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Grove GMK Training PDF

Computerized cranes now use laptop computers to calibrate and troubleshoot systems. Laptops connect to cranes using dongles and RS232 cables. To operate cranes, technicians need basic PC skills and knowledge of hardware like Pentium processors, RAM, hard drives and screens. They also need software like Windows and crane-specific programs. Files are stored on disks, zip disks and CD-ROMs and moved within computers by cutting, copying and pasting. The document outlines turning on PCs, loading software, file formats and extensions, and how files are organized on hard drives by sectors and tracks.

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100% found this document useful (10 votes)

4K views297 pages

Grove GMK Training PDF

Uploaded by

nurfathoni

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 297

GM K I I

PC Skills & Software

TRAINING INSTITUTE

Why do we need
Basic PC Skills
for the Crane Industry
These cranes use
computers now

GMK6350 GMK6300 GMK6220

GMK5210 GMK5120

…And this is just the

beginning

What is unique about these

cranes?

• They are computer operated

• They use Laptop Computers
to calibrate systems
• They use Laptop Computers
to troubleshoot systems
Computerized Crane System Layout
+BE700.A35024 +BE630.A4 +BE630.A2
ECOS

Length EKS4
Unit SLI
The Operator controls
F1 F2 F3 F4 F5 Esc Ente r

+BE630.S2

the crane
Can-Bus +BE630.A1 PLD
by sending metered inputs
Engine
Management

to the computer (EST0)

Joystick
EST 0 The
EST Computer
1 then
EST 2 controls
crane
+BE630.S1 functions
based on those inputs
+BE600.M

Logic
Block
P1 The Operator communicates
Y2110
+BE660.M

EKS4 Reel
with the crane
21 Proximity Switches
Monitor Pinning

through the ECOS Display

and Cylinder End
Position Functions
Length Unit Reel

Operating a Computerized Crane

+BE700.A35024 +BE630.A4 +BE630.A2
ECOS

Length EKS4
Unit SLI F1 F2 F3 F4 F5 Esc Ente r

+BE630.S2

Can-Bus +BE630.A1
PLD
Engine
Management

EST 0 EST 1 EST 2

Joystick
+BE630.S1
+BE600.M

Logic
Block
P1 Y2110
+BE660.M

EKS4 Reel
21 Proximity Switches
Monitor Pinning
and Cylinder End
Position Functions
Length Unit Reel
How does the Laptop
Computer communicate with
the crane?

RS232
Dongle
Cable Connector
Cable Connector

Technician’s
Laptop Computer
RS232
Serial Cable

What is a Dongle?

• Used as a security device

– Prevents Unathorized access to the
Computer
– Requires Training and Acheivement
Testing
to be issued a Dongle from Grove

• Without a Dongle:
– Communication signals are scrambled
– Access is denied
So What do I need to know?

• What hardware do I need?

• What software do I need?
• Once I get everything,
then what do I do?
– How do I turn the PC on?
– How do I load software on my PC?
– How do I handle files (Cut, Copy, Paste)
– What’s a file?

What Hardware do I need?

• Pentium I chip or higher
• 32 Meg RAM or Higher
• 100 Meg Hard Drive or Larger
• TFT Color Screen (as big as possible)
• PCMCI card slot
(future remote control access)
• Modem (future communications link)
What Software do I need?
• Windows 3.1 Operating System or
• Windows 95 Operating System or
• Windows 98 Operating System
• Optional Software:
– Mircosoft Word (Word Processing)
– Mircosoft Excel (Spreadsheet)
– Mircosoft Access (Database Management)
– Mircosoft Powerpoint (Presentation and
Graphics)

How do I turn it on?

• Some things you will have to
discover for yourself, Read your
computer’s manual to locate the
“On” button.
• Some “On” buttons are located on
the top panel, some on the side
panel, and some come on
automatically when you lift the
screen?
How do I load software ?
• Again Some things you will have to
discover for yourself, However we
have included some helpful tips.
• Read your computer’s manual for the
specific procedures for your PC.

What is Software
• Software can neither be seen or can
be felt.
• Software are the written instructions
(communications) that make your
computer do the tasks assigned to
it.
• Software can also be stored data
Software is Saved on these
Formats
3.5”
Diskettes Zip Disks CD-ROMs

3.5" Diskette
2.0 Megabyte ZIP Disk
100 Megabyte

Also Direct from

www.com’s
the Internet

How do I handle files?

• Turn on PC ( you have gotten this far I hope?)
• Windows should load Automatically
– “My Computer” will allow you to open
files
– Or Press “Start”/ “Programs”/
Double click “Windows Explorer”
• From Explorer you can look at your whole
computer
• Select Files by clicking with mouse on file
name
– Cut (ctrl X) to remove files
– Copy (ctrl C) save a duplicate of your file
– Paste (ctrl V) to place copies of files
– Undo (ctrl Z) to undo the last step
What is a file?
• Collection of data
• Orgainized as either a Program or
• Orgainized as Data Table
• Files are self contained and are
portable
• May be Copied, Cut, Pasted or Saved

Loading Program Files

Program Files on
CD-ROM

Insert CD-ROM
into Drive
Loading most Program Files

My Computer

Look for
setup.exe
D: Drive
CD-ROM
setup.exe
Service Software

to load most
software

What is in a file name?

Identifier
Name Extension

Command
Separator
What are some other
common Extensions?
• exe Executable • com Commercial (I)
• bat Batch File • org Organization (I)
• doc MS Document • gov Government (I)
• dot MS Document • edu Educational (I)
Template
• txt Text File
(I) Internet Addresses

What is a Hard-Drive?
Built-in to Laptop
or Desktop

Hard Drive
(HD)
How are files written
to the Hard-Drive?
• Data is saved on
this HD Disk
• Data is located by
Sectors and Tracks
Identification
• What is a Track?
• What is a Sector?

Sectors
Tracks

How are do look at the Hard-

Drive to see what files are
written?

• If you have
Windows 3.1 use
File Manager

to look at
• If Windows 95,98
your HD
or 2000 use
Windows Explorer

Use File Manager or Windows Explorer

Windows Explorer Window

Files
Files and
and Current Selection
Folders
Folders Start Button Work Area
Window Task Bar
Window (Shows Current Selection
Enables Direct Access
and toother
Displays Current Programs Open/Running
DisplaysProgram Files, Document
Scroll Bars
Files
All (Note: the available
more programs components)
open
All Files The of
Files and Other Areas Menu
the PCBar
and
and Folders
Folders
the slower the PC
Address
(pull Click-on
Bar
down
will run)
menus)
within Enables
Mouse
(Reads Current you to
Commands
Selection and Bar
within current
current
view additional
Pull down menu gives
Selection
Selection (point and click)
items
quickin window
access to
other components)
Now lets install your
GMK II Software.

Click on the Start button

Click on the Run button

You will see a window like this,

click on the Browse button.

Click on the drop down menu

and look for your CD Rom drive
(could be drive “D” or “E”) under
Desktop or My Computer.

Then click on the CD Rom

drive.

At this point you will see all the

folders on the CD.

Remember, folders hold additional

programs, so if you see only one
folder, click on it to open and
additional files.

YOU MUST UNINSTALL Acrobat 3.0

Click on ACRD4ENU
In the Run menu click on OK.

After you have

completely
installed this file,
now follow the
same steps to
install “WINDIC”.

Now you ready to open files…

Click on “My Computer” on your desktop

Click on your CD Rom drive

At this point you will see all of the folders and files on the CD. To proceed , double click
on a folder or file.

Navigation View

To open Acrobat Reader

files you can either double
click on the file in
“Explorer” or “My
Computer”. You can also
open Acrobat from
Desktop/ Start/ Program
Files/ Acrobat Reader or
click the shortcut on your
Desktop screen .

Once you have opened Acrobat Reader, click on “File\Open\CD Drive\

a file you wish to open”

Use your right and left arrow keys on your keyboard to advance or
reverse the slides or pages.

To close your program,

click on File\Exit.
Group Exercise (GMK II)
• Turn On Laptop PC
• Open Windows Explorer (Win 95/98/2000)
– Create File Folder
– Rename File Folder (use the name “Transfer”)
– Copy Files into Folder (any files)
• Create Desktop Short-cut
for Windows Explorer
• Insert CD (any CD) copy files from CD into Transfer
File Folder
• Remove and all files from Transfer Folder and Folder
Carrier
Component
Identification
TRAINING INSTITUTE

Traditional Carrier
Suspension System
• Conventional axle & hydrogas suspension

Hydrogas Suspension Principle

Accumulator

P
Suspension Axle blocking
control valve valve
Pump
Megatrak Design

Automatic gearbox

Hydraulic system

Drive
Suspension
cylinder
Differential

Steering Transfer case

Engine Outrigger
Pump drive box

Megatrak System
• Suspension struts & no axles

• Introduced in 1989
Early Suspension Struts
• Early Magatrak
models 3045 - 4070
(4071 technical) all
used small suspension
struts
• Identification by
double mounting
blocks
• Stroke = 240 mm/9.44
inches

Large Suspension Struts

• Large struts used from
4070 (4072 technical)
and on all current
models
• single mounting block
• Cylinder stroke is now
300 mm/12 inches
Large Suspension Struts
Detail of top
fixing band

• Large struts have a

single weldment
mounting with a frame
dowel retained by a
steel band & plastic
insert

Large Suspension Struts

• Lubricating oil chamber

• Hydraulic cylinder

• Housing fixed to carrier

Suspension System Control

• On various models suspension levelling
control solenoid valves are remote mounted,
typically above the outrigger boxes
• Axle blocking valves are typically adjacent
to the suspension cylinders
Suspension Control System
Accumulators
Typical system
layout

