GMK II

Amplifier Boards
 Amp Board Layout
Flip Down Extension

PVR 3 - 6Y11
1 2 3 4 5 6 7 8 9 10

RVR GLR
Swing Circuit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PVR 1 - P1 PVR 2 - P2
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

Swing Down Compartment under Superstructure Dashboard

PVR Board System

Proportional
Solenoid P1
Valve
Relay Relay
Board Board

1 2 3 4 5 6 7 8 9 10 Sys Ground -

24 volt vdc +

PVR 1 - P1
PVR Board System
PVR 2 - P2 Proportional
Solenoid P2
1 2 3 4 5 6 7 8 9 10
Valve

Proportional
Solenoid P1
Valve
Relay Relay
Board Board

1 2 3 4 5 6 7 8 9 10

Sys Ground -
High
Speed
Switch 24 volt vdc +
PVR 1 - P1
PVR Board System
Hydraulic
Lift Cylinder Tank
Gravity Down
Only!

Hyd
Oil Proportional
Solenoid 6Y11
Valve

Relay Relay
Board Board
1 2 3 4 5 6 7 8 9 10

Sys Ground -

24 volt vdc +
PVR 3 - 6Y11
 PVR Board
• Board Fault LEDs
(2 Yellow)

• Up Directional LED 1 2 3 4 5 6 7 8 9 10
(Green)

• Down Directional
LED (Red)
• 1.6 Amp Fuse (Board
Mounted)

• Adjustable Trim Pots

• Terminal Strips (10
poles)
RVR Board System
Proportional
Swing Brake Solenoid Left
Valve
Release
Proportional
Solenoid Right
Valve
Relay Relay
Board Board

Sys Ground -

24 volt vdc +
 RVR Board

• Main Power LED (Green)

• Board Active LED (Red)
• Board Fault LEDs (2 Red)
• Right Directional LED
(Yellow)

• Left Directional LED (Green)

• 1.6 Amp Fuse (Board Mounted)
• Adjustable Trim Pots
• Terminal Strips (16 poles)
 GLR Board
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

H1

• H1 - H4 LED’s H2
• R1 - R9 Trim Pots H3
• 16 pole Terminal
H4
Strips
• 1.6 Amp Fuse (Board
Mounted)

• Main Power LED

(Green)

• Pin #7 : 4.25 Volts

 GMK5160 System Layout
GLR Main Hoist Aux Hoist Lift & Tele Swing
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Joystick Joystick Joystick Joystick

Pin #7

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

r.p.m.
sensor
PVR 1 PVR 2 PVR 3

6Y11 RVR

Throttle Position 1Y7 11Y7

Potentiometer Pump 1 Pump 2 Swing
Directional
Valve
GMK 5160 Amplifier
Board Adjustments
PVR Board Pins
Gnd. to Joystick
Potentiometer

0v - 4.25v Input Superstr. Ground

from Joystick

+24 vdc Input

+4.25 vdc
Output

1 2 3 4 5 6 7 8 9 10
PVR Board Pins
Pump Prop.
Solenoid
1Y7

1 2 3 4 5 6 7 8 9 10

Current Output to Pump Solenoid

 PVR Board Potentiometer Adjustment
Points

P1:Time Ramp
1 2 3 4 5 6 7 8 9 10
P2:I-Max. Red

P3:I-Min. Red

P4:I-Max. Green P1 P2 P3 P4 P5
P5:I-Min. Green

Direction LED’s
 PVR Board Adjustments
Step 1: Remove wire
from pin #6

Step 2: Connect wire 1Y7

to amp meter

Step 3: Connect ground wire

from meter to pin #6
1 2 3 4 5 6 7 8 9 10

P1P2P3P4P5
 Meter is now installed
PVR Board we are now ready to begin
board adjustments 1Y7
Adjustments

