Operating instructions

EKS 5 light

2 084 976 en
Serial number 07.07.2005
 Important note

Duplications of any kind and excerpts from this

document are not subject to the revision service.
Original documents of Deutsche GROVE GmbH
are marked with the blue serial number of the
truck crane on the cover sheet.

Duplications and printouts from data carriers

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

© Copyright reserved by Deutsche GROVE GmbH

07.07.2005

Dissemination or duplication of this document as well as utilization and disclosure of its contents are prohibited
unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent
or utility model are reserved.

2 084 976 en Operating instructions EKS 5 light

 1
1 Safe load indicator EKS 5 light
1.1 Information about these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

1.2 Overview of the operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

1.2.1 In the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
1.2.2 On the control unit SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.3 Short description of the operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

1.4 Operation of the safe load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19

1.4.1 Switching on SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 20
1.4.2 Enter rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 23
1.4.3 Checks to be carried out before crane operation . . . . . . . . . . . . . . . . . . . . . . . . 1- 31
1.4.4 Displays during crane operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 33
1.4.5 SLI early warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 37
1.4.6 SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 38
1.4.7 Error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 39
1.4.8 SLI override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 40
1.4.9 Displaying and entering the time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 41
1.5 Finding and eliminating malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 43
1.5.1 General malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 43
1.5.2 Error messages on the SLI control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 44
1.5.3 Fuses of the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 48
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Operating instructions EKS 5 light 2 084 976 en

 07.07.2005

2 084 976 en Operating instructions EKS 5 light

 Safe load indicator EKS 5 light
1.1 Information about these operating instructions

1 Safe load indicator EKS 5 light

1.1 Information about these operating instructions

These operating instructions only apply to the truck cranes with serial num-
bers that are on the cover she1et of these operating instructions.
These truck cranes are equipped with the safe load indicator EKS 5 light.
These operating instructions describe the control of the SLI EKS 5 light and
complement the truck crane operating instructions supplied in which the
older version – the safe load indicator EKS 4 – is described.

Abbreviation The safe load indicator is abbreviated in these operating instructions as SLI
(Safe-Load-Indicator).
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Safe load indicator EKS 5 light
1.1 Information about these operating instructions

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 Safe load indicator EKS 5 light
1.2 Overview of the operating elements

1.2 Overview of the operating elements

1.2.1 In the crane cab

1 Control unit SLI à p. 1 - 4

2 Key-operated override switch à p. 1 - 11
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Safe load indicator EKS 5 light
1.2 Overview of the operating elements

1.2.2 On the control unit SLI

H
The following tables only designate the symbols. The function of each but-
07.07.2005

ton always corresponds to the symbol that is on the button.

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 Safe load indicator EKS 5 light
1.2 Overview of the operating elements

1 Lattice extension angle input1) à p. 1 - 13

No function2)
1.1 Lattice extension angle display1) à p. 1 - 13
Current lattice extension inclination display2) à p. 1 - 16
2 Lattice extension length input à p. 1 - 13
2.1 Lattice extension length display à p. 1 - 13
3 Reeving input à p. 1 - 12
3.1 Reeving display à p. 1 - 12
4 Counterweight input à p. 1 - 13
4.1 Counterweight display à p. 1 - 13
5 SLI code input à p. 1 - 12
5.1 SLI code display à p. 1 - 12
6 Outrigger span input à p. 1 - 15
6.1 Outrigger span display à p. 1 - 14
7 Additional function F1 on à p. 1 - 12
8 Numerical pad with the buttons 1 to 0 à p. 1 - 11
9 Acknowledge à p. 1 - 13
10 Confirm entry à p. 1 - 13
11 Display / enter time and date à p. 1 - 41
1)
With additional equipment with manually inclinable lattice extension
2)
With additional equipment with hydraulically derricking lattice exten-
sion

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Safe load indicator EKS 5 light
1.2 Overview of the operating elements

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1.2 Overview of the operating elements

1 Current telescoping status display à p. 1 - 16

2 Maximum load display à p. 1 - 17
3 SLI early warning à p. 1 - 17
4 SLI shutdown à p. 1 - 17
5 Hoisting gear display à p. 1 - 18
6 Sensor for brightness à p. 1 - 18
7 Current main boom angle display à p. 1 - 16
8 Display for the current degree of utilisation à p. 1 - 17
9 Current load display à p. 1 - 16
10 Current working radius display à p. 1 - 16
11 Additional function F2 on à p. 1 - 18
12 Lamp test (as additional function F2) à p. 1 - 18
13 Service F3 à p. 1 - 18
14 Service F4 à p. 1 - 18
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Safe load indicator EKS 5 light
1.2 Overview of the operating elements

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1.2 Overview of the operating elements

1 Information / error display à p. 1 - 18

2 Displaying error information à p. 1 - 35
3 Displaying degree of utilization à p. 1 - 35
4 Displaying oil pressure derricking cylinder à p. 1 - 36
(as additional function F5 and F6)
5 Displaying current slewing angle à p. 1 - 36
6 Displaying current overall height à p. 1 - 36
7 Displaying current working radius à p. 1 - 35
8 Additional function F5 on à p. 1 - 36
9 Additional function F6 on à p. 1 - 36
10 Displaying current main boom length à p. 1 - 35
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Safe load indicator EKS 5 light
1.2 Overview of the operating elements

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 Safe load indicator EKS 5 light
1.3 Short description of the operating elements

1.3 Short description of the operating elements

G
Risk of accidents due to operating error!
This section is not a complete operating manual. It only provides a general
overview of the operating element functions.
Before using the operating elements for the first time, read through the fol-
lowing chapter and the safety instructions listed there.

