Section 7

GMK II Superstructure Hydraulic TRAINING INSTITUTE

GMK 5160 S/S Hydraulics M

M

M

Swing Control

Monoblock

Swing Brake Release Piston Motors

Tank

Gear Motors

Counter Weight Removal System

To P1 & P2

P4 To Rexroth Mono-Blk. 40 Bar

P3.2

P3.1 To Swing Directional Valve

GMK 5160 Gear Pumps

Mono-Blk. Drain

5 Bar

5 Bar

Mono-Blk. 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 R2 X

A1

A2

Y1

11Y7 X R1

1Y7

P1

P2

S

23S1

23S1

3 bar

3 bar

GMK A8VO Pump (5160)

Y1 R2 X

A1

A2

Y1

11Y7 X R1

1Y7 200-600 mA

P1

P2

S

23S1

23S3 OK11 OK12

3 bar

3 bar

Rexroth Monoblock 40 Bar

23Y11

Aux. Hoist

Main Hoist

P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

TRAINING INSTITUTE

Rexroth Mono Block

Pump P4 40 Bar Pilot Pressure 40 Bar

23Y11

Aux. Hoist

Main Hoist

P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

Pump P1 Ramping Up Main Hoist Only 40 Bar

23Y11

Aux. Hoist

Main Hoist

P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

Pump P2 Ramping Up Tele or Lift Only 40 Bar

23Y11

Aux. Hoist

Main Hoist

P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

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

23Y11

Aux. Hoist

Main Hoist

P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

M

Pump P1 Ramping Up Main Hoist 40 Bar

23Y11

Aux. Hoist

Main Hoist

P4 P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

Pump P2 Ramping Up Telescope

23Y11

Aux. Hoist

Main Hoist

40 Bar

P4 P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

Pump P2 Ramping Up Lift Up (only)

23Y11

Aux. Hoist

Main Hoist

Direct to Tank

40 Bar

P4 P4

23Y12

Lift

Telescope

P1

P2 Concept Drawing Only

M Auxilary Hoist

Pump P1 Ramping Up Aux Hoist

P4 P4

23Y12

23Y11

Aux. Hoist

Main Hoist

40 Bar

Lift

Telescope

P1

P2 Concept Drawing Only

GMK 5160 Lift Circuit Raising Boom 1

2

3

4

5

6

7

8

9

10

6Y11

PVR 3 Board

3 Bar 23S4

40 Bar 5 Bar

TANK

Rexroth Mono-Blk.

P4

Lift Joystick

300 Bar 0 - 4.25 Volts 1

P2 P2

6Y2

Lift

Large Current

2

3

4

5

6

7

8

9

10

PVR 2 Board

GMK 5160 Lift Circuit Lowering Boom 1

6Y11

2

3

4

5

6

7

8

9

10

Large Current

PVR 3 Board

3 Bar 23S4 0 - 4.25 Volts

40 Bar 5 Bar

Rexroth Mono-Blk.

TANK

P4

Lift Joystick

300 Bar

1

2

3

4

P2

6Y2

6

7

8

9

10

PVR 2 Board

Lift

Main Hoist Circuit

5

Hoist Brake

12Y3

12Y5

Main Hoist Joystick 0 - 4.25 Volts 11

22 33 44 55

66

77 88 99 10 10

Micro Switch

40 Bar

320 Bar

TANK

Large Current

P4 Rexroth Mono-Block

P1

Hoist Down 1Y12

1Y11

Main Hoist Circuit

Hoist Brake

12Y3

12Y5

Main Hoist Joystick 0 - 4.25 Volts 11

22 33 44 55

66

77 88 99 10 10

Micro Switch

40 Bar

320 Bar

TANK

Large Current

P4 Rexroth Mono-Block

P1

Hoist Up 1Y12

1Y11

T1 Tele Section Pin Locking System

Pinned

Unpinned

Pinned

Unpinned

Pinned

Unpinned

Section T1 Pins Locked 5Y10 I

Pins Locked Indicator T1Lamp I

φ2

P2

The control panel has a T1Boom Boom Section Pinned indicator lamp. Section When illuminated the operator confirms the boom section is pinned.

60 bar

φ0.6

Pins Locked Mechanical Spring Closed When the pins are in a locked Base Section hydraulic pressure is released position they trip When proximity the pinswill are not mechanically engaged. switches. These switches 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 Pinned

Unpinned

The pinning circuit is protected by a 60 bar relief. This insures smooth, controlled release of the pins. 5Y10 I

II

P2

T1 Boom Section Pins Moving; Lamp Flashing

60 bar

f2

f0.6

The control panel has a T1 Boom Section Unlocked indicator lamp. When flashing the operator confirms Both Proximity Switches Off the pins are moving.