1 2 3 4 5 6 7 8 9 10
Relay Board
Joystick

0 to 4.25v Output
P1P2P3P4P5
P3 I-Min.
Move joystick until the LED
just lights, then make
current adjustment
Using a small technicians
screwdriver adjust the
P3 pot. till it reads 200ma Red LED lights
(Counterclockwise=Decrease when P3 Min threshold
Clockwise=Increases is reached
 PVR Board
Adjustments 1Y7

1 2 3 4 5 6 7 8 9 10
Relay Board
Joystick

0 to 4.25v Output
P1P2P3P4P5
P2 I-Max.
Move joystick to full span,
then make current adjustment
Using a small technicians
screwdriver adjust the
P2 pot. till it reads 600ma Red LED will stay on
(Counterclockwise=Decrease during this adjustment
Clockwise=Increases
 PVR Board
Adjustments 1Y7

1 2 3 4 5 6 7 8 9 10
Relay Board
Joystick

0 to 4.25v Output
P1P2P3P4P5
P5 I-Min.
Move joystick until the LED
just lights, then make
current adjustment
Using a small technicians
screwdriver adjust the
P5 pot. till it reads 200ma Green LED lights
(Counterclockwise=Decrease when P5 Min threshold
Clockwise=Increases is reached
 PVR Board
Adjustments 1Y7

1 2 3 4 5 6 7 8 9 10
Relay Board
Joystick

0 to 4.25v Output
P1P2P3P4P5
P4 I-Max.
Move joystick to full span,
then make current adjustment
Using a small technicians
screwdriver adjust the
P4 pot. till it reads 600ma Green LED will stay on
(Counterclockwise=Decrease during this adjustment
Clockwise=Increases
 PVR Board 1Y7
Adjustments
Full 1 2 3 4 5 6 7 8 9 10
Deflection Relay Board
Joystick
Joystick

0 to 4.25v Output
P1P2P3P4P5
P1 Time Ramp
Adjust the time required
for the current to fall from Fully deflect Joystick
and release.
I-Max. to I-Min.
Observe needle sweep return on
analog meter.
Adjust P1 pot. to
.6 sec. return
** Special Note: Repeat this step as required **
PVR Board Adjustment
Values

1Y7 PVR 1 & 2

Hoists, Lift & Tele
I-Min I-Max Time Ramp LED
200mA 600mA .6 Sec. Green

1 2 3 4 5 6 7 8 9 10 200mA 600mA .6 Sec. Red

P1 = Time Ramp
P2 = I-Max. Red
P3 = I Min. Red
P4 = I-Max. Green
P1P2P3P4P5
P5 = I Min. Green
PVR Board Adjustment
Values

PVR 3
6Y11
Lift Down
I-Min I-Max Time Ramp LED
250mA 700mA .6 Sec. Green
250mA 700mA .6 Sec. Red
1 2 3 4 5 6 7 8 9 10
P1 = Time Ramp
P2 = I-Max. Red
P3 = I Min. Red
P4 = I-Max. Green
P1P2P3P4P5 P5 = I Min. Green
 Pin #16 +24vdc Supply

1 2 3 4 5 6 7 8 9 101112131415 16

R1 R2 R3 R4 R5 R6 R7 R8
Pin #15 S/S Ground

Pin #8 - 13.2 vdc output

supply to swing Joystick RVR Board Pin
Identification
Pin #7 - 13.2 to 0 vdc
input from swing joystick

Pin #6 - Ground for swing

joystick potentiometer
Swing Fine Speed Supply from
4.7 K RVR
Control
Potentiometer 3 Output Signal 2 1

Ground to
RVR
1 2 3 4 5 6 7 8 9 101112131415 16

RVR Board Pin

Identification R1 R2 R3 R4 R5 R6 R7 R8
 Pin #6 Pin #8 -13.2 vdc
Swing Joystick RVR Ground
Joystick
Supply
Potentiometer RVR Input
Signal Pin #7

1 2 3 4 5 6 7 8 9 101112131415 16

RVR Board Pin

R1 R2 R3 R4 R5 R6 R7 R8
Identification
 LEFT RIGHT
Swing Proportional 4Y3 4Y4
Directional Solenoids