H
This section does not contain all the requirements which much be fulfilled
so that certain operating elements can function.
Should some operating elements not function, then read the following sec-
tions first which are referred to at the respective places before you turn to
CraneCARE for help.

Key-operated override switch

– Turn to the right: SLI shutdown bypassed –

Crane functions released, no more monitoring;
à p. 1 - 40
– Turning to the left: SLI shutdown and Lifting limit switch shutdown
bypassed –
Crane functions released, no more monitoring.

Input elements à Operation of the safe load indicator, p. 1 - 19.

with displays

Displays
Display – maximum four digits
1 Point for decimal places
2 Signalling point

Numerical pad

– Button 1 to 0 – SLI code input, reeving

– Date / time display
– Additional functions: – Date / time input
– Lamp test

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Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Additional function F1 on
Use always in combination with other buttons:

– Reeving input mode

Press +button, additionally press S button once – (1) display flashes –
input mode on
– SLI code input mode
Press +button, additionally press O button once – (2) display flashes –
input mode on
à p. 1 - 23

SLI code display and input

1 Display: SLI code, four digits

2 Input: In the input mode
– Press O button once – next SLI code
– or input using the numerical pad
à p. 1 - 24

Reeving display and input

1 Display: Required quantity of reeved ropes for maximum load (3)

2 Input: In the input mode
– Press S button once – quantity +1
– or input using the numerical pad
à p. 1 - 26

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 Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Confirm entry

– Press button once: Input mode off

– Signalling point (1) is displayed
– Value does not flash anymore

Acknowledge

– Press button once: Buzzer tone off, error message acknowledged

or
Time input aborted

Counterweight display and input

1 Display: Counterweight combination in tonnes (t) – for displayed

SLI code
2 Input: In the input mode
Press I button once – next combination
à p. 1 - 28

Lattice extension length display and input

1 Display: Lattice extension length in metres (m) or feet (ft) –

for displayed SLI code
2 Input: In the input mode
Press R button once – next length
à p. 1 - 28

Lattice extension angle display and input

The manual inclinable lattice extension is connected.
1 Display: Angle between lattice extension and main boom in
degrees (°) – for displayed SLI code
2 Input: In the input mode
Press T button once – next angle
à p. 1 - 28

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Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Outrigger span display

– Display
Necessary outrigger span for displayed SLI code The displays are differ-
ent depending on the crane type.

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 Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Type of crane
Display GMK 2035 GMK 3050 GMK 4075 GMK 5100
m (ft) m (ft) m (ft) m (ft)
6.33 x 6.20 6.63 x 6.20 8.10 x 7.00 7.80 x 7.50
1
(20.8 x 20.3) (21.7 x 20.3) (26.6 x 23.0) (25.6 x 24.6)
6.33 x 4.40 6.63 x 4.40 8.10 x 6.00 7.80 x 5.10
2
(20.8 x 14.4) (21.7 x 14.4) (26.6 x 19.7) (25.6 x 16.7)
8.10 x 5.00
3 –
(26.6 x 16.4)
8.10 x 2.32 7.80 x 2.50
4 – –
(26.6 x 7.6) (25.6 x 8.2)
7 Free on wheels Free on wheels Free on wheels –

Type of crane
Display GMK 5200 GMK 6220 GMK 6300
GMK 5180 GMK 6220-L GMK 6250
m (ft) GMK 6200-1 m (ft)
m (ft)
8.50 x 8.30 8.70 x 8.50 8.70 x 8.50
1
(27.9 x 27.2) (28.5 x 27.9) (28.5 x 27.9)
8.50 x 5.70 8.70 x 6.00 8.70 x 6.00
2
(27.9 x 18.7) (28.5 x 19.7) (28.5 x 19.7)
3 – – –
8.50 x 2.72 8.70 x 2.68 8.70 x 2.68
4
(27.9 x 8.9) (28.5 x 8.8) (28.5 x 8.8)
8.70 x 8.50 / 2.84
5 – –
(28.5 x 27.9 / 9.3)
8.70 x 8.50 / 2.40 8.70 x 8.50 / 2.40
6 –
(28.5 x 27.9 / 7.9) (28.5 x 27.9 / 7.9)

Outrigger span input

In the input mode
Press J button once – next outrigger span
à p. 1 - 28

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Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Display elements à Displays during crane operation, p. 1 - 33

Current telescoping status display

1 Telescoping of all telescopic sections

– Fixed lengths as a decimal value – two places after the point
– Intermediate lengths in percentages
Surplus displays have no function
à p. 1 - 33

Current main boom angle display

Main boom angle to the horizontal position in degrees (°) –
Display of negative angles, e.g. –3°
à p. 1 - 33

Current working radius display

Working radius in metres (m) or feet (ft) – without a decimal place
à p. 1 - 33

Current lattice extension inclination display

The hydraulically derricking lattice extension is connected.
1 The angle between lattice extension and the main boom in degrees (°)
2 Additional function:
Press T
button once – display of current angle between lattice exten-
sion and horizontal position, for two seconds.
à p. 1 - 33