Blocking valve Blocking valve

Direction valves

Suspension cylinder
assemblies

Suspension System Control

• Integrated suspension levelling and axle

blocking control valves are being used on
some current, and new models
Suspension Control System
• On some current, and new
models
• Axle blocking is controlled
by pneumatically operated
valves
• Suspension levelling is
controlled by integrated
solenoid valves

Large Suspension Struts

• Large struts also have

integrated proximity
switches for suspension
control
Suspension Proximity Switches
Proximity switches
• They look identical,
but one is normally
open and the other
normally closed
• Upper switch = N/O
• Lower switch = N/C

Suspension Proximity Switches

• All small and some
early large struts have
external proximity
switches between the
steering linkage within
a vertical tube
Steering Geometry
• Steering levers.
Known by other terms
- Wishbone or
compulsion levers.
They transfer steering
control to the wheels

Steering Geometry
• Steering levers are now fitted with
“Swiss cheese” bushings in place
of hard steel bushings
Steering Geometry
Typical standard drive steer configuration

Steering Geometry
The steering idler allows the rear axle to steer on highway or
the rear two axles to steer independently of the front axles

View of all wheel steer & all wheel drive option

Steering idler
Steering Geometry
• Rear steering idler assembly
• Used from KMK 4070 (4072
technical) - GMK 5160
• It allows highway rear wheel
steering when locked and
independent rear wheel
steering when unlocked

Steering Geometry
• Rear steering idler
assembly
• Proximity switch for
locking control
• Mechanical switches
for transmission and
hydraulic control
Power Train
• Kessler transfer case
• They may look identical, but the ratio may differ!
Transfer case

Power Train
• A transfer case manufactured by MAN was
used on all GMT models with more than
three axles
• All KMK & GMK models use a separate
Kessler transfer case on models with more
than three axles
Power Train
Kessler transfer case

Drive from
transmission

Drive to front
axles
Drive to rear
axles

Power Train
• Kessler transfer case
• It divides the drive
power to the axles
• It has two speeds
• It also drives the
emergency steering
pump
Power Train
• All conventional drive axles are manufactured by
Kessler
• Early Megatrak -KMK 3040 - KMK 4060 used
differentials & wheel heads manufactured by ZF
• KMK 4070 and current models all use
differentials & wheel heads from Kessler

Power Train
Conventional axle with disk or drum brakes

Megatrak axle, only with drum brakes

Power Train
• Megatrak, Kessler
differential assembly
• With internal air
actuated differential
cross locks

Power Train
• Megatrack, Kessler differential with
inter-axle differential
Power Train
• Inter-axle differential gives equal power split to axles

Power Train
• Electric retarder
shown installed on the
rear differential. It is
also known as an eddy
current brake.
• Manufacturers Kloft &
Telma are used
Power Train
• Double and single joint
cardan (half shafts) are
used depending on
application
• The assembly part number
can be found here

Power Train
Fixed ring gear Principle of
reduction hub
3 & 4 planet
gear versions
are used
Power Train
• View of reduction hub
& wheel drive
• This casing is driven
by internal sun &
planet gears

Power Train
• It is a general rule that
when replacing a
broken wheel stud -
also replace the wheel
stud on either side of
the broken one and fit
new wheel nuts
POWER TRAIN
• Wheel studs vary in length depending on
application
• Drive axles = 96 mm = 3.77 inches
• Non drive axles = 88 mm = 3.46 inches
• Double wheel drive axles = 110 mm = 4.33
inches

Power Train
• Brake design can be wedge or S cam - the latter is
not used on KMK or GMK models
Wedge S cam
Power Train
• Brake drums and brake linings also vary in
width depending on axle location
• The term “simplex or duplex” is used to
indicate single or double air actuators on
wedge brake applications
• Disk brakes were only used on pre-
Megatrak AT models up to 70 tonnes

Pneumatic Systems
• View of Wabco air dryer. The desicant cartridge
should be changed at least every two years
Pneumatic Systems
• Pneumatic solenoids are often assembled in a
sandwich block

Pneumatic Systems
• The cooling coil between the compressor &
air dryer is copper pipe
• Coloured plastic air pipes are not used, they
are all black plastic
• In addition to the olive (compression ring)
plastic pipes need an internal reinforcing
sleeve
Hydraulic Pumps
Various pump drive methods are used
• Engine crankshaft
• Engine auxiliary drive
• Drive box between engine & transmission
• PTO from transmission
• Drive from transfer case for steering backup
pumps

Hydraulic System
Principle of carrier remote pump drive box

Superstructure hyd motor/pump

Hyd swivel
Pump drive box

Engine Transmission
Hydraulic Systems
• View of hydraulic pump
drive box for GMK 4070
(4072 technical)

Hydraulic System
• View of remote hydraulic pump drive box

Hydraulic pump

Through drive

Engine to
transmission

Hydraulic pump
Hydraulic Pumps
• View of Chelsea transmission mounted PTO for
hydraulic pump drive & live pump drive on a GMK
3050 - both are left & right mounted to the Allison
world series

Swivel - Hydraulic
• Multi port hydraulic
swivels are used on
current models upto
70 tonnes
Hydraulic Systems
• Outriggers are H configuration and controlled by
electric solenoid direction valves

Swivel - Electric
• The electric swivel (if
used) is mounted directly
to the carrier or mounted
on top of the hydraulic
swivel as shown
• Cannon plug connections
Electrical System
• Any model with plastic junction boxes no longer has
a traditional chassis harness. It has now been
replaced with multi core cables & junction boxes

Electrical Systems
Electrical Relay Suppliers:
• Bosch - single & double leg (standard).
Single leg (micro)
• Siemens - multi leg (stacking). Double or
triple leg (clear plastic)
• Telemecanique - multi leg
Electrical Systems
Relay versions SIEMENS
clear plastic
SIEMENS
stacking relay

BOSCH
standard micro

Electrical Systems

• 15 pin AMP plugs are

the most common
interface/bulkhead
plug
Electrical Systems
• View of multi-pin plugs used for boom &
transmission connections

GMK Superstructures
Precision by Design
Hydraulic Systems
The typical open circuit system consists of :
• 1. A separate reservoir
• 2. A gear or piston hydraulic pump
• 3. A direction control block
• 4. An actuator - cylinder or motor

Hydraulic Reservoir
• Typical view
• Gate valves
• Temperature sensor
• Drain point
Hydraulic Reservoir

• The reservoir is open to atmosphere via a

breather element
• The return line hydraulic filter is integrated
into the reservoir
• Suction filters are not used

Hydraulic Reservoir
• Typical view of return line filters
Hydraulic Systems
• All models 50 tonnes & below use the carrier
engine to drive the hydraulic pumps
• GMT 60/70 & some KMK 70 tonne models (pre-
Megatrak) used a superstructure engine
• All Megatrak & current GMK models up to 70
tonnes use the carrier engine
• All larger models use a superstructure engine

Hydraulic Systems

• All models 50 tonnes & below use a

transmission power take off for the pump
drive
• KMK 60/70 (Megatrak) and current GMK
70 tonne models use a remote mounted
pump drive box between the engine &
transmission for pump drive
Hydraulic Systems
• GMT & KMK models up to 35 tonnes used
gear pumps for all functions
• Larger models used axial piston pumps for
primary crane functions
• All current GMK models use axial piston
pumps for primary crane functions

Hydraulic Pumps

• There are two basic types of piston pumps

used for crane functions
• 1. Swash plate, this can have through drive
and be in combination (piggy back).
• 2. Bent axis, this can not have through drive
and is only a single unit or double side by
side unit in a common housing
Hydraulic Pumps
• View of A10VO swash plate piston pump

Hydraulic Pumps
• View of A7VO bent axis piston pump
Hydraulic Pumps
• Typical view of
A8VO bent axis piston
pump
• This has two bent axis
pumps in one housing

Hydraulic Pumps
• Installed view of
A8VO bent axis piston
pump
• Mounted directly to
engine
• Auxiliary drive for
gear pumps
Hydraulic Pumps
• The hydraulic pumps are controlled by pilot
pressure from the hydraulic control
joysticks in the operators cab
• Current GMK models from 5160 - 6200 use
electric pump control via electric joy stick
controls and amplifier boards

Hydraulic Pumps

• Pump identification codes e.g.

• A8VO107LR3CH
• A = Axial. 8 = Series. V = Variable
• O = Open circuit. 107 = displacement
• LR = Constant horsepower. 3 = 3rd input
• C = Cross sensing
• H = Pilot pressure dependent
Hydraulic Pumps

• Pump identification codes e.g.