Swing Right
1 2 3 4 5 6 7 8 9 101112131415 16

Pin #13 Output

RVR Board Pin

R1 R2 R3 R4 R5 R6 R7 R8

Identification
 Swing Proportional LEFT RIGHT
Directional Solenoids 4Y3 4Y4

Swing Left
1 2 3 4 5 6 7 8 9 101112131415 16

Pin #12 Output

RVR Board Pin

R1 R2 R3 R4 R5 R6 R7 R8

Identification
 RVR Board
Adjustments
1 2 3 4 5 6 7 8 9 101112131415 16

R1 I-Max. Left
R2 I-Min. Left
R3 I-Max. Right
R4 I-Min. Right
R5 DO NOT ADJUST Board Frequency
R6 Special Switching Function
R7 Ramp Time #1
R8 Ramp Time #2

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments

Install Amp meter

Joystick in-line between
wires and
Pin #14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Step 1: Remove wire from pin #14

Step 2: Connect wire to Ammeter

Step 3: Connect Ammeter to Pin #14

Important Caution!
R1 R2 R3 R4 R5 R6 R7 R8
Pin #15 is hot with 24V
(fused power)
Shorting Danger
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Swing Left
Joystick

R2 I-Min. Swing Left

1 2 3 4 5 6 7 8 9 101112131415 16
Move joystick slightly until
Green LED just lights

Deflect Joystick Slightly

Green LED lights
Output begins

R2, I-Min
Adjust to 360 mA
Counter Clockwise Decrease Output
Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Full Deflection
Joystick

R1 I-Max. Swing Left

1 2 3 4 5 6 7 8 9 101112131415 16 Move joystick
full deflection left
Green LED on bright
Deflect Joystick Full
Green LED lights
Output Full

R1, I-Max
Adjust to 750 mA
Counter Clockwise Decrease Output
Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Swing Right
Joystick

R4 I-Min. Swing Right

1 2 3 4 5 6 7 8 9 101112131415 16
Move joystick slightly until
Yellow LED just lights

Deflect Joystick Slightly

Yellow LED lights
Output begins
R4, I-Min
Adjust to 360 mA

Counter Clockwise Decrease Output

Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Full Deflection
Joystick

R3 I-Max. Swing Right

1 2 3 4 5 6 7 8 9 101112131415 16
Move joystick
full deflection right
Yellow LED on bright
Deflect Joystick Full
Yellow LED lights
Output Full
R3, I-Max
Adjust to 750 mA
Counter Clockwise Decrease Output
Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Full Deflection
Joystick

1 2 3 4 5 6 7 8 9 101112131415 16
R7 Time Ramp #1
Adjust the time
required to go from I-Min
to I Max to 0 Sec.

R7, Ramp Time

Observe Analog Needle
Adjust to Smooth Sweep
(Repeat as required)

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Swing Right
Joystick

1 2 3 4 5 6 7 8 9 101112131415 16 R8 Time Ramp #2

Ground Pin 1, adjust the time
required to go
from I-Max to neutral
Adjust to 2 Sec.

Deflect Joystick Full

Connect Grounding
Wire to Pin #1
(note ground to superstructure)
R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments
Swing Right
Joystick

1 2 3 4 5 6 7 8 9 10111213141516

R8 Time Ramp #2
Ground Pin 1, adjust the time
required to go
from I-Max to neutral
Adjust to 2 Sec.

Release Joystick and Observe Needle

Sweep
Adjust R8 to
R1R2R3R4R5R6R7R8
R1 R2 R3 R4 R5 R6 R7 R8 approx. 2 sec. sweep
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments

Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R6 Special
Swing Brake Release.

