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GMK 5160
Superstructure Electrical/Electronics
Note: This manual is only intended for technology appreciation. For system detail
always refer to schematic drawings and operating/repair manuals supplied with the
crane.
Should you have any comments or suggestions regarding this document please
contact:
Robin Chester: telephone +44 (0) 1609 771255 fax +44 (0) 1609 778021
Marian Kutz / Martin Wessels: telephone +49 4421 294255 fax +49 4421 294307
2
Superstructure Electrics/Electronics
To initially glance at the schematics for a hydraulic crane and see the amount of
electrical/electronic circuits, it can seem rather complicated and intimidating.
The most important aspect for Service Technicians is "To know the operating
principle" of any system.
Once you have the ability to apply the principles to the schematics troubleshooting is
much easier as you will often find the same principles keep repeating themselves.
It is a mistake often made when Technicians try to remember all the system detail and
then lose comprehension of the operating principles.
Superstructure Electrics/Electronics
Without doubt, as technology advances you will see more electric/ electronic control
systems. However, much greater diagnostic skill is required from the service
technician as the level of technical sophistication rises.
As long as you can accept the design reasons for the introduction of electric/electronic
control and, that the schematic diagrams are a vital tool to the technician. They are
the only source of appreciating system principles without doing it the hard way by
hit and miss methods
Very
expensive!
4
Superstructure Electrics/Electronics
Good diagnostic ability demands that the troubleshooter has knowledge of electro
/hydraulic integration and the system components: Where they are??? What they
do??? why they do it???
Access to information is vital for good diagnostic ability. Having made any repair,
thought should be given to both the cause and the consequence of the failure.
Superstructure Electrics/Electronics
Relays
Relay Guide
Superstructure Schematic 2304154 sheet 1 of 5
* This is an independent supply taken from the battery side of the ignition switch to
prevent, the oil cooler motor start up affecting the S.L.I.
** Only active for long fixed jib configurations 23/28/33 m with main boom angle
<75o
7
Relay guide
Superstructure schematic 2304154 sheet 2 of 5
Relay guide
Superstructure schematic 2304154 sheet 2 of 5
* Function only applicable when special 1800 over rear capacity chart is selected
9
Relay Guide
Superstructure schematic 2304154 sheet 3 of 5
Relay Guide
Relay Guide
Superstructure schematic 2304154 sheet 4 of 5
The GLR board controls the input voltage to the cabin joysticks O - 4.25v for
hoists/telescope & derricking functions. The system makes continuous comparison of
throttle position and actual RPM. Should the actual RPM for a given throttle position
deviate by more than a pre-set amount the input voltage to the joysticks would be
reduced automatically. AS this voltage is used via the PVR board to control the ramp
angle (displacement) of the main hydraulic pumps. Any reduction in voltage causes a
reduction of flow and less load on the engine. Therefore, the system is self-regulating
without any corrective measures being necessary by the crane operator.
13
GMK application
The correct adjustments to the GLR board will give 4.25 volts output from pin 7 to the
joystick potentiometers at 1200 rpm. Even under full load, this voltage (4.25) should
not reduce until the engine rpm is pulled below 1200.
Please remember; a fixed output voltage of 4.25 is also available from pin 1 of any
PVR board, this is to be used for amplifier adjustments and emergency operation
should the GLR board fail.
Note: The slewing gear system is independently controlled from the RVR board.
There is no interface to GLR
15
Theory of Operation
Hoists/telescope & derricking, primary crane functions are all controlled by joysticks
mounted within the operators cabin. Assembled within the joysticks are electrical
contacts (switches) and potentiometers. The potentiometers give an analogue output in
direct proportion to the joystick position = 0 - 4.25v.
On operation of the joystick, the first portion of travel will close the electrical switch.
This 24v signal will then be routed through several relays to select the desired
direction of movement on the main hydraulic control block.
Further movement of the joystick will then cause the potentiometer to give an output
value 0 - 4.25v. This signal is then used (via amplifiers) to control the ramp angle
(volumetric output) of the bent axis hydraulic Pumps.
PVR Amplifiers are used to control hoist/telescope and derrick functions. * See data
sheet: Proportional Amplifier PVR - RE 95022/03.89 * See superstructure schematic
2304154 sheet 3 of 5
Relay boards are interfaced between the control potentiometers and amplifiers. * See
"Relaisplatine" (German for relay board) on schematics 2304154 sheet 2 and 3 of 5.
The relay boards are used to control the direction and value of the control
potentiometer voltage command to the associated PVR amplifier.
16
Relay board function: Example - Consider the main hoist in high-speed. Should the
maximum flow of both pumps be available this would cause the hoist motor to exceed
the maximum permissible speed.
