Carrier Malfunctions - EU PDF

Malfunctions on the carrier
7.1 Emergency stop device on carrier
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7
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 unintentionally or if the ignition locks malfunctions).
Turning off the

vehicle engine
You can turn off the truck crane from ouside of the drivers cab by
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 selector handle so that it can be pulled off.
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The crane engine switches off.
Operating Instructions GMK 5100
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7-1

7.1 Emergency stop device on carrier
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7-2
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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!
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.
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, particularly 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.
28.01.2000
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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7-3

7.2 Breakdown in road traffic
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7-4
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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 10 t. 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
case of motor
damage
If the truck crane has to be towed because of motor damage, just how you
should proceed depends on the length of the towing distance. The factors
to consider are:
towing out of the danger area
towing distance up to 100 km
towing distance over 100 km.
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; Compressed-air supply for vehicle engine breakdown, p. 7-7.
Select neutral on the transmission; Shifting the transmission to neutral
position, p. 6-22.
Switch the Transmission emergency switch to the NH position; Emergency
transmission shifting, p. 7-37.
Tow the vehicle at a maximum of 10 km/h.
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Tow the truck crane no more than 1 km; for further towing distances;
Towing distance up to 100 km, in the following section.
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7-5

Towing distance up to 100 km
To provide compressed air supply, connect the filler connection of the

truck crane to the Supply coupling head of the towing vehicle; Compressed-air supply for vehicle engine breakdown, p. 7-7.
Select neutral on the transmission; Shifting the transmission to neutral
position, p. 6-22.
Switch the Transmission emergency switch to the NH position; Emergency
transmission shifting, p. 7-37.
For towing distances up to a maximum of
100 km, 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 possible into the gearbox and tighten it.
7-6
Tow the vehicle at a maximum of 40 km/h.

The engine-dependent power steering is only supported by the emergency 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.
Steering will become difficult if the power steering is only supplied by the
emergency steering pump.
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G
H
S
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.

Towing distances over 100 km

If the towing distance is more than 100 km, you have to disconnect and tie
up the cardan shaft between the transmission and the transfer case at the
transfer case.
Observe all information which applies to towing up to 100 km.

When the cardan shaft is disconnected and tied up, the towing speed can
be more than 40 km/h.
Towing when the

transmission has
been damaged
If the transmission has been damaged, you have to disconnect and tie up
the cardan shaft between the transmission and the transfer case at the
transfer case.
Risk of damage to the cardan shaft!
The vehicle engine must not be started while the cardan shaft is disconnected 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.
Compressed-air
supply in the
event of engine
failure
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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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7-7

Monitor the supply pressure on the Supply pressure brake circuits I and II
status display during towing.
The supply pressure must be at least 6 bar for towing!
8
9
1
0
bar
10
C0005
The Supply pressure brake circuits I and II warning lamp must not light up!
Power supply
Switch on the battery master switch.
Switch on the ignition.
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.
Switch all the transverse differential and longitudinal differential locks;

Longitudinal differential lock / drive of the 3rd axle line, p. 6-42.
Transverse differential lock, p.6-44.
Axle drives
Parking brake
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Release the parking brake.
C0107
7-8
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H
f
The Parking brake indicator lamp goes out.

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
G
The parking brake should only be released mechanically if it can no

longer be pneumatically released. It should only be released mechanically if the truck crane must be towed!
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.
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Continue to unscrew the hexagon

screw (1) until the wheel brake is released
(torque 5 to 15 Nm).
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7-9

G
Towing
procedure
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!
The towing vehicle must start driving slowly.
Removing the
mechanical
locking from all
spring-loaded
brake cylinders
Gf
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.
Fill the compressed-air supply completely (the Supply pressure brake

circuits I and II warning lamp must not light up).
Do not operate the service brake.
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
+10
40 0 Nm.
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Let trained personnel carry out a functional test or the service brake and the
parking brake.
7 - 10
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Tow starting
Switch on the ignition.

Select the 3rd or 4th gear with the Transmission gearshift lever as the
starting gear. The selected gear has to be displayed in the Gearbox control
display.
Start towing the truck crane slowly. The towing speed may not exceed
20 km/h.
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
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greater pressure on the accelerator will cause fast clutching
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7 - 11

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7 - 12
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7.4 Wheel change
7.4
Wheel change
If a tyre puncture occurs while driving:
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
Removing a
damaged tyre
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.
Engage the vehicle parking brake.