Connect Ohmmeter
to Superstructure
Ground

Connect Pin #11

to Ohmmeter

R1 R2 R3 R4 R5 R6 R7 R8
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments

Joystick

R6 Special
1 2 3 4 5 6 7 8 9 101112131415 16 Swing Brake Release.
Turn R6
Observe Needle Sweep
Adjust to full sweep
absolute ground

Turn Counter Clockwise

until Ohmmeter reads
No Resistance
(meter pegged)
Then,
R1 R2 R3 R4 R5 R6 R7 R8 Turn Clockwise
1/4 turn to Set
 LEFT RIGHT RVR
4Y3 4Y4 Adjustments

Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R5 Board Frequency
Do not Adjust

R1 R2 R3 R4 R5 R6 R7 R8
 RVR Adjustment Summary
4Y3 4Y4

1 2 3 4 5 6 7 8 9 101112131415 16
Direct. I-Min I-Max Ramp LED
#1 = 0 Sec.
Left 360mA 750mA #2 = 2 Sec Green
#1 = 0 Sec.
Right 360mA 750mA #2 = 2 Sec Red

R1 =I-Max. Left - Green

R2 =I-Min. Left - Green
R3 =I-Max. Right - Red
R4 =I-Min. Right - Red
R5 =DO NOT ADJUST
R6 =Special Func. Swing Brake Release
R1 R2 R3 R4 R5 R6 R7 R8
R7 = Time Ramp #1
R8 = Time Ramp #2
 GMK/KMK Amplifier Adjustment instructions
1. General

Adjustment is based on the following documentation:

• KMK 6200/7250
Electrical circuit diagram, superstructure
Drawing No. 2079658 sheet 2

• KMK 6201
Electrical circuit diagram, superstructure
Drawing No. 2225822 sheet 2

• KMK 6180
Electrical circuit diagram, superstructure
Drawing No. 2087339 sheet 2

• KMK 5160
Electrical circuit diagram, superstructure
Drawing No. 2304154 sheets 2 & 3

* Data sheet, proportional amplifier PVR

(Hydromatic — RE 95022 / 03.89

* Data sheet, control amplifier RVR

(1-ydromatic — RE 95031 / 06.90
spersedes RE 95031 / 08.87

* Data sheet, load limit sensing control for

automotive reversing gear drives GLR
(Hydromatic — RE 95046 / 03,89

* Data sheet, inductive pulse transducer ID

(Hydromatic — RE 95038 / 02.87

The data sheets should be consulted to facilitate system appreciation but are not
absolutely necessary. The adjustment instructions printed in the data sheets are to
be replaced completely by the following instructions.
2. Checking the functions

Crane Function Pre—adjustment Check Procedure

Prior to system adjustment, the correct operation of direction valve control

(Siemens relay switching) and associated amplifier output signals should be
carried out.

Siemens (hydraulic direction control) relays

Each control relay has a manual override pin which will also move when the coil is
energized.

Amplifiers PVR / RVR

Each amplifier has light emitting diodes (LED’s) installed to indicate that a solenoid
valve output threshold has been attained = I min / current rise to minimum value
required for pump delivery to begin. Red or green LED’s are illuminated according
to the function direction selected with the joystick.

Note: It is most important that direction control relays are energized before the
LED’s are illuminated, hydraulic direction control must occur before pump
delivery begins.
This is applicable to Hoists/Derricking & Telescoping.

Slewing Gear

Only, the KMK 5160 slewing system uses an open (load independent) hydraulic
circuit with proportional direction valves, all other models use a closed loop
hydraulic circuit, which has no direction control solenoid valves. Both systems are
actuated by a safety relay 4K5 KMK 5160 & K10 for all others). The safety relay
controls the slewing brake via an additional pin (11) on the RVR board.
 Slewing gear continued...

The same condition applies, it is essential that the safety relay operates prior to
LED’s being illuminated when the control lever (joystick) is moved.
This means; The slewing brake must be released before pump delivery
begins. The switching point can be adjusted with P6—special switching
function, see below.

The table below shows the direction control relays and associated LED’s and
amplifiers for primary crane functions.
Should any of the LED’s illuminate before the direction control / brake relays are
energized there may be a fault with the joystick (control lever) switches or
potentiometers. Without the correct control sequence satisfactory amplifier
adjustment will be impossible.