• A8VO107EP
• The last two letters (EP) indicate that this
pump is (E) electric (P) proportional and
would only be used on a GMK 5160

Hydraulic Pump Control

• Cabin electric joystick
with pancake
potentiometer
• The potentiometer
type & value will
differ on model type
Hydraulic Pump Control
• View of amplifiers & horsepower control circuit
board installation - Located in operators cab behind
drop down flap - Applicable to Megatrack models
5160 - 6200

PVR

RVR GLR

Hydraulic Pump Control

• There are two amplifier types:
• PVR for open circuits (smallest boards)
• RVR for closed loop control (swing)
• The amplifiers convert the joystick signal
voltage into a milliamp output to control the
hydraulic pump output
Hydraulic Pump Control
• The GLR board is used to regulate the
hydraulic pumps output according to the
available engine power
• Replacement PVR, RVR & GLR boards
must all be calibrated on the crane - contact
Service Department

Control Block
• The control block is used to control the
direction of the oil flow to the actuator
• The block is of modular design
• spool switching control is by integrated
electric solenoids
• Spool switching control by pilot pressure
was used on pre-Megatrak models - except
the KMK 5100 AT
Control Block
• Typical view of modular control block

Control Block

• Logic valves are

similar to direction
valves
• They are integrated
within the control
block and are
controlled by
solenoids
Control Block

• Main pressure and

circuit relief valves are
often integrated into
the control block
• Direction control
solenoid valves

Hydraulic motors
• Most motors are bent axis piston motors -
used on hoist & swing box drives
• Some vane motors are used on swing box
drives
• Orbital motors are used on some 3050 PTJ
applications for extending the jib
• Gear motors are not used
Hydraulic motors

• Typical view of A2F

bent axis piston motor

Hydraulic Motors

• Two A2F bent axis

motors in parallel
drive - GMK 5130
application
Hydraulic Motors
• A2F bent axis piston
motor - application in
main hoist drive
• Brake release solenoids
• Motor control valve
• Brake/motor control
synchronising valve

Hydraulic Motors

• Detail view of brake/motor control synchronising valve

Hydraulic Motors
• A2F bent axis motor being used to drive an
A8VOLRCH bent axis pump - GMK 4070

Hydraulic Oil Coolers

• View of oil cooler installation with electric fan
motors
GMK Crane Configurations
• Current models may use:
• Main boom
• Fixed & offset jib
• Power tilt jib
• Luffing jib

GMK Crane Configurations

• Main boom
GMK Crane Configurations
• Fixed jib
• The jib may also be
manually offset

GMK Crane Configurations

• Fixed jib
• two lengths are
possible
• offset position is
obtained by
mechanical links
GMK Crane Configurations
• Power tilt jib
• The jib angle is altered
from controls in the
operators cab by a
hydraulic cylinder on the
base of the jib

GMK Crane Configurations

• Power tilt jib
in stowed
position
Crane Configurations
• Luffing Jib
A Frames
Pendent - Steel links or
Back masts

Main hoist controls hook

Auxiliary hoist controls jib

angle via bridle

GMK booms

• The boom lift/derricking

cylinder is often referred to
as a luffing cylinder
GMK Booms
• Boom telescoping sections are identified by
numerical reference counting from the base
section
• The base section is not included in the
numerical reference

GMK Booms
Telescope sections
• 3

• 2

• 1
GMK Booms
• On current models from KMK//GMK 4080
and higher, one or more boom telescope
sections are mechanically pinned
• All models that only pin the first telescope
section are hydraulic control
• All other models are pneumatic control

GMK Booms
• On large cranes - GMK 6200, the right hand side
of the boom carries pneumatic hose reels
GMK Booms
• On various models boom sections are locked by
mechanical pins - View of KMK 6140

GMK Booms
• Several models use
hydraulic boom
pinning, only on the
first telescope section
GMK Booms
• Several models from 70
to 130 tonnes all use a
retaining clamp to hold
the head section
• Belville washers provide
the clamping force

GMK Booms
• For safety, the boom and
locking pin positions are
monitored by either
proximity or micro switches
• Locking pin micro switches
• Boom proximity switches
GMK Booms
• The left hand side of the
boom base section carries
electrical recoil drums for
the LMI/SLI/RCI and
boom pinning functions if
applicable

GMK Booms

• Large cranes with a

luffing jib also carry
an electrical recoil
drum on the right side
of the boom base
section
GMK Booms

• Skymaster & 6250

booms also have
internal cable drums to
monitor cylinder
position and control
solenoids

BoomWear Pads
• Top rear wear pads are
often machined to suit
the particular boom
section
• New top pads may
need machining to
specification from the
machine file
Telescope Cylinder arrangements
• 1. Telescope cylinders & manual section
• 2. Telescope cylinders for all sections
• 3. Telescope cylinders & power pin section
• 4. Telescope cylinders & cable
synchronized sections
• 5. Travelling telescope cylinder for all
sections
• 6. Static, pin & push telescope
cylinder for all sections

Telescope Cylinder Arrangement

• Shown below is a skymaster telescope system
Telescope Cylinder Arrangement

• View of skymaster telescope cylinder

• Internal cylinder to section locking pins

Telescope Cylinder Arrangement

• View of 70 tonne model telescope cylinders

SSi inngglele t teelelessccooppee ccyylilinnddeerr

CCyylilinnddeerr bbooxx

DDoouubblele t teelelessccooppi inngg ccyylilinnddeerr

BBaassee SSeecct ti ioonn 11 SSeecct ti ioonn 22 S e c t i o n 3

S e c tio n 3
Telescope cylinders
• The cylinders have internal transfer tubes to
supply oil to themselves and other cylinders
- a power -track arrangement is used on
travelling cylinders
• Hydraulic hose reels are not used

Telescope Cylinders
• Single stage and two
stage cylinders are
often used in
combination
• Shown is a two stage
cylinder with
integrated solenoid
valve control
• Cable routing is up
body of cylinder
Telescope cylinders
• View of cylinder head
with control by integrated
solenoid valves
• The solenoids are
mounted at the head of the
cylinder along with the
holding/logic valves

EKS LMI/SLI/RCI Indicators

• There are four types of system in current use
• 1. EKS 83 uses a Kruger transducer box & single
boom recoil drum
• 2. EKS 83 new generation uses Dynisco
transducers & has multiple boom recoil drums
• 3. EKS 3 with softpad interactive faceplate - This
system also uses Dynisco transducers & multiple
recoil drums
• 4. EKS 4 with softpad interactive faceplate - This
system is being used ECOS technology.
EKS 83

• EKS 83 uses digital

switches on the
faceplate
• This is known as the
central unit

EKS 83
• There are several central unit software
versions that may be fitted to early cranes
• Only one type (D) is now available as a
replacement
• Please seek Service Department advice for
correct configuration
EKS 83
• View of central unit
with cover removed
showing location of
main fuse = 3.15 amps
• NOTE: a larger fuse
will destroy the unit

EKS 83
• View of central unit
with cover removed
showing location of
Data Bus fuse
= 1.25 amps
• NOTE: a larger fuse
will destroy the unit
EKS 83
• View inside Kruger
transducer box, it is
mounted on the lift
cylinder
• Two transducers are
left & right behind
compensation board

EKS 83
• Compensation board -
resistors must be
changed to suit model
type
EKS 83
• View with
compensation board
removed
• Transducers
• By-pass solenoid

EKS 83
• NOTE: the compensation board part
number is for a standard board
• The standard board may need some
resistors changed to suit the particular
model
• Please contact the Service Department for
advice
EKS 83
• Cranes that have Kruger transducers only
have a single boom length recoil drum on
the left side of the boom
• The single recoil drum is a very good way
to identify the original version of EKS 83 &
only applies to pre-Megatrak models

EKS 83
• View of boom
length/angle drum on
left side of main boom
• There are two length
cable sizes up to 70
tonnes = 2.5 mm.
All larger cranes
= 4.0 mm
EKS 83

• It is very important to supply the correct

diamater boom length cable
• 2.5 mm part no = 0553323
• 4.0 mm part no = 1374345

EKS 83 New Generation

• View showing
location of piston
transducer on the
boom lift cylinder
EKS 83 New Generation
• View of transducer on
the rod side of the lift
cylinder

EKS all versions

• A load pin or load strap is used
on luffing jibs to measure the
load signal
• View of load pin - This is fitted
in the centre of the hoist rope top
sheave on the boom head
• The load strap is used in the rope
anchor
EKS 83 New Generation
• View of multiple recoil drums on left side of boom

EKS 83 New Generation

• Many of the models now use 8 core cable
on the recoil drums = part no 1924065
• The correct diamater & length is critical
• Housed inside & driven by the drum are
potentiometers, these give a length signal to
the data transmitters
EKS 83 New Generation
• The data transmitters are enclosed in boxes as close as
possible to the potentiometers/transducers

EKS 83 New Generation

• View inside angle/length transmitter box showing:
angle potentiometer and data transmitters
EKS 83 New Generation
• The boom length potentiometers are inside these
housings

EKS 83 New Generation

• View of recoil drum potentiometer drive & slip rings
EKS 3

• EKS 3 uses softpad

switches on the
interactive faceplate
• This is known as the
central unit

EKS 3
• Rear view of central
unit showing fuse
locations
• F1. Main fuse = 3.15
amps
• F2. Data bus fuse =
1.25 amps
• F3. Data bus fuse =
1.25 amps
EKS Generic Compatability
All models use the same:
• Boom length potentiometers
• Boom angle potentiometers
• Data transmitters

End of Superstructure Presentation

GM K I I
S yst e m
Pneumatics

TRAINING INSTITUTE

Air Schematic Layout

Compressor runs
continuously 8.1 Bar

Purge
GMK Equipped Tank

with
Mercedes Engine

Compressor runs
8.1 Bar
intermittently

Purge
GMK Equipped Tank

with
Cummins Engine Valid since
approx. 1998
8.1 Bar

Compressor

Pressurizing Purge
Tank
Air Dryer
System
To Tanks
&toUnloader
8.1 Bar and Air System

8.1 Bar

Compressor

Backflush
At 8.1 Bar Purge
Tank

Unloading
the Filter
To Tanks
and
Occurs
Dryer and Air System
21

6.0 Bar 5.5 Bar

Input Air
18 x 2 1
From
Air Dryer

24
6.0 Bar 5.5 Bar

22
GMK5160
Air Tank V2 V4 V3
60 L
V1 V1
100 L 10 L 40 L 40 L
Distribution

6.0 Bar 5.5 Bar

Input Air
18 x 2 1
From
Air Dryer

24
6.0 Bar 5.5 Bar

IfMaxi
If Braking
Auxiliary Circuit
Circuit V2
V4
If If
Main Brake
Brake #1Circuit
CircuitV3 V1
ruptures
ruptures
ruptures or
or
or fails
fails
fails V2 V4 V3 V1 V1
ruptures or fails
the
theline
the linepressure
line pressurewill
pressure will
will
100 L 10 L 60 L 40 L 40 L
the line pressure will
fall
fall
fall to
to 6 Bar
5.5 Bar
falltoto5.5 Bar
6 Bar
Pedal
Pressure S20
Down
5.5 Bar