Lock the suspension system.
Lift the truck crane with the outrigger until the tyre that is to be changed
leaves the ground.

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.
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Secure the wheel against falling over if you temporarily lean it against
the vehicle.
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7 - 13

7.4 Wheel change
Removing the
wheel from the
spare wheel
holder
G
G
You can lift the spare wheel (additional equipment) with a chain hoist or,
if at least the 1 t counterweight version is mounted on the turntable, also
with the truck crane itself.
Risk of overturning with rigged 7.80 m x 2.50 m outrigger span!

For the 7.80 x 2.50 m outrigger span, you can only slew the superstructure 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.

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;

p. 8-9.
Weight of wheels,
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 damaged wheel on

the spare wheel
holder
If you lift the wheel with the truck crane onto the spare wheel holder,
observe the safety instruction Risk of overturning with a rigged outrigger span of
7.80 x 2.50 m! in the previous section before turning.
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Raise the wheel onto the spare wheel holder.

7.4 Wheel change
Screw the wheel onto the spare wheel

holder using the four nuts (1).
Tightening torque: 500 Nm in each case.
Mounting the
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 manufacturers 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.
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Screw on the rest of the wheel nuts hand-tight.
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7 - 15

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:
200 Nm
Second level:
400 Nm
Third level:
650 Nm
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Tighten the wheel nuts again after driving

50 km and again after 150 km!
7 - 16
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7.5 Electrical system
7.5
Electrical system
7.5.1
Plug-in modules
Front plug-in
module
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Pos.
Designation of plug-in
module in the electronic
circuit diagram
Function
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
4.3 D
Speed indicator and tachograph (below

the plug-in module)
5.9 D
Vehicle engine temperature and oil

pressure/ vehicle engine monitoring,
parking brake, coolant level, differential
locking, lighting, fuel reserve
Heating plug-in module
Heating and ventilation on driver and

passenger side, gearbox control display
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7 - 17

Side plug-in
module
Pos.
6.2 D
Function
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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Designation of plug-in
module in the electronic
circuit diagram
7 - 18
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7.5.2
Fuses
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 indicated ratings.
The fuses are divided into 9 groups F 1 to F 9.
The groups F1 to F6 are located under the
cover at the right next to the front instrument 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 correspond to the order from top to bottom
(fuse 1 is always the top fuse).
28.01.2000
Designation in
circuit diagram:
F1
Rating (A)
Function
20
E-control for vehicle engine
10
engine electronics (FMR and ADM)

Mercedes Benz diagnostic plug
10
flame-start device (additional

equipment)
15
hazard warning system / brake lights
10
ABS
10
ABS
10
drivers cab ceiling lighting /

cigarette lighter/
24 V/12V voltage transformer / radio
15
electronic gear system
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7 - 19

Function
10
E-control for vehicle engine
10
engine electronic system (FMR and

ADM),
Mercedes Benz diagnostics plug,
transmission gearshift lever and display,
bridge collision display (additional
equipment)
10
flame-start device (additional

equipment) ABS
10
constant throttle for motor brake
10
level adjustment system / axle spring

accumulator
10
suspension locking system / steering

circuit display I + II / separate steering
10
differential locks / transfer case
10
outriggers / electronic level

(inclination indicator) / outrigger
pressure display
Designation in
circuit diagram:
F3
7 - 20
Rating (A)
Rating (A)
Function
speed indicator
indicator lamp battery charge indicator
electronic gear system
15
heater fan
10
mirror heating
15
windscreen wiper and washing pump /

roof ventilator (additional equipment) /
horn
10
reversing light
20
rotating warning lights
15
turn indicators
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Designation in
circuit diagram:
F2

Designation in
circuit diagram:
F4
Rating (A)
Function
15
heating system
10
radio, telephone (additional equipment)
10
no function
10
no function
10
no function
10
no function
10
fog lamp (additional equipment)/

rear fog light
Designation in
circuit diagram:
F5
Rating (A)
transmission diagnostics plug
Function
position lamps left superstructure /

left parking light
10
position lamps right superstructure /

right parking light
10
left rear circumference lamps /

instrument lighting
right rear profile lamps
10
fog lamp/
left headlight - full beam
10
right headlight - full beams/

headlight - full beam indicator lamp
10
left low-beam headlight
10
right low-beam headlight
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7 - 21

