Carrier Malfunctions - EU PDF

Malfunctions on the carrier
7.1 Emergency stop device on carrier
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7 Malfunctions on the 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 uninten-
tionally 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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Operating Instructions GMK 5100 2 084 530 en 7-1

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7-2 2 084 530 en Operating Instructions GMK 5100

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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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 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
– 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; ➠ Com-
pressed-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.
• 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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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; ➠ Com-
pressed-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 pos-
sible 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.
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.
S
Steering will become difficult if the power steering is only supplied by the
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emergency steering pump.

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 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.
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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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 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. 6-42.
➠ Transverse differential lock, p.6-44.
Parking brake
• Release the parking brake.

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C0107

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 mecha-
nically 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 5 to 15 Nm).
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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!
Removing the • Use chocks or corresponding aids to prevent the vehicle from rolling.
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
+10
40 −0 Nm.
• Let trained personnel carry out a func-
tional test or the service brake and the
parking brake.
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7 - 10 2 084 530 en Operating Instructions GMK 5100

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.
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 2 084 530 en 7 - 11

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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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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 7.80 m x 2.50 m outrigger span!
For the 7.80 x 2.50 m 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 dam- If you lift the wheel with the truck crane onto the spare wheel holder,
aged wheel on observe the safety instruction Risk of overturning with a rigged outrigger span of
the spare wheel 7.80 x 2.50 m! in the previous section before turning.
holder
• Raise the wheel onto the spare wheel holder.
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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
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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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
• Tighten the wheel nuts again after driving

50 km and again after 150 km!
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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 4.3 D Speed indicator and tachograph (below

the plug-in module)
3 5.9 D Vehicle engine temperature and oil

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

passenger side, gearbox control display
s
Side plug-in
module
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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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.

The groups F1 to F6 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 (A) Function

circuit diagram:
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/
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24 V/12V voltage transformer / radio
8 15 electronic gear system
s

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

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


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

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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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)
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).
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 /
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3 F9 20 fuse for all consumer equipment, which has to

be supplied with power when the battery
master switch is switched off

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. 6-22.
Parking brake not engaged Engage parking brake;
➠ p. ➠ S. 6-22.
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. 6-13
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. 6-45.
The truck crane does not Level adjustment system Switch off level adjustment
travel at more than 20 km/h switched on system; ➠ p. 6-45.
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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 manufac_
turer
The fan wheel on the heat Switch the fan thermostat to
exchangers does not turn 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 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 (fan vehicle engine manufacturer.
wheel is not turning). Function in the charge air
thermostat switch the
thermostat to Emergency
operation; ➠ p. 7-33.
The motor electronics warning In the event of engine electronics malfunctions the perform-
lamp is on during driving, ance of the engine reduces continously. The engine does not
the engine performance gets switch off, however, and you can therefore continue driving
worse and worse until you get an opportunity to stop.
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The motor electronics warning Cooling water level too low, Cooling water level; ➠ p. 5-6;
lamp is on during driving, oil level too low, Oil level; ➠ p. 5-5;
the 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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7.6.2 Malfunctions of the transmission with automatic gear change
Neutral position cannot be Gearshift lever or two-stop Move the gearshift lever and
selected rocker is not in the home two-stop rocker into the home
position position
Transmission does not shift Rocker switch Automatic/ Rocker switch Switch automatic/
automatically manual operating mode is in the manual operating mode to
position M position A
Clutch emergency pedal is Lock clutch emergency pedal;
unlocked ➠ p. 7-35
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. 6-45.
Transmission does not react Fuse F2/2 Carrier defective Check fuses, replace if
when the gearshift lever necessary; ➠ p. 7-19.
or the two-stop rocker is
actuated
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 clutch
indicator lamp lights no longer possible emergency pedal; ➠ p. 7-35.
Gearbox control display Electronic gear system has ➠ Error message on display;
shows the service symbol or recognised a malfunction p. 7-34.
another error message Clutch emergency pedal is Lock clutch emergency pedal;
unlocked ➠ p. 7-35.
Transmission does not react Electronic gear system is no Do transmission emergenca
to the gearshift lever or the longer linked to the shifting; ➠ p. 7-37.
two-stop rocker, no more dis- transmission
play on the Gearbox control
display
After the ignition has been When the ignition is switched Engage the parking brake
switched on, the trans- off, the parking brake are before the next time the
mission is no longer in the released ignition is switched off
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neutral position 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.

