current hoist unit shown by the following indicator lamps:
status
Locking status:
The Counterweight hoist unit locked indicator lamp lights if both lifting cylin-
N ders are turned to the Locked position.

The Counterweight hoist unit unlocked indicator lamp lights if both lifting
O cylinders are turned to the Unlocked position.

If the hoist unit is not in one of the two end positions, the indicator lamps
will flash alternately.

Lifting cylinder position

The Counterweight lifting cylinder retracted indicator lamp lights if both
P lifting cylinders are completely retracted.

The Counterweight lifting cylinder extended indicator lamp lights if both

Q lifting cylinders are completely extended.

If the lifting cylinders are not in one of the two end positions, the indicator
lamps will flash alternately.

Indication of a When the two Counterweight lifting cylinder retracted/extended indicator

11.05.2000

malfunction lamps or the two Counterweight hoist unit locked/unlocked indicator lamps
flash simultaneously, a malfunction has occurred.

13 - 58 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

The cause could be either an electric fault (e. g., at a proximity switch) or a
logic error (e.g. the electronic system gets the signal that the lifting cylin-
ders are simultaneously extended and retracted).
• In this case, actuate the Extend / retract lifting cylinder rocker switch or the
:R Lock / unlock counterweight rocker switch.
The indicator lamps then no longer flash and now show the status last de-
termined by the electronic system. If, for example, the two Counterweight
hoist unit locked and Counterweight hoist unit unlocked indicator lamps are
now lit and the counterweight is on the counterweight platform, then the
upper proximity switch is defective. If you cannot correct the problem,
please contact GROVE Product Support.

Extending / • Enable the counterweight hoist unit.

retracting the
lifting cylinder
To extend or retract the lifting cylinder without counterweight, either the
ON Counterweight unlocked or the Counterweight locked indicator lamp has to be
lit.

To extend or retract the lifting cylinder with counterweight, the Counter-

N weight locked indicator lamp has to be lit.
Only when this lamp is lit is it assured that both lifting cylinders are
locked or unlocked and that the movement of the lifting cylinders is
electrically enabled.

S
Danger of damage to the hoist unit!
The counterweight lifting gear can be damaged if the lifting cylinders
(when they are in the Locked position) move against the supporting frame
of the 3 t counterweight section. The hoist unit may only be extended in
the Locked position if there in no counterweight section on the counter-
weight platform or the superstructure is rotated to the side.

• To extend, press the Extend / retract counterweight lifting cylinder rocker

: switch down and hold it in this position.
As soon as the lifting cylinders leave the retracted position, the Counter-
QP weight lifting cylinder extended and the Counterweight lifting cylinder retracted
indicator lamps will flash alternately.

If both counterweight lifting cylinders are completely extended (or the

Q counterweight is lowered), the Counterweight lifting cylinder extended indica-

H
tor lamp lights.
11.05.2000

If warning and indicator lamps simultaneously flash; ➠Indication of a mal-

function, p. 13-58.

s
Operating Instructions GMK 5100 2 084 575 en 13 - 59
Rigging work
13.5 Counterweight

S
Danger of damage when hoisting the 24 t and 31 t counterweight
versions.
Before you hoist with these counterweight versions, be sure that the
locking pins at the 3 t counterweight section are in the Unlocked position.
In this way, you prevent the locking pins and the retaining plates of the
2 t counterweight section from pressing against each other and becoming
damaged.

• To retract, press the Extend / retract counterweight lifting cylinder rocker

: switch up and hold it in this position.
As soon as the lifting cylinders leave the extended position, the Counter-
QP weight lifting cylinder extended and the Counterweight lifting cylinder retracted
indicator lamps will flash alternately.

When both counterweight lifting cylinders are completely retracted (or the
P counterweight is lifted), the Counterweight lifting cylinder retracted indicator

H
lamp lights.

If warning and indicator lamps simultaneously flash; ➠ Indication of a mal-

function, p. 13-58.

Unlock /lock • Enable the counterweight hoist unit.

counterweight
It is only possible to unlock the counterweight hoist unit if the lifting cylin-
hoist unit
ders are completely extended.
The Counterweight lifting cylinder extended and Counterweight locked indicator
QN lamps have to be lit.

• Press down and hold the Lock / unlock counterweight rocker switch.
R
As soon as the lifting cylinder leaves the Locked position, the Counterweight
ON unlocked warning lamp and the Counterweight locked indicator lamp start to
flash alternately.

If both the lifting cylinders are turned to the Unlocked position the counter-
O weight hoist unit is unlocked and the Counterweight unlocked warning lamp

H
will light. The Counterweight locked indicator lamp goes out.

If warning and indicator lamps simultaneously flash; ➠ Indication of a mal-

11.05.2000

function, p. 13-58.

13 - 60 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

It is only possible to lock if the lifting cylinders are completely extended.

The Counterweight lifting cylinder completely extended and Counterweight un-

QO locked indicator lamps must light.

• Press the Lock counterweight rocker switch up and hold it this position.
R
• As soon as the lifting cylinder leaves the Unlocked position, the Counter-
ON weight unlocked warning lamp and the Counterweight locked indicator lamp
start to flash alternately.
If both the lifting cylinders are turned to the Locked position the counter-
N weight hoist unit is locked and the Counterweight locked warning lamp will

H
light. The Counterweight unlocked indicator lamp goes out.

If warning and indicator lamps simultaneously flash; ➠Indication of a mal-

H
function, p. 13-58.

If the lifting cylinders are retracted, then, for safety reasons, only those
functions (Locked or Unlocked) can be actuated which were set when the
lifting cylinder was in the lowest position.
if the counterweight is lifted, on the Lock function can be actuated.
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Operating Instructions GMK 5100 2 084 575 en 13 - 61

Rigging work
13.5 Counterweight

13.5.9 Locking / releasing the 2 t counterweight section on the

turntable

If the 3 t counterweight section is mounted to the turntable, the 2 t coun-

terweight section can be can be locked there. Locking is appropriate in
two cases:
– If you want to re-rig from 24 t or 32 t counterweight to 20 t, you do not
need to put down the 2 t counterweight section and the pick it up again.
– If you move the truck crane at the construction site with an axle load of
more than 12 t, the 2 t counterweight section can be transported on the
turntable.

Locking the 2 t When rigging the 20 t, 24 t or 31 t counterweight versions, the 2 t counter-

counterweight weight section is always on top. It does not have to be locked with the
section 3 t counterweight section during crane operation.
However, to lock the 2 t counterweight section with the 3 t counterweight
section, the 24 t (or the 31 t) counterweight version has to be rigged (both
additional equipment). Only then can the 2 t counterweight section be
locked to the 3 t counterweight section.

G
Danger of injury for fingers!
If the 2 t is locked with the 3 t counterweight section, you should not push
the pins with their stop pegs between the stop plates. The pins could sud-
denly move and crush your fingers with their momentum between the
stop peg and the stop plate.

• Lock the 2 t counterweight section to the 3

t counterweight section as follows:
– Remove the linchpin from the
pin (3).
– Push the pin from the stop plate (1)
against the stop plate (2).
– Secure the pins with the linchpin (4).
• The drawing only shows the pins on the
left side. Also lock the plates with the other
two pins to the rear and on the right side.
If you now lower the counterweight, the 2
t counterweight section will be stuck on
the turntable.
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 Rigging work
13.5 Counterweight

Releasing the 2 t
counterweight
section

G
Risk of accidents when unrigging the 2 t counterweight section!
Before you release the connection between the 3 t and 2 t counterweight
sections, you must assure that the 24 t counterweight version (without 2
t counterweight section) is rigged. Only this way can the counterweight
be lifted far enough under the 2 t counterweight section that the pins will
be relieved of pressure and can be unlocked. If less than 24 t or no coun-
terweight is rigged, the 2 t counterweight section would fall down.

G
Danger of injury for fingers!
If you release the connection between the 2 t and 3 t counterweight sec-
tions, you should not push the pins by their stop pegs between the stop
plates. The pins could suddenly move and crush your fingers with their
momentum between the stop peg and the stop plate.

• Assemble the 24 t counterweight version

without 2 t counterweight section.
• Lift the counterweight plates with the
lifting cylinders up to the stop.
• Release the locking pin of the 2 t counter-
weight section:
– Remove the linchpin from the pin (3).
– Push the pin from the stop plate (2)
– against the stop plate (1).
– Insert the linchpin in the position (4).
• The drawing only shows the pins on the
left side. Also release the other two pins to
the rear and on the right side.
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Operating Instructions GMK 5100 2 084 575 en 13 - 63

Rigging work
13.5 Counterweight

13.5.10 Removing or installing the 3 t counterweight section on the

turntable

H For the installing/removing procedures described in the following secti-

ons, you need at least the 24 t counterweight version (additional equip-
ment).
Otherwise you will have to hoist the 3 t counterweight section onto the
turntable with an auxiliary crane.

Removing Normally, the 3 t counterweight section at the counterweight lifting gear

is screwed together with the turntable. If need be, it can be removed. For
this purpose, two screws have to be loosened next to each lifting cylinder.
The corresponding nuts are located beneath the 3 t counterweight secti-
on. Proceed as follows.

• Place the 3 t base plate onto the counter-

weight platform;
• Place one after the other:
– the first 4 t counterweight section
– the 7 t counterweight section and
– the second 4 t counterweight section
on the 3 t base plate.
• Place wooden planks (1) which are at least
as high as the 2 t counterweight section on
the upper 4 t counterweight section.
• Place the wooden planks in such a way
that they do not cover the screw connec-
tion nuts (see next picture).

• Hoist the counterweight sections as far as possible below the 3 t coun-

terweight section.
The counterweight section is now relieved of pressure and the four
screws can be loosened.

G
Risk of crushing when loosening screw connections
To loosen the connections, you have to reach between the counterweight
sections. Use the wooden planks or other suitable support material which
can take the weight of the 3 t counterweight section.
In this way you prevent the support material from being crushed by the 3
t counterweight section when the screw connections are loosened and
11.05.2000

crushing your hands and arms.

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 Rigging work
13.5 Counterweight

• You can access the nuts (2) for the screw

connections from below.
• Loosen the two screws (1) next to each of
the two counterweight lifting cylinders.
• Lower the counterweight sections onto the
counterweight platform and remove it
from the superstructure.

Installation

• Place the 3 t base plate onto the counter-

weight platform;
• Place one after the other:
– the first 4 t counterweight section
– the 7 t counterweight section and
– the second 4 t counterweight section
on the 3 t base plate.
• Place wooden planks (1) which are at least
as high as the 2 t counterweight section on
the upper 4 t counterweight section.
• Place the 3 t counterweight section in such
a way on the wooden planks that they are
in the right position after lifting for
screwing.

• Pay attention that the wooden planks do not cover the screws and nuts
in the 3 t counterweight section. If need be, correct the position.
• Hoist the counterweight onto the turntable and screw the 3 t counter-
weight section on the turntable (tightening torque, 1890 Nm).
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Operating Instructions GMK 5100 2 084 575 en 13 - 65

Rigging work
13.5 Counterweight

13.5.11 Rig the 3.5 t counterweight section (additional equipment)

With the additional equipment, the 7 t counterweight section can be repla-

ced by two 3.5 t counterweight sections. Both 3.5 t counterweight sections
are placed next to each other on the 4 t counterweight section.

Both 3.5 t counterweight sections are identical and can be placed on the
right as well as on the left on the t 4 t counterweight section.

• Attach the 3.5 t counterweight section at

all attachment points (1).

• Place the two 3.5 t counterweight sections

next to each other on the 4 t counter-
weight section in such a way that:
– the weight information (3.5 t) is visible
from the rear and
– the 4 t counterweight section plugs (1)
engage in the rear recesses (2) of the
3.5 t plates.
If you place the plates in this fashion, they
are secured against being confused.

H
11.05.2000

Rigging further counterweight parts is done the same way as is done after
rigging the 7 t counterweight section.

13 - 66 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.5 Counterweight

13.5.12 Slewing with the counterweight rigged

You may only slew the superstructure with rigged counterweight if the
truck crane is stabilized with a sufficiently largeoutrigger span. If this mini-
mum outrigger span is not observed, the truck crane can overturn to the
rear.
The following table shows, depending on counterweight and outrigger
span, whether slewing the superstructure is permitted or whether the
superstructure must be locked after rigging the counterweight.

Rigged outrigger span

25.6 x 24.6 ft 25.6 x 16.7 ft 25.6 x 8.2 ft

Slewing only permitted, if

the main boom is inclined
1t to a permitted inclination
in the operating area.1)
rigged counterweight

4t

7t
slewing permitted slewing permitted
11 t
rigging mode not
20 t permissible, rotating not
permissible
24 t

31 t

1)
permitted inclination in the operating area ➠ Rigging graphs in the
lifting capacity table

G
Risk of overturning when slewing with too little outrigger span!
Check using the table whether sufficient outrigger span is set for the
rigged counterweight before you unlock and slew the superstructure.
Only turn the superstructure if the truck crane is sufficiently stabilized.
In this way you can avoid the truck crane overturning to the rear during
slewing because of too much counterweight mass.
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Operating Instructions GMK 5100 2 084 575 en 13 - 67

Rigging work
13.5 Counterweight

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 Rigging work
13.6 Rigging work on the main boom

13.6 Rigging work on the main boom

13.6.1 Hook block on the bumper

The hook block can be attached to a separate vehicle on the front bumper
or tied on the carrier. ➠ Hook block on separate vehicle, p. 13-71.

Picking up the The hook block can be attached with a holding rope on the front bumper.
hook block

S
Accidents may occur if your view is obstructed!
Have someone guide you when releasing the hook block from the
holding rope beacause the view of the hook block is obscured by the
driver’s cab.

The main boom must be completely retracted.

• Enter the rigging code for the current rigging mode of the truck crane
00== on the SLI.

• Slacken the hoist rope and raise the main

boom simultaneously.
• Lower the main boom until the boom head
is situated vertically above the hook block.
• Disconnect the hook block from the re-
taining rope (1).
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Operating Instructions GMK 5100 2 084 575 en 13 - 69
Rigging work
13.6 Rigging work on the main boom

Attaching the The hook block must be reattached to the attachment plates on the front
hook block bumper with the holding rope for on-road driving.

G
Accidents may occur if your view is obstructed!
The reeved hook block rope lines obstruct your view on the roadway.
The number of legally permissible rope lines can differ depending on the
country in which you are working.
During on-road driving, the hook block may be reeved up to a maximum
of four fall according to EU regulations.

G
Risk of accidents from undesired swinging of the hook block!
If the holding rope for the hook block breaks during tightening of the
hoist rope, the hook block suddenly swings forward.
Therefore ensure that the banksman or other persons always stand at a
safe distance to the side of the hook block. Noone may be in front of the
hook block during tightening of the hoist rope.

H Do not attach the hook block to the front towing coupling! The reason for
this is, if a breakdown should occur, you would have to transfer the hook
block to the attachment plates before you could attach the tow-rod to the
towing coupling.

• Raise the hook block until it is directly

above the holding rope.
• Lower the hook block until you can hook
the holding rope (1) into the load hook of
the hook block.
• Lower the main boom onto the boom
support and pull the hoist rope taut using
the hoist so that the hook block is securely
in place.

H If the lifting limit switch switches off during tightening of the hoist rope,
you can override the shutdown of the lifting limit switch with the key
switch Override from the crane cab, or the banksman must pull the rope at
the lifting limit switch by hand; ➠ Overriding the shutoff system of the lifting
11.05.2000

limit switch, p. 10-61.

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 Rigging work
13.6 Rigging work on the main boom

13.6.2 Hook block on a separate vehicle

Picking up the
hook block

G
Risk of overturning!
Support the truck crane on outriggers before rotating the superstructure;
➠ Outriggers, p. 13-13.

S
Be careful not to damage the other vehicle!
Only lift the hook block from the separate vehicle when the boom head is
located directly above the hook block! This prevents the hook block from
swaying and avoids damage to the vehicle.

S
Be careful not to damage the hoist rope!
Do not ease down too much hoist rope when picking up and reeving the
hook block so as to prevent slack rope!
Slack rope causes rope loops to form on the hoist drum which can lead to
load slipping and destruction of the hoist rope.

• Slew the superstructure and lower the main boom until the boom head
is directly over the hook block.
• Reel off the hoist rope.
• Reeve the hoist rope; ➠ Reeving the hoist rope, p. 13-75.
• Lift the hook block off the separate vehicle.
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Operating Instructions GMK 5100 2 084 575 en 13 - 71
Rigging work
13.6 Rigging work on the main boom

Setting down the

hook block and
securing the

H
hoist rope for
on-road driving

We recommend that you transport the hook block on a separate vehicle in

a holder in such a manner as to make it possible for you to reeve the hoist
rope directly onto the hook block.

• Fully retract the main boom and reel the hoist rope on until the hook
block is suspended approx. 3.3 ft below the boom head.
• Lower the main boom and place the hook block on the separate vehicle.
• Remove the rope holding rods on the boom head from the bores.
• Remove the holding rods from the bores in the hook block and fold the
guards down.
• Remove the lifting limit switch weight from the hoist rope.
• Remove the rope end clamp from the bracket on the boom head or
hook block.
• Unreeve the hoist rope. Unreeving is possible when the rope end clamp
is fastened.
• Re-insert the rope holding rods into the boom head bores. Secure the
rods into place using the retaining pins.
• Fold up the guards on the hook block again and insert the holding rods
into the bores. Secure the rods into place using the spring cotter pins.
• Lower the main boom onto the boom support.
• Attach the rope end clamp with holding ropes and shackles to the

H
attachment plates of the front bumper.