Designation in
circuit diagram:
F6
Rating (A)
Function
20
hydraulic oil cooler
no function
15
retarder (additional equipment)
10
no function
10
no function
tachograph
15
central lubrication
additional heating system (additional

equipment)
The fuses F7 to F9 are located in the battery

box.
Open the battery box lid and take the

cover off the terminal box:
fuses F7 (1), F8 (2) and F9 (3).
Rating (A)
Function
F7
100
carrier main fuse
F8
50
air conditioner (additional equipment)
20
pre-fuse for additional heating system, voltage

transformer and tachograph /
fuse for all consumer equipment, which has to
be supplied with power when the battery
master switch is switched off
7 - 22
Designation in
circuit diagram:
F9
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Terminal
box

7.6 Troubleshooting and malfunction correction
7.6
Troubleshooting and malfunction correction
7.6.1
Vehicle engine malfunctions
In the event of vehicle engine malfunctions also refer to the MercedesBenz Instruction Manual.
Malfunction
Cause
Action
Engine does not start

(starter does not turn over)
Battery master switch not

switched on
Switch battery master switch

on; p. 5-7.
Ignition switched off
Switch on ignition;
p. 5-9.
The transmission is not in

neutral position
Shift the transmission to N;

p. 6-22.
Parking brake not engaged
Engage parking brake;

p. S. 6-22.
Fuse F1/1 Carrier or F2/1

Carrier defective
Check fuse, replace if

necessary; p. 7-19.
Batteries flat
Charge batteries; also

Maintenance Manual.
Fuel tank empty
1.
Engine does not start

(starter motor turns over)
Fill fuel tank;

p. 6-13
2.
Ventilate fuel system;

operating manual for the
vehicle engine manufacturer

Carrier faulty
Check fuses and replace if

necessary; p. 7-19.
Vehicle engine air filter

warning lamp is on
Air filter is clogged
Replace dry-type air filter

( Maintenance manual)
Vehicle engine coolant level

warning lamp is on
Coolant level too low
Top up coolant;
p. 6-45.
The truck crane does not

travel at more than 20 km/h
Level adjustment system

switched on
Switch off level adjustment

system; p. 6-45.
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Flame-start device indicator

lamp (additional equipment)
does not go on during ignition of the motor when cold
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7 - 23

Malfunction
Cause
Action
Engine coolant temperature

too high
Coolant level too low

(warning lamp illuminates)
Fill coolant; p. 5-6.
Oil level in gear box too low
Check oil level, top up if

necessary; p. 5-4 and
Maintenance manual
Outside of heat exchanger

dirty
Clean outside of heat

exchanger
V-belt of the coolant pump on

the engine loose
Tighten V-belt;
operating manual for the
vehicle engine manufac_
turer
The fan wheel on the heat

exchangers does not turn
Switch the fan thermostat to

emergency operation;
p. 7-33
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

with the ignition key
Malfunction of the electronics
Switch of the engine with

emergency stop device;
p. 7-1.
Check fuses, replace if
necessary; p. 7-19.
Motor brake (retarder)

does not switch on
Fuse F2/4 Carrier defective

necessary; p. 7-19.
Vehicle engine diagnostic

plug no function

Carrier faulty

necessary; p. 7-19.
Power drop and abnormal

exhaust gas opacity
If the charge air temperature

is too high, the fault can be in
the charge air thermostat (fan
wheel is not turning).
Malfunctions in the
The motor electronics warning

lamp is on during driving,
the engine performance gets
worse and worse
In the event of engine electronics malfunctions the performance of the engine reduces continously. The engine does not
switch off, however, and you can therefore continue driving
until you get an opportunity to stop.
28.01.2000
operating manual of the

vehicle engine manufacturer.
Function in the charge air
thermostat switch the
thermostat to Emergency
operation; p. 7-33.
7 - 24
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Malfunction
Cause
Action
The motor electronics warning Cooling water level too low,

lamp is on during driving,
oil level too low,
the engine performance gets air filter dirty.
worse and worse
Cooling water level; p. 5-6;

Oil level; p. 5-5;
Air filter; Maintenance
manual
Check V-belt tension;
Operating manual
Mercedes-Benz
Plug or cable on the control

unit loose
Check the plug on the control

unit (on the right next to the
fuses)
Cabling behind the

accelerator pedal is damaged
Check cable, if damaged, inform GROVE Product Support
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V-belt too loose
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7 - 25