To overcome the problem relay board 2 (see schematic 3 of 5) has two micro relays
K1 and K2, energised by terminals 1 and two respectively. When the high-speed
function is selected, both micro relays are energised. This causes the supply voltage
to the joystick potentiometer to be routed through resistor R2 and R5 these each have
the same value 1.8 K. Subsequently, the maximum joystick potentiometer output is
reduced from 4.25v to approximately 3.4v. As the volumetric output of the bent axis
hydraulic pumps is dependent on a command voltage, which has been reduced by
20%, the hydraulic pumps can only attain 80 % of their maximum output. Since flow
dictates the speed, the reduced pump output keeps the hoist motor within the
maximum permissible speed.
Derrick out/Boom down: The lift cylinder hold valve is controlled via a PVR
amplifier board and a proportional solenoid valve. During operation the boom is
lowered by it's own weight and proportional control of the lift cylinder hold valve.
Note: Boom down is a gravity system. Operation of high/two-speed will not increase
the function speed.
17
KMK 5160
Superstructure Electrical/Electronic Control
Theory of Operation
Slewing Gear: The cabin joystick has the same electrical contacts (switches).
However, the potentiometer differs from others. The swing potentiometer gives an
analogue output (voltage span) of 0 - 13.2v approximately. The potentiometer wiper
output in neutral = 6.6v (approximately) to swing left = 6.6 - 13.2v, to swing right
= 6.6 - 0v (approximately).
On operation of the joystick, the first portion of travel will close the electrical switch.
This 24v signal will then be routed through several relays to give system safety.
Further movement of the joystick will cause the rising (swing left) / falling (swing
right) command value (voltage) to activate the RVR amplifier "special switching
feature" (release swing brake). The increasing / decreasing command will then result
in the control of the proportional direction solenoid valve (via the amplifier) to give
the desired swing left/right function.
Note: The swing brake must release before hydraulic pressure begins to rise.
* See data sheet: RE 95031/06.90 Proportional Amplifier RVR, this supersedes RE
95031/08.87
* See superstructure schematic sheet 2 of 5.
A relay board is interfaced between the control potentiometer and the RVR amplifier.
It has several functions:
Additional safety on Dead man operation, function inhibit for the amplifier command
value when free swing (load following) is selected, function inhibit for the amplifier
command value when the restricted slewing range is exceeded.
* See "Relaisplatine" (German for relay board) 3 on schematic 2 of 5
The output current level (0 - 1500ma) will rise in direct proportion to the command
voltage input signal (0 - 4.25v) from the joystick potentiometer after the I min or pilot
current value is attained. The I min/pilot current is the minimum current level
required for the proportional solenoid to begin movement / function = 200 ma for
5160 main hoist. This value is adjusted to suit the particular solenoid characteristic.
The I max (maximum ma output) is the current value required to move the
proportional solenoid valve to its maximum stroke / position = 600 ma for 5160 main
hoist. This value is also adjustable to suit the particular solenoid characteristic.
I Max
Solenoid current
I Min
0 4.25v
19
Using the timed ramp, a linear and symmetrical timed ramp for the rise and fall of the
output current can be set between 0.1 and 10 seconds (GMK 5160 main hoist = 0.6
seconds).
Note: time ramp values refer to maximum joystick position, once set the time ramp is
then in ratio to the position of the joystick.
Amplifier RVR:
Amplifier Function:
The amplifier is used for current regulated control of a proportional direction control
valve in the slewing hydraulic circuit. The RVR output current (0 - 750 ma) will rise
in direct proportion to the command voltage input signal from the joystick
potentiometer after the I min/pilot current value is attained. The command voltage
span is 13.2v with the electronic neutral in the centre = 6.6v. Therefore, from this
neutral reference a rising signal will cause the slew left solenoid to be energised and a
falling signal will energise the slew right solenoid
I Min I Min
0 + 6.6 + 13.2
20
Theory of Operation
Amplifier RVR:
The I min/pilot current is the minimum current level required for the proportional
direction control valve to begin movement (threshold).
The I max is the maximum current level required to move the proportional direction
control valve to it's maximum stroke/position.
The values differ on the GMK 5160 slewing gear system (I min 360 ma, I max 750
ma) as an open hydraulic circuit is used rather than a closed loop system.
Time ramp:
This integrated feature is the time setting for the current to rise or fall between I min
and I max, this subsequently allows controlled acceleration / deceleration of function
speeds.
The RVR constant time ramp system on the GMK 5160 differs from other models by
having two automatically selected time ramp settings.
Time ramp l = 5 - 6 seconds: this is active for normal operation on 360 deg' capacity
charts. Time ramp 2 = 1 - 2 seconds: this is active only for slewing gear motion cut to
prohibit exceeding the slewing range if operating on a restricted range capacity chart.
The crane then re-enters the permitted range on time ramp 1.
Using the timed ramp, a linear and symmetrical timed ramp for the rise and fall of the
output current can be set between 0.1 and 10 seconds.
21
Theory of Operation
Amplifier RVR:
Time ramp values refer to the maximum joystick position, once set the timed ramp is
then in ratio to the joystick position.