Do not attach the rope end clamp on the front towing coupling! Other-
wise, in case of a breakdown, you must remove the rope end clamp and
attach it on the attachment plates before you can attach the tow-rod in the
towing coupling.

• Wind up the hoist rope until it is slightly taut.

The hoist rope is now secured for driving.

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 Rigging work
13.6 Rigging work on the main boom

13.6.3 Reeving and unreeving the hoist rope

The hoist rope can be reeved differently depending on the required lifting
capacity.
The load bearing capacity of the crane depends, among other things, on
the tractive force of the hoist and the number of reevings on the hook
block. The load bearing capacity is never greater than the tractive force of
the hoist times the number of rope lines between the boom head and the
hook block (minus the amount of friction);
➠ Possible reeving methods on the main boom, p. 13-80.
Loads over 211 650 lbs can only be raised using supplementary equip-
ment.
When determining the required lifting capacity, please note that the
weight of the hook block and the lifting tackle must be added to the load!
The actual useful load is therefore less than the value specified in the
table!

Rope end clamp A rope end clamp is fastened to the end of the hoist rope. It can be
fastened to the end of the hoist rope before reeving; reeving may also be
carried out when a rope end clamp is attached.
If the hoist rope is loaded, the rope end
clamp always aligns itself so that the point
(2) at which the carrying rope (1) ends in the
rope end clamp is on the same axis (X-X) as
the slinging point (3) (pulling axis).
• Always thread the hoist rope so that the
carrying rope runs alonng this pulling axis
and is not kinked when under a load.
The hoist rope is correctly threaded if it runs
into the rope clamp at position (2) and the
free end projects out of the rope end clamp
at position (4).

G
Accidents may occur if the load falls!
Only thread the hoist rope as described in this section (free end at
position (4)). If you thread the hoist rope differently, the carrying rope
kinks under load and becomes damaged and the load can fall uncon-
trolled to the ground.
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Operating Instructions GMK 5100 2 084 575 en 13 - 73
Rigging work
13.6 Rigging work on the main boom

The rope end clamp and rope wedge are labelled with their respective
size and corresponding rope diameter. Ensure that the rope wedge
inserted into the rope end clamp is labelled with the same size and rope
diameter as the rope end clamp.

G
Accidents may occur if the load falls!
If you use a rope wedge which does not belong to the rope end clamp.
The hoist rope slips out of the rope end clamp during crane operation
and the load crashes uncontrolled to the ground.

• Insert the hoist rope and rope wedge (3)

into the rope end clamp (2).
• Secure the rope clamp (1) to the loose end
of the rope.
The rope clamp provides additional safety
and prevents the hoist rope from slipping
out of the rope end clamp.

• Pull the rope end taut until the hoist rope

fits snugly in the rope end clamp.

H Observe the regulations of the country in which you are working when
attaching the rope clamp!

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 Rigging work
13.6 Rigging work on the main boom

Reeving the The rope holding rods on the boom head must be removed before you
hoist rope can reeve the hoist rope with rope end clamp attached. The rods prevent
the hoist rope from slipping out of the rope pulley.

The two guards on either side of the hook block must be folded down.

• Loosen the retaining pins and remove the

rope holding rods (1) to (4) from the bore
holes on the boom head.

• Unreel the hoist rope and, while doing

this, guide it through under the rope
grab (1).
If the ropes are reeved from both hoists, you
must guide the auxiliary hoist rope via the
rope grab.

Also use the rope grab when working with

lattice extensions.
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Operating Instructions GMK 5100 2 084 575 en 13 - 75
Rigging work
13.6 Rigging work on the main boom

• Loosen the spring cotter pins (3) and re-

move the holding rods (1) and (2) from the
bores in the hook block.
• Fold the guards on either side of the hook
block down.
The hoist rope may now be reeved.

Depending on the reeving method used, the rope end clamp is secured
either on the boom head or on the hook block; ➠ Possible reeving methods
on the main boom, p. 13-80.
The rope end clamp is attached to the boom head if the number of lines is
even (two, four, six, etc.). The rope end clamp is attached to the hook
block if the number of lines is odd (one, three, five, etc.).

• To reeve, guide the rope from the outer-

most sheave on the head of the boom into
the hook block from the front.
• Guide the rope upwards from the back
over the next sheave on the boom head,
etc.
• Secure the rope end clamp to the bracket
on the boom head (1) or the hook block (2)
depending on the reeving. Secure the bolt
with a retaining pin. 11.05.2000

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 Rigging work
13.6 Rigging work on the main boom

• Fold both guards on the hook block back

up and insert the holding rods (1) and (2)
in the bore holes. Secure the rods into
place using the spring cotter pins.

• Insert the rope holding rods (1) to (4) back

into the bore holes on the boom head.
Secure the rods into place using the retai-
ning pins.

Lifting limit The lifting limit switch must be mounted on the main boom during crane
switch on the work with the main boom. The lifting limit switch weight must be
main boom attached and the hoist rope must be attached.
If no anchor-to-bracket-switch is installed on the main boom, remove the
switch from the two-stage swing-away lattice extension, if necessary. For
operation with the main boom and two-stage swing-away lattice exten-
sion, the same anchor-to-bracket-switch is used; ➠ Operating instructions
for lattice extension.
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s
Operating Instructions GMK 5100 2 084 575 en 13 - 77
Rigging work
13.6 Rigging work on the main boom

Installing lifting limit switch

• Release the retaining pin (1) and place the
holder (3) with the lifting limit switch on
the grip (2).
• Secure the holder with the retaining pin (1).
• Connect the lifting limit switch at the
socket (4) on the distributor box.

S
Risk of damage if the lifting limit switch is blocked!
The lifting limit switch must not be blocked. If the lifting limit switch is
blocked, remove the blockage.
If the lifting limit switch is blocked, the hook block can catch on the
bottom of the main boom head when hoisting, and the hook block, main
boom head and hoist rope can be damaged.

Check the blockage and remove it if necessary

• Check whether the lifting limit switch is
blocked:
The lifting limit switch is blocked if the
plastic cap (2) is on the socket (1) and the
wire cable (3) is threaded into the plastic cap.

• If the lifting limit switch is blocked, remove

the blockage. To do so, pull the wire cable
(3) and thread it out of the plastic cap (2).
• Remove the plastic cap from the socket (1)
and insert it into the holder (4) on the
lifting limit switch.
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 Rigging work
13.6 Rigging work on the main boom

Attaching and mounting the lifting limit

switch weight
Before working with the crane, you must
mount the lifting limit switch weight and
attach it to the hoist rope.

• Mount the lifting limit switch weight on the

shackle (1).

• Pull the retaining pin (1) on the lifting limit

switch weight upward and fold out the two
sides of the weight.

• Close the two halves of the weight around

the last rope line leading upward.
• Pull the retaining pin (1) upwards and
close the two sides of the weight together.
Ensure that the retaining pin locks into
place and the two halves of the weight are
securely attached to each other.
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Operating Instructions GMK 5100 2 084 575 en 13 - 79

Rigging work
13.6 Rigging work on the main boom

13.6.4 Possible reeving methods on the main boom

Possible reeving methods on the two-stage swing-away lattice extension

(additional equipment) and boom extension (additional equipment);
➠ Operating instructions for lattice extension.

H The maximum load bearing capacities of the hook blocks do not corre-
spond with the maximum load bearing capacity, that with the GMK 5100
in conjunction with this hook block. This load bearing capacity depends
on the wire cable, reeving, friction force and is less; ➠ Reeving/unreeving
hoist rope, p. 13-73.

7 pulley hook block

max. Load bearing capacity of the hook block 100 t (220 790 lbs)
max. Load bearing capacity with the GMK 5100:
for 14-fall reeving 96 t (211 960 lbs)
for 13-fall reeving 90 t (198 710 lbs)
for 12-fall reeving 83 t (183 250 lbs)

14 fall 13 fall 12 fall

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13 - 80 2 084 575 en Operating Instructions GMK 5100

 Rigging work
13.6 Rigging work on the main boom

5-pulley hook block

max. Load bearing capacity of the hook block 75 t (165 600 lbs)
max. Load bearing capacity with the GMK 5100:
for 11-fall reeving 75 t (165 590 lbs)
for 10-fall reeving 69 t (152 350 lbs)
for 9-fall reeving 62 t (136 890 lbs)
for 8-fall reeving 56 t (123 540 lbs)

11 fall 10 fall 9 fall 8 fall

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Operating Instructions GMK 5100 2 084 575 en 13 - 81

Rigging work
13.6 Rigging work on the main boom

3-pulley hook block

max. Load bearing capacity of the hook block 50 t (110 390 lbs)
max. Load bearing capacity with the GMK 5100:
for 7-fall reeving 49 t (108 190 lbs)
for 6-fall reeving 42 t ( 92 730 lbs)
for 5-fall reeving 35 t ( 77 280 lbs)
for 4-fall reeving 28 t ( 61 820 lbs)

7 fall 6 fall 5 fall 4 fall

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 Rigging work
13.6 Rigging work on the main boom

1-pulley hook block

max. Load bearing capacity of the hook block 20 t ( 44 160 lbs)
max. Load bearing capacity with the GMK 5100:
for 3-fall reeving 20 t (44 160 lbs)
for 2-fall reeving 14 t (30 910 lbs)
for 1-fall reeving 7 t (15 460 lbs)

2 fall 1 fall
3 fall

1 fall

Hook tackle
max. Load bearing capacity of the hook tackle 8 t (17 660 lbs)
max. Load bearing capacity with the GMK 5100 7 t (15 460 lbs)
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Operating Instructions GMK 5100 2 084 575 en 13 - 83

Rigging work
13.6 Rigging work on the main boom

13.6.5 Anemometer

When operating the main boom you should install the anemometer onto
the holder on the main boom head.

5 6
• Fit the anemometer (1) onto the holder (4)
4 on the main boom head.
• Turn the anemometer so that the bores (5)
and (6) in the anemometer and holder are
aligned with each other.
• Insert the retaining pin (3) into the bore.
• Swivel out the anemometer and let it go. It
has to place itself in the vertical position
again after being swiveled out. The anemo-
meter also has to hang in a vertical positi-
3
1 on when the boom is raised.
2
• The connecting flange (2) is connnected at
the terminal box on the main boom head.

H
C0437

Lay the cable in such a way that it cannot be chafed or crushed.

• Connect the plug of the connecting cable

to the socket (1) of the terminal box on the
head of the main boom.

H The anemometer must be removed before unrigging the main boom.

The retaining pin remains in the holder.
11.05.2000

If the anemometer is not to be plugged into the two-stage swing-away lat-

tice extension, it must be stored away safely.

13 - 84 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.1 Superstructure emergency stop device

14 Malfunctions on the superstructure

14.1 Superstructure emergency stop device

The GMK 5100 truck crane is equipped with two emergency stop devices
on the superstructure. With these devices you:

– can turn off the crane engine even when outside the crane cab
(e. g. with an ignition lock malfunction or when access to the crane cab
is blocked);
– can turn off the crane control when a crane movement can not be
switched off (e. g. when there is a crane control malfunction).

Switching off the You can turn off the crane engine from outside the crane cab by switching
crane engine off the battery master switch.

The battery master switch (1) is located on

the right-hand side of the superstructure,
under the battery box behind the side plate,
and is accessible from below.

• Switch off the main battery switch. Turn

the selector handle so that it can be pulled
off.
The crane engine switches off.
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Operating Instructions GMK 5100 2 084 575 en 14 - 1
Malfunctions on the superstructure
14.1 Superstructure emergency stop device

Crane control In an emergency you can switch off the crane control with the Crane
emergency stop control emergency stop switch. The switch is located on the middle plug-in
switch module in the crane cab.

G
Risk of overload if used improperly!
The Crane control unit emergency stop switch is only intended for the emer-
gency when the crane functions cannot be braked or stopped by the
corresponding control lever movements. Never use this switch to brake
crane movements in normal crane operation.
The sudden stopping of the crane movement can lead to an overload of
the truck crane at high working speeds and unfavourable combinations
between the working position and rigging mode.

• Press the Crane control emergency stop switch. The switch clicks in.
The crane engine is immediately switched off; the crane functions are
abruptly stopped.

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

Releasing crane functions again

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

• Turn off the ignition.

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

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

If the crane movements are not carried out as normal or if you need to
carry out an emergency shut down, notify the GROVE Product Support
responsible.
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 Malfunctions on the superstructure
14.2 Troubleshooting for malfunctions that occur during crane operation

14.2 Troubleshooting for malfunctions that occur during

crane operation
If a malfunction occurs:
• Keep calm!
• If possible put down the load immediately. Retract the main boom
completely and set it down on the boom support.
• Use warning signs in the crane cab to prevent unauthorized use of the
truck crane. Remove the ignition key.
• Inform your supervisor.

G
Risk of accidents when the load is suspended!
Under no circumstances is repair work to be carried out with a suspended
load!

You may override the SLI to set down the load if SLI malfunctions occur.
Observe the warning and safety information in the section SLI overriding
when doing so; ➠ p. 12-34.

G
Risk of accidents!
Do not perform any crane movements that may increase the size of the
load moment when a load is on the hook block and the SLI is overriden.

• Try to repair the malfunction. Notify your local GROVE Product Support
if you cannot repair the problem yourself.

Load cannot be • Secure the danger zone using cordons and assigned personnel.
lowered
• Notify qualified repair personnel or local GROVE Product Support.

G
Accidents may occur due to inappropriate emergency operation!
Only trained, qualified personnel may carry out an emergency operation
if unrigging requires the manual operation of solenoid valves.
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Operating Instructions GMK 5100 2 084 575 en 14 - 3

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

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 Malfunctions on the superstructure
14.3 Electrical system

14.3 Electrical system

14.3.1 Plug-in modules and consoles

Name in
Pos. the elec. Function
circ. diag.
1 1.6 D monitoring of crane engine and hydraulicsystem
/ headlight / windscreen wiper/washing system /
additional heating system or additional heating
system with timer (both additional equipment)
2 5.2 D display, input and crane control emergency stop /
telescoping gear display / telescoping control
level function display, derrick / display and
counterweight hoist unit control
3 6.2 D anemometer / spirit level or electronic level (can
be switched over) (additional equipment)/
superstructure lock / lifting limit switch shutoff
system display/ slewing gear permanent brake
display/ SLI override, lifting limit switch /
outrigger pressure indicator (additional
equipment)
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s
Operating Instructions GMK 5100 2 084 575 en 14 - 5
Malfunctions on the superstructure
14.3 Electrical system

Plug-in module
Pos. name in the Function
elec. circ. diag.

1 Safe load indicator (SLI)

7.1 D set crane engine constant motor speed /

2
outrigger operation (additional equipment)
+BE 630. clutch control lever for telescoping, derricking and
rev. main hoist / disconnect main hoist,
3 derricking gear, telescoping gear /
control level function change-over
derricking ↔ telescoping
+BE 630. KL control lever for slewing gear, auxiliary
hoist (additional equipment) / disconnect
4
auxiliary hoist / slewing gear permanent
brake / incline crane cab
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 Malfunctions on the superstructure
14.3 Electrical system

14.3.2 Fuses

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

The fuses are divided into the groups F 1 to F 13.

Groups F 1 to F 9

The fuse groups F 1 to F 9 can be accessed

from outside by opening the flap on the front
of the crane cab (8 mm hexagon spanner).

Each group consists of six fuses:

The following tables show the designations

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

Designation in Rating (A) Function

circuit diagram:
F1

1 20 Crane engine E-control

2 10 Crane engine diagnostic plug

3 10 Flame start system (additional

equipment)

4 15 No function

5 10 Crane cab ceiling lamp,

cigarette lighter
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6 10 No function

s
Operating Instructions GMK 5100 2 084 575 en 14 - 7
Malfunctions on the superstructure
14.3 Electrical system

Designation in Rating (A) Function

circuit diagram:
F2

1 10 No function
2 10 No function
3 10 No function
4 10 No function
5 10 No function
6 15 No function

Designation in Rating (A) Function

circuit diagram:
F3

1 10 Indicator and warning lamps for engine,

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

Designation in Rating (A) Function

circuit diagram:
F4

1 5 Switches and indicator lamps

2 15 working area spotlight ,
switch and indicator lamps for working
area spotlight and derricking gear
shutdown / telescoping gear /
disconnect main hoist
3 5 Horn, Switch and indicator lamps for
11.05.2000

auxiliary hoist shutdown, Slewing gear

permanent brake and crane cab incline
4 10 Crane cab heating

14 - 8 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.3 Electrical system

Designation in Rating (A) Function

circuit diagram:
F4

5 15 crane cab electronic level (additional

equipment) / SLI pre-warning,
shutdown / outrigger pressure
indicator (additional equipment)

6 10 SLI deactivation, anchor-to-bracket-

switch shutdown,
dead man’s switch, seat contact

Designation in Rating (A) Function

circuit diagram:
F5

1 15 Crane control power supply

2 15 Crane control power supply

3 15 Crane control power supply

4 15 Crane control power supply

5 15 Crane control power supply

6 15 Crane control power supply

Designation in Rating (A) Function

circuit diagram:
F6

1 10 Shutdown of main hoist,

main hoist slewing indicator

2 10 Shutdown for auxiliary hoist,

auxiliary hoist slewing indicator

3 10 Shutdown for derricking gear

Telescoping gear locking/unlocking

4 10 Control lever initial position left, right

5 10 Slewing gear

6 10 No function
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Operating Instructions GMK 5100 2 084 575 en 14 - 9
Malfunctions on the superstructure
14.3 Electrical system

Designation in Rating (A) Function

circuit diagram:
F7

1 10 SLI

2 10 Proximity switch telescoping cylinder

3 5 No function

4 10 Crane control display

Emergency operation crane control

5 10 Crane control

6 10 Crane engine E-control

Designation in Rating (A) Function

circuit diagram:
F8

1 15 Crane cab heating

2 15 Radio / voltage transformer

3 15 No function

4 5 Crane control unit 0

5 5 Crane control unit 1

6 5 Crane control unit 2

Designation in Rating (A) Function

circuit diagram:
F9

1 20 Oil cooler

2 3 Oil cooler (relay)

3 15 No function

4 10 No function

5 5 Central lubrication system

6 10 No function
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 Malfunctions on the superstructure
14.3 Electrical system

Groups F 10 The fuse groups F 10 to F 13 are located in the battery box. These fuse
to F 13 groups consists of only one fuse each.