7.6.2
Malfunctions of the transmission with automatic gear change
Malfunction
Cause
Action
Neutral position cannot be

selected
Gearshift lever or two-stop

rocker is not in the home
position
Move the gearshift lever and

two-stop rocker into the home
position
Transmission does not shift

automatically
Rocker switch Automatic/

manual operating mode is in the
position M
Rocker switch Switch automatic/

manual operating mode to
position A
Clutch emergency pedal is

unlocked
Lock clutch emergency pedal;

p. 7-35
Fuse F1/8 Carrier or F 3/2

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
built up on the reservoirs
pressure has built up.
ged and the Brake circuit I
and II supply pressure
warning lamp lights
Gear box does not switch up
to 4th gear

switched on
Switch off level adjustment

system; p. 6-45.
Transmission does not react

when the gearshift lever
or the two-stop rocker is
actuated

necessary; p. 7-19.
Apply brakes indicator lamp

lights during driving
Transmission can not

downshift, because the
maximum engine speed was
exceeded in a low gear
Slow down truck crane, until

indicator lamp goes out
Unlock clutch emergency pedal Automatic clutch actuation is

indicator lamp lights
no longer possible
Drive the truck crane with clutch

emergency pedal; p. 7-35.
Gearbox control display

Electronic gear system has
shows the service symbol or recognised a malfunction
another error message
Clutch emergency pedal is
unlocked
Error message on display;
Transmission does not react

to the gearshift lever or the
two-stop rocker, no more display on the Gearbox control
display
Electronic gear system is no

longer linked to the
transmission
Do transmission emergenca
shifting; p. 7-37.
After the ignition has been

switched on, the transmission is no longer in the
neutral position
When the ignition is switched

off, the parking brake are
released
Engage the parking brake

before the next time the
ignition is switched off
7 - 26
If the engine can not be started because a gear is engaged and

the air pressure is under 5.5 bar, mechanically shift the
transmission into the neutral position; p. 7-39.
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28.01.2000
p. 7-34.
Lock clutch emergency pedal;
p. 7-35.

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

switched on
Level adjustment system not

switched on
Switch on level adjustment

system key-operated switch
Drive train twisted
Shift transmission in neutral

position
Compressed air equipment

not sufficiently filled
Let the engine run, until

pressure has built up. The
circuit for secondary
consumers takes a few
minutes to fill after the
indicator lamp goes out.

necessary; p. 7-19.
Drive train under tension
Drive truck crane backwards

and forwards slowly with the
steering straight.
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Differential locks cannot be

switched off
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7 - 27

7.6.4
Service brake malfunctions
Malfunction
Cause
Action
Supply pressure brake circuits I and II warning lamp

lights up during driving or
does not go out after the
engine has started
Air pressure in one of the two

circuits has dropped below
5,5 bar, check pressure gauge
for compressed air supply
Vehicle can be driven slowly

as far as the next workshop.
Air pressure in both circuits

below 5,5 bar, check pressure
gauge for compressed-air
supply
1.
Fill compressed-air supply

at connection for external
filling; p. 7-7.
2.
Tow truck crane

using a tow-rod.
Let the engine run in neutral

with the parking brake
engaged until the air pressure
in circuit 3 is high enough.
Warning lamp ABS1 lights

also at speeds over 6 km/h
ABS brake system in the 2nd

and 3rd axle line failed
Drive to the nearest

workshop; Braking without
ABS support is still possible.
Warning lamp ABS2 lights

also at speeds over 6 km/h
ABS brake system in the 1st,

4th and 5th axle line failed
Drive to the nearest

workshop; Braking without
ABS support is still possible.
Eddy current retarder (additional equipment) cannot be

turned on

necessary; p. 7-19.
28.01.2000
Parking brake does not disen- Air pressure in circuit 3 is too

gage, Parking brake indica- low
tor lamp does not go out,
Supply pressure brake
circuits I and II warning lamp
is off
7 - 28
2 084 530 en

7.6.5
Steering system malfunctions
Malfunction
Cause
Action
Steering wheel stiff, creaking

noises during steering
Too little oil in hydraulic oil

tank
Check the level of the

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

steering circuit I or II is on
Too little oil in hydraulic oil

tank
Check the level of the

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.

