Section 7

7/15/2019 Section 7

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G GG GM MM MK KK K I II II II I G GG GM MM MK KK K I II II II I S SS Su uu up pp pe ee er rr rs ss st tt tr rr ru uu uc cc ct tt tu uu ur rr re ee e S SS Su uu up pp pe ee er rr rs ss st tt tr rr ru uu uc cc ct tt tu uu ur rr re ee e

T R A I N I N G I N S T I T U T E

GMK 5160 S/S Hydraulics

Monoblock

M

Swing

Control

M

Counter Weight

Removal System

Swing Brake Release

Tank

M

Piston Motors

Gear Motors

7/15/2019 Section 7


GMK 5160 Gear Pumps

P4

P3.2

P3.1

To Swing

Directional Valve

To Rexroth

Mono-Blk.40 Bar

To P1 & P2

GMK 5160 Hydraulic Tank

5 Bar 5 Bar

3 Bar

Optional

Coolers

To Pumps

OS55

Mono-Blk.

Drain

Mono-Blk.

Drain

Drain L ine

7/15/2019 Section 7


A8VO...Superstructure Pump Assembly

T R A I N I N G I N S T I T U T E

23S1

3 bar

1Y7 11Y7

Y1 A1 A2 Y1

P1 P2

XR2XR1

23S1

3 bar

S

GMK A8VO Pump (5160)

7/15/2019 Section 7


23S1

3 bar

1Y7 11Y7

Y1 A1 A2 Y1

P1 P2

XR2 XR1

23S3

3 bar

S

OK11

OK12

200-600 mA

GMK A8VO Pump (5160)

P1

23Y11 23Y12

Concept Drawing Only

Main Hoist Aux. Hoist Telescope Lift

P2

40 Bar

P4

RexrothMonoblock

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Rexroth Mono BlockT R A I N I N G I N S T I T U T E

P1

23Y11 23Y12


Main Hoist Aux. Hoist Telescope Lift

P2

40 Bar

P4P4

Pump P440 Bar Pilot Pressure

P4

7/15/2019 Section 7


P1

23Y11 23Y12


Main Hoist Aux . Hoist Telescope Lift

P2

40 Bar

P4

P1

Pump P1 Ramping Up

Main Hoist Only

P1

P1

23Y11 23Y12



P2

40 Bar

P4

P1

Pump P2 Ramping UpTele or Lift Only

P2

7/15/2019 Section 7


P1

23Y11 23Y12



P2

40 Bar

P4

P1P1 P2

Pump P1 & P2 Ramping Up

Main Hoist and Tele or Li ft

P1 P2

P1

23Y11 23Y12



P2

40 Bar

P4

P1

P4P4

P1

M

Pump P1 Ramping Up

Main Hoist

M

7/15/2019 Section 7


P1

23Y11 23Y12



P2

40 Bar

P4

P1

P4P4

P2

Pump P2 Ramping Up

Telescope

P1

23Y11 23Y12



P2

40 Bar

P4

P1 P2

Pump P2 Ramping Up

Lift Up (only)

P4P4

P2

Direct

to

Tank

7/15/2019 Section 7


P1

23Y11 23Y12



P2

40 Bar

P4

P1

P4P4

P1

Pump P1 Ramping Up

Aux Hoist

Auxilary Hoist

M

1 2 3 4 5 6 7 8 9 10

Lift

GMK 5160 Lif t Circuit

300

Bar

6Y2

40Bar

Rexroth

Mono-Blk.