G
Battery poses a danger from lead and connections containing lead!
Battery poles, clamps, and parts of the battery itself contain lead and lea-
ded connections.
Wash hands after working directly or indirectly with these parts!

• Open the lid of the battery box.

You can access fuses F 10 (1) and F 11 (2) if
you take the cover off the terminal box.

Fuses F 12 (3) and F 13 (4) are in the holder

behind the terminal box.

Pos. Designation Designation Function

in circuit in circuit
diagram: diagram:

Central fuse for the SLI supply

1 F 10 50
line

Preliminary fuse for

2 F 11 50 central fuse
superstructure

Preliminary fuse for crane control

3 F 12 20
power supply

Heating system preliminary fuse,

voltage transformer/
fuse for all consumer equipment,
4 F 13 20 which is still supplied with power
when the battery master switch is
switched off.
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Malfunctions on the superstructure
14.3 Electrical system

Blank page

11.05.2000

14 - 12 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.3 Electrical system

14.3.3 SLI fuses

On the SLI you will find a fuse for the central unit and several fuses for the
SLI outlets.
All outlets are individually protected by fuses. If one of the fuses is
defective you can no longer carry out the corresponding crane function.

Replacing fuses

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

EKS 3 To change a fuse you need to remove the

SLI plug-in module.

• Remove the four retaining bolts at the

corners of the front plate of the SLI
plug-in module and pull out the plug-in
module.
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Operating Instructions GMK 5100 2 084 575 en 14 - 13
Malfunctions on the superstructure
14.3 Electrical system

The fuses are on the back of the plug-in

module and are labelled S I 1 to S I 13.

The following table shows the assignment of

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

Designation in Rating (A) Function

circuit diagram:

SI1 5 SLI internal

SI2 5 SLI shutdown display

SI3 5 Lift main hoist shutdown

SI4 5 Shutdown lowering

SI5 5 Shutdown extending

SI6 5 Lift auxiliary hoist shutdown

SI7 5 Shutdown raising

SI8 5 Shutdown retracting

SI9 5 Lower auxiliary hoist shutdown

S I 10 5 free

S I 11 5 SLI early warning display

S I 12 5 free

H
S I 13 5 SLI central unit

If the fuse on an SLI outlet fails again, notify your local GROVE Product
Support.
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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4 Troubleshooting and malfunction correction

14.4.1 Crane engine malfunctions

Malfunction Cause Action

Engine does not start (starter Battery master switch not Switch battery master switch
motor does not turn over) switched on on; ➠ p. 11-7.
Ignition switched off Switch on ignition;
➠ p. 11-11.
Engine does not start Batteries not charged enough Charge batteries
(starter motor turns over) Fuel tank empty 1. Fill fuel tank,
➠ p. 11-9.
2. Bleed fuel system,
➠ Crane engine
manufacturer’s operating
manual
fuse F1/1 SS, F1/2 SS or F7/6 Check fuse, replace if
SS defective necessary; ➠ p. 14-7.
Flame-start system indicator Check fuses and replace if
lamp does not go on, fuse necessary; ➠ p. 14-7.
F1/3 faulty
Engine coolant temperature Coolant level too low Top up coolant
too high Radiator dirty outside Clean outside of radiator
V-belt for coolant pump on Tension V-belts, see crane
engine slack engine manufacturer’s
operating manual
Engine oil pressure too low Engine oil level too low Check oil level, fill if
necessary; ➠ p. 11-4 and
Maintenance manual
Engine can not be turned off Malfunction in the electronics Turn off engine with
with the ignition key emergency stop device,
➠ p. 14-1
Indicator lamp Crane engine Crane engine air filter is dirty Replace crane engine air filter
air filter lights up

Indicator lamp Flame start Problem with flame-start Inform GROVE Product
system lights up when crane system Support or the service
engine is running department of the crane
engine manufacturer and
have the flame-start device
checked.
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Operating Instructions GMK 5100 2 084 575 en 14 - 15
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Malfunction Cause Action

No function, rane engine dia- Fuse F3/5 SS faulty

gnostics plug

Engine electronic system war- Malfunctions in the motor electronics cause engine
ning lamp lights during opera- performance to decrease continuously. The engine will not
tion, the power of the engine switch off, however so lowering the load and unrigging the
continuously drops truck crane can still be done.
Coolant level too low, Coolant level; ➠ p. 11-8;
Oil level too low, Oil level; ➠p. 11-4;
Air filter dirty. Air filter;
➠ Maintenance manual
V-belt too loose Check V-belt tension;
➠ Crane engine manufacturer’s
operating manual
Plug or cable on the control Check plug on control unit
unit loose (near the diagnostic plug);
➠ p. 10-58
Cabling behind the Check cable, Notify GROVE
accelerator damaged Product Support of any
damage

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.2 Main hoist malfunctions

Malfunction Cause Action

Main hoist not functioning Rocker switch Shutdown main Switch off rocker switch
or malfunctioning (lifting, hoist switched on Shutdown main hoist
lowering or fast speed not
Fuse F3/4 Superstructure or Check fuse, replace if
functioning)
F4/2 Superstructure defective necessary; ➠ p. 14-7.
Dead man’s switch not Press dead man’s switch
activated
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-94.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 14-57.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 14-2.
Main hoist lowering not func- Lowering limit switch Leave shutdown area,
tioning (in addition, check all triggered Lift main hoist
causes in the “Main hoist not
functioning” section!)
Main hoist lifting not Lifting limit switch triggered Leave shutdown area, lower
functioning (warning lamp on) main hoist
(in addition, check all causes
SLI shutdown Leave shutdown area;
in the “Main hoist not func-
tioning” section!)
(warning lamp on) ➠ p. 12-31.
Fuse F4/6 Superstructure or Check fuse, replace if
F7/1 Superstructure defective necessary; ➠ p. 14-7.
Lifting, lowering or fast speed Corresponding function is Acknowledge error message
do not function blocked by the crane control once; ➠ p. 12-93.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-86.
11.05.2000

Lifting does not function Fuse on corresponding SLI Replace if necessary;

outlet defective ➠ p. 14-7.

Operating Instructions GMK 5100 2 084 575 en 14 - 17

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Malfunction Cause Action

No lifting or lowering, or pos- Maximum speed set too low Increase maximum speed on
sible only at very low speed the display Enter power unit
speed; ➠ p. 12-89.
Lifting or lowering function Malfunction on the crane Stop the movement with the
can not be switched off control Crane control emergency stop

H
switch; ➠ p. 14-2.

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

movement.
In this case also check the causes listed in the Main hoist not functioning
section!

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.3 Auxiliary hoist malfunctions

Malfunction Cause Action

Auxiliary hoist not Rocker switch Shutdown Switch off rocker switch
functioning or malfunctioning auxiliary hoist switched on Shutdown auxiliary hoist
(lifting, lowering or fast speed Fuses F3/4 Superstructure or Check fuses, replace if
not functioning) F4/3 Superstructure or F6/2 necessary; ➠ p. 14-7.
Superstructure defective
Dead man’s switch not Press dead man’s switch;
activated ➠ p. 10-62.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ ➠ p. 12-94.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 14-57.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 14-2.
Auxiliary hoist lowering not Lowering limit switch Leave shutdown area,
functioning (Also check all triggered Lift main hoist
causes in the “Auxiliary hoist
not functioning” section!)
Auxiliary hoist lifting not Lifting limit switch triggered Leave shutdown area,
functioning (Also check all (warning lamp on) Lower the auxiliary hoist
causes in the “Auxiliary hoist SLI shutdown Leave shutdown area; down
not functioning” section!) (warning lamp on) area; ➠ p. 12-31.
Fuse F4/6 Superstructure or Check fuse, replace if
F7/1 Superstructure defective necessary; ➠ p. 14-7.
Lifting, lowering or fast speed Corresponding function is Acknowledge error message
do not function blocked by the crane control once; ➠ ➠ p. 12-94.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58 , 14-58.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
11.05.2000

Support; ➠ p. 12-86.

s
Operating Instructions GMK 5100 2 084 575 en 14 - 19
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Malfunction Cause Action

No lifting or lowering, or pos- Maximum speed set too low Increase maximum speed on
sible only at very low speed the display Enter power unit
speed; ➠ p. 12-89.
Lowering does not function Fuse on corresponding SLI Replace if necessary;
outlet defective ➠ p. 14-13.
Lifting or lowering function Malfunction on the crane Stop the movement with the
can not be switched off control Crane control emergency stop

H
switch; ➠ p. 14-2.

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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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.4 Derricking gear malfunctions

Malfunction Cause Action

Derricking gear not func- Dead man’s switch system Press dead man’s switch,
tioning or malfunctioning not activated ➠ p. 10-62.
(raise boom, lower boom or
Fuse F4/2 Superstructure or Check fuse, replace if
fast speed not functioning)
F6/3 Superstructure defective necessary; ➠ p. 14-7.
Right-hand control lever set to Set control lever to Derricking
Telescoping function or Derrick- function
ing lattice extension switched on
Rocker switch Shutdown Switch off rocker switch
derricking gear switched on Shutdown derricking gear
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ ➠ p. 12-94. If the
message is displayed) error message is repeated,
change the connections on
the control units; ➠ p. 14-57.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 14-2.
Lower boom not functioning Lifting limit switch triggered Leave shutdown area,
(Also check all causes in the (warning light on) raise boom
“Derricking gear not func-
SLI shutdown Leave shutdown area;
tioning” section!)
(warning lamp on) ➠ p. 12-31
Fuse F4/6 Superstructure or Check fuse, replace if
F7/1 Superstructure defective necessary
Raising or lowering the boom Corresponding function is Acknowledge error message
do not function blocked by the crane control once; ➠ ➠ p. 12-94.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-86.
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Operating Instructions GMK 5100 2 084 575 en 14 - 21
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Raising or lowering the boom Fuse on corresponding SLI Replace if necessary;

does not function outlet defective ➠ p. 14-13.
No raising or lowering the Maximum speed set too low Increase maximum speed on
boom, or possible only at the display Enter power unit
very low speed speed; ➠ p. 12-89.

Raising or lowering the boom Malfunction on the crane Stop the movement with the
function can not be switched control Crane control emergency stop

H
off switch; ➠ p. 14-2.

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!

14.4.5 Telescoping gear malfunctions

Malfunction Cause Action

Telescoping gear not Dead man’s switch system Press dead man’s switch;
functioning or malfunctioning not activated ➠ p. 10-62.
(telescope in, telescope out or Fuse F7/2 Superstructure or Check fuses, replace if
fast speed not functioning) F4/2 Superstructure or F6/3 necessary; ➠ p. 14-7.
Superstructure defective
Right-hand control lever set to Set control lever to Telescoping
Derricking function
Telescoping gear shutdown Switch off rocker switch
rocker switch switched Shutdown telescoping gear;
➠ p. 10-37.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ ➠ p. 12-94.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 14-57.
Crane control emergency stop Release crane functions
again; ➠ p. 14-2.
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switch pressed in

14 - 22 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Telescope section and tele- Valve defective Note down the Display status –
scoping cylinder do not locking number code on the
display and inform GROVE
lock/unlock any functions
Product Support; ➠ p. 14-58.
Extension of the telescoping SLI shutdown Leave shutdown area
not functioning (warning lamp on)
(Also check all causes in the Fuse F4/6 Superstructure or Check fuse, replace if
“Telescoping gear not F7/1 Superstructure defective necessary; ➠ p. 14-7.
functioning” section!) Lifting limit switch triggered Leave shutdown area,
(warning lamp on) Lower hoist
Telescope retracting not Insufficient boom lubrication Lubricate boom,
functioning (Also check all ➠ Maintenance manual
causes in the “Telescoping Boom too flat Raise boom
gear not functioning”
section!)

Telescope section does not Telescope section is still Unlock telescope section;
move when the control lever locked ➠ p. 12-71.
is extended

Telescoping cylinder is not Lock telescope cylinder;

locked ➠ p. 12-68.
Lock telescope section/ Defective hydraulics/electrics Note down the number code
telescoping cylinder not on the status display when
functioning locking and inform GROVE
Product Support; ➠ p. 12-85.
Telescoping out or in or fast Corresponding function is Acknowledge error message
speed not functioning blocked by the crane control once; ➠ ➠ p. 12-94.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-86.
Retracting or extending does Fuse on corresponding SLI Replace if necessary;
not function outlet defective ➠ p. 14-13.
No retracting or extending, or Maximum speed set too low Increase maximum speed on
11.05.2000

possible only at very low the display Enter power unit

speed speed; ➠ p. 12-89.

Operating Instructions GMK 5100 2 084 575 en 14 - 23

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Retracting or extending Malfunction on the crane Stop the movement with the
function can not be switched control Crane control emergency stop
off switch; ➠ p. 12-89.
The boom can no longer be The electric controller of the Retract the telescope section
extended, the locking/un- hydraulic system is using hydraulic emergency
locking mechanism no longer interrupted (e.g. a cable in the mode; ➠ Retracting emergency
reacts to the control instru- main boom is broken) mode, p. 13-43.
ments in the crane cab

The boom can no longer be The hydraulic supply is Extend the telescope section
extended, the telescoping interrupted with mechanical emergency
cylinder can no longer be mode; ➠ Retracting emergency

H
moved mode, p. 13-43.

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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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.6 Slewing gear malfunctions

Malfunction Cause Action

Slewing gear does not Mechanical superstructure Disengage lock;

function lock engaged ➠ p. 12-9.
Slewing gear permanent Release slewing gear
brake applied permanent brak; ➠ p. 12-48.
Dead man’s switch not Press dead man’s switch;
activated ➠ p. 10-62.
Fuses F6/5 Superstructure or Check fuses, replace if
F3/4 Superstructure defective necessary; ➠ p. 14-7.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ ➠ p. 12-94.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 14-64.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 14-2.
Slewing to left or right not Corresponding function is Acknowledge error message
functioning blocked by the crane control once; ➠ ➠ p. 12-94.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-86.
Slewing is not, possible, or Maximum speed set too low Increase maximum speed on
only at a very low speed the display Enter power unit
speed; ➠ p. 12-89.
Slewing can not be Malfunction on the crane Stop the movement with the
switched off control Crane control emergency stop
switch; ➠ p. 14-2.
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Operating Instructions GMK 5100 2 084 575 en 14 - 25

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.7 Malfunctions at the counterweight hoist unit

Malfunction Cause Action

No function, counterweight A control unit of the crane Acknowledge error message

hoist unit control has failed (error once; ➠ ➠ p. 12-94.
message will be shown) If the error message is
repeated, change the
connections on the control
units;
➠ p. 14-57.
Crane control emergency stop Release crane functions
switch pressed again; ➠ p. 14-2.
Counterweight hoist unit is Press down the Release counter-
not released weight hoist unit rocker switch.
Fuse F 3/5 SS faulty Check fuses, replace if
necessary; ➠ p. 14-7.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-86.
Corresponding function is Acknowledge error message
blocked by the crane control once; ➠ p. 12-94.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 14-58.
Indicator lamps for “lifting The electronic system has recognised an electrical or a logic
cylinder extended” or indica- error; ➠Indication of a malfunction, p. 13-58.
tor and warning lamps for lok-
king/unlocking are flashing si-
multaneously

No function, lock/unlock Counterweight lifting cylinder Counterweight lifting cylinder

counterweight hoist unit retracted extended

No function, extend/retract counterweight hoist unit not completely lock or unlock

counterweight lifting cylinder locked or unlocked in end counterweight hoist unit
position (indicator or warning lamp
must light)
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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.8 Crane control malfunctions

Malfunction Cause Action

The Crane control display re- One or more of the following Check the fuses, replace if
mains dark even though the superstructure fuses is necessary; ➠ p. 14-7.
ignition is switched on. defective:
F5 1 / 2 / 3 / 4 / 5 / 6
F7 4 / 5 or F8 4 / 5 / 6
On the Crane control display Length indicator or proximity With emergency operation,
the EMERGENCY OPERATION switch defective or no retract the main boom and
message appears connection any more (e. g. drive to a repair station;
cable broken or damaged) ➠ p. 13-43.
At the Crane control display, The electrical connection Establish the plug connection
the NOT CONNECTED messa- between the main boom and under the main boom before
ge appears the turntable is interrupted the derricking cylinder foot
(plug connection not made or axis or check the cable for
cable damaged or broken) damage and have it repaired.
In the Crane control display The current telescoping or Acknowledge error (the
the two ECOS number codes locking status does not agree display automatically changes
appear one above the with the values stored in the to the Enter telescoping after
other: 00001000 control system (e. g. after emergency operation menu) and
STATUS: 0 0 0 0 0 0 0 1 telescope with emergency enter the current telescoping;

H
operation) ➠ p. 14-76.
If there are further malfunctions on the crane control, the corresponding
error messages will appear on the Crane control display; ➠ p. 14-57.
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Operating Instructions GMK 5100 2 084 575 en 14 - 27

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.9 Hydraulic system / hydraulic oil cooler malfunctions

Malfunction Cause Action

Hydraulic oil temperature Hydraulic system under Stop crane operations and
above 80 °C (176 °F) severe strain allow the crane engine to run
Fan in hydraulic oil cooler is until the oil has cooled down.
running.
Hydraulic oil temperature Fuse F 9/1 superstrucure or Check fuses, replace if
over 80 °C (176 °F) F 9/2 faulty necessary; ➠ p. 14-7.
Fan in the hydraulic oil cooler
Thermostat valve of the fan Have thermostat valve
not running
defective replaced
Hydraulic oil filter control Hydraulic oil filter Change hydraulic oil filter;
circuit warning lamp lights ➠ Maintenance manual
Hydraulic oil return flow filter Hydraulic oil filter dirty Change hydraulic oil filter;
warning lamp lights ➠ Maintenance manual

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.10 Malfunctions on the SLI

S
You must halt crane operation immediately when SLI error messages
appear!