Function Relay Relay LED Amplifier

6200
7250
6160
(movement of control levers) 6201 5140 (5160)
Main Hoist-Lift K12 1K1 Green PVR 1
Main Hoist-Lower K13 1K2 Red PVR1
Boom Lower/ K14 - Green PVR2/2
Tele Extend K14 3K1 Green PVR2/1
Boom Raise/
Tele Retract K15 3K2 Red PVR2/1
Aux. Hoist-Lift K16 2K1 Green PVR 3
Aux. Hoist-Lower K17 2K2 Red PVR 3
Slewing Safety relay K40 4K3
-Left pin 11 K10 4K5 Green RVR
Slewing Safety relay K41 4K4
-Right pin 11 K10 4K5 Red RVR

Table 1: Overview of functions when the control levers are moved

PVR 2/2 applies to the KMK 5140, 6160 and 6201for the lift cylinder holding valve.
3. Preadjusting the amplifiers

Proceed as follows in order to permit you to preadjust the amplifiers with the engine
not running:

- Set the servicing switch on the interface to ON

(bypassing dead man’s and voltage relays)

- Disconnect the cable from pin 7 on the load limit sensing control and connect it
to pin 1 of a PVR amplifier (4.25 V supply for the control lever potentiometers)
KMK 5140: Switch over switch GLR so that the internal lamp lights up brightly.

The potentiometers for Imin and Imax and for the time ramp must be preadjusted
on amplifiers PVR and RVR. Also, potentiometer P6 for the special switching
function (releasing the slewing gear brake) must be set on the
RVR.

You will require an amp meter as the measuring instrument.

Connect the ammeter as follows:

PVR: Disconnect the cable from pin 6 and connect the amp meter in between
(negative terminal of the amp meter to pin 6, positive terminal to end of
cable).

RVR: Disconnect both cables from pin 14 and connect the amp meter in between
(negative terminal of the amp meter to pin 14, positive terminal to both ends
of the cable simultaneously).

Adjusting P6 on amplifier RVR:

Function:
Releasing the slewing gear brake before the LEDs for the relevant directions light
up. This prevents pressure build—up before the sieving gear brake is released.

Turn the potentiometer counterclockwise almost as far as it will go.

Then adjust precisely, starting from this setting.

Important! This is a critical adjustment!

K10 and 4K5 respectively must release reliably when the control lever is in zero
position.
(Note the hysteresis).
one quarter of a turn of the potentiometer will generally suffice for precise
adjustment.
The time ramp and the special switching function (pin 11) must be very precisely
intermatched on the slewing gear.
Bear in mind that K10 and 4K5 respectively must always release once when the
control lever passes through zero (whipping through the control lever).
Otherwise, the safety relay is energized when the control lever is moved in the
opposite direction after it has passed through zero (the operator is already turning in
the opposite direction), this means that the slewing gear brake is applied, the
slewing gear moves jerkily or the slewing gear does not operate.

There are 2 possible causes for the above effect:

— The time ramp is set too short (less than 4 sec.).

This means that relay K10 and 4K5 respectively
cannot release reliably owing to their inertia.

— The special switching function has not been adjusted

correctly. It does not suffice to only adjust it
approximately so that K10 or 4K5 releases when the
control lever is in zero position. This relay may
not be energized (lamp on the slewing gear brake
goes out) until directly before cut-in of I min (a
direction LED lights up).

This adjustment maximizes the range around the zero

position in which the above—mentioned relay can
release.

Always check the above function after carrying out any adjustment work on
the RVR amplifier.

First, notch up in one direction.

Then abruptly move the control lever in the opposite
direction.
After expiry of the set safety time of 6 seconds,*(time relay)
the slewing gear brake may not be applied. Rather,
the slewing gear must continue to turn smoothly in
the opposite direction.