12 x 1,5

V1
Low V2
V2 V1
Volume
100 L 40 L
Air
Signals 12 x 1,5
the
Brakes 5.5 Bar

S21

High Volume Air Activates the Brakes

GMK 5160 Axle #1

Axle 1
Braking Circuit

Pedal
Pressure S20
Released
5.5 Bar

12 x 1,5

V1
V2
V2 V1
100 L 40 L

Low 12 x 1,5
Volume
Air 5.5 Bar
Signals
to
release S21
the
High Volume Air is blocked and
Brakes
awaits further activation

GMK 5160 Axle #1

Axle 1
Braking Circuit
TRAINING INSTITUTE

Relay Valve

Relay Valve
Cluster Located
looking up from
underneath.
Central part of
Carrier

Pedal
Pressure S20
Down
5.5 Bar

12 x 1,5

V1
Low
V2
Volume V2 V1
Air 100 L 40 L
Signals 12 x 1,5
the
Brakes
5.5 Bar

S21

High Volume Air Activates the Brakes

GMK 5160 Axle #2

Axle 2
Braking Circuit #1
Pedal
Pressure S20
Released
5.5 Bar

12 x 1,5

V1
V2
V2 V1
100 L 40 L

Low 12 x 1,5
Volume
Air 5.5 Bar
Signals
to
release S21
the
High Volume Air is blocked and
Brakes
awaits further activation

GMK 5160 Axle #2

Axle 2
Braking Circuit #1

Pedal S20
Pressure
5.5 Bar
Braking Circuit #2
Down 12 x 1,5

V1
V2 V2 V1 V1
100 L 40 L 40 L
12 x 1,5

5.5 Bar

S21

Axle #3 Axle #4 Axle #5

S20
Pedal
Pressure 5.5 Bar
Braking Circuit #2
Released 12 x 1,5

V1
V2 V2 V1 V1
100 L 60 L 40 L
12 x 1,5

5.5 Bar

S21

Axle #3 Axle #4 Axle #5

12 x 1,5

V3
GMK
GMK 5160
5160 60 L
Maxi
Maxi Brake
Brake Circuit
Spring
Axle #2 Engaged
Released
Low
Volume
Air High Volume Air is blocked
Vents and awaits further activation
to
Atmosphere
High Volume Air
Releases the Maxi Brakes
Axle 2
12 x 1,5

Low
Volume V3
Air GMK 5160 60 L
Signals
the Maxi Brake
Brakes
Engaged
Axle #2 Released

High Volume Air

Releases the Maxi Brakes
Axle 2

Low
Volume
Air
12 x 1,5
Vents
to
Atmosphere
When
HighGMK
Air is5160
Volumeblocked
Air
Maxi Brakes Released V3
Axles
Maxi #3, #4
is Brakes
Blocked &-#5
Engage
and 60 L
with High Volume Air
Maxi
awaits Brake
with Spring Circuit
furtherTension
activation

Axle #3 Axle #4 Axle #5

Low
Volume
Air 12 x 1,5
Signals
the
Brakes
Spring Tension
to release Maxi
MaxiBrakes Released
Brake Engaged V3
is overpowered 60 L
with
withHigh Volume
Spring Air
Tension
with High Volume Air

Axle #3 Axle #4 Axle #5

V3 V1 V1
60 L 40 L 40 L

Anti-Compounding
Axle 2 Valve
Air Schematic Layout
Air Solenoids and Functions

We now will examine, when the air solenoids

are fired and which functions they activate.

TRAINING INSTITUTE

Air Solenoid Bank

Air Solenoid Valve Bank

Cluster Located with right side of carrier above
outrigger box
GMK II
Carrier Hydraulics

TRAINING INSTITUTE

Rexroth A10V0 Hydraulic Pumps

1 2 3

Mark II Carrier
(Shown)
P1, P2 and P3 Pumps are ganged together. All carriers since the
Grove Acquisition Pre-Grove pumps are individually driven through a
separate gear box. Pump 3, located After P1 and P2 through a
common shaft.
Group Exercise :
Variable Displacement Pump Operation

Instructor Hand Out Worksheet!

Use the Hydraulic Pump Worksheet
Describe how the the Pump De-ramps
How the Pump comes on Stroke?
How does this Pump use load sense?

To System

Rexroth
Flow
A10V0 Control
Orifice

Variable Displacement
Piston Pump

L
To System

Rexroth
Flow 14 Bar
A10V0 Control
Orifice

Start -Up No Load,

Pump De-ramps to 14 Bar

Pressure Builds
SystemTo System
Demand

Rexroth
Flow 14 Bar
A10V0 Control
Orifice

As System demands Flow

Pump Ramps up

L
Group Exercise :
ZF Steering Control Circuit Operation

Instructor Hand Out Worksheet!

Use the ZF Steering Circuit Worksheet
Describe what makes the (2) Red Lamps go off?
Describe what is indicated when you
see Steer Pump II Lamp Only?
Describe what is indicated when you
see Steer Pump I Lamp Only?

GMK ZF Steering Circuit

To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

Panel Panel
Indicator Indicator
Lamp Lamp

P2 Ground P
DFR
Driven 3DFR
Pump
GMK ZF Steering Circuit
To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

P2 Ground P
No Flow DFR
Driven 3DFR
Pump

GMK ZF Steering Circuit

To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

P2 Ground P3
Flow Begins DFR
Driven
DFR
Pump
GMK ZF Steering Circuit
To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

Carrier Begins P2 Ground P3

Driven
Moving DFR
Pump DFR

GMK ZF Steering Circuit

To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

Carrier Steers P2 Ground P3

Driven
Left DFR
Pump DFR
GMK ZF Steering Circuit
To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

Carrier Steers P2 Ground P3

Driven
Right DFR
Pump DFR
DFR

GMK ZF Steering Circuit

To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

P2 Pump Failure P2 Ground P3

Driven
DFR DFR
Pump
GMK ZF Steering Circuit
To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

P3 Pump Failure P2 Ground P3

Driven
DFR DFR
Pump

GMK ZF Steering Circuit

To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

Ground P2 Ground
Driven
P3

Driven Pump DFR

Pump DFR

Failure
GMK ZF Steering Circuit
To Steering Cylinders

Left 3 4 Right 4 3

To Steering Cylinders

1 2 1 2

II I

P2 & P3 Pump P2 Ground P3

Driven
Failure DFR
Pump DFR

Group Exercise :
ZF Steering Cylinder Operation

Instructor Hand Out Worksheet!

Use the ZF Steering Cylinder Circuit Worksheet
Describe what cylinders steer when in Highway?
Describe what cylinders steer when in Off Road?
Describe what does the Valve Bank do?
Describe what do the relief valves do?
Axle #1 Axle #2 Axle #3 Axle #5

Axle #4

6Y21

6Y22

6Y31

6Y32
6Y2

Independent Rear P1
Steering Disengaged 6Y3
6Y4

Lock Can Engaged 2 mm

Axle #1 Axle #2 Axle #3 Axle #5

Axle #4

6Y21

Left Turn
6Y22

6Y31

6Y32
6Y2

On Road Steering
P1
4th Axle Fixed
6Y4
5th Axle 6Y3

Opposite Steer 2 mm
Axle #1 Axle #2 Axle #3 Axle #5

Axle #4

6Y21

Right Turn
6Y22

6Y31

6Y32
6Y2

On Road Steering
P1
4th Axle Fixed
6Y4
5th Axle 6Y3

Opposite Steer 2 mm

Axle #1 Axle #2 Axle #3 Axle #5

Axle #4

Place in 6Y21

Off Road Gear

Unlock 6Y22

Independent
Rear Steer
6Y31

6Y32
6Y2

Off Road
P1
Independent Rear 6Y4
Steering Engaged 6Y3

2 mm
Lock Can Disengaged
TRAINING INSTITUTE

Rear Steering Valve Block

Rear Steer Valve Block

6Y2 and 6Y3 valves in view
6Y21, 6Y22, 6Y31 and 6Y32 attached, however in
background (out of view).
Located between axles 3 & 4 internal left side frame

Axle #1 Axle #2 Axle #3 Axle #5

Axle #4

6Y21

Left Rear Turn

6Y22

6Y31

6Y32
6Y2

Independent Rear P1
Steering Engaged 6Y3
6Y4

Lock Can Disengaged 2 mm

Axle #1 Axle #2 Axle #3 Axle #5

Axle #4

6Y21

Right Rear Turn

6Y22

6Y31

6Y32
6Y2

Independent Rear P1
Steering Engaged 6Y3
6Y4

Lock Can Disengaged 2 mm

TRAINING INSTITUTE

8Y1 Set-Up Control Valve

8Y1 Solenoid Valve

Located in the engine compartment on the
right side of carrier after the hydraulic pumps.
GMK 5 -Axle Cooling Circuit

Slow T
Flow
Motor Through
Rotation Thermostat

50 -58 C
P Max
280 Bar

25
LPM

-8Y1

Minimal Flow
Requirement
315 Bar

P1
DFR

GMK 5 -Axle Cooling Circuit

Fast
T
Motor
Rotation
50 -58 C
P Max
280 Bar

25
LPM

-8Y1
Thermostat
Relief Closes
315 Bar When Temp Exceeds
50o-58oC
P1
DFR
Group Exercise :
Outrigger Hydraulic Operation

Instructor Hand Out Worksheet!

Use the Outrigger Hydraulic Worksheet
Describe what does the 8Y1 valve do?
Describe what does the special symbol in the
Jack Cylinder indicate?
Describe what does the Relief Valve in the
Jack Cylinder do?