Repairs to the SLI may only be carried out by properly qualified

personnel.

If malfunctions cannot be eliminated by means of the actions described

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

1. During which crane operation did the malfunction occur?

2. What is indicated on the SLI status display?
3. What is indicated on the SLI information display?
4. What is shown in the status displays Rigging mode and Reeving?
5. What is indicated on the information display when the information
selector switch is moved to different positions?
6. Have the fuses been replaced?

Other malfunc-
tions on the SLI

Malfunction Cause Action

SLI does not function Power supply switched off Switch on ignition
(displays not lit, no buzzer
Fuse F7/1 Superstructure or Check fuses, replace if
signal)
F4/6 Superstructure defective necessary; ➠ p. 14-13.
(fuses behind the flap on the
front panel of the crane cab)
Fuse S I 13 defective
(fuse at the rear on the SLI
plug-in module)
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Operating Instructions GMK 5100 2 084 575 en 14 - 29

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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

Error messages from error group 1, sensory mechanism

Error Cause Action

message

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

chamber does not react If line is O.K., switch off
pressure sensor 1;
➠ p. 14-38 and notify
GROVE Product Support

1. 01. 2...6 Pressure sensor A, lower Switch off pressure sensor 1;

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

1. 01. 7 Notify GROVE Product Support

1. 01. 8 Information message; Message remains as long as

You have switched off the ignition is switched off
pressure sensor A because of
an error message

1. 02. 1 Pressure sensor B, lower Check line; ➠ p. 14-40

chamber does not react If line is O.K., switch off
pressure sensor 2;
➠ p. 14-38 and notify
GROVE Product Support

1. 02. 2...6 Pressure sensor B, lower Switch off pressure sensor 2;

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

1. 02. 7 Notify GROVE Product Support

1. 02. 8 Information message; Message remains as long as

You have switched off the ignition is switched off
pressure sensor B because of
an error message

1. 03. 1 Pressure sensor upper Check line; ➠ p. 14-40. If line

chamber does not react is O.K., notify GROVE Product
Support

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

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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

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

1. 04. 2...6 Angle sensor A, Switch off angle sensor A,

basic section reports error basic section; ➠ p. 14-38 and
notify GROVE Product Support

1. 04. 7 Notify GROVE Product Support

1. 04. 8 Information message; Message remains as long as

You have switched off angle the ignition is switched off
sensor A, basic section
because of an error message

1. 05. 1 Angle sensor B, Check line; ➠ p. 14-40.

basic section does not react If line is O.K., switch off angle
sensor B; ➠ p. 14-38 and
notify GROVE Product Support

1. 05. 2...6 Angle sensor B, Switch off angle sensor B,

basic section reports error basic section; ➠ p. 14-38 and
notify GROVE Product Support

1. 05. 7 Notify GROVE Product Support

1. 05. 8 Information message; Message remains as long as

You have switched off angle the ignition is switched off
sensor B, basic section
because of an error message

1. 06. 1 Length indicator A for Check line; ➠ p. 14-40.

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

1. 06. 2...6 Length indicator A for Switch off length indicator A

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

1. 06. 7 Notify GROVE Product Support

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Operating Instructions GMK 5100 2 084 575 en 14 - 31

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

1. 06. 8 Information message; Message remains as long as

You have switched off length the ignition is switched off
indicator A for telescope
section IV because of an error
message

1. 07. 1 Length indicator B for Check line; ➠ p. 14-40.

telescope section IV does not If line is O.K., switch off
react length indicator B; ➠ p. 14-38
and notify GROVE Product
Support

1. 07. 2...6 Length indicator B for Switch off length indicator B

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

1. 07. 7 Notify GROVE Product Support

1. 07. 8 Information message; Message remains as long as

You have switched off length the ignition is switched off
indicator B for telescope
section IV because of an error
message

1. 08. 1 Length indicator A of the Check line; ➠ p. 14-40.

telescoping cylinder does not If line is O.K., switch off
react length indicator A of the
telescoping cylinder;
➠ p. 14-38 and notify
GROVE Product Support

1. 08. 2...6 Length indicator A of the Switch off length indicator A

telescoping cylinder reports of the telescoping cylinder;
an error ➠ p. 14-38 and notify
GROVE Product Support

1. 08. 7 Notify GROVE Product Support

1. 08. 8 Information message; Message remains as long as

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

1. 09. 1 Length indicator B of the Check line; ➠ p. 14-40.

telescoping cylinder does not If the line is O.K., switch off
react length indicator B of the tele-
11.05.2000

scoping cylinder; ➠ p. 14-38

and notify GROVE Product
Support

14 - 32 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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

telescoping cylinder reports of the telescoping cylinder;
an error ➠ p. 14-38 and notify
GROVE Product Support

1. 09. 7 Notify GROVE Product Support

1. 09. 8 Information message; Message remains as long as

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

1.15.1...6 Inform GROVE Product Support

1.16.1...6 Inform GROVE Product Support

1.18.1...6 Inform GROVE Product Support

1.19. 1 Differences between main Check, length indicator, plug

boom length and length connections and supply lines;
indicator are too large. ➠ p. 14-40.
The Actual load and Current Check the illustration from
radius displays are flashing the outside.
If necessary, contact GROVE
Product Support.

1.21. 1 Differences between rope Notify GROVE Product

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

Error messages from error group 2, digital inlets

Error Cause Remedy
message
2. 01. 1 Recognition of locking point
for telescopic section line
breakage
Check supply line;
2. 01. 4 Recognition of locking point ➠ p. 14-40.
for telescopic section earth
contact
2. 01. 5 Inform GROVE Product Support
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Operating Instructions GMK 5100 2 084 575 en 14 - 33

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

2. 05. 1 Line breakage recognition

between SLI and rocker
switch Disconnect main hoist
2. 05. 4 Loose connection recognition Check supply line.
in the line between SLI and
rocker switch Disconnect main
hoist
2. 05. 5 Inform GROVE Product Support
2. 06. 1 (only for additional
equipment)
line breakage recognition Check supply line
between SLI and
superstructure lock
2. 06. 4 (only for additional
equipment)
loose connection recognition Check supply line
in the line between the SLI
and the superstructure lock
2. 07. 1 Line breakage recognition
between SLI and rocker
switch Disconnect auxiliary hoist
2. 07. 4 Loose connection recognition Check supply line
in the line between SLI and
rocker switch Disconnect
auxiliary hoist
2. 07. 5 Inform GROVE Product Support
2. 11. 1 Recognition of locking point
for telescopic section line
breakage
2. 01. 4 Recognition of locking point Check supply line;
for telescopic section earth
contact
➠ p. 14-40.
2. 11. 5 Inform GROVE Product
Support
2. 12. 1 telescopic part locked
recognition (at the
telescoping cylinder) line
breakage
Check supply line;
2. 12. 4 telescopic part locked ➠ p. 14-40.
recognition (at the
11.05.2000

telescoping cylinder) loose

connection
2. 12. 5 Inform GROVE Product Support

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

2. 13. 1 Line breakage recognition

telescoping cylinder left
locked
Check supply line; ➠ p. 14-40.
2.13. 4 Loose connection recognition
telescoping cylinder left locked
2.13. 5 Inform GROVE Product Support
2.14. 1 Line breakage recognition
telescoping cylinder right
locked
Check supply line; ➠ p. 14-40.
2.14. 4 Loose connection recognition
telescoping cylinder right
locked
2.14. 5 Inform GROVE Product Support
2.17. 1 Key switch recognition Remove line SLI override or
Override line breakage check the supply line;
➠ p. 14-40.
2.17. 4 Key switch recognition Remove line SLI override or
Override loose connection check the supply line;
➠ p. 14-40.

Error messages from error group 3, kinematic system

Error Cause Remedy

message

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

control interrupted

3.02. 4 Communications with crane Acknowledge fault and call up

control interrupted during teleautomatism again.
telescoping with
teleautomatism

3. 06. 3 Differences occurred in when the current telescope

comparison with the crane status is indicated on the -
control telescope status; Crane control display, take over
(e. g. if the current telescope telescoping from the crane
status was entered on the control; ➠ p. 14-40.
Crane control display after If neither the SLI not the Crane
mechanical emergency control display shows the
operation) current telescoping, inform
GROVE Product Support.
11.05.2000

Operating Instructions GMK 5100 2 084 575 en 14 - 35

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Error messages from error group 5, Range of cranes

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

Error messages from error group 6,

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

Error messages from error group 8, software

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

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Error Cause of error Countermeasure

message
9.01.2 The newly entered value for Confirm reeving and/or
the reeving or the rigging rigging mode
mode was not yet confirmed.
9.03.6 SLI is overridden Error message goes out
when the override is removed

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

the GROVE Product Support responsible.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 14 - 37
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Switch off sensor/ The SLI works with a two-channel sensory system in which most pressure
indicator during sensors, length indicators and angle sensors are in duplicate. If there is an
malfunction error on one of these sensors or indicators with a corresponding error
message, you can switch it off and thus cancel the SLI shutdown.

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

If you have switched off a sensor or pickup because of a malfunction,

immediately inform the GROVE Product Support responsible and have
the cause of error rectified as quickly as possible.

Switching off sensors or indicators

• Press the membrane switch Error information until the error message of
r the sensor or indicator which should be switched off appears on the
display Information.
This error message always ends with a sensor or indicator on one of the
!0"4 numbers 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
no Switch on 2nd level. Keep both membrane switches pressed.
• Press the Acknowledge membrane switch once and let go of all mem-
p brane switches again.
The last number in the error message now changes to an 8.
!0"8 With this final number you can see that a sensor or indicator is switched off.

H After switching off a sensor/indicator, you should check that the remai-
ning sensor/indicator is functioning correctly; ➠ p. 14-39.

Releasing shutdown
The sensor or indicator remains switched off until the ignition is switched off.
If you turn the ignition back on before the error has been eliminated, a
new error message will appear for this sensor or indicator (with a final
number of 2 to 6) and there will be another SLI shutdown.
11.05.2000

14 - 38 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Check that the The Error message table ( ➠ page 14-30) shows next to the error messa-
remaining ge if the sensor/indicator which was switched off is
sensor/indicator – a pressure sensor,
is working – an angle sensor,

H
– a length indicator.

With the tests described here you can briefly test for the presence of the
function of the remaining sensor/indicator but there is no measuring accu-
racy.

Check pressure sensor

• Hoist the hook block without a load.
The remaining pressure sensor is functioning if the status display Actual
§6 tklbs load indicates the approximate weight of the hook block.

H The weight of the hook block is stated in the technical data in the operat-
ing instructions.

Checking an angle sensor

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

Checking the length indicator of the telescoping cylinder

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

Checking the length indicator for telescope section IV

• Fully retract the main boom.
• Press the Entry mode membrane switch and the Hydraulic oil pressure
nk derricking cylinder lower chamber sensor A membrane switch.
The remaining length indicator is functioning if the Information display
11.05.2000

=0 indicates a length of approx. 0 m.

s
Operating Instructions GMK 5100 2 084 575 en 14 - 39
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Accepting the The SLI and the crane control detect the telescope status independently.
telescope status The SLI compares its displayed telescope status with the value which the
from the crane control has detected. If the values differ, the SLI deactivates, the sta-
crane control tus display Current telescope status flashes and the error message 3.06.3 is
displayed.

The error message can have two causes:

– Either, the malfunction is on the length indicators, the SLI or the crane
control
– or a telescope status was manually entered on the crane control display
which does not agree with the SLI display (e. g., after an emergency
operation).

• Compare the current telescope status with the telescope status indica-
ted on the Crane control display:
– If the current telescope status is not indicated, a malfunction has occur-
red. Notify GROVE Product Support.
– If the Crane control display indicates the actual telescope status, you can
accept this telescope status into the SLI.

Accepting the telescope status

• Press the membrane switch Error information until the error message
r 3.06.3 is indicated on the status display Information.

§0&3
• Press the Entry mode membrane switch and additionaly Switch on 2nd level
no membrane switch. Hold down both membrane switches.
Press Acknowledge membrane switch and release all membrane switches
p again.

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

Checking SLI If there is an error message which indicates that a sensor or indicator
lines and connec- does not react any more or there is a line breakage or short circuit to
tions frame, the cause may be
11.05.2000

– a loose plug connection or

– a damaged line.

14 - 40 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

The defective sensor or indicator can be found in the error tables, the
following diagrams show where to find the control boxes with the plug
connections for the sensors and indicators and the central connections.

• Check the plug connections and their electric lines outside on the main
boom or the lattice extension (additional equipment).

1 Control box pressure sensors upper chamber and lower chamber

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

3 Derricking cylinder lower chamber pressure sensor

4 Derricking cylinder upper chamber pressure sensor

5 SLI connecting box

6 Length indicator

7 Angle sensor basic section control box A and B

11.05.2000

Operating Instructions GMK 5100 2 084 575 en 14 - 41

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

14.4.11 Retraction emergency operation

If the locking mechanism on the head of the telescoping cylinder does not
react to the operating instruments in the crane cab any longer, malfunc-
tions in the electrical control system of the locking mechanism, the mecha-
nical system or the hydraulic system could be the cause. For these cases,
there is
– a mechanical emergency activation system with which you can
manually lock and unlock the telescope sections. This emergency mode
is for cases where the telescoping cylinder can no longer be moved
hydraulically. In this case you need one or two auxiliary cranes.
– a hydraulic emergency mode with which you can move the locking and
unlocking mechanism on the head of the telescoping cylinder directly.
This emergency mode is for cases where the telescoping cylinder can
still be moved but you cannot control the locking mechanism from the
with the operating instruments.
In the worst case, emergency operations must be carried out by trained
specialists because the risk of injury and damage to the main boom is too
great if one proceeds incorrectly. These cases are described later in the
section. Always check the following possibility first.

Check before all First check whether the main boom may be lowered into the horizontal po-
emergency sition with the current telescoping status and the current rigging mode of
operation the truck crane (if a lattice extension or a boom extension is rigged, the
main boom must be fully retracted for this purpose.) Proceed as follows:
• Enter the rigging code for the current rigging mode of the truck crane
on the SLI according to the Lifting capacity table.

H
• Lower the main boom.

If it is possible to lower but there is not sufficient space, you can check
whether the truck crane can be driven in the current rigging mode;
➠ Driving with the crane rigged, p. 12-99.
If the SLI allows lowering to the horizontal position,
danger from the raised truck crane is impossible and you can:
– check whether it is possible for you to carry out hydraulic emergency
operation in the horizontal position; ➠ When can hydraulic emergency
operation be carried out?, p. 14-46.
– carry out mechanical emergency operation without an auxiliary crane
using a personal transport vehicle because you can reach the locking
points with the extendable ladder.
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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

If the SLI switches off before you can lower the main boom to the
horizontal position,
you must:
– check whether it is possible for you to carry out hydraulic emergency
operation; ➠ When can hydraulic emergency operation be carried out?,
p. 14-46.
– have two auxiliary cranes ready for mechanical emergency operation,
one of them a registered personal transport vehicle.

Procedure for There are different procedures for retracting in emergency mode. Which
retracting procedure is is the best for your particular case depends both on which
functions are still possible and on the circumstances at the site. You can
e.g.:

– unlock the telescope sections in mechanical emergency mode if the

locking mechanism on the head of the telescoping cylinder is defective
and retract with an auxiliary crane (up to the section in which the tele-
scoping cylinder is located) or
– first extend the main boom with one or two auxiliary cranes far enough
that the main boom can be lowered to the horizontal position and then
retract the rest of the telescope sections in the horizontal position or
– if the electrical controller for the head of the telescoping cylinder is
defective, retract the telescope sections using hydraulic emergency ope-
ration (with the main boom raised or horizontal, depending on circum-
stances).
Not all possible situations can be described here, only activities for mecha-
nical emergency operation and hydraulic emergency operation under
certain circumstances.
Select the best procedure for your particular case and seek advice from
the responsible GROVE Product Support specialists. This applies especial-
ly if the conditions for hydraulic emergency operation are different than
described here.
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Operating Instructions GMK 5100 2 084 575 en 14 - 43

Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Mechanical emer- Mechanical emergency mode must be used if the telescoping cylinder can
gency operation no longer be moved.
For manual unlocking and locking of the telescope sections, a screw is
screwed into the telescope section on each side above the locking pin.
This screw actuates a lever mechanism which pulls the locking pins into
the telescope section and thus unlocks the telescope section.
This screw is unscrewed again for manual locking.