Current load display

Current raised load in tonnes (t) or in kilopounds (klbs) – first decimal place
Signalling point behind the value = shutdown
à p. 1 - 33
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 Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Maximum load display

1 Maximum load in tonnes (t) or in kilopounds (klbs) for displayed SLI

code – first decimal place
(Display: 55.2 klbs correspond to 55 200 lbs)
2 Special case – max and n= entries flash:
Maximum load reduced by reeving –
Press O button once – display (1) maximum possible load for dis-
played SLI code, for three seconds
à p. 1 - 33

Display for the current degree of utilisation

Degree of utilization = 100 x actual load / maximum load –
coloured lights for percentage range,
– Green: 0 - 90 %
– Yellow: About 90 -100 % – early warning
– Red: greater than 100 % – shutdown
à p. 1 - 33

SLI early warning

– Flashing: Direction indicator 90 - 100 % – buzzer tone on

– On: Degree of utilization ca. 100 % – buzzer tone on –
shutdown
– Off: Degree of utilization 0 - 90 %
à p. 1 - 37

SLI shutdown
– On: Shutdown – buzzer tone on
– Degree of utilization ca. 100 % or
– Error
– Off: Degree of utilization below 100 %, no error
à p. 1 - 38

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Safe load indicator EKS 5 light
1.3 Short description of the operating elements

Hoisting gear display

I on: Main hoist switched on first –

displayed reeving is valid for main hoist
II on: Auxiliary hoist switched on first –
displayed reeving is valid for auxiliary hoist
I and II flashes: Corresponding hoisting gear additionally switched
on –
displayed reeving is valid for the other hoisting gear
I and II off: Corresponding hoisting gear switched off
à p. 1 - 32.

Additional function F2 on
Use always in combination with other buttons:

– Lamp test
,U! Press , button, additionally press
All lights on, for two seconds
! button once –
à p. 1 - 23

Sensor for brightness

Registers the brightness of the operating environment. The brightness of all
displays is automatically adjusted; àp. 1 - 22.

F3 and F4 service buttons

For access to the service software, with connected service device.

Information / error display

Press the necessary button on the display field once – light in the button on
– display shows the corresponding value.
à p. 1 - 35
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4 Operation of the safe load indicator

If the current rigging mode of the truck crane is recorded correctly, then the
SLI prevents the permissible lifting capacity from being exceeded and the
truck crane from being overloaded.

G
Danger of accidents due to incorrectly set SLI
Before operating the crane, ensure that the current rigging mode is cor-
rectly entered. An incorrect input will give you a false sense of security.
This results in the truck crane overloading and causing an accident!

The current rigging mode is recorded partly using measured values and
partly using manual inputs.

Recorded using measured values Recorded using manual inputs

– Main boom length – Outrigger span
– Main boom angle – Counterweight
– Current load – Lattice extension length
– Lattice extension inclination1) – Lattice extension angle2)
– Reeving

1) For a hydraulically derricked lattice extension

2) For a manually inclinable lattice extension

During crane operation, an visual and acoustic early warning is given first
before the load limit is reached and then the functions that would lead into
the overload range are shutdown.

G
Risk of accidents in the event of an overridden or defective SLI!
The SLI may never be overridden.
It is forbidden to operate the crane if the SLI is switched off, overridden, out
of service or defective!

G
Danger of overturning in two-hook operation mode!
The safe load indicator only secures operations with one hook! The two-
hook operation mode is not permitted.
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.1 Switching on SLI

H
The SLI is not switched off if you turn the ignition key to position R instead
of position 0 when restarting the engine. The test program will not run and
you will not have to acknowledge the settings again.

Switching on The SLI is switched on together with the ignition.

• Turn on the ignition.
A test program runs after switching on the ignition. A continuous buzzer
tone sounds for about five seconds and a lamp test is performed.

• Check whether you can hear a buzzer tone.

G
Danger of accidents in the event of defective safety devices!
If the lamps or the buzzer fail, notify CraneCARE and have the error elimi-
nated.
In the mean time, pay particular attention to the lamps in the event of a fail-
ure of the buzzer tone and vice versa.

• Check whether the following lights go on

after switching on the ignition:
– in the buttons (1),
– in the displays (4), (5) and (6)
– and the lights (2) and (3).

• Check whether all digits are flashing on all

displays.
• If a safety device is defective, notify
CraneCARE and have the fault repaired.
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

H
If you cannot check all the lights in the time available, you can carry out the
lamp test again at the SLI control unit; à p. 1 - 22.

After the test program is over:

– The lights (1) and (2) light up,
– The continuous buzzer tone continues to sound.
– All power units are disabled.
The current display behaves according to whether the SLI:
– Had been switched less than 48 hours or
– Had been switched off longer than 48 hours.

After a standstill of less than 48 hours

The displays (1) and (4) correspond to the last
set rigging mode. The display (1) shows the
signalling point (5).
You can save the displayed values if they cor-
respond to the current rigging mode:
• Press the button (2) once.
The signalling point is now shown in
display (4).
• Press the button (3) once.
The signalling point display goes out.

The continuous buzzer tone stops buzzing and lights (1) and (2) go out. The
SLI code is accepted.
If no error message is displayed, the SLI is now ready for crane operation
and the crane movements are released; à
Checks to be carried out before crane
operation, p. 1 - 31.