defective pump
Vehicle can be driven slowly

as far as the next workshop.
Both warning lamps for

steering circuits I and II
are on
Both steering circuits have

failed
Vehicle cannot be driven, as it

cannot be steered!
Hydraulic oil temperature too

high
Oil level in hydraulic oil tank

too low
Check hydraulic oil level and

top up if necessary
Hydraulic oil cooler does not

switch on, fuses F 6/1
defective

necessary; p. 7-19.
Hydraulic oil return flow filter

contaminated
Change hydraulic oil return

filter I and II
28.01.2000
Warning lamp for hydraulic

oil return filter I and II lights
up
2 084 530 en
7 - 29

7.6.6
Tachograph malfunctions
When there is a tachograph malfunction, the Tachograph malfunction warning light will light on the speed indicator and an error message will be
shown on the Tachograph display;
Cause
Action
! 4A050
Driving without diagram

sheet for driver 1
Insert diagram sheet for

driver 1 and press any key.
! 4A051
Diagram sheet for driver 1

missing
Insert diagram sheet for

driver 1 and press any key.
! 49052
Diagram sheet for driver 2

missing
Set 1-driver-operation time

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
! 4A400
Voltage interruption
! 4A411
Interruption of the line to the

speed indicator
! 4A423
Error for transmitter

communication
Acknowledge the error

message by pressing any
button, until the basic display
appears. If the error message
cannot be acknowledged,
inform service
! 4900F
Keyboard error
28.01.2000
Malfunction
7 - 30
2 084 530 en

7.6.7
Outrigger malfunctions
Malfunction
Cause
Action
Strut cylinder and outrigger

Fuse F 2/8 Carrier defective
beams cannot be extended or
retracted and the electronic
Solenoid valves jammed
level does not display
7.6.8

necessary; p. 7-19.
Operate solenoid valves by
hand; Emergency operation
of the solenoid valves for the
outriggers, p. 7-41.
Suspension locking system malfunctions
Malfunction
Cause
Action
Suspension lock cannot be

switced off
Compressed-air system not

filled sufficiently
Let engine run until pressure

has built up. The circuit for
secondary consumers takes a
few minutes to fill after the
indicator lamp goes out.

necessary; p. 7-19.
7.6.9
Level adjustment system malfunctions

Cause
Action

does not function
Level adjustment system key

switch switched off
Switch on level adjustment

system key switch
The transmission is not in

neutral position
Shift the transmission to N
suspension locking system

switched on
Switch off suspension locking

system

necessary; p. 7-19.
28.01.2000
Malfunction
2 084 530 en
7 - 31

28.01.2000
Blank page
7 - 32
2 084 530 en

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.
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!
28.01.2000
After installing a new thermostat, the corresponding tap must be opened

again!
2 084 530 en
7 - 33

7.7.2
What to do if there is a transmission malfunction

If the transmission malfunctions, the electronic gear system will try to
establish a secure operating condition for the transmission with the remaining functions.
Error messages
on the Gearbox
control display
There are different error messages which are shown on the Gearbox control
display in the event of a malfunction.
status display EE,
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 electronic 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 manufacturers service department.
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
As long as the transmission continues to carry out all shifts, you can continue to drive.
If the transmission no longer shifts:
7 - 34
2 084 530 en
28.01.2000
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.

Check whether the Unlock clutch emergency pedal indicator lamp lights.
In this case, you need the clutch emergency pedal to continue driving.
Operation with the clutch emergency pedal, p. 7-35.
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
H
Operation with
the clutch emergency pedal

If the transmission still does not shift, you can carry out an emergency
gear shift; Carring out an emergency gear shift, p. 7-37.
If the service symbol is displayed, you should inform GROVE Product
Support 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.
If there is a malfunction in the automatic clutch operating mechanism,

you can clutch with the clutch emergency pedal.
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 automatically 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.
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.
28.01.2000
s
2 084 530 en
7 - 35

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.
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.
7 - 36
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 display 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
carried out.
As long as the clutch emergency pedal is actuated, the vehicle engine cannot be turned off.
2 084 530 en
28.01.2000
H
H
Only let the clutch emergency pedal go when the newly engaged gear is
shown on the Gearbox control display.

Locking the clutch emergency pedal

When the malfunction has been corrected, you can lock the clutch emergency 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
emergency gear
shift
An emergency gear shift should only be carried out when:

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. 7-34) does not help.
28.01.2000
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.
s
2 084 530 en
7 - 37

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.
NL: for servicing purposes1)
NH: for servicing purposes1)
and for towing
5: in 5th gear
R: in reverse gear
G: home position
2: in 2nd 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
7 - 38
28.01.2000
from R to G
2 084 530 en

Changing gears while the truck crane is moving
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
Mechanical emergency shifting to
neutral
Danger of the transmission wearing out too quickly!