* Note: Please remember that the time relay setting must always exceed/overlap
the ramp time. Additionally, remember that any I min / I max
adjustments to the RVR amplifier should be with the fine control set to the
maximum speed.
 System Safety Time Relays

Time relays are installed for additional system safety and carry
out a watchdog/monitoring function for each amplifier.

Once the control lever (joystick) input command has been removed
by the operator releasing the lever, should any primary crane
function fail to decelerate/stop within the amplifier time ramp
span. The time relay will then disconnect the power supply to the
direction valve/brake and stop the function operation.

The time relays will break at the pre—adjusted time setting after
the coil power supply is removed.

Please see page 8 for time relay settings.

Note: The time relay settings Must Always overlap the time ramp
setting of the amplifiers.
 LED MAIN AUX. Boom Boom Slewing
HOIST HOIST lift lower
telesc.
6200/7250 450 450 450 — 180
Imin 6201/6160 green 200 200 200 300 180
(mA) 5140 200 — 200 250 350

6200/7250 890 890 890 — 570

Imax 6201/6160 green 600 600 600 800 570
(mA) 5140 600 ---- 600 700 720

6200/7250 450 450 450 180

Imin 6201/6160 red 200 200 200 200 180
(mA) 5140 200 — 200 250 350

6200/7250 890 890 890 — 570

Imax 6201/6160 red 600 600 600 800 570
(mA) 5140 600 — 600 700 720

[Sec] Time ramp 1 0.6 0.6 0.6 0.6 5 -6

Time ramp 2 --— --— —- — 1-2
5140

Pressure switch 23S1 23S2 23S3 23S4

Relay 6160-7250 K7 K6 K18 K18
Relay 5140 0K9 — 0K11 0K11

Table 2: Values for preadjustment of the amplifiers

! After preadjusting, always carry out precise adjustment as specified in

Point 5 !
The current values may differ from the preadjusted values!

Preadjust all other potentiometers of the amplifiers as specified in Table 2. Note that
Imin must always be adjusted before Imax since Imin has a major influence on
Imax but, conversely, Imax influences Imin only slightly. In order to preadjust Imin,
slowly move the control lever until the point is reached at which the relevant
direction LED just lights up. Imax must be adjusted with the control lever moved to
extreme position.

Important: On the boom lift / telescoping gear, the values apply only to boom
raising and telescoping out. The max currents are obtained by dropping resistors
during boom lowering (KMK 6200/7250 only) and telescoping in.

Repeat adjustment after exchanging pumps or amplifiers.

The time ramp values always refer to maximum drive of the amplifier (deflection of
the control levers). The ramp time will be shorter accordingly if the levers are moved
less.

The ramps of the PVR amplifiers can be adjusted only by estimation and their
settings must be checked subsequently when executing the relevant movements:

Turn potentiometer R1 fully counterclockwise -and

then one half a turn back clockwise.

Adjust the time ramp in the slewing gear amplifier (RVR) as follows:

Move the control lever to extreme position and wait until the maximum current is
reached. Then release the control lever and measure the time taken until the current
has dropped to zero again.

Special feature on KMK 5140

The KMK 5140 has an active slewing gear cut—out function with slewing-angle-
limited load curve. If the crane moves within the permitted slewing-angle
range, the slewing gear is stopped on the basis of the preadjusted ramp (5 - 6 sec).
However, as soon as the crane moves out of the permitted slewing—angle range,
the sieving gear is cut out actively with a short ramp (1 - 2 sec).
The crane then re—enters the permitted range on the basis of ramp 5 — 6 sec.

Preadjustment:

Disconnect the lead from terminal 1 of the RVR amplifier and connect the ground
connection directly.

This terminal controls ramp 1 and 2 respectively.

Time ramp 1 (ground not connected to terminal 1)

corresponds to the normal setting (R7, 5 - 6 sec).

Time ramp 2 is required only for cut-out of the

slewing gear in the case of sieving-angle-limited
load curve if the sieving range is exceeded.