If there is an error message, both lights light up in the button (1); à Error
message, p. 1 - 39.

You must re-enter the current rigging mode if the displayed values do not
correspond to the current rigging mode of the truck crane; à
Enter rigging
mode, p. 1 - 23.

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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

After a standstill of more than 48 hours

The displays (1) and (3) show the entries 1 and
1000.
On display (1), the input mode is switched on
and the entry 1 flashes.
• Enter the current reeving;
à Entering individual components, p. 1 - 28,
à Confirming entry, p. 1 - 25,
à Accepting the SLI code, p. 1 - 26.
After accepting the value, the display (3) is set
to the input mode and the entry 1000 flashes.
• Enter the SLI code for the current rigging
mode; à Enter rigging mode, p. 1 - 23.

Lamp test You can perform a lamp test on the SLI control unit at any time.
on the SLI
• Keep the button (2) pressed and then press the button (1) one time.
All displays and lights must illuminate with the maximum brightness.
After about two seconds, the current display appears with the brightness
automatically set.

Brightness of After the ignition is switched on, the brightness of all displays and lights is
the displays adjusted to the ambient light automatically.

The ambient brightness is measured by the sensor (1). Do not cover the sen-
sor and keep it clean to avoid affecting the regulation of the brightness.
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.2 Enter rigging mode

For a complete rigging mode input, you must enter, confirm and accept the
rigging mode and the reeving separately.

G
Risk of accidents if rigging mode is incompletely set.
The crane movements are already enabled when you accept the SLI code
or reeving. Therefore, always check whether both values match the current
rigging mode before crane operation.
In this way you prevent the SLI from incorrectly calculating the permitted
load and causing the truck crane to be overloaded or overturn.

There are two ways of entering the rigging

mode.
– You can enter the SLI code for the current
rigging mode in the display (6).
or
– You can select the individual components
(1) to (5) for the current rigging mode one
after another.
With both ways, you must confirm and accept
the current rigging mode on the display (6).

The following section describes the entire input procedure for the SLI code.
If you wish to enter the rigging mode through individual components;
à Entering individual components, p. 1 - 28.

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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Entering the You must enter the SLI code for the rigging mode according to the Lifting
SLI code capacity table.
• Refer to the Lifting capacity table for the current rigging mode. The corre-
sponding SLI code (1) is specified at the bottom of the table (e.g. 1100).
Entries are made in four steps:
– Switch on input mode.
– Enter the SLI code.
– Confirm the entry.
– Accept the SLI code.

Switching on input mode

• Press the button (6), and the button (5) one
time in addition.
The value on the display (4) flashes.
Lights (2) and (3) light up.

The input mode on this display (4) is now on

and you can enter a new SLI code.

The display (1) automatically switches to dis-

playing the permissible slewing range.

If an error occurs now, only a buzzer tone sounds and the lights in the
button (2) light up. The display (1) does not automatically display the error
code.
To view the error code, you must press the button (2).
You can then switch back to the display of the permissible slewing range by
pressing the button (3) once.
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Entering the SLI code

You can enter the LMB code as individual digits or select a permissible
value.

Entry as digits
• Use the keys referred to by (8) to enter the
digits of the required SLI code.
The entered value flashes on the display (6),
and the corresponding rigging mode is dis-
played on displays (1) through (5).

Selecting the SLI code

• Keep pressing the button (7) until the
required SLI code blinks in the display (6).
The values are displayed again in ascending
order.

Confirming entry
• Press the button (1) once.
The SLI code in the display (2) does not flash any more flashes and the sig-
nalling point is displayed. The entry is now confirmed.
Now, you can accept the entered SLI code.

H
If you have entered a value that, according to the Lifting capacity table, is not
permitted, the value will not be accepted after pressing the button v. The
display continues to flash and an error message (5011) is displayed;
à Error message, p. 1 - 39.

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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Accepting the SLI code

You can accept the SLI code when the display (2) shows the signalling point.
• Press the button (1) once.
The signalling point goes out and the SLI code is saved.

G
Risk of accidents if rigging mode is incompletely set.
The crane movements are enabled after accepting the SLI code. Make cer-
tain, however, that the current reeving value is entered before you begin.
In this way you prevent the SLI from incorrectly calculating the permitted
load and causing the truck crane to be overloaded or overturn.

• Check whether the current reeving value is displayed on the display (1).
You must enter the current reeving value if a different reeving value is dis-
played; à
p. 1 - 26.

When there are no more error messages and all error messages displayed
have been acknowledged, lights (1) and (2) go out. The crane movements
are now enabled; à
Checks to be carried out before crane operation, p. 1 - 31.

Entering reeving The rigging mode is only fully entered once you have entered the current
values reeving value after the SLI code has been accepted.

The newly-entered reeving value always applies to the hoisting gear whose
lamp (I or II) is on, for example lamp I for the main hoist.
• Check whether the displayed hoist is the one that will be used to raise the
load and, if necessary, switch the display to the other hoist; à Example of
how to switch over the display, p. 1 - 32.
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Switching on input mode

• Press the button (3), and the button (2) one
time in addition.
The value on the display (1) flashes.

Entering a reeving value

• Enter the number of reeved rope lines with
the button (4).
or
• Select the value using the button (2).

H
When the entry n= flashes next to the display (1), the number of entered
rope lines is too small to lift the maximum possible load according to the
à
Lifting capacity table; p. 1 - 34.