GMK 5- Axle -9Y1 -10Y5

Outrigger Circuit
Front Left
Beam Extending

25
LPM

- 9Y5 - 10Y1
-8Y1

Tank

315 Bar

P1
DFR

Concept Drawing Only!

GMK 5- Axle -9Y1 -10Y5
Outrigger Circuit
Front Left
Beam Retracting

25
LPM

- 9Y5 - 10Y1
-8Y1

Tank

315 Bar

P1
DFR

Concept Drawing Only!

GMK 5- Axle -9Y1 -10Y5

Outrigger Circuit
Front Left
Jack Extending

25
LPM

- 9Y5 - 10Y1
-8Y1

Tank

315 Bar

P1
DFR

Concept Drawing Only!

GMK 5- Axle -9Y1 -10Y5
Outrigger Circuit
Front Left
Jack Retracting

25
LPM

- 9Y5 - 10Y1
-8Y1

Tank

315 Bar

P1
DFR

Concept Drawing Only!

Group Exercise :
Outrigger Hydraulic Operation

Instructor Hand Out Worksheet!

Use the Outrigger Hydraulic Worksheet
How does the double holding valve operate?
Describe what does the 330 bar Relief Valve do?
Jack Double Holding Valve

Jack
10Y5 Cylinder

Pump

Tank

10Y1

TRAINING INSTITUTE

Suspension Control Panel

Suspension Pressure Gauges

Located in the Carrier Cab compartment
on the right side of driver’s seat.
TRAINING INSTITUTE

Suspension Control Panel

Suspension
Control Switches
Raises or lowers all
megatrak cylinders
front only, rear only,
left side only or right
side only.

Suspension Control Key Lock

Unlocks suspension control

solenoids. Permits raising and lower
of suspension.

Group Exercise :
Suspension Hydraulic Operation

Instructor Hand Out Worksheet!

Use the Suspension Hydraulic Worksheet
Describe what does the 8Y1 valve do?
How does the valve (above the accumulator) energize?
Describe what does the 330 bar Relief Valve do?
Describe Locked vs. Unlocked
Describe Raising these Cylinders?
Describe Lowering these Cylinders?
Axle 2 Right Side Axle 3

Suspension
Locked

25
LPM

-8Y1 Tank

-Y04

315 Bar
330
Bar

Accumulator and
P1 Relief Protect
DFR Accumulator
Circuit from Shocks

Concept Drawing Only!

Axle 2 Right Side Axle 3

Suspension
Unlocked

25
LPM

-8Y1 Tank

-Y04

315 Bar
330
Bar

Accumulator and
P1 Relief Protect
DFR Accumulator
Circuit from Shocks

Concept Drawing Only!

TRAINING INSTITUTE

Lock Valve and Accumulator

Axle 2 Right Side Axle 3

Suspension Unlocked As Cylinder is
extended
As Cylinder is
compressed
Struts Floating Oils are Shared
Between Cylinders
Oils are Shared
Between Cylinders

25
LPM

-8Y1 Tank

-Y04

315 Bar
330
Bar

P1
DFR Accumulator

Concept Drawing Only!

Axle 2 Right Side Axle 3

Suspension As Cylinder is
extended
Rod Oil flows out
As Cylinder is
compressed
Rod Oils flows in

Unlocked

25
LPM

-8Y1 Tank

-Y04
Oil is shared
between
Cylinders and
Rods/Pistons
315 Bar
330
Bar

Accumulator and
P1 Relief Protect
DFR Accumulator Circuit from Shocks

Concept Drawing Only!

Axle 2 Right Side Axle 3

Suspension Carrier rises as

Cylinders are

Raising extended

Rod Side Oil is

regenerated back
into piston side

25
LPM

-8Y1 Tank

-Y04

315 Bar
330
Bar

P1
DFR
DFR Accumulator

Concept Drawing Only!

Axle 2 Right Side Axle 3

Suspension Carrier lowers as

Cylinders drain

Lowering
Rod Side
fills with Oil
from Piston Side

25
LPM

-8Y1 Tank

-Y04

As Rod Side is
filled, Excess Oil
315 Bar exhausts to tank
330
Bar

P1
DFR Accumulator

Concept Drawing Only!

GMK II
Carrier Systems

TRAINING INSTITUTE

+BE 550 Discription of Location

+BE 540

.AK2
.UR1 .UR2 .UR3 .UR4 .UR5
V5 V4

.UM1 .UM2 .UM3 .UM4 .UM5

.UL1 .UL2 .UL3 .AK1 .UL4 .UL5

Carrier Cab
+BE 550
Dash Panel Enclosures

.A1 .A2 .A3 .A4 .A5 .A6

.A7
.LS .S1
Steering .A8
Wheel
.A9
.A10
.A11

Drivers Seat Relay Box

+24 v Supply

20A 5A 20A 10A 15A 5A

1 2 3 -F6 4 5 6

.A11 -F6.6
-F6.1
+BE540 .UL2

87 K1 86

30
Oil Cooler Fan
85
Running
M T
GMK Carrier Electrical
OIL TEMPERATURE SWITCH Schem. 3008087 Pg. 1
RADIATOR 1
-F1.3 -F6.2 -F1.4 -F4.1
.A4

.A5 X 1 13
F4.1- 6

3.21
F3.5
3.10

F2.5
3.16
4.6
+BE550

X1 14

X2 1
X1 11
X1 7

X1 8

X1 9

X2 3

X2 4

X2 5
S2 S3
58 56 15
P0123

30 30 K1 86

P1 P2 P3
GE RT
SW RT K3 86 K4 86 K5 86

H2 H3
H4 H1 85 85 85

X3 13

X3 11

X3 12

X3 14
X2 13
X2 10

X3 6

X3 7

X3 9
X3 4
X2 8
X2 6
X2 7

.A5 X6 5

.A13 X2 12
50 A
X4 1
X4 2
X4 3

2.16

2.20
+BE540 .UL1

T P
-S3

Engine
Water
P Level
Engine Temp. Fuel Engine Oil
Sender Sender Pressure
Air Filter

Enclosure .A4 Schem. 3008087 Pg. 1

Left Control Box .AK1 +BE540 .AK2 +BE540 Right Control Box

S8 H1 S8 H1

S2 S3 S7 S6 S5 S4 S2 S3 S7 S6 S5 S4

S1 V1 V2 S1 V1 V2

8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7

S1 Powerswitch S6 Front Right

S2 Out In S7 Front Left
S3 Jack Beam S8 Illumination
S4 Rear Right
S5 Rear Left
GMK Outrigger Circuit
Schem. 3008087 Pg. 4
Outrigger Control Relay Card:

K-7 K-8 K-9 K-10K-11 K-1 K-2 K-4 K-3 K-5 K-6
• Board Relay LEDs
• Relay Modules
• INTERN Wire Block
(Quick Disconnect) NC 26 9
26 27 9
By
253

1 1 1+ 10
• TASTER Wire Block
253

2 2 2 11 By
253

3 3 3 12 By
253

(Push Buttons)
By

4 4 4 13 253

5 5 5 14 By
253

6 6 6 15 By
253

• SRK Wire Block 7 By

7 7 16 253

8 8 8 17 By
253

NC NC 18 By
253

(Sliprings, used on 4080 S/S) NC NC 19

20
By
253

By
253

TASTER SRK 21 By
253

• VENTILE Wire Block

22 253

23 By
253

G 24 By
253

(Quick Disconnect) GROVE

25 By
253

VENTILE
• Diodes
(Arch Suppression)

-F5 .1
Left Control Box .AK1 +BE540
Bridge

S8 H1 1 2 3 4 5 6 7
2 3 4 5 6 7
8 8 26

S2 S3 S7 S6 S5 S4

S1 V1 V2
1 4 7 1 4 7
K1 K2
8 1 2 3 4 5 6 7 2 3 5 6 8 2 3 5 6 8

K8 K9 K10 K11

1 4 7 1 4 7
K5 K6
2 3 5 6 8 2 3 5 6 8

8Y1

Set-up
Pressure
Outrigger Relay Card .AK1
Outrigger Function Controls
Group Challenge:
Identify each of the relays that fire
for the following configurations?

Group 1 • Front Left Jacks & Beams

Group 2 • Front Right Jacks & Beams
Group 3 • Rear Left Jacks & Beams
Group 4 • Rear Right Jacks & Beams

Special Note: Do not forget the 8Y1 Set-up Valve

What is the Outrigger Function

If you see the following LED’s Illuminated?
The current
outrigger LED configuration: K-7 K-8 K-9 K-10K-11 K-1 K-2 K-4 K-3 K-5 K-6

K7,K10,K1,K2,
K5 & K6 LED’s 1
NC
26
1
26
27
1+
9
9
10
By
25 3

By
25 3

2 2 2 11 By
25 3

are on. 3
4
5
3
4
5
3
4
5
12
13
14
By
25 3

By
25 3

6 6 6 15 By
25 3

7 7 7 16 By
25 3

8 8 8 17 By
25 3

NC NC 18 By
25 3

NC NC 19 By
25 3

20 By
25 3

TASTER SRK 21 25 3

22 25 3

23 By
25 3

G GROVE 24 By
25 3

25 By
25 3

VENTILE
What is the Outrigger Function
If you see the following LED’s Illuminated?