Have the problem with the transmission or the electronic gear system
corrected as soon as possible. You cannot shift with the clutch emergency pedal as gently as you can with the electronic gear system.
When the truck crane is parked in gear and the pressure in the reservoir
falls below 5.5 bar:
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 and
the reservoir may not be filled because the engine is not running.
In this condition, the transmission can be shifted mechanically into
neutral in order to start the engine.
28.01.2000
Turn off the ignition.
s
2 084 530 en
7 - 39

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.
28.01.2000
Replace the cover plate and secure it.
7 - 40
2 084 530 en

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 outrigger 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. 7-42).
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.
Risk of crushing when supporting cylinder is retracted!

When you actuate valve 47-Y9 to lower the truck crane with the supporting 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.
28.01.2000
As long as the button (1) is pressed, the outrigger beams and cylinders can be moved
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
be found in the accompanying table.
2 084 530 en
7 - 41

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
V
3
V
7
2
H
4
6
H
SL
VL
HL
28.01.2000
C0523
7 - 42
2 084 530 en

Front emergency operation
Switch
V
Valve designation in
hydraulic circuit
diagram
left
44 Y 11
right
44 Y 6
left
44 Y 51
right
44 Y 2
left
44 Y 1
right
44 Y 61
left
44 Y 5
right
44 Y 21
Switch
V
Valve designation in
hydraulic circuit
diagram
left
44 Y 7
right
44 Y 8
left
44 Y 3
right
44 Y 4
left
44 Y 71
right
44 Y 81
left
44 Y 31
right
44 Y 41
retract
Support cylinder
front
extend
retract
Outrigger beam
front
extend
Rear emergency operation
retract
Support cylinder
rear
extend
retract
Outrigger beam
rear
28.08.2000
28.01.2000
extend
2 084 530 en
7 - 43

28.01.2000
Blank page
7 - 44
2 084 530 en

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Malfunctions on the carrier

7.1 Emergency stop device on carrier

Malfunctions on the carrier

Turning off the

The battery master switch (1) is located on

The crane engine switches off.

Operating Instructions GMK 5100

Malfunctions on the carrier

Operating Instructions GMK 5100

Malfunctions on the carrier

Breakdown in road traffic

Risk of accidents if visibility is poor!

Secure the vehicle!

Risk of accidents if visibility is poor!

Operating Instructions GMK 5100

Malfunctions on the carrier

Operating Instructions GMK 5100

Malfunctions on the carrier

Towing the truck crane

To provide compressed air supply, connect the filler connection of the

Malfunctions on the carrier

Towing distance up to 100 km

To provide compressed air supply, connect the filler connection of the

Loosen both clamping bolts and take off

Tow the vehicle at a maximum of 40 km/h.

Operating Instructions GMK 5100

Danger of accidents if the brakes fail!

Malfunctions on the carrier

Towing distances over 100 km

Observe all information which applies to towing up to 100 km.

Towing when the

Observe all information which applies to towing up to 100 km.

The filler connection (1) of the truck crane

Malfunctions on the carrier

Switch on the battery master switch.

Switch on the ignition.

Switch all the transverse differential and longitudinal differential locks;

Release the parking brake.

Operating Instructions GMK 5100

Malfunctions on the carrier

The Parking brake indicator lamp goes out.

The parking brake should only be released mechanically if it can no

Open all spring accumulators

Unscrew the hexagon screw (1) (spanner

Continue to unscrew the hexagon

Malfunctions on the carrier

Accidents may occur due to released parking brake!

The towing vehicle must start driving slowly.

Damage may occur to the chassis!

Use chocks or corresponding aids to prevent the vehicle from rolling.

Fill the compressed-air supply completely (the Supply pressure brake

Operating Instructions GMK 5100

Malfunctions on the carrier

Switch on the ignition.

When the maximum permissible engine speed is exceeded, a warning

greater pressure on the accelerator will cause fast clutching

Operating Instructions GMK 5100

Malfunctions on the carrier

Operating Instructions GMK 5100

Malfunctions on the carrier

Watch the traffic behind you and stop when it is safe.

Danger of accidents from overturning wheel!