Confirming entry
• Press the button (3) once.
The entry is confirmed and the display (1)
shows the signalling point.

Accepting reeving value

• Press the button (2) once.
The signalling point disappears and the reev-
ing value is accepted.

s
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Entering individ- You can also enter the current rigging mode by selecting the individual
ual components components on the displays.

G
Danger of overturning due to incorrectly set rigging mode.
Values which have already been set may be changed by entering individual
components. For this reason, you should always compare the displayed
rigging mode with the current rigging mode of the truck crane. In this way
you can prevent the SLI from calculating with incorrectly set components
and the truck crane from becoming overloaded or tipping over.

When you completely re-enter the rigging

mode, you can prevent changes to the compo-
nents already entered by always carrying out
the individual entries in the following order:
– Counterweight (3)
– Lattice extension length (2)
– Lattice extension angle (1), only with manu-
ally inclinable lattice extension
– Outrigger span (4)

In this order, the values which can be selected for the current entry are
always restricted by the previous entry. As a result, values which have
already been entered cannot be changed.

The respective SLI code is calculated from the components entered and is
displayed directly on the SLI code display.

Entries are made in four steps:

– Switch on input mode.
– Select values.
– Confirm the entry.
– Accept the values.
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1.4 Operation of the safe load indicator

Switching on input mode

• Press the button (5), and the button (7) one
time in addition.
The value on the display (6) flashes.
Input mode is switched on and the displays for
the components (3) and (4) are activated.
Displays (1) and (2) are only activated when a
corresponding lattice extension is electrically
connected.

Selecting values
You can now select the values permitted for
the individual components in accordance with
the Lifting capacity table. The numeric keypad
cannot be used to make these entries.

The selection procedure is the same for all components and is described
using the counterweight as an example.
The display (1) shows the counterweight for the SLI code set, e.g. 3.0 t.
• Press the button (2) once.

The display (2) shows the next higher value,

e.g. 6.0 t.
• Keep pressing the button (1) until the cur-
rent rigged counterweight flashes in the dis-
play (2).
The values are displayed again in ascending
order.

The display (3) shows the corresponding SLI

code for every newly selected value.

s
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Enter the current rigging mode on the other components in the same way.

– Lattice extension
Keep pressing the button (1) until the currently rigged lattice extension
length flashes in the display (2).

For a manually inclinable lattice extension:

Keep pressing the button (1) until the currently set lattice extension angle
flashes in the display (2).

– Outrigger span
Keep pressing the button (1) until the lights for the current outrigger span
light up, e.g. for the largest outrigger span.

You must confirm your entry after selecting the current rigging mode.

Confirming entry
The display (5) now shows the SLI code for the
newly entered rigging mode.
To confirm the newly entered components (1)
through (4), you must confirm this SLI code.
• Press the button (6) once.
The SLI code in the display (5) does not flash
any more flashes and the signalling point is
displayed.
The entry is confirmed and you can accept the
SLI code.

Accepting the SLI code

à Accepting the SLI code, p. 1 - 26.
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.3 Checks to be carried out before crane operation

G
Danger of accidents due to incorrectly set SLI.
When the actual rigging mode varies from the displayed rigging mode, the
maximum load displayed by the SLI does not correspond to the actually
permissible lifting capacity according to the Lifting capacity table.
Overloading and accidents are certain consequences.

• Check whether or not the current rigging mode of the truck crane corre-
sponds to the displayed rigging mode.

• Check:
– 5 The rigged counterweight.
– 2 The length of the lattice extension.
– 1 The angle of the rigged lattice
extension1).
– 6 The rigged outrigger span.
– 3 The number or reeved rope lines.
– 4 The hoisting gear that has been
switched on.

1)
only for manually inclinable lattice
extensions

The lamp which lights up must always be for the hoist with which the load
is to be lifted.
Lamp I: Must light up if the load is to be raised with the main hoist.
Lamp II: Must light up if the load is to be raised with the auxiliary hoist.

• Switch over the display if necessary; à Example of how to switch over the
display, p. 1 - 32.

You many only begin operating the crane when all displays show the cur-
07.07.2005

rent rigging mode of the truck crane.

Correct false entries, if needed.

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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Example of how to switch over the display

The load is to be raised with the main hoist, for example. However, the light II
lights up for the auxiliary hoist and light I for the main hoist flashes.
Switch over the display as follows:

• Switch off both hoists. Lights I and II go out.

• Switch on the main hoist.

Now light I for the main hoist lights up.

The display (1) now shows the last-entered reeving value for the main hoist
(e.g. 9).
If no reeving value has been entered for the main hoist, the SLI selects the reev-
ing value 1.

• If necessary, enter the current reeving value; à p. 1 - 26.

G
Danger of accidents due to incorrectly set SLI.
After switching over the hoisting gear, always check whether the displayed
reeving value corresponds to the current reeving value of the displayed
hoist and, if necessary, enter the current reeving value.
In this way, you can prevent the SLI from making calculations based on an
incorrect reeving value and the truck crane from becoming overloaded or
overturning.
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1.4 Operation of the safe load indicator

1.4.4 Displays during crane operation

Continuous In addition to the displays of the rigging mode, the following information is
displays always displayed:

The current telescoping

The displays (1) through (5) show the current
telescoping of the telescopic sections I
through V:
– Fixed lengths are displayed as decimal
values (e.g. 1.00 or 0.50).
– Intermediate and telescoping lengths are
displayed in percentages (e.g. 100 or 50).