Adjustment is made with potentiometer R8 on the RVR amplifier.

The ramp time is 1 - 2 sec. (Table 2).

Then disconnect the ground lead at terminal 1 of the RVR amplifier.

 Re-establish the normal connection.

Checking with active sieving mechanism and SLI not installed

Precondition: The sieving gear must be operable.

Apply positive potential to the interface X 37/11 (cf. electrical circuit diagram).
This corresponds to the SLI signal for the slewing-
angle-limited curve.

The limit switches for sieving angle in the turntable and relays 4K7 and 4K8 are now
activated. Check the functions explained above by moving the slewing gear control
levers and correct the preadjusted time if necessary on potentiometer R8.

Positive potential must be applied to the interface X 37/14 if the crane is in the
permitted slewing range.

4. Adjusting the safety relays

The safety relays (slow—releasing time—lag relays in the switch cabinet) must be
adjusted as follows:

K9 4K20 t =6 sec (> time ramp RVR) Slewing gear

K19 2K20 t =1 sec (> time ramp PVR) Aux.hoist
K20 3K20 t =1 sec (> time ramp PVR) Boom lift/telesc.
K21 1K20 t =1 sec (> time ramp PVR) Main hoist

5. Final adjustment of the amplifiers (precise adjustment)

Unlike preadjustment, the final adjustment is made with the engine running and
idling (approx. 800 rpm). In addition, the connectors must be disconnected from the
directional control valves in order to operate in closed condition. All other
preconditions as specified in Point 3 must be observed (servicing switch,
disconnecting the load limit sensing control and, on the KMK 5140:
switching over the load limit sensing control switch).

Final adjustment of the amplifiers involves precise adjustment of 1mm, the start of
pump delivery and checking the final speeds. The operating pressure of the
pumps is also measured when precisely adjusting the amplifiers since this is the
only way of establishing the start of pump delivery. On the KMK 6160, 6201 and
5140, equivalent information can be obtained from the relays
which are controlled by the pressure switches (see Table 2) since these pressure
switches measure the operating pressure.

The pilot pressure must be measured on the KMK 6200 / 7250.

Imin must be corrected as follows for each movement:

Move the control lever until the corresponding LED just lights up.

Adjust Imin so that the related pump builds up a pressure as specified in Table 3.

Then slowly increase 1mm until the pump starts to deliver (increasing pump
pressure approx. 30 bar). Then slowly reduce 1mm until the pump pressure has
dropped to the values specified in Table 3.

Then check the pump pressure at the start of pump delivery by moving the control
lever until the corresponding LED just lights up. The pump pressure at this point
must be as specified in Table 3.

KMK 6160, 6200, 7250, 6201 equal to or less than

10 bar

KMK 5140 equal to or less than

10 to 20 bar

Table 3: Pump pressure at Imin

Imax needs to be checked only if the maximum speed to be reached is not reached
(checking the operating time).

6. Adjustment of the load limit sensing control

The input signals of the load limit sensing control are the actual r.p.m. value
(inductive sensor on the engine ring gear) and the r.p.m. setpoint (potentiometer on
the linkage of the injection pump). All voltage values specified below relate to the
grounding point at terminal
1. The sensors must be adjusted as follows:

Inductive sensor:
Actual r.p.m value
Screw the inductive sensor in so that it contacts the teeth of the ring gear and
then unscrew it by approx. 1 mm (one turn). Then lock it in position. A signal
must be applied to terminal 2 (approx. 2 - 4 V AC) with the engine running.

Nominal r.p.m. sensor:

The output voltage of the potentiometer must be approx. 1 V DC when idling.
It must be approx. 7 V at maximum r.p.m. This can be corrected only by
turning the potentiometer spindle. The voltage range between idling
and maximum r.p.m. must be at least 5 V (U > 5 V). This can be measured at
terminal 3.
Adjust the load limit sensing control as follows after checking the input signals:
A. Actual idling r.p.m. value:

Keep the diesel engine idling and. adjust potentiometer R1 so that LED Hi,
red, next to the potentiometer, goes out.
Related measured value at terminal 5: U = 0 V.