The main boom is designed so that emergency activation of the locking

H
devices can be achieved from the outside at all possible fixed lengths.

If the telescoping cylinder is in the foot section of the telescope section, it

will not be possible to lock and unlock this telescope section by hand.

The following prerequisites must be fulfilled before you manually release

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

For manual unlocking a total of eight M 20 set screws and an appropriate

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

Unlocking of Length of the

corresponding threaded
pin M 20

telescopic part I 130 mm (5.2 inch)

telescopic part II 100 mm (3.9 inch)

telescopic part III 65 mm (2.5 inch)

telescopic part IV 65 mm (2.5 inch)

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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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 inser-
ted as far as possible and is behind the
side panel of the telescope section (3).
Now the lock has been manually released on
this side.

• Also release the lock on the other side of

the telescope section.

Locking telescope sections

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

• Continue to retract the telescope section

until it is set onto the recesses on the
locking pin.
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s
Operating Instructions GMK 5100 2 084 575 en 14 - 45
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Hydraulic emer- If the electrical supply line on the head of the telescoping cylinder is cut,
gency operation the locking and unlocking functions for the telescoping cylinders and the
telescope section can no longer be controlled from the crane cab. The
truck crane is equipped with a hydraulic emergency mode for this case.
When can hydraulic emergency operation be carried out?
You may only carry out hydraulic emergency operation if:
– the truck crane is in a state in which emergency operation can be
carried out without damaging the boom and
– you can still see the current status of the telescoping cylinder in the
crane cab.
• First check the status of the truck crane using the following diagram. Go
through the questions in the diagram consecutively and compare the
specifications with the status of your mobile crane and go to the next
question depending on the answer (yes/no).

The Crane control display shows:

– either in the third line the message - NOT CONNECTED

(and before the error message UNIT 01 : 00000010 was shown
➠ Error messages via control units, p. 14-57.)
– or in the second line the number string starting with 1 - STATUS : 1 0 0
(in this case you are asked to enter a keycode;
➠ Emergency program submenu, p. 14-70.)

Yes No

Check whether the current status of the telescoping cylinder can still
be read in the crane cab; ➠ p. 14-47.

None of the measures

in the section Malfunc-
Yes tions of the telescoping
No gear, p.14-22 lead to a
correction of the prob-
lem.
Check if the telescoping cylinder is locked with the telescope
section:
– unlocked telescope section can be telescoped
– or, if the telescope section is locked, the length data for
– the telescoping cylinder does not change during telescoping

Yes No

Consult GROVE
Product Support
Prepare necessary equipment ➠p. 14-48.
11.05.2000

and prepare truck crane for emergency operation

14 - 46 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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 If nothing more is displayed here, you can

have the extended length displayed on the
STATUS : 001
SLI.
EMERGENCY OPERATION
TELE: –– L: 30.5 ft

• Press the Entry mode membrane switch and the Hydraulic oil pressure of
no derricking cylinder lower chamber sensor B membrane switch.
• Check if the extended length of the telescoping cylinder is now shown
)3 in the Information display.

• Check if the displays are activated. To do this move the control lever for
telescoping out and check if the value for the extended length changes.
If the telescope section is locked you must press valve Y 21 33;
➠ p. 14-49.

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.
11.05.2000

s
Operating Instructions GMK 5100 2 084 575 en 14 - 47
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Connections, equipment and operating elements for emergency operation

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

Preparing the truck crane for emergency operation

During emergency operation, you have to actuate the superstructure lock
rocker switch, among other things. In order that the superstructure is not
unintentionally unlocked or that the locking pin does not move needlessly
on the carrier, you should secure it.

For this purpose, there is the safety tap (1)

between the storage box and the turntable at
the superstructure lock.

• Close the safety tap (1). The tap is closed

when the handle is diagonal to the line.
The locking pin can now no longer be moved.

To connect the hoses for emergency operation, you must retract the tele-
scopic section with which the telescoping cylinder is locked. You have to
11.05.2000

override the SLI in order to retract.

14 - 48 2 084 575 en Operating Instructions GMK 5100

 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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

• Put down the load.

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

If the telescope section is located at a locking point at the beginning of te-

lescoping or moves over a locking point during telescoping, the telescope
section locks there.

To unlock telescopic section, the hydraulic

valve Y 21 33 has to be pressed.
The valve (1) is on the valve block, in front of
the hydraulic tank.

• Have a second person hold valve Y 21 33

pressed.
• Press the Superstructure lock rocker switch
(§) down and keep it in this position.
• Move the control lever to retract.
Pressure now builds up on the locking me-
chanism; the telescope section is unlocked
and retracted.

As soon as the telescopic section has moved further about 10 cm, the
Y 21 33 valve and the Superstructure lock rocker switch can be let go. The
locking pins move again and come to rest against the inside wall of the te-

H
lescopic section which is above this.

If the locking pins cannot be retracted, the telescope section is stuck in the
recesses of the locking pins.
In this case extend the telescope section approx. 1.2 inch so that the lok-
king pins can be retracted.
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Operating Instructions GMK 5100 2 084 575 en 14 - 49
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

Connecting the hydraulic connections for emergency operation

• Raise the main boom until the rear
opening (3) can be reached.
• Put the two delivered hydraulic hoses (2)
in the middle of the turntable. Make sure
that the hoses do not become twisted or
knotted together.
• Guide both ends (1) to the oil cooler via
the side of the turntable.
• Guide the two other hose ends through the
rear opening (3) into the basic section.
These ends are connected to the telesco-
ping cylinder.

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

In order to connect the hydraulic hoses, you reach the telescoping cylin-
der:
– either through the rear opening in the basic section
– or, if you can extend telescope section I approx. 6.6 ft through the man-
hole at the top of the basic section.

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

The hydraulic hoses are connected directly

to the head of the telescoping cylinder.

• Insert the quick couplings in the two con-

nections (2) and (3).
• Close the two valves (1) and (4). The val-
ves are closed if the handles are perpendi-
cular to the lines.
• Mark a hose on the other end. For emer-
gency operation it is important that you
know which hose is connected with the
right connection (2) and which hose with
the left connection (3).

Operating the locking/unlocking mechanism in emergency mode

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

One of the two hydraulic hoses is connected

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

Function Make connection between

emergency supply and

Lock/unlock telescope section hose on connection 2 of the

telescoping cylinder (right)

Lock/unlock telescoping cylinder hose on connection 3 of the

telescoping cylinder (left)
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Operating Instructions GMK 5100 2 084 575 en 14 - 51
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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 cylin-
der.

• Attach the appropriate hose for the requi-

red locking/unlocking.
– To lock/unlock the telescoping cylinder,
the left connection (3) on the telescoping
cylinder must be connected with the emer-
gency supply.
– To lock/unlock the telescope section, the
right connection (2) on the telescoping
cylinder must be connected with the emer-
gency supply.

Unlocking
To unlock a telescopic section, you have to telescope out the telescopic
section about 1.2 inch.
• Press the Superstructure lock rocker switch down. The locking pins will be
§ drawn in.

Locking
• Let the Superstructure lock rocker switch go. The locking pins will extend
§ again.
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14.4 Troubleshooting and malfunction correction

Retracting with hydraulic hoses connected

If you have retracted the telescope section in which the telescoping cylin-
der was locked when the malfunction occured and the hoses are connec-
ted for hydraulic emergency operation, you can retract the main boom
completely.

S
If the telescope sections I and II are both extended to 100 % or telescope
section I to 50 % and telescope section II to 50 % you must not unlock
and retract the telescoping cylinder. In this way you can prevent the end
of the telescoping cylinder coming out of the guide in telescope section II
and falling into telescope section I.
In this case the main boom could no longer be extended or retracted.

S
Risk of damaging the hydraulic hoses!
While you telescope the main boom, a second person must ensure that
the two hoses run through the rear hole in the basic section and back out
without blockage or kinks.
Always stay in visual contact with this person during telescoping so that
you can stop telescoping immediately in an emergency.

S
Risk of damaging the hydraulic hoses when raising!
When raising the main boom the hydraulic hoses may get crushed. Be-
fore you raise the main boom you must therefore remove the hydraulic
hoses or place them so that they can not be crushed during the raising
process.

H
• Retract the telescope section until it has reached its locking point at 0 %.

If the telescopic section locks at the locking point at 50 % during retrac-

ting, then unlock it. Press the Superstructure lock rocker switch down, tele-
scope in about 4 inch and let go of the rocker switch again.

When the telescope section has reached the locking point at 0 %, it is

locked by the spring force.

• Put the telescope section on the recesses of the locking pins. To do this
retract the telescope section slowly until the value for the extended
length of the telescoping cylinder no longer changes.
Now the telescopic section retracted and locked, and you can move the te-
lescoping cylinder to the next telescopic section. Proceed as follows:
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Operating Instructions GMK 5100 2 084 575 en 14 - 53
Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

• Make the necessary connection for the emergency supply for lok-
king/unlocking the telescoping cylinder (left connection).
• See the table Extended lengths of the telescoping cylinder at the locking points
(➠ p. 14-55) for the length data for the locking point of the next exten-
ded telescopic section.
• Unlock the telescoping cylinder. To do this, press the Superstructure lock
§
H
rocker switch down and keep is in this position.

Keep the Superstructure lock rocker switch depressed while you extend the
telescoping cylinder. If you release the rocker switch, the locking pins ex-
tend and the telescoping cylinder will not reach the locking point of the
next telescopic section because the locking pins will strike the foot section
beforehand.

• Extend the telescoping cylinder until it is at the locking point.

If the Telescoping cylinder at locking point indicator lamps are still activated,
8 you can also recognisze the position of the telescoping cylinder in relation
to the locking point as well as details regarding length; ➠ p. 10-39.
9
• Lock the telescoping cylinder to the telescopic part by letting go of the
§ Superstructure lock rocker switch.

H If the Telescoping cylinder at locking point indicator lamps are not activated,
you can check as follows if the telescoping cylinder is locked:
At the locking point at 0% in the basic section you can see the locking pins
of telescopic section I. Extend the telescoping cylinder slowly. The telesco-
ping cylinder is locked when the locking pins of telescopic section I also
move.

Now you can unlock the telescopic section.

• Make the necessary connection for the emergency supply for lok-
king/unlocking the telescopic section (right connection).
• Extend the telescopic section approx. 1.2 ft so that the telescopic secti-
on is no longer on the recesses.
• Unlock the telescopic section by pressing the Superstructure lock rocker
switch down and keep is in this position.
• Retract the telescopic part. As soon as the telescopic section has moved
further by about 4 inch, you can let go of the Superstructure lock rocker
switch. The locking pins extend further and come to rest against the insi-
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 Malfunctions on the superstructure
14.4 Troubleshooting and malfunction correction

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

After telescoping in hydraulic emergency mode

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

Extended lengths of the telescoping cylinder at the locking points

Telescope section Locking point Extended length of

at fixed length the telescoping
[%] cylinder [ft]

0 0.00
T1 50 15.67
100 31.32
0 1.01
T2 50 16.66
100 32.30
0 1.96
T3 50 17.61
100 13.25
0 2.88
T4 50 18.53
100 34.17

• After emergency operation, reopen the safety tap at the superstructure

lock. ➠ Prepare the truck crane for emergency operation, p. 14-48.
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14.4 Troubleshooting and malfunction correction

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14.5 Crane control error messages

14.5 Crane control error messages

14.5.1 Error messages about control units

Three control units belong to the crane

control: If one control unit fails, the Crane
control display displays an error message as
in the diagram opposite:
ERROR MESSAGE SYSTEM is in the second line. In the third
SYSTEM line you will find UNIT 0, 1 or 2, for the
UNIT 1: 00000010 control units on the connections 0 to 2.
The number code in the fourth line is of
STATUS: 0 0 0 0 0 0 1 0
secondary importance.

The following table shows which crane functions are out of operation
when the control unit fails on a connection:

Error message Error and Action

on the display effect

control unit defective at By reconfiguring the

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

control unit defective at

connection 2, slewing
gear and high-speed
function, counterweight
UNIT 2: lifting cylinder and locking
pins, superstructure lock
and (for additional
equipment) crane cab
incline blocked
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Malfunctions on the superstructure
14.5 Crane control error messages

14.5.2 Error messages about power units

If there is an error message about power

units it will appear in the second line of the
affected power unit (e. g. the telescoping
gear). You also get different entries and num-
ERROR MESSAGE
ber codes in the two bottom lines.
TELESCOPING GEAR
J3502: 01000000
STATUS: 00000001

If you have already acknowledged the error message, you can call up the
+ Display states menu and then
>the memory error submenu and view the
error message there again; ➠ Display states menu - Memory error submenu,
p. 12-86.

In the first line you will see the message

ERROR MEMORY and the number of the
error (e. g. 3). The displays in the other lines
are the same as with the error message.
MEMORY ERROR
TELESCOPING GEAR The messages here are only an example
Y2301: 01000000 which will be dealt with at the end of the fol-
lowing sections.
STATUS: 00000100

Using the messages in the bottom two lines you can

– determine the part on which the error occurred; ➠ Determining defective
part, p. 14-59.
– determine the area of the error, depending on the detected part;
➠ Determining error area, p. 14-60.
– locate more precisely the cause of the error; ➠ Error causes and effects,

H
p. 14-61.

In the following sections you will find more information on the displayed
errors. If, in the sections, you are asked to contact GROVE Product Sup-
port, please note down the number code beforehand and have it ready.

When you have noted down the error codes you can acknowledge the
Ö error message. To do this press the ENTER key.
After you have carried out the acknowledgement process, the display
shows the indication which was displayed before the error message.
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14.5 Crane control error messages

Determining The first message in the third line of the display describes the defective
defective part part (e. g. Y2301). The following table shows all the possible messages
and their meaning.

Message Error Further troubleshooting

J3501
Error on a control lever
J3502

A3502 Error on length indicator Determine cause of

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

Logic error detected by

ECOS
crane control

Error on another part Determine error area;

Other message
(e. g. Y3201)
(valve, digital input, ➠ Determining error area,
pressure sensor) p. 14-60.

Example

In the display used as an example there is the

message Y2301; according to the table there is
an error on a part whereby you must first deter-
MEMORY ERROR mine the area of the error before you can deter-
TELESCOPING GEAR
mine the cause of the error.

Y2301: 01000000

STATUS: 00000100
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Malfunctions on the superstructure
14.5 Crane control error messages

Determining With some parts (e. g. a valve), you must first determine the error of the
error area area in order to get to the cause of the error.

The area where the error is is shown by the number code in the last line
behind STATUS (e. g. 0 0 0 0 0 1 0 0 ). The following table shows possible
number codes and the corresponding areas.

Number code Error in area Further troubleshooting

00000001 Control lever

00000010 Digital input

00000100 Output
Determine cause of error
00001000 Analogue input in the affected area;
➠ Error causes and effects,
CAN-Bus (always p. 14-61.
00010000 displayed together with
ECOS, A100 or A3502)

ECOS (also displayed as

10000000
a part)

Example

In the display used as an example the number

code 0 0 0 0 0 1 0 0 is in the last line.
The table assigns this number code an error in
MEMORY ERROR
3
the output area.
TELESCOPING GEAR The “output” area is in the table in the next secti-
Y2301: 00 000001 on. Here you can determine the cause of the er-
STATUS: 0 0 0 0 0 1 0 0 ror in this area.
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14.5 Crane control error messages

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

Defective Number code in Cause of error Effect/

part the third line on Remedy
or area the display

00000001 Analogue
indicator in
00000010 control lever
defective Control lever
Earth contact/ emergency
00000100 programme is
Control lever line breakage
activated;
J3501 or
J3502
00001000 24V short ➠ p. 14-68.
Earth contact/
00010000 Notify GROVE
line breakage
Product Support
00100000 24V short
Mechanical
01000000
error

Length No data
0 0 0 0 0 0 01 Inform GROVE
indicator reception
Product Support
A3502 00000010 Hardware error
0 0 0 0 0 0 01 When there is no
Communica- No data
display on the SLI,
tion with SLI reception from
00000010 check fuse SI13;
A100 SLI
➠p. 14-13.
After ledgement
start the menu
Locking status
00000001 Emergency operation
unrealistic
access;
ECOS
➠ p. 12-92.
displayed
00001000 telescope status ➠Telescoping error
messages p. 14-63
incorrect
Line breakage/
00000001 Inform GROVE
Digital input 24V short
Product Support
00000010 Earth contact
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Malfunctions on the superstructure
14.5 Crane control error messages

Defective Number code in Cause of error Effect/

part the third line on Remedy
or area the display

Line breakage/
00000001
24V short
00000010 Earth contact
00000100 Line breakage Inform GROVE
Output
Product Support
Output
00001000
overloaded
Output
00010000
underloaded
0000000 1 24V short
Analogue Notify GROVE
input Earth contact/ Product Support
00000010
line breakage

Example

In the display used as an example the number

code 0 0 0 0 0 0 0 1 is in the third line.

3 In the previous section we determined that the er-

MEMORY ERROR
ror was in the output area.
TELESCOPING GEAR According to the table this number code means
Y2301: 00 000001 that there is a line breakage or 24V short.
STATUS: 0 0 0 0 0 1 0 0 In this case you must inform GROVE Product
Support and have the supply line checked.

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14.5 Crane control error messages

14.5.3 Telescoping error messages

If the crane control recognises a divergence between the displayed and

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

The error message Divergent telescope status is

displayed by the following number codes:

ECOS 00001000
ERROR MESSAGE
STATUS 10000000
LOCKING SYSTEM
ECOS : 00001000
STATUS : 10000000

• Acknowledge the error message.