Surplus displays have no function. With four

telescopic sections e.g. displays (5) and (6).

The current main boom angle

The display (1) indicates the current main boom angle in relation to the hor-
izontal position. Angles under the horizontal position are displayed with a
minus sign, e.g. –3°.

The current working radius

The display (1) shows the current working radius = horizontal distance
between the turntable axle and the hook-block axle. The displayed value is
calculated using the telescoping and the main-boom or lattice extension
angle. The value displayed depends on whether meters (m) or feet (ft) have
been set.

s
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

The current lattice extension inclination

– When the hydraulically derricking lattice extension is rigged, the display (1)
shows the current lattice extension inclination in relation to the main
boom.
– When the manually inclinable lattice extension is rigged, the display (1)
shows the angle of the lattice extension belonging to the SLI code.
– When no lattice extension is rigged, the display (1) has no function.

The current load being lifted

The display (4) shows the sum of the payload + lifting gear + hook block.

The maximum load

The display (3) indicates the maximum load that can be lifted in the entered
rigging mode with the current radius.
The entry max flashes next to the display (3) if the maximum load is reduced
by the reeving value entered.
At the same time the unit n= flashes next to the display (1).
In this case, you can have the maximum possible load displayed for approx.
1 second.
• Press the button (2) once.
The display (3) shows the maximum possible weight according to the Lift-
ing capacity table that can be lifted with enough reeving.

The degree of utilisation

The degree of utilisation shows the weight of the current load as a percent-
age of the maximum possible load. The coloured lights (1) always light up
for the current degree of utilisation.
Green: 0 – 90 %
Yellow: approx. 90 -100 %
Red: greater than 100 %

The current degree of utilisation can also be displayed as a number;

à p. 1 - 35.
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1.4 Operation of the safe load indicator

Optional displays If an error message is shown during the following operation, it is shown
with priority.

You can call up various kinds of information on the display (2).

• Press a button on the display field (1).
The display (2) shows the corresponding value until another button is
pressed.

– Displaying error information

Lights (2) and (3) light up as long as there is an error.
All errors are shown one after the other by pressing the button (1);
à Error message, p. 1 - 39.

– Displaying degree of utilization

After pressing the button (1), the light (2) lights up, and the current degree
of utilization is shown in percent. Definition of the degree of utilization;
à Display for the current degree of utilisation, p. 1 - 17

– Displaying current working radius

The light (3) is not used.
After pressing the button (1), the green light (2) lights up, and the current
working radius is shown in percent. Definition of the working radius;
à The current working radius, p. 1 - 33

– Displaying the current main boom length

After pressing the button (1), the green light (2) lights up, and the current
main boom length is shown. The value displayed depends on whether
meters (m) or feet (ft) have been set.

s
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

– Displaying current slewing angle

The light (3) is not used.
After pressing the button (1), the green light (2) lights up, and the current
superstructure position is displayed.
0° means that the superstructure is turned to the back.

A full turn out of this working position is divided into two semicircles:
– Angles in the right-hand semi-circle are displayed as positive values
(0° to 180.0°).
– Angles in the left-hand semi-circle are displayed as negative values
(0° to –179.9°).

– Displaying current overall height

Overall height = vertical distance between the lower edge outrigger pad
and the highest point of the main boom or lattice extension.
After pressing the button (1), the green light (2) lights up, and the current
overall height is shown. The value displayed depends on whether meters (m)
or feet (ft) have been set.
The displayed value is valid for fully extended outrigger cylinders on the
largest outrigger span.
The light (3) is not used.

– Displaying oil pressure derricking cylinder

Oil pressure in the derricking cylinder lower chamber:
• Press the button (2) or (3).
• Press the button (1) one time additionally.

Oil pressure in the derricking cylinder upper chamber:

• Press the button (2) once.
• Press the button (1) one time additionally.
The lights light up in the buttons pressed. The corresponding value is dis-
played in bar.
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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.5 SLI early warning

If about 90 % of the maximum permissible load is exceeded, a SLI pre-warn-

ing is given.

– An intermittent buzzer tone sounds.

After five seconds, you can switch off the
buzzer tone using the button (5).
– The lamp (3) lights up.

– In the display (4), the yellow lights light up –

degree of utilization 90 - 100 %.
• Press the button (2) once for the exact value
of the degree of utilization.
The display (1) shows the current degree of
utilization, e.g. 91 %.

H
If the current crane movements continue to be carried out in the same direc-
tion, an SLI shutdown occurs.
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.6 SLI shutdown

There are different types of SLI shutdowns:

– Shutdown due to overload,
– Shutdown due to an error message; à Error messages with shutdown,
p. 1 - 45.

Shutdown due If about 100 % of the maximum permissible load is exceeded, shutdown
to overload occurs due to overload.

– All crane movements which increase the

load moment are switched off.
– A continuous buzzer tone sounds.
After five seconds, you can switch off the
buzzer tone using the button (6).
– Lights (2) and (3) light up.
– In the display (4), the red lights light up –
degree of utilization approx. 100 %.
– The value in the display (5) is the same or
greater than the value in the display (1).

Releasing shutdown
• If you have not switched off the buzzer tone, press teh button P once.
• Leave the shutdown range by driving the crane movement according to
the following table.