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
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
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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7.6.4 Service brake malfunctions
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, check pressure gauge
does not go out after the for compressed air supply
engine has started
Air pressure in both circuits 1. Fill compressed-air supply
below 5,5 bar, check pressure at connection for external
gauge for compressed-air filling; ➠ p. 7-7.
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 6 km/h 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 6 km/h 4th and 5th axle line failed workshop; Braking without
ABS support is still possible.
Eddy current retarder (addi- Fuse F6/3 Carrier defective Check fuse, replace if
tional equipment) cannot be necessary; ➠ p. 7-19.
turned on
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7.6.5 Steering system malfunctions
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 failed cannot be steered!
are 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
28.01.2000

7.6.6 Tachograph malfunctions
H When there is a tachograph malfunction, the Tachograph malfunction warn-

ing light will light on the speed indicator and an error message will be
shown on the Tachograph display;
! 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
28.01.2000

7.6.7 Outrigger malfunctions
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. 7-41.
7.6.8 Suspension locking system malfunctions
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.
7.6.9 Level adjustment system malfunctions
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
28.01.2000

Blank page
28.01.2000

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!
28.01.2000

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 re-
maining 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.
28.01.2000
As long as the transmission continues to carry out all shifts, you can con-
tinue to drive.
If the transmission no longer shifts:

• 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. 7-35.
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
– 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. 7-37.
H 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.
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.
28.01.2000
s
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 actuat-
ing the gearshift lever or the two-stop rocker. The gear change will be
H
carried out.
As long as the clutch emergency pedal is actuated, the vehicle engine can-
28.01.2000
not be turned off.

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. 7-34) 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.
28.01.2000
s
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 servicing purposes1)
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
28.01.2000

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 operati-
ons 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
corrected as soon as possible. You cannot shift with the clutch emergen-
cy 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:
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 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.
• Turn off the ignition.

28.01.2000
s
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.
28.01.2000

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. 7-42).
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.
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 out-

rigger housing.
As long as the button (1) is pressed, the out-

rigger beams and cylinders can be moved
with the buttons at the solenoid valves.
28.01.2000
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
s
be found in the accompanying table.

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
28.01.2000

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
28.01.2000
28.08.2000

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28.01.2000

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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

The battery master switch (1) is located on

• Switch off the main battery. Turn the selec-

Operating Instructions GMK 5100 2 084 530 en 7-1

7-2 2 084 530 en Operating Instructions GMK 5100

7.2 Breakdown in road traffic

Please observe the following if a breakdown occurs:

• Secure the vehicle!

Operating Instructions GMK 5100 2 084 530 en 7-3

7-4 2 084 530 en Operating Instructions GMK 5100

7.3 Towing the truck crane

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

Towing distance up to 100 km

For towing distances up to a maximum of

• Loosen both clamping bolts and take off

The engine-dependent power steering is only supported by the emer-

emergency steering pump.

7-6 2 084 530 en Operating Instructions GMK 5100

Towing distances over 100 km

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

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

• Switch on the battery master switch.

• Switch on the ignition.

• Release the parking brake.

7-8 2 084 530 en Operating Instructions GMK 5100

Open all spring accumulators

• Unscrew the hexagon screw (1) (spanner

Towing The towing vehicle must start driving slowly.

• Screw in the hexagon screw (1) completely.

7 - 10 2 084 530 en Operating Instructions GMK 5100

• Switch on the ignition.

Operating Instructions GMK 5100 2 084 530 en 7 - 11

7 - 12 2 084 530 en Operating Instructions GMK 5100

7.4 Wheel change

Removing a • Engage the vehicle parking brake.

• Unscrew the wheel nuts.

G Danger of accidents from overturning wheel!

• Attach the wheel; ➠ Weight of wheels,

7 - 14 2 084 530 en Operating Instructions GMK 5100

• Screw the wheel onto the spare wheel

• Tighten the wheel nuts crosswise in

Second level: 400 Nm

Third level: 650 Nm

• Tighten the wheel nuts again after driving

7 - 16 2 084 530 en Operating Instructions GMK 5100

7.5 Electrical system

7.5.1 Plug-in modules

Pos. Designation of plug-in Function

1 1.4 D Oil temperature and pressure display,

2 4.3 D Speed indicator and tachograph (below

3 5.9 D Vehicle engine temperature and oil

4 Heating plug-in module Heating and ventilation on driver and

Pos. Designation of plug-in Function

1 6.2 D Operation and monitoring transverse

7 - 18 2 084 530 en Operating Instructions GMK 5100

The fuses are divided into 9 groups F 1 to F 9.

Each group consists of 8 fuses.

The following tables show the designations

Designation in Rating (A) Function

1 20 E-control for vehicle engine