Ö
If the Display telescope status and teleautomatism
menu was selected before the error message
occurred, the crane control switches directly
to the menu to enter the telescope status.
SET TELESCOPING
> T1 < T2 – T3 – T4– T5
– ● – 0 – 0 – 0– 0

H If you had selected another menu before the error message, select:
– either the Show telescoping and teleautomatism menu at (
ä
the crane control changes directly to the menu for entering the
telescoping
),

– or you directly select the Enter the telescoping after emergency operation
menu (3 x
Ä).

• Enter the current telescoping in the crane control;

➠ Entering telescoping after emergency operation, p.14-76.
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Malfunctions on the superstructure
14.5 Crane control error messages

14.5.4 Changing the connections in the control units

Connections and The control units are behind the crane operator’s seat.
control units

S
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove connec-
tions from or insert them in the control units. If the ignition remains swit-
ched 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.

Slewing gear, fast traverses,

Crane control
counterweight lifting cylinder
main hoisting gear, Telescoping gear,
and locking, superstructure lok-
auxiliary lifting gear (additional derricking gear
king, cabin inclining (additional
equipment)
equipment)

Control unit Control unit Control unit

The crane control has three connections which are labelled 0, 1 and 2.
Each connection is inserted into a control unit and connects this with the
different power units. If this control unit fails, the power units connected
with it can no longer be driven. You can activate the power units again in
an emergency by changing this connection to another control unit. You
can thus unrig the truck crane when there is a defect on the control unit,
as described in the following.

Unrigging If, for example, the control unit under the 0 connection fails, you can no
mobile crane longer move the power units on this connection (main hoist, auxiliary
with defective hoist) and the whole crane control is blocked. You can therefore not move
control unit any more power units.
The display shows an error message over UNIT 0.
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14.5 Crane control error messages

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

If, for example, the control unit is defective at connection 0, you can reacti-
vate the crane control and the failed driving gears by pulling out the con-
nection from another control unit (e.g. 2 ) and inserting connection 0 in
this control unit;
➠ Inserting and removing connections, p. 14-67.

Slewing gear, fast traverses,

Crane control
counterweight lifting cylinder
main hoisting gear, Telescoping gear,
and locking, superstructure lok-
auxiliary lifting gear (additional derricking gear
king, cabin inclining (additional
equipment)
equipment)

e. g. defective

H After connection 2 has been removed, the crane control shows the rele-
vant error message UNIT 2. You can acknowledge this error message.

You can now carry out all crane movements connected with connections
0 and 1:
– putting down the load with the main and auxiliary hoist,
– telescoping and
– derricking.
All driving gears which are linked to connection 2 will now be out of ope-
ration (slewing gear, fast speed, counterweight lifting cylinder and locking
device, superstructure lock, incline cab (additional equipment).

If you need the slewing gear when unrigging, you must change the con-
nections again.
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Operating Instructions GMK 5100 2 084 575 en 14 - 65
Malfunctions on the superstructure
14.5 Crane control error messages

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

Slewing gear, fast traverses,

Crane control
counterweight lifting cylinder
main hoisting gear, Telescoping gear,
and locking, superstructure lok-
auxiliary lifting gear (additional derricking gear
king, cabin inclining (additional
equipment)
equipment)

e. g. defective

H Do not remove connection O, this connection serves the crane control and
must always be inserted in an intact control unit. Depending on the requi-
red crane movement, always insert either connection 1 or 2 in the intact
control unit.

You can thus carry out all crane movements for unrigging the truck crane
after each other. There are only two ways in which the connections need
to be inserted for a required crane movement:
either connections 0 and 1 (for main/auxiliary hoist,
slewing gear and fast speeds)

or connections 0 and 2 (for main hoist/auxiliary hoist,

derricking gear, telescoping gear
superstructure lock,
Counterweight lifting gear and

H
locking bolts, tilt cab)

As long as a connection is removed, the crane control shows the

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

Inserting All connections are equipped with plugs and safety holders.
and removing
connections

• Turn the ignition off in the crane cab before you remove connections
from or insert them in the control units.

S
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove con-
nections from or insert them in the control units. If the ignition remains
switched on, data necessary for the operation of the crane (e. g. the tele-
scope status) can become lost or damaged.
If this data is not available there will be malfunctions during the next
crane operation.

All connections are equipped with plugs and safety holders.

Removing connections
• Remove the holder (1) and then the plug
(3) from the control unit (2).

Inserting connections
• Check if the holder (1) is pulled out.
• Put the plug (3) on the control unit (2).
• Push the holder (1) in until you hear it
engage.
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Malfunctions on the superstructure
14.5 Crane control error messages

14.5.5 Control lever emergency program

If a control lever is blocked because of a malfunction, the Crane control dis-

play shows one of the two following messages in the third line:
J3501: 0 0 0 0 0 0 0 1 or J3502: 0 0 0 0 0 0 0 ; ➠ Error messages via power
units, p. 14-58.

Indications on
the display
• Call up the menu Control lever emergency program on the Crane control
ü display. To do this press the membrane switch Control lever emergency
program once.
In this menu you will see the message
EMERGENCY PROGRAM in the first line.
In the second line the control lever to which
the messages in the two lower lines refer
EMERGENCY PROGRAM (e. g. RIGHT CONTROL LEVER) is displayed.
RIGHT CONTROL LEVER
X AXLE: OFF

Y AXLE: ON

By repeatedly pressing the membrane switch Control lever emergency

ü program the message alternates between the left and the right control lever.

The message X axle indicates the extension

to the left and right.

The message Y axle indicates the extension

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

In the example illustrated here, the message ON is next to the Y AXLE of

the right hand control lever. The functions which are controlled by extending
this control lever forward or back are thus blocked. You can therefore carry out
the main hoist functions lift and lower only with the emergency programme.
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14.5 Crane control error messages

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

In addition, press the membrane switch when you have extended the
< control lever back.

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.

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

In the emergency program all crane movements are restricted to 10 % of

the maximum speed.
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Malfunctions on the superstructure
14.5 Crane control error messages

14.5.6 Emergency operation submenu

Emergency operation serves the purpose of allowing you to retract the

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

The submenu can be recognised by the messa-

ge EMERGENCY OPERATION in the third line.

The remaining running time is displayed on

TELESCOPING
the left in the fourth line (e.g. 180 sec.).
STATUS: 0 0 1 When the time has run out, the display swit-
EMERGENCY OPERATION ches again to the Access emergency operation
submenu and you can re-start emergency
T: 180 s L:8.40 m operation.

The three-digit number code (e. g. 001) after

the message STATUS in the second line indi-
cates which error the crane control recogni-
zed.
TELESCOPING
STATUS: 0 0 1
EMERGENCY OPERATION
T: 180 s L:8.40 m

Deciphering the number code:

0 0 1: – Length indicator faulty
0 1 0: – Proximity switch faulty or signals received through
locking status are unrealistic
1 0 0: – Error recognised in a valve for the locking mechanism,

When multiple errors occur simultaneously, all errors are displayed simul-

H
taneously with a 1 at the respective position.

If a 1 is displayed at the first position of the number code (e. g. 1 0 0),

the locking and unlocking mechanism can no longer be operated. In this
case, consult the responsible GROVE Product Support. As long as this
error is present, you can only retract the main boom with mechanical
emergency operation; ➠ Retract emergency operation, p. 13-43.
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 Malfunctions on the superstructure
14.5 Crane control error messages

G
Risk of damage to the main boom!
Never telescope the main boom if both the length indicator and the proxi-
mity switch have failed, i.e. with the number code 1 0 1 or 1 1 1. Other-
wise you will no longer have any possibility to monitor and can damage
components in the boom or put the boom in a condition in which it can
no longer be extended.

S
Risk of damage to the main boom!
Depending on which error has occurred, you can only track the telescop-
ing with certain warning and indicator lights. Use as a guide only the
lights which are stated for the respective error in the following sections.
If you observe the incorrect indicator and warning lights, boom compo-
nents could be damaged or you could put the main boom in a condition
in which telescoping is no longer possible.

When you are in the Emergency operation menu, all functions for tele-
scoping in the main boom are still released as long there are no other
errors (hydraulic or mechanical).

If the error is due to a proximity switch (number code 0 1 0);

➠ Retracting with an error on the proximity switch, p. 14-74.

If the error is due to a length indicator (number code 0 0 1), retract the
main boom as described in the following section:

Retracting with If the error is on the length indicator, you can no longer read the extended
an error on the length of the telescoping cylinder on the Crane control display.
length indicator The following status display elements are still available:

Check the position of the locking pins of the telescoping cylinder and tele-
ihjj scope section with the red warning/green indicator lamps Telescoping cylin-
der unlocked and locked and Telescope section unlocked and locked.

Check the telescoping at the SLI display

1 2 3 4 Current telescoping telescopic section I to IV.
!= != != != C0645
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Operating Instructions GMK 5100 2 084 575 en 14 - 71
Malfunctions on the superstructure
14.5 Crane control error messages

H To have the current extended length of the telescoping cylinder displayed

by the SLI in the Information display, proceed as follows:

Press the Entry mode membrane switch and the Hydraulic oil pressure of
no derricking cylinder lower chamber sensor B membrane switch.

The display Information now indicates the current extended length in

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

Before you telescope:

– both indicator lamps Telescoping cylinder at locking point must be lit (then
89 the telescoping cylinder is at the locking point); ➠ p. 10-39
– the telescoping cylinder has to be locked with the telescopic section;
h the Telescoping cylinder locked indicator lamp has to light;
– the telescopic section has to be unlocked; the telescopic section unlocked
j warning lamp has to light;
– the Select locking/unlocking rocker switch has to be pressed upwards in
. the Unlock telescopic section position.

Retracting the telescope section

S
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 im-
mediately and they can damage or tear the electrical or hydraulic compo-
nents in the main boom.

• Only telescope the telescope section slowly.

• Telescope in the telescope section as far as possible.
• Extend the locking pins on the telescope section by putting the rocker
switch Select locking/unlocking in the central position.
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 Malfunctions on the superstructure
14.5 Crane control error messages

The locking pins on the telescope section are slid out, the green indicator
jj lamp Telescope section locked lights up and the red warning lamp Telescope
section unlocked goes out.

• Unlock the telescoping cylinder. To do this press the Select locking/unlock-

. ing rocker switch down.

Extending the telescoping cylinder without the telescope section

S
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 electri-
cal or hydraulic components in the main boom.

• Extend the telescoping cylinder slowly.

• Extend the telescoping cylinder to the locking point of the nearest foot
section. The locking point has been reached if both Telescoping cylinder at
locking point indicator lamps are lit.
89 The Information display shows the respective extended length of the
%08 telescoping cylinder (e. g. 16.7 ft for the locking point of telescope
section II at 50 %, values ➠ p. 14-75)

S
Risk of damaging the telescoping gear!
To check the position of the telescoping cylinder in relation to the locking
point, always observe both display elements (indicator lamp and display
Information).
In this way, you avoid going beyond the locking point and damaging the
telescoping gear in case a display element fails (e. g. if the position light
is faulty or if a proximity switch fails).

When you have reached the locking point, lock the telescoping cylinder.
. To do this move the rocker switch Select locking/unlocking to the central po-
sition.

When the telescoping cylinder is locked, the green indicator lamp Telesco-
h ping cylinder locked lights up.
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Operating Instructions GMK 5100 2 084 575 en 14 - 73
Malfunctions on the superstructure
14.5 Crane control error messages

H If you have retracted the main boom with a defective length indicator, the
current telescope status does not correspond with the last telescope sta-
tus stored from the crane control. You must input the current telescoping
status on the Crane control display after repairs and before the next crane
operation; ➠ Enter telescope status after emergency operation menu, p. 14-76.

Retracting with If the error is on a proximity switch of the locking pins, one or more of the
an error on the following warning and indicator lamps no longer display the actual values:
proximity switch
– Warning lamp Telescoping cylinder unlocked,
i – Warning lamp Telescope section unlocked,
j – Indicator lamp Telescoping cylinder locked,
h – Indicator lamp Telescope section locked.
j When locking the telescoping cylinder, observe the following:
• Always move the telescoping cylinder to
the correct length for the locking point be-
fore you lock it with the telescope section.
The length is indicated on the Crane control
TELESCOPING
display (e. g. 16.7 ft for the locking point of
– 0 – 0 – 0 – 0 – 0 telescope section II at 50 %, values
EMERGENCY OPERATION ➠ p. 14-75).
T. 180 s L: 16.7 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.
Otherwise, you can retract the main boom exactly as with an error on a

H
length indicator (➠ p. 14-71).

Some warning and indicator lamps may show correct displays of the
locking status. While locking and unlocking, you can check if individual

H
lamps still display correctly.

When there is an error on a proximity switch, the hydraulic/mechanical

safety circuit continues to prevent the simultaneous unlocking of the tele-
scope section and the telescoping cylinder, but this is no longer electroni-
cally monitored.
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 Malfunctions on the superstructure
14.5 Crane control error messages

Table for approa- The following table shows the extended length of the telescoping cylinder
ching the locking at the locking positions of the various telescope sections.
points

Telescope section Locking point Extended length of the

at fixed length telescoping
[%] cylinder [m]

0 0.00
T1 50 15.67
100 31.32
0 1.01
T2 50 16.67
100 32.30
0 1.96
T3 50 17.61
100 33.25
0 2.88
T4 50 18.53
100 34.17
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Operating Instructions GMK 5100 2 084 575 en 14 - 75

Malfunctions on the superstructure
14.5 Crane control error messages

14.5.7 Entering telescope status after emergency operation menu

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

In the first line there is the message SET

TELESCOPE STATUS.
In the second line there are telescope sec-
tions T1 to T4 and in the line underneath the
SET TELESCOPE STATUS numerical value 0 is displayed for every tele-
> T1 < T2 – T3 – T4 – T5 scope section.
> ● < 0 – 0 – 0 – 0 In addition, the entry request (●) flashes on
the numerical value for T1.

You can enter the actual telescope status for every telescope section with
the membrane switches View and entry display, located to the right, next to
the display.

You can only enter the value on which the entry request flashes.

• Press one of these two membrane switches as many times as necessary

+ until the entry request flashes on the numerical value which you would
like to enter.
*
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 Malfunctions on the superstructure
14.5 Crane control error messages

• Enter the actual telescope status for the telescope section with these
: two membrane switches. The following values are available:
For T1 : 0 50 100 >n<
< For T2 : 0
For T3 : 0
50 100 >n<
50 100 >n<
For T4 : 0 50 100 >n<
n here represents the displayed numerical value of the last saved current

H
intermediate length (e. g. 37 %)

If a telescope section is at an intermediate length, select the indicated

value n between the two angular brackets.

• Enter the actual telescope status for all telescope sections.

• If you have entered an incorrect telescope status, you can restart the
ö menu by pressing the Enter telescope status after emergency operation mem-
brane switch three times quickly.
Ö • 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.

To confirm the entered telescope status, you

SET TELESCOPE STATUS must enter in this line the same key code
> T1 < T2 – T3 – T4 – which you need to start the emergency pro-
– 100 – 0 – 0 – 0 gram;

KEYCODE:—
➠ Access emergency operation menu, p. 12-92.

The crane control now saves the entered telescope status and switches to
the Display telescope status and teleautomatism menu.

If the crane control recognises an error in the entered telescope status,

the display shows the error message Divergent telescope status; ➠ p. 14-63.

Ö H The crane control accepts the newly set telescope status only when you
store the new values with the ENTER key and enter the appropriate key
code after making your selection.
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Operating Instructions GMK 5100 2 084 575 en 14 - 77
Malfunctions on the superstructure
14.5 Crane control error messages

S
Risk of damage during telescoping!
Before working with the crane, check that the telescope status now indica-
ted corresponds with the actual telescope status. If you accidentally enter
an incorrect telescope status, then you must enter the actual value again.
In this way you prevent the crane control unit from using an incorrect
value for calculations which could lead to damage and malfunctions
during telescoping.

The Enter telescope status after emergency operation menu remains switched
>@üä on until you select another menu with the respective membrane switch,

ö exit the menu with the membrane switch

occurs. ö or until an error message

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 Technical information for superstructure
15.1 Technical description of the superstructure

15 Technical information for superstructure

15.1 Technical description of the superstructure

15.1.1 Turntable

The following components are installed on the turntable:

– the crane engine with fuel tank,

– the pumps, the oil tank and the oil cooler of the crane’s hydraulic
– system,
– the main boom,
– the hoists,
– the slewing gears,
– the derricking cylinder,
– the crane operator’s cab,
– the counterweight hoist unit.

15.1.2 Crane operator’s cab

All operating and control instruments required for crane operation are in-
stalled in the crane operator’s cab on the front left-hand side of the turn-
table. With additional equipment, the crane cab can be inclined about 20°
to the rear

The aluminium cab is surrounded by safety glass. The sliding door and
the rear wall have one sliding window each. The windscreen can be ope-
ned to ventilate the cab.

The cab is heated via a heat exchanger using the engine coolant. The coo-
lant can also be heated with an additional water heating system to pre-
heat the engine and the cab.
As additional equipment, the additional heating system can be equipped
with a timer.
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Operating Instructions GMK 5100 2 084 575 en 15 - 1
Technical information for superstructure
15.1 Technical description of the superstructure

15.1.3 Crane engine and hydraulic system

The hydraulic system consists of three separate circuits. The supply for
the circuits from the hydraulic tank at the superstructure is done via two
hydraulic pumps, which are flanged to the crane engine.