K-7 K-8 K-9 K-10K-11 K-1 K-2 K-4 K-3 K-5 K-6

NC 26 9
26 27 9
By
25 3

1 1 1+ 10 25 3

2 2 2 11 By
25 3

3 3 3 12 By
25 3

4 4 4 13 25 3

5 5 5 14 By
25 3

6 6 6 15 By
25 3

7 7 7 16 By
25 3

8
Answer: 8 8 17 By
25 3

NC NC 18 By
25 3

NC NC 19 By
25 3

20 By
25 3

TASTER SRK 21 25 3

22 25 3

Rear Left Beam G GROVE

23
24
25
By
25 3

By
25 3

In/Retract VENTILE
GMK II
Megastrut
Suspension Controls

TRAINING INSTITUTE

Suspension Control Panel

TRAINING INSTITUTE

Suspension
Control Module

.A9 Carrier Enclosure Right Side

E1
E2
E3
E4
E5
E6
X1 X2
E7
E8 A1
A2
E9 A3
E10
A4
E11
E12 A5
E13 A6
E14
A7
E15
E16 A8

Electronic Suspension Control

Unlocking Suspension

Suspension Lock/Unlock
Suspension
Locked

Indicator
Lamp
(H18)

Selector
Switch
(S8)
Suspension Lock/Unlock
Suspension
Unlocked

Indicator
Lamp
(H18)

Selector
Switch
(S8)

Now lets see what happened…

Suspension Locked
-F1.6 -F1.3
Schem. 3008087 Pg.2
.A5
When K15 is activated the
contacts allow a ground S8 0 1
to power the K40, K41,
1 2
K42 and K43 relay coils 1 1
7 1 8 2 10
(found on page 4
enclosure .A9)

These coils send power to

Y03 and Y04 allowing K15
K15 K14 K5
axles 1,2 & 3 to share oil To
K6 Enclosure .A9
during P P
P
Page 4.14
Off-the-Road Operation

Y66 and Y68 are also -Y61 -Y62 Y66

-Y66 -Y68
Y68
1 Axle Block
2-5 Axle Block

powered to permit an K26

extra accumulator on the
rear axles to improve Off-

2-5 Axle Block

Accumulator
Accumulator
S1
the-Road suspension 1 Axle Block

Right

Left
Concept Drawing Only!

-F5 1 -K15
.A9
S1 K26
K 30 Allison Trans
K26 K40
K40 K41
K41 K42
K42 K43
K43
Inhibit Ground Signal

Auto
Level Up/Down
0 1 0 1 0 1 0 1 0 1 0 1 S7
S8 S3 S2 S4 S5 S6 0 1 Level
Front Right Rear Left
H1 H2 H3
All Raise/
K30 Lower

Electronik Suspension Control Unit

K41 K40 K42 K43

-B2 br bl -B1 br bl -B4 br bl -B3 br bl

-Y66 -Y68
sw sw sw sw
Front Front Rear Rear -Y01 -Y02 -Y06
Right Left Right Left
4 - 5 Axle Right
1 Axle Right

-Y03
-Y03 -Y04
-Y04 -Y05
1 Axle Left

-A2 br bl -A1 br bl -A4 br bl -A3 br bl

2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left

-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

Suspension Unlocked
-F1.6 -F1.3 Schem. 3008087 Pg.2

.A5

S8 0 1

1 2
1 1
7 1 8 2 10

K15
K15 K14
K14 K5
-Y5
To
K6
K6 Enclosure .A9
P Page 4.14
P P

-Y61
-Y61 -Y62
-Y62 Y66
-Y66
-Y66 -Y68
Y68
-Y68
1 Axle Block
2-5 Axle Block

K26

2-5 Axle Block

Accumulator
Accumulator
S1
1 Axle Block

Right

Left
Concept Drawing Only!

.A9 -F5 1
Suspension
Unlocked
S1
provides Ground K26
K 30
K40 K41 K42 K43
Allison Trans
K26 (from enclosure .A5, Page 2,
Inhibit Ground Signal
grid 1)
Auto
Level Up/Down
0 1 0 1 0 1 0 1 0 1 0 1 S7
S8 S3 S2 S4 S5 S6 0 1 Level
Front Right Rear Left
H1 H2 H3
All Raise/
K30 Lower

Electronik Suspension Control Unit

K41 K40 K42 K43

-B2 br bl -B1 br bl -B4 br bl -B3 br bl

sw sw sw sw
Front Front Rear Rear -Y01 -Y02 -Y06
Right Left Right Left
4 - 5 Axle Right
1 Axle Right

-Y03 -Y04 -Y05

1 Axle Left

-A2 br bl -A1 br bl -A4 br bl -A3 br bl

2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left

-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

Group Exercise #1:
The Operator will raise the
Front Struts Axles 1, 2 and 3

Top View

Side View

Suspension Control Panel

Step 1 : Ensure Suspension
is unlocked!
Step 2 : Arm Suspension
Control Panel, by turning and
locking key
Step 3 : Select “Raise” on
the Raise/Lower Direction
Rocker Switch
Step 4 : Push “Front” on the
Front Strut Momentary
Switch

Indicator
Lamp
(H18)

Selector
Switch
(S8)
Suspension Control Panel

Indicator
Lamp
(H18)

Selector
Switch
(S8)

.A9 -F5 1

S1 K26
K 30
K40 K41 K42 K43
Allison Trans
K26
K26
Inhibit Ground Signal

Auto
Level Up/Down
0 1 0 1 0 1 0 1 0 1 0 1 S7
S8 S3 S2 S4 S5 S6 0 1 Level
Front Right Rear Left
H1 H2 H3
All Raise/
K30
K30 Lower

Electronik Engage S1 Key

Suspension SwitchUnit
Control
Suspension Unlocked
Transmission Ground Signal
provides Ground
When S1 Switch is engaged a ground is providedK41the K40 K42 K43
-B2 -B1 -B4 -B3
br bl
transmission
br bl
that inhibits
br
upshifting beyond 2nd
bl br bl

sw
Gear Forward sw sw sw
Front Front Rear Rear -Y01 -Y02 -Y06
Right Left Right Left

This remains in effect until-A1the S1-A4Key is disengaged

4 - 5 Axle Right
1 Axle Right

-Y03 -Y04 -Y05

1 Axle Left

-A2 br -A3 bl br bl br bl br bl
and removed from switch.
2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left

-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

Which LED’s
The A2 Output will beare Illuminated?
The A3 Output
illuminated will be
indicating
illuminated
the Front Leftindicating
Solenoids
the Front Right Solenoids are areThe
What areare theenergized What
Output Signals? theE9Input
Input Signals?
will be
energized
E1 illuminated indicating front
E2
struts have been engaged
The A8E3 Output will be
E4
illuminated indicating
E5
the 8Y1 E6
Solenoid is are X1 X2
The E15 Input will be
E7
energized illuminated indicating
E8 indicates the A1
This LED raise A2
has been engaged
module has E9
been powered
A3
E10
A4
E11
E12 A5
E13 A6
E14
A7
E15
E16 A8

Suspension Control Module

In the previous exercise we saw the

front 3 axles raised manually…

In the next exercise the crane

carrier will start with the
front 3 axles raised and
rear 2 axles lowered.

The operator will now

auto-level the crane carrier.
Group Exercise #2:
The Operator will
Auto-Level the Crane Carrier

Top View

Side View

Low
? High ? ? ?

Suspension Control Panel

The Auto-Level Indicator
Lamp comes on when the
carrier is seeking level.
Step :Using
2 :Lampthe
3 The
Step goes
control panel,
out when level
Indicator Step 1 What
: steps does the
Lamp is achieved.
(H18)
Select Operator
“Auto
Arm Suspension take to on
Ride Height”
Control the
Panel,
Ensure Suspension
Auto-Level is unlocked!
to Switch
Auto
byRide Height
turning andRocker
locking key
Highway Ride Height?
Selector
Switch
(S8)
Suspension Control Panel

Indicator
Lamp The Auto-Level Indicator
(H18) Lamp is now out.
Indicating the Crane is now level

Selector
Switch
(S8)

Suspension Control Panel

Your Crane
is now ready for
Highway Travel Unlock and Remove Key
from suspension control
Now lets see what happened…

.A9 -F5 1

Proximity
S1 Switch
K26 Inputs K 30 Allison Trans
K26
K26 Proximity Switch Inputs Inhibit Ground Signal
K40 K41 K42 K43

B3 & B4 Upper Prox Switches, NO

Auto
Level
Proximity
B1, B2, Switch
B3 & B4 Upper Inputs NO
Prox Switches, Up/Down
0 1 0 1 0 1 0 1 0 1 0 1 S7
Now are closed and send a signal, to the
S8 S3 A2 &A1, A1
S2 A2,Lower Prox
A3S4Rear
& Switches,
A4 LowerS5 ProxNCS6
Switches, NC 0 1 Level
control
Front module.
Right The signal indicates
Left the rear
H1 H2 H3
carrier is low All Raise/
K30
K30 Now are Closed and send a signal to the Lower

control module. This indicates

Engage theSwitch
S1Control
Key front of the
Electronik
Suspension Unlocked
Transmission
carrier is high. Suspension
Ground Signal Unit
provides Ground
When S1 Switch is engaged a ground is provided K41 the K40 K42 K43
-B2 -B1 -B4 -B3
br bl
transmission
br bl
that inhibits
br bl
upshifting beyond 2nd
br bl

sw
Gear Forwardsw sw sw
Front Front Rear Rear -Y01 -Y02 -Y06
Right Left Right Left

This remains in effect until the S1 Key is -A3

disengaged
4 - 5 Axle Right
1 Axle Right

-Y03 -Y04 -Y05

1 Axle Left

-A2 -A1 -A4 br bl br bl br bl br bl

and removed from switch.
2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left

-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

The Front Struts are High
the Lower Proximity Switches are tripped
(A2 & A1)

A2 B4
Lower Upper
Proximity Switches Proximity Switches
Tripped Tripped

A1 B3
The Rear Struts are Low
the Upper Proximity Switches are tripped
(B3 & B4)

Which LED’s are Illuminated?