Baseand Section The pins are transitioning not in a safe condition. Once they have acknowledged fully unlocked the boom will be free to move. P4

5Y10 I

III

P2

T1 Boom Section Pins Unlocked; Lamp On

60 bar

f2

The control panel has a T1 Boom Section Unlocked indicator lamp. When on solid the operator confirms Unpinned Switches the Proximity pins have moved and areOn completely unlocked. Base The boom is The pins are unlocked and are ready to Section now ready to move. allow the boom to move. f0.6

P4

Staged Monton Telescope Cylinder System

Unpinned

Pinned

Pinned

Unpinned

Section T1 Pins Unlocked

5Y13 5Y11

Cylinder #1 Holding Valves Hydraulic Directional Valve

5Y12 This cylinder These valves directly hold theis a two stage cylinder that Both acts similar to the Cylinder #2 cylinder oil while extended. are This valve is the directional control valveGrove “Trombone” domestic pilot operated and shifted when a mounted on the Mono-Block which controls is to beCylinder. retracted. This cylindercylinder is a single stage 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 runs through Section T4 is cable extended switch which adds pump P1 . feed cylinder #2 Shuttle Valve sychronized to the T3 section

GMK5160

Logic Valve Allows the highest pressure the LogictoCartridge Valve back side of the cartridge valve andValves Logic Control This logic or poppet valve directs

permits smooth#2opening and This logic orclosing. poppet cartridge valve oil to cylinder controls Thesewhich valves directly hold the oil toor the different stages of section T3 &cylinder T4. directs This opens oil while extended. Both are #1 on which controls boom closes based on cylinder oil control pilot operated and shifted when a sections T1 & T2. This valve opens or topside of cylinder. cylinder is to be retracted. closes the different passages based on oil from the 3 solenoid control valves.

Staged Monton Cylinder System

P2

5Y13 5Y11

5Y12

T1 Power 5Y32 P2

Section T1 Extending Cylinder #1

5Y13 5Y11

5Y12

Power 5Y11

T2

Section T2 Extending Cylinder #1

Power 5Y32 P2

5Y13 5Y11

T3 & T4

5Y12

Power 5Y12 & 5Y13

Power 5Y32 P2

Section T3 & T4 Extending Cylinder #2

5Y13

5Y11

5Y12

Power 5Y12

T1 Power 5Y42

Section T1 Retracting Cylinder #1

P2

5Y13 5Y11

5Y12

T2

Power 5Y42 P2

Power 5Y13

Section T2 Retracting Cylinder #1

5Y13 5Y11

T3

5Y12

Power 5Y12

Section T3 Retracting Cylinder #2

Power 5Y42 P2

R 5Y11

P

GMK 5160 Operating Principle of Telescoping System

A A

When section 2 is in the fully extended position it is then pinned / bolted.

Section 1 Section 2

5Y10

B

Extend Retract

5Y12 A B

R

P

CYLINDER 1 5Y13

A

Solenoid Control Table 5Y11 5Y12 5Y13 0 0 0 X 0 0 0 0 X 0 X 0 0 0 X 0 X 0

Cyl 1 section 2 ext Cyl 1 section 1 ext Cyl 2 section 3/4 ext Cyl 1 section 2 ret Cyl 1 section 1 ret Cyl 2 section 3/4 ret

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 Pilot Press.

4S1 1Bar

4Y1

4Y3

P3.2

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

Swing Joystick

P3.1 4Y10 4Y10

40 Bar

1.4mm

RVR

GMK 5160 Swing System 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3

4Y10Solenoid SolenoidValve Valve 4Y1 This This valve permits control release of of the the swing brake control valve and and is electrically is 4S1 Brake Release Indicator electrically activated with 4Y1 valve. activated with 4Y10 valve.

Swing Joystick

220 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 pressure is present, the light is on.

P3.2

P3.1

RVR

1.4mm

4Y10

40 Bar

GMK System 5160 Pumps SwingFlowing System 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3

Swing Joystick

P3.2

220 Bar 4Y4

P3.1 4Y10

40 Bar

1.4mm

RVR

Releasing the Brake 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3

Swing Joystick

220 Bar

P3.2

4Y4

P3.1 RVR

1.4mm

4Y10

40 Bar

Swing Left 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3 0- 750 ma Current

Swing Joystick 6.3 - .75

P3.2

Volts

220 Bar 4Y4

P3.1 4Y10

40 Bar

1.4mm

RVR

Swing Left 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3 0- 750 ma Current

Swing Joystick 6.3 - .75

Volts

220 Bar

P3.2

4Y4

P3.1 RVR

1.4mm

4Y10

40 Bar

Swing Right 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3

Swing Joystick 6.3 - 12.6

P3.2

Volts

220 Bar 4Y4

P3.1 4Y10

40 Bar

RVR

1.4mm

0- 750 ma Current

Swing Right 40 Bar Pilot Press.

4S1 1Bar

4Y1

4Y3

Swing Joystick 6.3 - 12.6

Volts

220 Bar

P3.2

4Y4

P3.1 RVR

1.4mm

4Y10

40 Bar

0- 750 ma Current

Applying the Brake 40 Bar Foot Pilot Pressure Press.

4S1 1Bar

4Y1

4Y3

Swing Joystick 6.3 - 12.6

P3.2

Volts

220 Bar 4Y4

P3.1 4Y10

40 Bar

RVR

1.4mm

0- 750 ma Current