– An axial piston pump supplies the main and auxiliary hoists, telesco-
ping gear and derricking gear, as well as all locking units, the counter-
weight hoist unit and the cylinder for inclining the crane cab.
– A gear pump supplies the slewing gears.
The oil tank of the crane’s hydraulic system (hydraulic tank) is on the left
side of the turntable behind the crane driver’s cab and the storage com-
partment and has a capacity of approx. 222 gal.
The hydraulic oil is cooled via an electrically driven, thermostat-controlled
oil cooler. As additional equipment, the cooling can be expanded with a
second oil cooler.

To clean the hydraulic oil, four oil filters are built into the hydraulic circuit.
There is a return filter at the hydraulic tank. At the rear of the crane cab
there is an additional filter for the control system circuit.

15.1.4 Control system

All crane movements can be controlled on an infinitely variable basis with

the electrical-hydraulic pilot operated cross control levers in the control
consoles on the armrests of the crane operator’s seat. The control levers
have an automatic initial position.

A fully electronic crane control system controls and monitors all crane
functions, the hydraulic parts and some of the electrical parts. The crane
control system has 3 control units and is connected to the safe load indica-
tor via a CAN BUS.

On a display on the front instrument panel, information on the individual

power units and the crane engine can be called up, the telescoping proce-
dure can be followed and various values can be entered. In addition, the
crane control system displays error messages in this display.
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 Technical information for superstructure
15.1 Technical description of the superstructure

15.1.5 Main boom

The main boom consists of the basic section and 5 telescope sections.
As additional equipment, the main boom can be extended with a two-
stage swing-away lattice extension and a boom extension (both pipe
grille construction).
The boom extension consists of the two-stage swing-away lattice exten-
sion and two additional intermediate sections.

15.1.6 Telescoping gear

The telescoping gear consists of the basic section, four telescope sections
and a single-level telescoping cylinder with a locking mechanism. Each
telescope section is equipped with locking pins which are extended by
spring force. All telescope sections can be locked at the fixed lengths.
The telescoping cylinder is also equipped with locking pins. These locking
pins make the connection between the telescoping cylinder and the tele-
scope section to be telescoped.

All telescopic sections are individually telescoped. To telescope, the tele-

scope cylinder locks itself together with the appropriate telescope section.
Subsequently, the telescoping cylinder unlocks the telescope section with
its mechanism and extends it or retracts it to the desired length. With 0%,
50% and 100% telescope statuses, the telescoping cylinder can lock the te-
lescope section there again with the mechanism, release its lock with the
telescope section and move to the next telescope section.

Locking or unlocking can be selected and is automatically carried out by

the crane control system. Fully automatic telescoping of the telescope sec-
tions to 0%, 50% and 100% is also possible. The desired end state of the
telescoping gear is entered in the crane control here.

The telescoping gear is equipped with a mechanical and hydraulic emer-

gency operation with which the telescoping gear can be retracted during
a malfunction.
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Operating Instructions GMK 5100 2 084 575 en 15 - 3
Technical information for superstructure
15.1 Technical description of the superstructure

15.1.7 Hoists

The main hoist is located in the rear turntable area. The crane may also be
equipped with an auxiliary hoist (additional equipment) that is installed
behind the main hoist.
The lifting units are powered by hydraulic axial piston motors via planeta-
ry gears. The hoists are fitted with hydraulically ventilatable pressure-
spring multiple-disk brakes.
Both hoists are equipped with electrical lowering limit switches. When
reeling off, five turns of hoist rope must remain wound on. Lifting limit
switches on the main boom and the lattice extension limit the upward
stroke
The auxiliary hoist (additional equipment) is an integral part of the coun-
terweight and is replaced by a compensation weight, if necessary.

15.1.8 Slewing gear units

The turntable is equipped with 2 slewing gear units. The slewing gear
units are located on the right side of the turntable and affect the external
toothing of the ball bearing slewing through the meshing of a pinion.

Both slewing gears are equipped with a multiple-disk brake as service bra-
ke. The service brake is regulated using a foot pedal.
Both slewing gears also have a multiple-disk brake for use as a
multiple-disk brake. The holding brake is actuated via a rocker switch.

In addition to the slewing gear brake, the superstructure can be mechani-

cally locked in the 0° and 180° positions with a pin on the superstructure
lock (for on-road driving or moving on the construction site with a rigged
crane and the working position 0° to the rear).

15.1.9 Derricking cylinder

The angle of the main boom is adjusted by means of a hydraulic pressure

cylinder. The cylinder is connected to the turntable and the basic section
of the main boom.
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 Technical information for superstructure
15.1 Technical description of the superstructure

15.1.10 Electrical system

The superstructure’s 24 V electrical system is fed by the alternator in the

crane engine and by two batteries in the battery box located in front of
the crane engine. The batteries are in a battery box in the storage com-
partment in front of the crane engine.

The electrical system includes the crane system with lighting and control
instruments as well as electro-hydraulic switches and all safety equip-
ment.

15.1.11 Electrical connection to the carrier

To supply the marking lights, the position lights and the rotating warning
light with power for on-road driving, the superstructure and the carrier
are linked with a cable.
For additional equipment with inclinable crane cab, electronic level, opera-
ting the outriggers from superstructure or outrigger pressure indicator,
this link is not applicable and the electrical supply is done via a slip ring
assembly.

15.1.12 Counterweight

The counterweight sections can be assembled into four (with additional

equipment, into seven) counterweight versions; ➠ Counterweight versions,
p. 15-10.

Depending on the driving mode, the counterweight will be transported

partly on the superstructure, partly on the counterweight platform and
partly on a separate vehicle ; ➠ Driving modes, p. 6-5.
Measurements and weights of the individual counterweight parts for
transport; ➠ Dimensions and weights - counterweight sections, p. 15-9.

For rigging the counterweight, the individual counterweight parts are as-
sembled with the truck crane on the 3 t base plate on the crane carrier.
There is a counterweight lifting unit on the turntable which lifts the 3 t
base plate and all the other counterweight sections and locks them on the
turntable.

The auxiliary hoist (additional equipment) is an integral part of the coun-

terweight. If no auxiliary hoist is available, the weight loss is compensa-
11.05.2000

ted for using a compensation weight.

Operating Instructions GMK 5100 2 084 575 en 15 - 5

Technical information for superstructure
15.1 Technical description of the superstructure

15.1.13 Safety equipment

The truck crane GMK 5100 is equipped with the following safety devices:

– Electronic safe load indicator (SLI) (overload shutdown device)

– Limiting of the highest and lowest boom position by means of safe load
indicator (SLI) and mechanical stop
– Dead man’s switches in the control levers and seat switches
– Lifting limit switch
– Lowering limit switch
– Pressure relief valves in the hydraulic circuits
– Pipe break safety valves, safety lowering shut-off valve in telescoping
gear, outriggers and derricking cylinder
– Emergency stop switch for the electronic crane control system

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 Technical information for superstructure
15.2 Technical data

15.2 Technical data

GROVE truck crane GMK 5100

Max. load bearing capacity: 220 460 lbs (DIN/ ISO/ EN)
220 460 lbs (85 %)

Max. Load moment: 2 675 500 lbf ft 1) (DIN/ ISO/ EN)

2 964 800 lbf ft 2) (85 %)

Permitted temperature range: –19 °F up to +104 °F

1)
10 m x 37 t (32.8 ft x 81 578 lbs)

2)
10 m x 41 t (32.8 ft x 90 390 lbs)
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Operating Instructions GMK 5100 2 084 575 en 15 - 7
Technical information for superstructure
15.2 Technical data

15.2.1 Measurements and weights of the truck crane

Dimensions for Length: 48.16 ft (without auxiliary hoist or spare wheel)

driving on public Width: max. 9.02 ft with 14.00 R25 tyres
roads max. 9.84 ft with 16.00 R25 tyres
Height for 12.82 ft –5.11 / +6.69 inch suspension range
on-the-road level: with 14.00 R 25 tyres
12.98 ft –5.11 / +6.69 inch
suspension range with 16.00 R 25 tyres
Angle of negotiable approx. 20° at on-the-road level
banks at front
Total weight: depending on the driving mode: 110 230 lbs or
132 280 lbs
Axle load depending on the driving mode: 22 050 lbs or
26 455 lbs
Driving mode during on-road driving ➠ Section Driving mode,6-5.
Dimensions and weights of the parts which must be transported on a
separate vehicle during on-road driving ➠ Dimensions and weights of remo-
vable parts, p. 15-9.

all measurements in mm

*) max. 2 750 with 14.00 R 25 and 16.00 R 25 tyres

max. 3 000 with 16.00 R25 tyres

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over 3 000 with 20.50 R25 tyres

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 Technical information for superstructure
15.2 Technical data

15.2.2 Dimensions and weights of removable parts

This section contains the transport dimensions and weights of those

parts of the superstructure which can be transported on separate vehicles
during on-road driving.
On-the-road mode according to requirements ➠ p. 6-5 .

Counterweight-
sections
Name Length x width x Weight
height (ft) (lbs) 1)

2.0 t counterweight section 2) 7.70 x 5.57 x 0.82 4 818

3.0 t base plate 9.02 x 5.08 x 3.11 6 182
3.0 t counterweight section 7.70 x 4.59 x 0.49 6 292
3.5 t counterweight sections 2), each 5.08 x 3.93 x 1.31 7 524
4.0 t counterweight section 9.02 x 5.08 x 0.98 9 592
without recesses
4.0 t counterweight section 9.02 x 5.08 x 0.65 8 866
with recesses 2)
7.0 t counterweight section2) 9.02 x 5.08 x 1.31 15 224
3.5 t counterweight blocks, each 3.60 x 3.28 x 3.28 7 392
block 2)
centering rings, each ∅ 1.14 / 0.32 high 31
1) Due to manufacturing and technical considerations, deviations of up
to ± 2.5 % are possible.
2) additional equipment

The stability of the crane rigged with the delivered counterweight sections
has been checked.
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Operating Instructions GMK 5100 2 084 575 en 15 - 9
Technical information for superstructure
15.2 Technical data

Name Length x width x Weight

height (ft) (lbs)

double hook, 6.23 x 2.13 x 2.29 2 530

7 sheaves, load bearing capacity
100 t
Double hook 5.90 x 2.46 x 1.47 1 870
5 sheaves, load bearing capacity 75 t
Double hook 5.41 x 2.29 x 1.31 1 485
3 sheaves, load bearing capacity 50 t
double hook 4.42 x 2.13 x 0.82 715
1 sheave, load bearing capacity 20 t
hook tackle, load bearing capacity 2.95 x 1.14 x 1.14 440
8t

Counterweight The counterweight versions are shown in the following diagrams on the
versions next pages.

1t
1 t - compensation weight or
auxiliary hoist (additional equipment)

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 Technical information for superstructure
15.2 Technical data

4t (after driving with 12 t axle load)

1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight

4t (after driving with 10 t axle load)

1 t - compensation weight or auxiliary
hoist (additional equipment)

3 t - base plate

7t
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section

3 t - base plate

11 t
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section
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4 t - base plate
3 t - base plate

Operating Instructions GMK 5100 2 084 575 en 15 - 11

Technical information for superstructure
15.2 Technical data

20 t (additional equipment)
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section

2 t - counterweight section

7 t - counterweight section
(or as additional equipment 2 x3.5t)
4 t - counterweight section
3 t - base plate

24 t (additional equipment)
1 t - compensation weight or auxiliary
hoist (additional equipment)
3 t - counterweight section
2 t - counterweight section
4 t - counterweight section

7 t - counterweight section
(or as additional equipment 2 x 3.5 t)
4 t - base plate
3 t - base plate

31 t (additional equipment)
1 t - compensation weight or auxilia-
ry hoist (additional equipment)
3 t - counterweight section
2 t - counterweight section
4 t - counterweight section

7 t counterweight section
(or as additional equipment 2 x 3.5 t)
4 t - counterweight section
3 t - base plate
11.05.2000

2 x 3.5 t - counterweight block

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 Technical information for superstructure
15.2 Technical data

15.2.3 Technical data for superstructure

Crane engine Make: Mercedes-Benz

Type: OM 904 LA
Performance: 125 kW (170 PS) with 2300 rpm
(EC 80/1269 rigid fan)
Fuel tank: capacity ≈ 52.8 gals

Crane’s electrical Alternator: 28 V / 80 A

system
Batteries: 2 each 12 V / 170 Ah
On-board voltage: 24 V

Main hoist Make: Siebenhaar

Type: 5044
Drum diameter: 15.7 inches (cable center to cable center)
Rope diameter: 0.74 inches
Cable length: 738 ft
Max. Wire cable: 15 740 lbf/line (≅ 15 650 lbs)
Power unit group: M3
Load spectrum: L1
Factor of the load spectrum: Km = 0.125
Theoretical service life: D = 3 200 h
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Technical information for superstructure
15.2 Technical data

Auxiliary hoist Make: Siebenhaar

(additional
equipment)
Type: 5044

Drum diameter: 15.7 inch (cable centre to cable centre)

Rope diameter: 0.74 inch

Rope length: 590 ft

Max. wire cable: 15 740 lbf (≅ 15 615 lbs)

Power unit group: M3

Load spectrum: L1

Factor of the load spectrum: Km = 0.125

Theoretical service life: D = 3 200 h

Slewing gears Make: Siebenhaar

Type: 01 DD

Derricking gear Cylinder: differential cylinder

Adjusting angle: -3.0° to + 83° from horizontal

Main boom Main boom lengths: 42.0 ft / 73.5 ft / 104.6 ft / 136.1 ft / 167.3 ft

Main boom head 7 sheaves

Cylinder: a 1 stage telescoping cylinder with inte-

grated locking / unlocking mechanism
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15 - 14 2 084 575 en Operating Instructions GMK 5100

 Technical information for superstructure
15.2 Technical data

Operating speeds The operating speeds below apply to an engine speed of

and times approx. 2 300 rpm
without a load
Main hoist: rope speed for hoisting and lowering
maximum 394 ft/min (high-speed)

Auxiliary hoist: rope speed for hoisting and lowering

maximum 394 ft/min (high-speed)

Slewing gear: 0 to 1.7 rotations per minute

Telescoping gear: extend main boom telescoping

from 42.0 ft to 167.3 ft: ca. 400 s 1)

Derricking gear: ca. 60 s (- 3° to 83°) (high-speed)

1) In automatic mode, for doing unrigged locking and

telescoping procedures.
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Operating Instructions GMK 5100 2 084 575 en 15 - 15

Technical information for superstructure
15.2 Technical data

Blank page

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15 - 16 2 084 575 en Operating Instructions GMK 5100

 16 Alphabetical index

H Explanations on how to use this index; ➠ p. 1-16.

In order to avoid unnecessary length and confusion in the alphabetical
index, not every single element of the instrument panels has been
included.
These elements such as rocker switches, warning and indicator lamps as
well as status displays are described and named in detail in the overviews
of Chapter 4 and 7 Description of the truck crane.
From there you will be referred to more detailed descriptions of these
elements.
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Operating Instructions GMK 5100 2 084 575 en 16 - 1

 Blank page

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16 - 2 2 084 575 en Operating Instructions GMK 5100

 ALPHABETICAL INDEX

A Access ladders to the superstructure . . . . . . . . . . . . . . . . . . 4-44

Activating the ignition
carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Adding oil
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Additional heating system . . . . . . . . . . . . . . . . . . . . . 4-35, 6-62
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
display time, setting . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
additional heating system
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-108
Additional heating system with timer . . . . . . . . . . . . . . . . . . 6-64
automatic heating start, switch on and save . . . . . . . . . . . . 6-65
switching off automatic heating start . . . . . . . . . . . . . . . . 6-66
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
time, display/setting . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Additional water heating system
see Additional heating system
Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
on the superstructure . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Adjusting the seat
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Air-conditioning system
in the crane cab . . . . . . . . . . . . . . . . . 10-55, 12-110 to 12-112
in the driver’s cab . . . . . . . . . . . . . . . . . . . . 4-41, 6-67 to 6-70
All-wheel steering: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Anemometer
installing on the main boom . . . . . . . . . . . . . . . . . . . . 13-84
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Auxiliary hoist
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
working with the auxiliary hoist . . . . . . . . . . . . . . . . . . 12-44
Auxiliary hoist gear
display and operating instruments . . . . . . . . . . . . . . . . 10-34
axle drive
display and operating instruments in the driver’s cab . . . . . . . 4-25

B Battery master switch

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Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
bonnet
opening and closing . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Operating Instructions GMK 5100 2 084 575 en 16 - 3

 Boom floating position
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Boom initial tension
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Brakes
auxiliary brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
checking the brakes system . . . . . . . . . . . . . . . . . . . . . . 6-9
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
display and operating instruments in the driver’s cab . . . . . . . 4-26
eddy current retarder . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Breakdown
towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-12
Breakdown
procedure in road traffic . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4

C Carrier hydraulic system

check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
checking the position of the stop cocks . . . . . . . . . . . . . . . . 5-8
charge indicator
warning lamp, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Charge indicator lamp
after ignition has been switched on . . . . . . . . . . . . . . 5-9, 11-11
after the engine has been started . . . . . . . . . . . . . . . . . 11-13
after the vehicle engine has been started . . . . . . . . . . . . . . 5-13
CHECK LIST
retracting the outriggers . . . . . . . . . . . . . . . . . 13-15 to 13-40
rigging the counterweight . . . . . . . . . . . . . . . . . . . . . 13-46
unrigging the counterweight . . . . . . . . . . . . . . . . . . . . 13-48
Check the oil level
in the carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . 5-7
in the superstructure hydraulic system . . . . . . . . . . . . . . . 11-6
Checking the coolant level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Checking the oil level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Checking the steering lock . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Checking the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Checking the windscreen washing system
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in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
CHECKLIST
before starting crane work in winter . . . . . . . . . . . . . . . . . 11-3
condition of the truck crane for on-road driving . . . . . . . . . . . 6-1