A4 & A5 LED’s On
E2 LED On
These two LED’s indicate that the
A8 LED On E4LED’s
LED On
control module isE1sending outputs E5 & E7 On
The E2 LED E5indicates
LED On that the
to open the solenoids
E2 at rear of
A8carrier.
the comes on to E3shift the
E4
A1
These E4E10
TheProximity
two LEDInput
LED’s
E7
LED On
Switch
indicatesOn that
indicates
LED the
that
8Y1 valve. This valve is on
The the
E5 Front
LED Left Strut
indicates is
that tripped
the
E5 theA2
shifted to raiseE6the rear of low. B3
E10
Proximity
rear
(lower X1
switch).
Proximity
Auto-Level Switch
Input
X2
Switchis
of the carrier
LED
E7
on the
E7Front
TheThe control Left Strut
module
LED indicates is
will
that tripped
the
the carrier E8
on
comesthe
(lower
address Rear
on
thisonceLeft
switch).
A1issue
B4 Proximity Strut
Auto-Levelis
first by
Switch tripped
(upper
Switch switch).
is depressed.
A2
S8 Switch
E9
Energizedsending
on theoutputs
Rear Rightto A4 andisA5
Strut
and A3
A8. (upper switch).
E10 tripped
E11 This signalsA4 the Suspension
The Board Power LED is A5
E12 Control Module to begin Auto-
on once the E13S8 is energized A6
E14 Leveling
A7
E15
E16 A8

Suspension Control Module

.A9 -F5 1

S1 The A8,K26 A4 The

andS8 A5Auto-Level
LED Switch
B4, B3
K 30 and A2, A1 Proximity Allison Trans
K26
K26 provide
Output Signals K40 K41 the needed
provide
K42 K43 inputs
Inhibit Groundto
Signal
Switches
signals to power thethe
control
8Y1, module.
Auto send input signals to the
Level -Y05 and -Y06 Solenoids Up/Down
0 1 0 1 0 1 control module 0 1 S7 0 1 0 1

S8 S3 S2 S4 S5 S6 0 1 Level
Front Right Rear Left
H1 H2 H3
All Raise/
K30
K30 Lower

Electronik Suspension Control Unit

K41 K40 K42 K43

-B2 br bl -B1 br bl -B4 br bl -B3 br bl

sw sw sw sw
Front Front Rear Rear -Y01 -Y02 -Y06
-Y06
Right Left Right Left

4 - 5 Axle Right
1 Axle Right
-Y03 -Y04 -Y05
-Y05

1 Axle Left
-A2 br bl -A1 br bl -A4 br bl -A3 br bl

2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left
-8Y1
-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

Which LED’s are Illuminated?

A4 & A5 LED’s go Out
A8 LEDE1goes Out
This indicatesE2that the rear
E3
carriers solenoids
This indicates turned off.
E4that the 8Y1
E5
solenoid turned
E6
off. X1 X2
E7
E8 A1
A2
A2 & A3 LED’s come On
E9 Once the
A3 Rear Carrier
E10
has been
A4 raised to
This indicates thatE11
the front
E12 HighwayA5 Ride Height
carrier’s solenoidsE13
come on A6 LED’s go out
E2 and E4
and are allowed to drain off
E14
A7
E15
Thereby lowering the E16front. A8

Suspension Control Module

.A9 -F5 1

S1 K26
K 30
K40 K41 K42 K43
Allison Trans
K26
K26
-Y01,-Y02,-Y03 and -Y04 Inhibit Ground Signal

Auto
Solenoids
Level Up/Down
0 1 0 1 0 1 0 1 0 1 0 1 S7
S8
These S3
Solenoids
S2
will remain
S4
on S5
until the S6 0 1 Level

front suspension cylinders haveLeft

Front Right Rear
lowered H1 H2 H3
All Raise/
to ride
K30 height.
K30 Lower

Electronik Suspension Control Unit

K41 K40 K42 K43

-B2 br bl -B1 br bl -B4 br bl -B3 br bl

sw sw sw sw -Y01 -Y02
Front Front Rear Rear -Y01 -Y02 -Y06
Right Left Right Left

4 - 5 Axle Right
1 Axle Right
-Y03
-Y03 -Y04
-Y04 -Y05

1 Axle Left
-A2 br bl -A1 br bl -A4 br bl -A3 br bl

2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left
-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

.A9 -F5 1

S1 K26
A2 & A1 Allison Trans
K 30
K26
K26 K40 K41 K43 K42
Proximity Switches
Inhibit Ground Signal

Auto
Level Up/Down
0 1 0 1 0 1
A2 and A1 Proximity SwitchS7lines have
0 1 0 1 0 1

S8 S3 S2 now beenS5restoredS6to no signal

S4 Level 0 1
Front Right Rear Left
indicating the Front CarrierH1is atH2Highway
H3
All Raise/
K30
K30 Ride Height. Lower

Electronik Suspension Control Unit

K41 K40 K42 K43

-B2 br bl -B1 br bl -B4 br bl -B3 br bl

sw sw sw sw -Y01 -Y02
Front Front Rear Rear -Y01 -Y02 -Y06
Right Left Right Left
4 - 5 Axle Right
1 Axle Right

-Y03
-Y03 -Y04
-Y04 -Y05
1 Axle Left

-A2 br bl -A1 br bl -A4 br bl -A3 br bl

2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left

-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

.A9 -F5 1

S1 K26
K 30
K40 K41 K42 K43
Allison Trans
K26
K26
Inhibit Ground Signal

Auto
Level Up/Down
0 1 0 1 0 1 0 1 0 1 0 1 S7
S8 S3 S2 S4 S5 S6 0 1 Level
Front Right Rear Left
H1 H2 H3
All Raise/
K30
K30 Lower

Electronik Suspension Control Unit

Highway Ride Height
K41 K40 K42 K43
-B2 br bl -B1 br bl -B4 br bl -B3 br bl

Once all proximity switches have

sw sw sw sw
Front
Right returned
Front
Left to normal
Rear
Right Leftand the unit is at
Rear -Y01 -Y02 -Y06

highway ride height the H3 Yellow Lamp

4 - 5 Axle Right
1 Axle Right
-Y03 -Y04 -Y05

1 Axle Left
-A2 -A1 -A4 -A3
br bl br bl br bl br bl
goes out.

2 - 3 Axle Right
2 - 3 Axle Left

4 - 5 Axle Left
-8Y1
sw sw sw sw
Front Front Rear Rear
Right Left Right Left

Carrier Suspension Circuit Schem. 3008087 Pg.4

GMK II
Superstructure
Hydraulic

TRAINING INSTITUTE

GMK 5160 S/S Hydraulics

M M
M

Monoblock Swing Counter Weight

Control Removal System

Swing Brake Release

Piston Motors

Tank

Gear Motors
To P1 & P2
P4

To Rexroth
Mono-Blk.
P3.2 40 Bar

P3.1

To Swing
Directional Valve

GMK 5160 Gear Pumps

Mono-Blk. Mono-Blk.
Drain 5 Bar 5 Bar Drain

Drain Line

3 Bar OS55

Optional
Coolers

To Pumps

GMK 5160 Hydraulic Tank

TRAINING INSTITUTE

A8VO...Superstructure Pump Assembly

GMK A8VO Pump (5160)

Y1 A1 A2 Y1

R2 X 1Y7 11Y7 X R1

P1 P2

23S1 23S1

3 bar 3 bar
GMK A8VO Pump (5160)

Y1 A1 A2 Y1

R2 X 1Y7 11Y7 X R1
200-600 mA

P1 P2

23S1 23S3
OK11
OK12

3 bar 3 bar

Rexroth
Monoblock
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
TRAINING INSTITUTE

Rexroth Mono Block

Pump P4
40 Bar Pilot Pressure
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P1 Ramping Up
Main Hoist Only
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only

Pump P2 Ramping Up
Tele or Lift Only
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P1 & P2 Ramping Up
Main Hoist and Tele or Lift
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only

Pump P1 Ramping Up
Main Hoist
40 Bar

23Y12 P4
P4
23Y11

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P2 Ramping Up
Telescope
40 Bar

23Y11 23Y12 P4
P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only

Pump P2 Ramping Up Direct

Lift Up (only) to
40 Bar Tank

23Y11 23Y12 P4
P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
M
Auxilary Hoist

Pump P1 Ramping Up
Aux Hoist
40 Bar

23Y11 23Y12 P4
P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only

GMK 5160 Lift Circuit

Raising Boom
1 2 3 4 5 6 7 8 9 10

6Y11

3 Bar
PVR 3
23S4 Board

40
Bar
5 Bar

Lift
Rexroth P4
Joystick
TANK Mono-Blk. 300
Bar
0 - 4.25
Volts

1 2 3 4 5 6 7 8 9 10

P2
P2
PVR 2
6Y2 Lift Large Board
Current
GMK 5160 Lift Circuit
Lowering Boom
1 2 3 4 5 6 7 8 9 10

6Y11
Large
Current

3 Bar
PVR 3
23S4 Board
0 - 4.25
40 Volts
Bar
5 Bar

Lift
Rexroth P4
Joystick
TANK Mono-Blk. 300
Bar

1 2 3 4 5 6 7 8 9 10

P2
PVR 2
6Y2 Lift Board

Main Hoist Hoist Brake

Circuit

12Y3 12Y5
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar
Large
Current P4
Rexroth
Mono-Block

Hoist Down
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

12Y3 12Y5
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar
Large
Current P4
Rexroth
Mono-Block

Hoist Up
1Y12 1Y11

T1 Tele Section
Pin Locking
System
Section T1 Pins Locked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I
Pins Locked Indicator
T1Lamp
The control panel has a T1Boom
Boom
I 60 bar Section Pinned indicator lamp.
Section
When illuminated the operator
confirms the boom section is pinned.
φ2 φ0.6
P2
Pins Locked
Mechanical Spring Closed
When the pins are in a locked
Base Section
position they trip When hydraulic pressure
proximity is released
the pinswill
switches. These switches are not
mechanically engaged.
They will only trip the proimity
trip if the pins are transitioning or
not in position. switch when fully engaged or locked.
P4

Section T1 Transitioning
Circuit is regulated to 60 bar
The pinning circuit is protected by a
Unpinned

Unpinned
Pinned

Pinned
60 bar relief. This insures smooth,
controlled release of the pins.
5Y10
I

T1
Boom
II 60 bar
Section
Pins Moving; Lamp Flashing
The control panel has a T1 Boom
f2 f0.6
P2 Section Unlocked indicator lamp.
When flashing the operator confirms
Both Proximity Switches Off
the pins are moving.
Baseand
The pins are transitioning Section
not in
a safe condition. Once they have
acknowledged fully unlocked the
boom will be free to move.
P4
Section T1 Pins Unlocked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
III 60 bar
Section
Pins Unlocked; Lamp On

The control panel has a T1 Boom

f2 f0.6
P2 Section Unlocked indicator lamp.
When on solid the operator confirms
Unpinned the Proximity Switches
pins have moved and areOn
completely unlocked. Base
to Section
The boom is
The pins are unlocked and are ready
now ready to move.
allow the boom to move.