Note: this only applies when the speed pre-select (fine control) is set to the maximum
value.
The ramp time remains the same with each speed pre-selection
Example: (l)
Maximum joystick command voltage with speed pre-selection set to maximum speed
with a pre-adjusted ramp time of 5 seconds.
Example: (2)
Maximum joystick command voltage with speed pre-selection set to half speed. The
ramp time still maintains the original 5 seconds.
For example, (2) the slewing gear now accelerates at half the speed of example (1).
0
Ramp time t
22
Theory of Operation
Amplifier RVR:
Safety functions:
The amplifier is equipped with safety monitors for the joystick potentiometer.
Precondition for the safety function: The joystick potentiometer must have a
resistance value of 4 K Ohm.
With regard to PVR/RVR amplifier functions, the I min / I max current values listed
on preceding pages are only pre-adjusted (calculated) values.
The final current values are adjusted with the engine running, these may differ from
the pre-adjusted values.
Theory of Operation
The heart of the hydraulic system is an A8V107EP variable displacement bent axis
hydraulic pump. This single unit bolted directly to the engine actually contains two
pump units, P1 and P2.
P1 is assigned to the hoist system. An auxiliary drive from the main pump is used for
a pilot pressure pump P4. The pilot pressure (40 bar) is supplied to the P1 pump
integrated proportional solenoid valve (1Y7).
When the operator selects hoist raise with the cabin joystick the initial lever travel
closes an integrated micro switch. This causes a relay chain to be energised, which
then selects and subsequently energises the main hydraulic control block solenoid
(lYll).
Part of the relay chain (1K3) is used to energise terminal 3 on relay board number 2.
This activates micro relay (K3). The normally open contacts, 3 & 4 are then closed.
This establishes a voltage command route from the joystick potentiometer to the hoist
PVR amplifier. The cabin joystick potentiometer voltage command (0 - 4.25v) will
begin to rise in direct proportion to the lever travel. Assuming engine speed and load
allow the GLR board to provide maximum voltage to the potentiometer from terminal
16 on relay board number 2.
24
Theory of Operation
The hoist PVR amplifier is used for current regulated control of the proportional
solenoid valve (1Y7) which is integrated within the P1 pump body and controls the
pump delivery.
Without any control current, the hydraulic pump group will only rotate. At a pre-
adjusted threshold current (I min 200 ma approx) pump delivery will begin. Oil flow
is then routed through the direction solenoid lYll to the hoist motor; further movement
of the joystick will cause the rising input command voltage to give a corresponding
rising output current. At a pre-adjusted max output current (I max 600 ma approx) the
hydraulic pump attains its maximum flow capability. Subsequently, the hoist motor is
now at maximum single function speed.
An auxiliary hoist (option) may be fitted; this is also supplied by hydraulic pump P1
for normal operation. Two hook/twin hoist operation demands independent control, to
achieve this, additional electro/hydraulic circuits are installed to change the auxiliary
hoist to hydraulic pump P2 during two hook/twin hoist operation.
Although the electrical circuits for the auxiliary hoist seem more complex, it is just
two control systems in parallel. Study of the theory and component description of the
main hoist example should also make the other systems appreciation much easier.
25
Theory of Operation
Please see: Main hoist raise, component description and theory of operation for details
of the primary relay chain and relay board micro relay chain.
The following information is only intended to assist with main hoist appreciation. For
complete system detail, please refer to superstructure electrical schematics
Oberwagen (superstructure) 2304154 sheets 1 through 5 and hydraulic schematic
(Oberwagen) 2226803. Blatt = sheet & can be found bottom right of the schematics.
The reference numbering shown in brackets beneath the relay number will help you
find the actual relay coil on the electrical schematics.
Example: lK20 (3.8) the first digit in brackets = 3. So, first find sheet number 3 the
second digit in brackets = 8, this is a grid reference, look at the top or bottom of sheet
3 for grid number 8 and vertically scan looking for lK20. The number of contacts and
the location guide is shown directly beneath the relay coil.
Theory of operation
Function Numbers:
H/LIMIT
1K2-C/P
LMI
OK9
JOYSTICK CONTACTS
1K3
1K5
OK9 1K3 1K1 1K3
1K20 1K3
19
PCB 4
0V 24 Volts
1Y11 13
+24V
1Y11
3 10
23S1 23S1
Amplifier PVR
OK9
0V
6 7 9
NOTE: The illustration above is only intended to de monstrate the operating principle. Please see
schematic diagrams for details.
28
GMK 5160
Theory of operation
Main Hoist Raise
Component Description and Theory of Operation
Theory of operation
Main Hoist Raise
Component Description and Theory of Operation
Theory of operation
Main Hoist Raise
Component Description and Theory of Operation
Theory of operation
Main Hoist Raise
Component Description and Theory of Operation
Main Hoist Primary Relay Chain:
0K9
Note: The contacts marked with * have no application on drawing of the main hoist
circuit (Principle of Proportional Control).