16 - 4 2 084 575 en Operating Instructions GMK 5100

 extending the outriggers . . . . . . . . . . . . . . . . . . . . . . 13-13
rigging for crane operation with main boom . . . . . . . . . . . . 13-1
rigging mode when truck crane is rigged . . . . . . . . . . . . . . 12-1
starting the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-1
starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
unrigging for crane operation with main boom . . . . . . . . . . 13-4
working with the crane in winter . . . . . . . . . . . . . . . . . . . 5-3
Checks
after starting the crane engine . . . . . . . . . . . . . . . . . . . 11-13
after the engine has been started . . . . . . . . . . . . . . . . . . 5-12
before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
before starting the crane engine . . . . . . . . . . . . . . . . . . . 11-4
boom not set down warning lamp . . . . . . . . . . . . . . . . . . 6-11
of the safety equipment . . . . . . . . . . . . . . . . . . . . . . 12-14
prior to starting vehicle engine . . . . . . . . . . . . . . . . . . . . 5-4
while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Choosing the site . . . . . . . . . . . . . . . . . . . . . . . . 13-6 to 13-12
Compressed air system
see Brakes
Constant engine speed . . . . . . . . . . . . . . . . . . . . . . . . . 12-95
constant speed
see Tempostat
Control lever emergency program . . . . . . . . . . . . . . . . . . . 14-68
Conversion table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Counterweight lifting unit
current status, checking . . . . . . . . . . . . . . . . . . . . . . 13-58
2 t counterweight section on the turntable, locking / releasing . 13-62
3 t base plate, placing onto the counterweight platform . . . . . 13-50
3 t counterweight section, installing/removing . . . . . . . . . . 13-64
Extending/retracting the lifting cylinder . . . . . . . . . . . . . . 13-59
indication of a malfunction . . . . . . . . . . . . . . . . . . . . . 13-58
release/block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
unlock / lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Crab travel mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Crane cab
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53, 12-106
inclining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-109
Crane cab windscreen wipers . . . . . . . . . . . . . . . . . . . . . 10-50
Crane control
see acknowledging error messages
display and operating instruments . . . . . . . . . . . . . . . . 10-31
display of an error message . . . . . . . . . . . . . . . . . . . . 12-93
emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . 14-2
enter telescope status menu . . . . . . . . . . . . . . . . . . . . 14-76
entering power unit speeds menu . . . . . . . . . . . . . . . . . 12-89
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error memory sub-menu . . . . . . . . . . . . . . . . . . . . . . 12-86

error messages . . . . . . . . . . . . . . . . . . . . . . 14-57 to 14-78

Operating Instructions GMK 5100 2 084 575 en 16 - 5

 menu Display states . . . . . . . . . . . . . . . . . . . . . . . . 12-85
menu Display telescoping status . . . . . . . . . . . . . . . . . 12-88
menus on the display . . . . . . . . . . . . . . . . . . . . . . . . 12-85

Crane control emergency stop switch . . . . . . . . . . . . . . . . . . 14-2

Crane control error messages . . . . . . . . . . . . . . . . 14-57 to 14-78
Crane engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . 11-4
display and operating instruments . . . . . . . . . . . . . . . . 10-25
inspections after starting . . . . . . . . . . . . . . . . . . . . . . 11-13
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
setting a constant engine speed . . . . . . . . . . . . . . . . . . 12-95
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
starting - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
VDO electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
crane work
critical load control . . . . . . . . . . . . . . . . . . . . . . . . . 12-96
during the winter - CHECKLIST . . . . . . . . . . . . . . . . . . . . 5-3
in winter - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . 11-3
permissible slewing ranges . . . . . . . . . . . . . . . . . . . . 12-39
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
troubleshooting for malfunctions . . . . . . . . . . . . . . 14-3 to 14-4
Crane work with main boom
rigging - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
unrigging - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Critical load control . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96

D Dead man’s switch system . . . . . . . . . . . . . . . . . . . . . . . 10-62

derricking gear
display and operating instruments . . . . . . . . . . . . . . . . 10-36
lowering the main boom for maintenance . . . . . . . . . . . . 12-83
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
working with the derricking gear . . . . . . . . . . . . . . . . . 12-46
Differential locks
see Transverse differential locks
Door
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Drive of third axle line / longitudinal differential locks . . . . . . . . . . 7-8
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
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Driver’s cab
adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
adjusting the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

16 - 6 2 084 575 en Operating Instructions GMK 5100

 ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Driving
breakdown procedure . . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4
checks before driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
checks while driving . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
off-road . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 to 6-54
on uphill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
with a rigged crane . . . . . . . . . . . . . . . . . . . . 12-99 to 12-104
driving direction indicator . . . . . . . . . . . . . . . . . . . . . . . . 4-31
driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

E Earthing
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
electrical system
connection between the carrier and superstructure . . . . . . . . 6-24
display and operating instruments in the crane cab . . . . . . . 10-49
display and operating instruments in the driver’s cab . . . . . . . 4-30
fuses in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
fuses in the superstructure . . . . . . . . . . . . . . . . . . . . . . 14-7
plug-in modules and consoles in the crane cab . . . . . . . . . . 14-5
plug-in modules in the driver’s cab . . . . . . . . . . . . . . . . . 7-17
SLI fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Electronic level
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36
Emergency operation
solenoid valves for the outriggers . . . . . . . . . . . . . . . . . . 7-43
Emergency operation submenu on the Crane control display) . . . . 14-75
Emergency stop device
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 to 7-2
on the superstructure . . . . . . . . . . . . . . . . . . . . . 14-1 to 14-2
Enlarging the surface area of the outrigger . . . . . . . . . . . . . . . 13-8
Error messages
control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57
power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-58
SLI, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30

F Fast speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-84

Fire extinguisher
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
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Flame start system

in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel tank

Operating Instructions GMK 5100 2 084 575 en 16 - 7

 crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Fuses
in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
in the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
of the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13

H hazard warning system . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Heating system
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53, 12-106
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34, 6-59
Hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
checking the position . . . . . . . . . . . . . . . . . . . . . . . . 12-12
reeving on the main boom . . . . . . . . . . . . . . . . . . . . . 13-75
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-41
Hook block
on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . . . 13-71
on the bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Hydraulic system
display and control instruments . . . . . . . . . . . . . . . . . . . 4-28

I Identification
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
Instrument panels
in the crane cab - overview . . . . . . . . . . . . . . . . . . . . . . 10-6
in the driver’s cab - overview . . . . . . . . . . . . . . . . . . . . . 4-8

K Keys
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

L Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Lamp test SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
display and operating instruments . . . . . . . . . . . . . . . . . 4-31
moving the truck crane into on-road driving position . . . . . . . 6-52
raising or lowering the entire truck crane . . . . . . . . . . . . . . 6-50
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switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
tilting the truck crane lengthwise or crosswise . . . . . . . . . . . 6-51
Level of on-road driving
see On-the-road level

16 - 8 2 084 575 en Operating Instructions GMK 5100

 lifting limit switch
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
Lifting limit switch weight . . . . . . . . . . . . . . . . . . . . . . . 13-79
Load bearing capacity of the ground . . . . . . . . . . . . . . . . . . . 13-6
table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Locking the superstructure . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60

M Main boom
lower the boom for maintenance purposes . . . . . . . . . . . . 12-83
rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Main hoist
display and operating instruments . . . . . . . . . . . . . . . . 10-33
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
working with the main hoist . . . . . . . . . . . . . . . . . . . . 12-41
Main rope, possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-80
Malfunctions
hydraulic oil cooler for superstructure . . . . . . . . . . . . . . 14-28
counterweight lifting unit . . . . . . . . . . . . . . . . . . . . . 14-26
crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
differential locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
procedure in the event of malfunctions . . . . . . . . . . . 7-35 to 7-46
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
sevel adjustment system . . . . . . . . . . . . . . . . . . . . . . . 7-33
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
suspension locking system . . . . . . . . . . . . . . . . . . . . . . 7-33
tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
transmission with automatic gear change . . . . . . . . . . . . . 7-28
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
when working with the crane . . . . . . . . . . . . . . . . . . . . 14-3
Malfunctions on
crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
mirror heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Mounting wheel
on the spare wheel holder . . . . . . . . . . . . . . . . . . . . . . 7-14
on the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
movements which can be carried out simultaneously
for operation with the main boom . . . . . . . . . . . . . . . . . 12-98
multipurpose switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
11.05.2000

O Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 to 6-54

On-the-road level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Operating Instructions GMK 5100 2 084 575 en 16 - 9

 moving the crane into on-the-road level . . . . . . . . . . . . . . 6-52
Operating hour counter
see crane control, display status menu
Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-14
actuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
display and operating instruments . . . . . . . . . . . . . . . . 10-26
extending - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . 13-13
see also Level adjustment system
retracting - CHECKLIST . . . . . . . . . . . . . . . . . . 13-15 to 13-40
variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Outrigger beams
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
outrigger cylinders
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32, 13-40
Outrigger pads
moving into driving position . . . . . . . . . . . . . . . . . . . . 13-29
moving into working position . . . . . . . . . . . . . . . . . . . 13-28
Outrigger pressure displays
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-39
Outrigger spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Overview
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
crane section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
display and operating instruments . . . . . . . . . . . . . 4-1 to 4-20
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
of display and operating instruments . . . . . . . . . . . 10-1 to 10-24
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

P Parking brake
display and operating instruments . . . . . . . . . . . . . . . . . 4-27
releasing mechanically . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
removing the mechanical lock . . . . . . . . . . . . . . . . . . . . 7-10
while towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-80
Power unit speed
see crane control, entering power unit speeds

R Refuelling
11.05.2000

fuel for the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-9

fuel for the vehicle engine . . . . . . . . . . . . . . . . . . . . . . 6-17
Removing the tyre
from the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

16 - 10 2 084 575 en Operating Instructions GMK 5100

 Rigging mode
before starting work - CHECKLIST . . . . . . . . . . . . . . . . . . 12-1
setting on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20
Rigging work
main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-14
rigging for crane operation - CHECKLIST . . . . . . . . . . . . . . 13-1
unrigging after crane work - CHECKLIST . . . . . . . . . . . . . . 13-4
Roof ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Rope end clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
rotating warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

S Safe distance
from banks and pits . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
from electrical lines . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Safe load indicator
see SLI
Safety equipment
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
functional description . . . . . . . . . . . . . . . . . . 10-59 to 10-62
Sensor/indicator
releasing shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 14-38
switch off during malfunction . . . . . . . . . . . . . . . . . . . 14-38
Separate steering
checking the steering lock . . . . . . . . . . . . . . . . . . . . . . 6-11
unlocking fourth axle line steering . . . . . . . . . . . . . 6-56 to 6-57
general . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 to 6-58
steering the 4th and 5th axle lines . . . . . . . . . . . . . . . . . . 6-56
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
display and operating instruments . . . . . . . . . . . . . . . . 10-35
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
slewing gear permanent brake . . . . . . . . . . . . . . . . . . . 12-48
tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-50
Slewing gear freewheel
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
SLI
display and operating instruments . . . . . . . . . . . . . . . . 10-41
during crane work . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
functional description . . . . . . . . . . . . . . . . . . . . . . . 10-59
fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
input of values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21
11.05.2000

lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
setting rigging mode . . . . . . . . . . . . . . . . . . . . . . . . 12-20
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

Operating Instructions GMK 5100 2 084 575 en 16 - 11

 SLI error message table . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
Spotlight for working area . . . . . . . . . . . . . . . . . . . . . . . 10-49
Steering
display and operating instruments in the driver’s cab . . . . . . . 4-29
steering column
operating instruments on the steering column . . . . . . . . . . . 4-20
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Stop engine cable
see emergency stop device
Superstructure hydraulic system
Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
checking the position of the stop cock . . . . . . . . . . . . . . . 11-7
cooling the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 12-97
display and control instruments . . . . . . . . . . . . . . . . . . 10-49
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
Superstructure lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Superstructure, access ladder . . . . . . . . . . . . . . . . . . . . . . 4-44
Suspension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Switching off the
crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Switching the fan thermostat to emergency operation . . . . . . . . . 7-35
Symbols in the operating instructions, explanation . . . . . . . . . . . 2-1

T Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
diagram sheets, inserting . . . . . . . . . . . . . . . . . . . . . . 6-22
open the drawer and check the time settings . . . . . . . . . . . . 6-21
time group, setting . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Technical data
superstructure . . . . . . . . . . . . . . . . . . . . . . . . 15-7 to 15-16
Technical description of the carrier . . . . . . . . . . . . . . . . 8-1 to 8-6
Technical description of the truck crane
superstructure . . . . . . . . . . . . . . . . . . . . . . . . 15-1 to 15-6
Technical specifications . . . . . . . . . . . . . . . . . . . . . . 8-7 to 8-14
Telescoping gear
display and operating instruments . . . . . . . . . . . . . . . . 10-37
example of procedures when telescoping . . . . . . . . . . . . 12-62
function of the control lever . . . . . . . . . . . . . . . . . . . . 12-60
functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-54
main boom fixed length . . . . . . . . . . . . . . . . . . . . . . 12-55
main boom intermediate length . . . . . . . . . . . . . . . . . . 12-56
main boom telescoping length . . . . . . . . . . . . . . . . . . 12-56
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
11.05.2000

telescope status, status display on the SLI . . . . . . . . . . . . 12-56

telescoping sequence . . . . . . . . . . . . . . . . . . . . . . . . 12-59
telescoping, indicated on the crane control display. . . . . . . . 12-88
tempomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
driving with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

16 - 12 2 084 575 en Operating Instructions GMK 5100

 switching off: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
switching on: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
temposet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
driving with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
time
setting time in the crane cab . . . . . . . . . . . . . . . . . . . . . 4-36
topping up oil
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-12
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
in case of motor damage . . . . . . . . . . . . . . . . . . . . . . . . 7-5
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
with damaged transmission . . . . . . . . . . . . . . . . . . . . . . 7-7
Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 to 6-76
towing free
forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
transmission with automatic gear change
after ignition has been switched on . . . . . . . . . . . . . . . . . 6-25
directing of travel, changing . . . . . . . . . . . . . . . . . . . . . 6-30
direction of travel and starting gear, select . . . . . . . . . . . . . 6-27
display and operating instruments . . . . . . . . . . . . . . . . . 4-22
display and operating instruments in the driver’s cab . . . . . . . 4-22
display of the engaged gears . . . . . . . . . . . . . . . . . . . . 6-27
emergency gear shift . . . . . . . . . . . . . . . . . . . . . . . . 7-39
error messages on the gearbox control display . . . . . . . . . . 7-36
gear, changing while driving . . . . . . . . . . . . . . . . . . . . . 6-29
operating mode, select . . . . . . . . . . . . . . . . . . . . . . . . 6-26
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
operation with clutch emergency pedal . . . . . . . . . . . . . . . 7-37
procedure in the event of malfunctions . . . . . . . . . . . . . . . 7-36
shift in neutral position . . . . . . . . . . . . . . . . . . . . . . . . 6-26
starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Transverse differential locks
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Transverse differential locks in all driven axle lines . . . . . . . . . . . 6-48
Truck crane
checking horizontal alignment . . . . . . . . . . . . . . . . . . . 12-35
earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
freeing the crane by its own power . . . . . . . . . . . . . . . . . 6-52
horizontally align . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
in on-road driving position . . . . . . . . . . . . . . . . . . . . . . 6-52
11.05.2000

overview of the crane section . . . . . . . . . . . . . . . . . . . . 10-1

overview of the vehicle section . . . . . . . . . . . . . . . . . . . . 4-1
raising or lowering . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
rocking it free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

Operating Instructions GMK 5100 2 084 575 en 16 - 13

 safe distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
securing the truck crane from rolling . . . . . . . . . . . . . . . . 6-43
tilting the crane lengthwise or crosswise . . . . . . . . . . . . . . 6-51
towing free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Tyre change
see Wheel change

V Vehicle engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
diagnostics plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
display and operating instruments . . . . . . . . . . . . . . . . . 4-21
inspections after starting . . . . . . . . . . . . . . . . . . . . . . . 5-12
preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62, 6-64
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9, 11-10
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
starting - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
starting a warm engine . . . . . . . . . . . . . . . . . . . . . . . . 5-11
starting cold vehicle engine . . . . . . . . . . . . . . . . . . . . . 5-10
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Ventilation
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-109
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34, 6-61

W Warning plates for vehicle width

connection between the carrier and superstructure . . . . . . . . 6-24
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 to 7-16
wheel, removing
from the spare wheel holder . . . . . . . . . . . . . . . . . . . . . 7-14
Wind
influence of wind on crane work . . . . . . . . . . . . . . . . . . 12-36
permissible wind load . . . . . . . . . . . . . . . . . . . . . . . 12-38
wind speed table . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Wirbelstromretarder
see Bremsen
Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-105
for work breaks lasting more than 8 hours . . . . . . . . . . . . 12-105
short work break . . . . . . . . . . . . . . . . . . . . . . . . . . 12-105
11.05.2000

16 - 14 2 084 575 en Operating Instructions GMK 5100