3 Bar

23S4

TANK

6Y11

PVR 2

Board

P2

Raising Boom

P4P4

1 2 3 4 5 6 7 8 9 10

0 - 4.25

Volts

Lift

Joystick

1 2 3 4 5 6 7 8 9 10

Large

Current

PVR 3Board

P2

5 Bar

7/15/2019 Section 7


Lift

Joystick

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

Lift

GMK 5160 Lif t Circuit

300

Bar

6Y2

40

Bar

Rexroth

Mono-Blk.TANK

3 Bar

23S4

6Y11

PVR 2Board

P2

Lowering Boom

P4P4

1 2 3 4 5 6 7 8 9 10

0 - 4.25

Volts

Large

Current

PVR 3Board

5 Bar

MicroSwitch

Main HoistCircuit

320Bar

Hoist Brake

12Y3 12Y5

TANK

P4

40Bar

Rexroth

Mono-Block

1Y12 1Y11

1 2 3 4 5 6 7 8 9 10

Main

Hoist

Joystick

Hoist Down

MicroSwitch

0 - 4.25

Volts

1 2 3 4 5 6 7 8 9 1 0

Large

Current

P1

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Micro

Switch

Main Hoist

Circuit

320

Bar

Hoist Brake

12Y3 12Y5

TANK

P4

40Bar

Rexroth

Mono-Block

1Y12 1Y11

1 2 3 4 5 6 7 8 9 10

MainHoist

Joystick

Hoist Up

Micro

Switch

0 - 4.25Volts

1 2 3 4 5 6 7 8 9 1 0

Large

Current

P1

T1 Tele Section

Pin Locking

System

7/15/2019 Section 7


I

Base Section

T1

Boom

Section

U n p i n n e d

Section T1 Pins Locked

P2

P4

φφφφ0.6φφφφ2

5Y10

60 bar

P i n n e d

U n p i n n e d

P i n n e d

Mechanical Spring Closed

When hydraulic pressure is released

the pins are mechanically engaged.

They will only trip the proimityswitch when fully engaged or locked.

Pins Locked

When the pins are in a locked

position they trip proximity

switches. These switches will not

trip if the pins are transitioning or

not in position.

II

Pins Locked Indicator Lamp

The control panel has a T1 Boom

Section Pinned indicator lamp.

When illuminated the operator

confirms the boom section is pinned.

I

I

Base Section

T1

Boom

Section

U n p i n n e d

Section T1 Transitioning

P2

P4

f0.6f2

5Y10

60 bar

P i n n e d

U n p i n n e d

P i n n e d

P2

Base Section

T1

Boom

Section

P i n n e d

P i n n e d

I

IIIIIIII

Pins Moving; Lamp Flashing


Section Unlocked indicator lamp.

When flashing the operator confirms

the pins are moving.Both Proximity Switches Off

The pins are transitioning and not in

a safe condi tion. Once they have

acknowledged fully un locked the

boom wi ll be free to move.

Circuit is regulated to 60 bar

The pinning circuit is protected by a

60 bar relief. This insures smooth,

contro lled release of the pins.

7/15/2019 Section 7


I

P i n n e d

P i n n e d

Base Section

T1

Boom

Section

Section T1 Pins Unlocked

IIIIII

Base Section

T1

Boom

Section

U n p i n n e d

P2

P4

f0.6f2

5Y10

60 bar

U n p i n n e d

P2

U n p i n n e d

U n p i n n e d

I

I

Pins Unlocked; Lamp On


Section Unlocked indicator lamp.

When on solid the operator conf irms

the pins have moved and are

completely unlocked. The boom is

now ready to move.

Unpinned Proximity Switches On

The pins are unlocked and are ready to

allow the boom to move.

Staged Monton

Telescope Cylinder

System

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Staged

Monton Cylinder

System

5Y13

5Y12

GMK5160

P2

5Y11

Hydraulic Directional Valve

This valve is the directional control valve

mounted on the Mono-Block which controls

direction of the telescope circuit . Pump P2 is

shown here which is the primary pump. High

speed can be engaged by pressing the floor

switch which adds pump P1 .

Cylinder #1

This cylinder is a two stage

cylinder that acts similar to the

domestic Grove “ Trombone”

Cylinder.

It also has transfer tube that

runs through cylinder #1 to

feed cylinder #2

Cylinder #2

This cylinder is a single stage

cylinder that entends section T3

Section T4 is cable extended

sychronized to the T3 section

Holding ValvesThese valves directly hold the

cylinder oil while extended. Both are

pilot operated and shifted when a

cylinder is to be retracted.

Logic Valve

This logic or poppet valve directs

oil to cylinder #2 which controls

section T3 & T4. This opens or

closes based on oil control on

topside of cylinder.

Logic Cartridge Valve

This logic or poppet cartridge valve

directs oil to the different stages of

cylinder #1 which controls boom

sections T1 & T2. This valve opens or

closes the different passages based on

oil from the 3 solenoid control valves.

Logic Control Valves

These valves directly hold the

cylinder oil while extended. Both are

pilot operated and shifted when a

cylinder is to be retracted.

Shuttle Valve

Al lows the highest pressure to the

back side of the cartridge valve and

permits smooth opening and closing.