Staged Monton
Telescope Cylinder
System
5Y13
5Y11
Cylinder #1
Holding
Hydraulic Directional Valves
Valve
5Y12
This cylinder
These valves directly hold theis a two stage
Cylinder #2 cylinder
cylinder oil while extended.that Both
acts similar
are to the
This valve is the directional control valveGrove “Trombone”
domestic
pilot operated and shifted when a
mounted on the Mono-Block which controls
This cylindercylinder is to
is a single beCylinder.
stageretracted.
direction of the telescope circuit. Pump P2 is
cylinder that entends section T3
shown here which is the primary pump.
It also has High
transfer tube that
speed can be engaged by pressing the floorcylinder #1 to
Section T4 is cable extended
switch which adds
Shuttle
sychronized Valve GMK5160
runs through
pump P1 . feed cylinder #2
to the T3 section
Logic Valve
Allows the highest pressure
LogictoCartridge
the Valve
Logic Control
back side of the cartridge valve andValves
This logic or poppet valve directs
permits smooth#2opening
oil to cylinder This logicandorclosing.
poppet cartridge valve
Thesewhich controls
section T3 &cylinder
valves
T4. directs
This opens Staged
directly hold the
oil toor
the different stages of
oil while extended. Both are
closes based on cylinder
oil control#1 on
which controls boom
pilot operated
topside of cylinder. Monton Cylinder
and shifted when a
sections T1 & T2. This valve opens or
cylinder is to be retracted.
closes the different passages based on
P2 System
oil from the 3 solenoid control valves.

5Y13
5Y11

5Y12

Section T1
T1
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y11

T2
Section T2
Extending
Power 5Y32
Cylinder #1
P2

5Y13
5Y11
T3
& 5Y12
T4

Power 5Y12 & 5Y13

Section T3 & T4
Extending
Power 5Y32
Cylinder #2
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T1
T1
Retracting
Power 5Y42 Cylinder #1
P2

5Y13
5Y11

5Y12

T2 Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

T3 5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2

GMK 5160 Operating Principle

R
P of Telescoping System When section 2 is in the fully
extended position it is then
5Y11 pinned / bolted.
A

Section 1
A
Section 2
5Y10
B

5Y12 Extend
A Retract
B Solenoid Control Table
5Y11 5Y12 5Y13
Cyl 1 section 2 ext 0 0 0
R Cyl 1 section 1 ext X 0 0
P
Cyl 2 section 3/4 ext 0 0 X
CYLINDER 1 Cyl 1 section 2 ret 0 X 0
5Y13 Cyl 1 section 1 ret 0 0 X
A
Cyl 2 section 3/4 ret 0 X 0

0 = Solenoid de-energized
X = Solenoid energized

CYLINDER 2
Swing System

GMK 5160 Swing SystemSwing Control Valve

This assembly/enclosure controls
the hydraulic oil flow to the swing circuit.
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
Single Swing Dual
Swing Gear
Brake
40Motor
Bar Pumps
Pedal
Pilot Pressure
Joy
TheseStick Control
gear pumps P3.1 andisP3.2
Older RVR
Generation
This
Thebrake
Amp GMK’s
Board
40 have
barcontrol
pilot is primarily
pressure created Swing
are
single largeused
by driven
capacity
as
gear a through
swing
holding
pump P4.the same
motors.
brake. It shaft.
is Joystick
The Joy Stick Control sends signal
This board to Two
controls pumps arecontrolled.
theboard.
proportionallyMin, provided to create
Max
directly the RVR The
New
and275
Ramping the
Generation needed
GMK’s
Functions volume.
have
RVR theofswing
In this diagram
then controls the P4 is not shown
smaller multiple motor
Swing delayssystems
P3.2 Bar circuit. Time
components .
prevents back checking and shock
4Y4
loading.

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
4Y10Solenoid
4Y1 SolenoidValve
Valve

This
This valve permits control
release of
of the
the Swing
swing brake control
and is electrically is
valve and Joystick

4S1 Brake Release

electrically
activated Indicator
activated
with with 4Y1 valve.
4Y10 valve.
220
P3.2 Bar Switch is activated when the
The 4S1
hydraulic line sees a 1 bar4Y4
signal. The
yellow indicator light in the cab goes out
indicating the brake is released. When no
P3.1 pressure is present, the light is on.
1.4mm RVR
4Y10

40 Bar

GMK
System
5160
Pumps
SwingFlowing
System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
Releasing the Brake
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar

Swing Left
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
0- 750 ma
Current

Swing
Joystick

6.3 - .75 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
Swing Left
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
0- 750 ma
Current

Swing
Joystick

6.3 - .75 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar

Swing Right
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

6.3 - 12.6 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar 0- 750 ma
Current
Swing Right
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

6.3 - 12.6 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar 0- 750 ma
Current

Applying the Brake

40 Bar
Foot 4S1
4Y1
Pilot
Pressure 1Bar
Press.

4Y3

Swing
Joystick

6.3 - 12.6 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar 0- 750 ma
Current
GMK II
Superstructure
Electric

TRAINING INSTITUTE

+BE660 +BE600.R
V2 V34
V3
+BE620

V13
V14
+BE600.M

+BE630 +BE600.L
VB6 VB5 VB1
.A7
.S1 .S2 GMK 5160
.KR .A5
.A3 .A2 Superstructure
-A100 .K
.A4 .A1 .KL .A4 Grid Locator Map
.A6
GMK S/S Electrical
Relay Prefix Guide
Prefix 0 = Pump Control 0K9
Prefix 1 = Main Hoist 1K2
Prefix 2 = Aux. Hoist 2K4
Prefix 3 = Tele/Lift 3K1
Prefix 4 = Swing 4K5

Main Pump Distribution

Guide - GMK 5160
P1 = Main Hoist & Aux. Hoist
P2 = Tele, Lift & Counterweight
Auxiliary Hoist in Two Hook
P3 = Swing Supply (Gear Pump)
P4 = 40 Bar Pilot Pressure
2K5 A1
21
14
2K5 2K5
18 4.18
13 22
A2

44
19 13 14 2K5
3.3 21 22 4.18
43
--
33 34
43 44
2.6

Locating the Remote

Relay Contacts

Individual
Latching Circuits
Logic GMK 5160
Schematic # 3008088
Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Pump Flowing

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 44 0K9
1K5 1K5
Board #2 5
34
4
34
5 2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Release Joystick

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 44 0K9
1K5 1K5
Board #2 5
34
4
34
5 2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

After One Second

Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 44 0K9
1K5 1K5
Board #2 5
34
4
34
5 2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

1K2 Lets Go
Main Hoist
+24v Schem. 3008088 Pg.3
Joystick
F3.1
10 K 10 K
F3.1

8S1 21

Hoist 1K1 22
9
Lower 24

Limit 1K4 23 13 83 15
5 1K20
1K4 14
0K9 84 8 18
5 2.2
13 1 Sec
1K2 Relay 4 33 33 43 71 43 A1
14
4
1K4 1K2 1K4 0K9 1K5 1K5
Board #2 5
34
4
34
5
44
2.2
72
2
44

A2
A1 A1
+24v 1K4 1K2 9 13 14
B1 A1 2.17 21 22
1Y12 1Y1 A2 A2 2.13 31 32
1K20 4 43 44

Directional 1 Sec. A2 5 13 14 10 13 14
- 53 54
6 9 3 61 62
Control & Brake 15 18 5
23
33
24
34 5
21
33
22
34 - 73 74
Release Solenoids 2 5 43 44 - 43 44 - 83 84

Main Hoist Lower Circuit

GMK 5160
Main Hoist Raise
Circuit Logic
F3.3
+24v Schem.
F3.1
3008088 Pg. 3
24
EKS
13
1K3 23 Relay 10 K 10 K

8 K11 14
1.3
F3.1
21

Relay
Relay 33 1K2 22
Main Hoist Joystick
4
Board
Board #2
#2
13 53
15
13
1K3 14
0K9 54 1K20
8 2.2 18
1K1 8
14
9 14 61 44 34 1 Sec
34
A1
1K5 13
0K9 62 1K3 43 1K1 33 1K3 33
2 2.2 8 9 8 1K5
+24v
A1 A1 B1 A1 A2
1K1 1K3 1K20 9
1Y11 1Y2 13 14
2.17 21 22
A2 A2 1 Sec. A2
31 32
Directional 2.13
43 44
15 18 4
Control & Brake 10 13 14 9 13 14 2 - 53 54
4 21 22 7 23 24
Release Solenoids 8 33 34 8 33 34 3 61 62
43 44 43 44 - 73 74
- 8 83 84
-