Deactivated crane movements Permitted crane movements

Raising loads Lowering loads
Lower the main boom. Raise the main boom.
Extending main boom telescoping Retracting the main boom1)
07.07.2005

Lowering the lattice extension. Raising the lattice extension.

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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

H
1) The SLI also partly switches the retraction of the telescoping off. In this
situation, leave the shutdown range by raising the boom. If this is not
possible, set down the load, telescope to the next fixed length and raise
the load again.

If you have left the shutdown range, the light (1) goes out.
The crane movements are now released.

1.4.7 Error message

If an error occurs, it is displayed as follows:

– Depending on the type of error, the buzzer
tone sounds once or as a continuous buzz-
ing.
– Both lights in the button (1) light up.

Further displays are shown according to the

type of error; à Error messages on the SLI con-
trol unit, p. 1 - 44.
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Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.8 SLI override

If the SLI is overridden, the crane operation is not monitored and deacti-
vated crane movements are released again.

G
Risk of accidents in the event of an overridden or defective SLI!
It is not permitted to work with an overridden or defective SLI!
Set down the load immediately and stop operating the crane if the SLI is
defective!
You may only override the SLI in the event of an emergency in order to put
the truck crane into a safe condition in the event of a malfunction. In this
case, do not perform any more movements that would increase the load
moment.

Overriding SLI
• Insert the key into the key-operated switch (2).
• (A) – Turn the key towards the right and keep
it in this position.
The display (1) shows the error message 8022.

Cancelling the override

• (B) – Let go of the key.
• Remove the key.
• Press the button P once, the error message
is acknowledged.

S
Risk of accidents due to accidental override!
The key may not be left in the key-operated switch when operating the
crane. In this way, you avoid accidentally overriding the SLI. 07.07.2005

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 Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

1.4.9 Displaying and entering the time and date

On the display (1), you can

– have the time and date shown and
– enter the time and date.

On the displays (2) and (3), the input mode

may not be switched on.

Display The buttons for the display have the following assignments.

Display of the time, e.g. eight minutes past nine.

&

Display of the seconds, e. g. 14 seconds

V

Display of the day and month, e. g. 10 May

(

Display of the year, e. g. 2004

)
07.07.2005

s
Operating instructions EKS 5 light 2 084 976 en 1 - 41
Safe load indicator EKS 5 light
1.4 Operation of the safe load indicator

Input You can abort the following input procedure at any time by pressing the but-
ton p.
Let us assume that you would like to enter the time as 9:08 and 14 seconds,
and the date as 10 May 2004.

• Using the button &, V, ( or ), call up the display that you wish to
change and enter the new value in the following way:

– Entering the time

• Press +U &. The number 0 flashes.
• Press buttons 9, 0 and 8 one after the other.

– Entering seconds
• Press +U &. The number 0 flashes.
• Press buttons 1 and 4 one after the other.

– Entering the day and month

• Press +U &. The number 0 flashes.
• Press buttons 1, 0, 0 and 5 one after the other.

– Entering the year

• Press +U &. The number 0 flashes.
• Press buttons 2, 0, 0 and 4 one after the other.

• Press Q once.
The entry is confirmed. The display does not flash anymore, and the new
entry is shown, e.g. 9:08.

H
Illogical values (e.g. 77 seconds) are not saved and the display continues to
flash.
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 Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

1.5 Finding and eliminating malfunctions

This section contains general malfunctions which are not displayed on the
SLI operating unit as well as malfunctions which prompt an error display on
the SLI control unit.

G
Risk of accidents
You must immediately stop operating the crane as soon as any error mes-
sage is displayed.
The SLI may only be repaired by trained, qualified personnel.

G
Risk of accidents in the event of a faulty or overridden SLI.
In the event of a faulty SLI, first try to correct the error with the information
in this section. Only override the SLI if it becomes absolutely necessary in
order to lower the load in the event of an emergency.
Do not carry out any movements which increase the load moment in the
event of a faulty or overridden SLI.
If the SLI is overridden, the crane operations are not monitored and no
shutdown procedures are initiated when leaving the working range.

1.5.1 General malfunctions

Malfunction Cause Remedy

SLI not working (dark dis-
plays, no buzzer tone)
Power supply not switched on
Blown fuse on superstructure
The LMB F6 fuse at the SLI
control system is defective.
Turn on the ignition.
Replace the blown fuse;
à Operating instructions of the
truck crane – part 2.
Replace the defective fuse;
à p. 1 - 48.

H
If further malfunctions of the SLI occur, the corresponding error messages
are displayed on the SLI control unit.
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Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

1.5.2 Error messages on the SLI control unit

If the safe load indicator recognizes an error, an error message is shown on

the SLI control unit.
There are different types of error messages:
– Error messages without shutdown
– Error messages with shutdown

G
Risk of accidents
You must immediately stop operating the crane as soon as any error mes-
sage is displayed.
The SLI may only be repaired by trained, qualified personnel.

Error message If an error is detected, it is displayed as follows:

without shutdown

– The buzzer tone sounds once.

– Both lights in the button (2) light up.
– The display (1) shows an error code,
e.g. 1138.
When the display (3) of the entry mode is
switched on, you must press the button (2)
once to show the error code.

You can have all existing errors displayed by

pressing the button (2) again.