Section T1Extending

Cylinder #1

5Y13

5Y12

P2

Power 5Y32

5Y11

P2

T1

7/15/2019 Section 7


Section T2

Extending

Cylinder #1

5Y13

5Y12

P2

Power 5Y32

5Y11

P2

Power 5Y11

T2

Section T3 & T4Extending

Cylinder #2

5Y13

5Y12

P2

Power 5Y32

5Y11

P2

Power 5Y12 & 5Y13

T3

&

T4

7/15/2019 Section 7


Section T1

Retracting

Cylinder #1

5Y13

5Y12

P2

Power 5Y42

5Y11

Power 5Y12

P2

T1

Section T2Retracting

Cylinder #1

5Y13

5Y12

P2

Power 5Y42

5Y11

Power 5Y13

P2

T2

7/15/2019 Section 7


Section T3

Retracting

Cylinder #2

5Y13

5Y12

P2

Power 5Y42

5Y11

Power 5Y12

P2

T3

GMK 5160 Operating Principle

of Telescoping System5Y11

5Y13

5Y12

A

B

A

R P

A

RP

Section 1Section 2

CYLINDER 1

A

B

When section 2 is in the fully

extended position it is thenpinned / bolted.

Extend

Retract

Solenoid Control Table

Cyl 1 section 2 ext 0 0 0

Cyl 1 section 1 ext X 0 0

Cyl 2 section 3/4 ext 0 0 X

Cyl 1 section 2 ret 0 X 0

Cyl 1 section 1 ret 0 0 X

Cyl 2 section 3/4 ret 0 X 0

0 = Solenoid d e-energized

X = Solenoid energized

5Y11 5Y12 5Y13

CYLINDER 2

5Y10

7/15/2019 Section 7


Swing System

GMK 5160 Swing System

40 Bar

Pilot

Press.

4Y1

275

Bar

4S1

1Bar

4Y3

4Y4

1.4mm4Y10

40 Bar

Swing

Joystick

P3.2

P3.1

Swing Brake Pedal

This brake contro l is primarily

used as a holding brake. It is

proportionally controlled.

4Y10

Swing Control Valve

This assembly/enclosure controls

the hydraulic oil flow to the swing circuit.

RVR

Dual Gear Pumps

These gear pumps P3.1 and P3.2

are driven through the same shaft.

Two pumps are provided to createthe needed volume.

RVR Amp Board

This board con trols the Min, Maxand Ramping Functions of the

Swing circuit. Time delays

prevents back checking and shock

loading.

40 Bar Pilot Pressure

The 40 bar pilot pressure is created

by gear pump P4.

In this diagram P4 is not shown

Single Swing Motor

Older Generation GMK’s have

single large capacity swing motors.

New Generation GMK’s have

smaller multiple motor systems

Joy Stick Control

The Joy Stick Control sends s ignal

directly to the RVR board. The

RVR then controls the swing

components .

7/15/2019 Section 7


4Y10


40 Bar

Pilot

Press.

4Y1

220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

40 Bar

Swing

Joystick

P3.2

P3.1

4Y1 Solenoid Valve

This valve permits release of the

swing brake and is electrically

activated with 4Y10 valve.4S1 Brake Release Indicator

The 4S1 Switch is activated when the

hydraulic line sees a 1 bar signal. The

yellow indicator light in the cab goes out

indicating the brake is released. When no

pressure is present, the light is on.

4Y10 Solenoid Valve

This valve permits cont rol of the

swing brake control valve and is

electrically activated with 4Y1 valve.

RVR


40 Bar

Pilot

Press.

4Y1

220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

40 Bar

P3.2

P3.1

Swing

Joystick

System Pumps Flowing

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10RVR

7/15/2019 Section 7


220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

4Y1

P3.2

P3.1

Swing

Joystick

Releasing the Brake

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10RVR

220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

4Y1

P3.2

P3.1

Swing

Joystick

Swing Left

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10

6.3 - .75 Volt s

0- 750 ma

Current

RVR

7/15/2019 Section 7


220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

4Y1

P3.2

P3.1

Swing

Joystick

Swing Left

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10

6.3 - .75 Volt s

0- 750 ma

Current

RVR

220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

4Y1

P3.2

P3.1

Swing

Joystick

Swing Right

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10

6.3 - 12.6 Volt s

0- 750 ma

Current

RVR

7/15/2019 Section 7


220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

4Y1

P3.2

P3.1

Swing

Joystick

Swing Right

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10

6.3 - 12.6 Volt s

0- 750 ma

Current

RVR

220

Bar

4S1

1Bar

4Y3

4Y4

1.4mm

4Y1

P3.2

P3.1

Swing

Joystick

Applying the Brake

P3.2

P3.1

40 Bar

Pilot

Press.

40 Bar

4Y10

6.3 - 12.6 Volt s

0- 750 ma

RVR

Foot

Pressure

Date post:	29-Oct-2015
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