B. Actual final r.p.m. value:

Adjust the diesel engine to maximum r.p.m. and adjust potentiometer R2 so

that LED H2, green, next-to the potentiometer, lights up.
Related measured value at terminal 5: U = 5 V.

Note: repeat adjustments A and B alternately since the adjustments influence

each other.

C. Accelerator potentiometer adjustment when idling:

Keep the diesel engine idling and adjust potentiometer R1 so that LED H3,
red, next to the potentiometer, goes out. Related measured value at terminal
4: U 0 V.

D. Accelerator potentiometer adjustment at maximum r.p.m.:

Adjust the diesel engine to maximum r.p.m. and adjust potentiometer R4 so

that LED H4, green, next to the potentiometer, lights up.
Related measured value at terminal 4: U = 5 V.

Note: Recheck adjustments C and D.

E. Supply voltage for the control lever potentiometers:

Adjust the diesel engine to maximum r.p.m. (not under load) and adjust the
voltage at terminal 7 to 4.25 V with potentiometer R9. This voltage
corresponds to the value at terminal 1 of amplifiers PVR.

F. Slope of the starting characteristic:

Turn potentiometer R6 fully counterclockwise (the end position is indicated by

a slight click — 20—turn potentiometer). This sets the break point of the
characteristic curve, i.e. the r.p.m. value at which the maximum voltage of 4.25
V is reached at terminal 7, to the lowest r.p.m. value.
 G. Start of critical load:

R5 normally does not need to be adjusted.

However, if the pump still vibrates, turn potentiometer R5 fully

counterclockwise (i.e. the engine is critically loaded to maximum — approx.
1200 r.p.m. — before control action and, thus, vibration cuts in).
Potentiometers R7 and RB do not affect the load limit sensing control.

7. Adjustment of the flow monitor (KMK 6200/7250 only)

A digital voltmeter must be connected to terminals 5 and 6 of the evaluation

unit (positive terminal of the voltmeter to terminal 6) in order to adjust the flow
monitor whose evaluation circuitry is located on the interface plate. Adjustment
can now be checked as a voltage value in the mV range.

The evaluation circuitry has a permanently set switching threshold in the range
5 — 6 mV. Below a value of 5 - 6 mV, the evaluation circuitry signals “flow
present” (LED on the circuitry lights up). Above a value of 5 - 6
mV, the evaluation circuitry signals “no flow present” (LED off).

During adjustment, it is possible, using the mV reading, to establish the

amount by which the setting lies below or above the switching threshold.
(< 5 - 6 mV LED lights up > 5 - 6 mV LED goes out)

Adjustment:

Extend telescope section 4 and lock with telescope section 3. The telescope
cylinder can now be moved freely in telescope section 4.

In idle condition — “no flow present” - adjust the voltage at terminals 5 and 6
of the evaluation circuitry to approx. +40 — 50 mV with potentiometer “FINE”.

Retract the telescopic cylinder and observe the voltage. The actual voltage
value must have dropped below the switching threshold of 5 - 6 my after
approx. 9 sec., and the value must settle at around —2 mV — “flow present” -.

When the telescopic cylinder reaches the bottommost stop position, the
voltage increases again and exceeds the switching voltage of 5 — 6 mV after
approx. 3 sec. — “no flow present” —. The voltage value must be approx. —2
mV at maximum flow in normal operation in order to obtain a safe distance.
from the switching threshold. This value can be corrected with potentiometer
“FINE”.
(Turning clockwise: increases the distance and renders the voltage more
negative)
 ! Important !

Set the servicing switch on the interface

back to OFF after adjustment.

Annex:

Block diagrams and pin assignments

Proportional amplifier PVR Page 14

Proportional amplifier RVR new Page 15

Proportional amplifier RVR old Page 16

Load limit sensing control GLR Page 17