Try to remedy the error by turning off the ignition and turning it on again
after about 15 seconds.
If the error is displayed again, check whether or not the error code is con-
tained in the Error codes tables. These tables also contain information about
remedies for errors; à p. 1 - 46.
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1.5 Finding and eliminating malfunctions

Error messages Certain error messages initiate a shutdown.

with shutdown

– All crane movements are shut down.

– A continuous buzzer tone sounds.
After five seconds, you can switch off the
buzzer tone using the button (5).
– Lights (3) and (4) light up.
– Both lights in the button (2) light up.
The display (1) shows error codes in the same
way as with error messages without a shut-
down.

Some error messages with a shutdown have

additional displays.
The following displays flash:
– Either the display (1)
– Or displays (2) and (3)
– Or displays (1) through (3).
When values blink, the deviation between the
calculated and measured value is too large.
If the error message 3033 is displayed;
à Table – error messages, p. 1 - 46.

s
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Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

Table – The following table contains several error codes, their causes and possible
error messages remedial measures.
An error code consists, from left to right, of a one-digit number (e.g. 5), a
two-digit number (e.g. 13) and a one-digit number (e.g. 2).

• Check whether or not the table contains the displayed error code. Should
the information in the table not be of help to remedy an error, note the
error code(s) down and contact CraneCARE.
When all errors are remedied, the lights in the button (1) go out.

Error code Cause Remedy

3 03 3 The telescope diagrams of
the crane control and SLI
vary.
5 01 1 There is no capacity dia-
gram available for the
entered rigging mode.
5 01 2 Main boom angle too small
(not steep enough) when
operating with the main
boom
5 01 3 Main boom angle too large
(too steep) when operating
with the main boom
5 02 1 There is no SLI code avail-
able for the entered rigging
mode.
5 02 2 Main boom angle too small
(not steep enough) when
operating with the lattice
extension
Compare the actual telescoping sta-
tus with the values on the Crane con-
trol display and, if necessary, re-enter
the telescoping status.
Accept the telescoping status from the
crane control if an incorrect telescop-
ing status is displayed on the SLI:
1. Press the buttons ü+ p once.
The SLI shows the new values.
2. Acknowledge the error.
Re-enter the current rigging mode.
If the error is displayed again, check
whether the current rigging mode is
permissible.
Raise the main boom.
Lower the main boom.
Re-enter the current rigging mode.
If the error is displayed again, check
whether the current rigging mode is
permissible.
Raise the main boom.
07.07.2005

5 02 3 Main boom angle too large Lower the main boom.

(too steep) when operating
with the lattice extension

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 Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

Error code Cause Remedy

5 02 4 Lattice extension inclination Raising the lattice extension.
is too small.
5 02 5 Lattice extension inclination Lowering the lattice extension.
is too large.
5 02 6 Current load greater than 1. Raising the lattice extension.
derricking load – movement
Lower lattice extension is dis- 2. Press button P once
abled.
3. If necessary, increase the work-
ing radius using the movement
Lower main boom
5 04 4 Maximum permissible Slew the superstructure into the per-
slewing angle exceeded missible working range.
5 04 5 Value below minimum load After setting down the main boom,
value raise it and acknowledge the error.
Notify CraneCARE if the error is unable
to be acknowledged.
6 02 1 Fuse no. 1 on the SLI control
unit defective
6 02 2 Fuse no. 2 on the SLI control
unit defective
6 02 3 Fuse no. 3 on the SLI control Replace the defective fuse;
unit defective à p. 1 - 48.
6 02 4 Fuse no. 11 on the SLI con-
trol unit defective
6 02 5 Fuse no. 12 on the SLI con-
trol unit defective
6 02 6 More than one fuse on the Replace the defective fuse;
SLI control unit is defective à p. 1 - 48.
or there is no switching
voltage.
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Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

1.5.3 Fuses of the SLI

There are six fuses on the control unit of the SLI.

When a fuse is blown, a corresponding error code is displayed; à Table –
error messages, p. 1 - 46.

• Switch off the ignition whenever a fuse has to be replaced.

S
Risk of damage when replacing fuses with the ignition switched on.
Switch off the ignition whenever a fuse has to be replaced. In this way you
can prevent the new fuse from being damaged by the increased starting
current immediately after inserting it.

S
Danger of fire
Never repair a blown fuse with a nail, wire, aluminium foil or other electri-
cally conductive materials.
Only replace blown fuses with fuses of the indicated amperage.

S
Risk of damage due to overloading.
Only replace defective fuses with new fuses of the same amperage. In this
way you can prevent parts from being overloaded and damaged or the fuse
from being immediately damaged again.
Inform CraneCARE if a fuse of the same amperage blows again after turning
on the ignition.
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 Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

The fuses are located on the SLI control unit

under the SLI control unit.

• Unscrew the screws (1) and take out the SLI

control unit.

The fuses are arranged as follows:

1: Fuse F 1
2: Fuse F 2
3: Fuse F 3
4: Fuse F 11
5: Fuse F 12
6: Fuse F 6

Designation in Amper- Function

the Error mes- age (A)
sage submenu
F1 5 For internal main relay
F2 5 Display for external SLI shutdown (additional equipment)
F3 5 Power supply for movements of all power units at connection 0
F6 5 SLI power supply
Display for external SLI early warning function (additional
F 11 5
equipment)
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F 12 5 Unassigned

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Safe load indicator EKS 5 light
1.5 Finding and eliminating malfunctions

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