Deutsche GROVE GmbH

GMK 4075
Instructions for Adjusting Current Signals

Imin & Imax

for Controlling Proportional Valves

Superstructure Hydraulic System

1. General Description....................................................................................................................... 1
2. Necessary Preparations for the Adjustments............................................................................. 1
3. Main Hoist....................................................................................................................................... 2
3.1. Main Hoist – Adjust Imin – Raise Function .......................................................................... 2
3.2. Main Hoist – Adjust Imin – Lower Function ......................................................................... 4
3.3. Main Hoist – Adjust Imax – Raise Function.......................................................................... 5
3.4. Lower Main Hoist – Checking and Correcting the Starting Time & Starting Value
Parameters...................................................................................................................................... 7
4. Telescoping Gear........................................................................................................................... 8
4.1. Telescoping Gear – Adjust Imin – Retract Telescope Function......................................... 8
4.2. Telescoping Gear – Adjust Imin – Extend Telescope Function ....................................... 10
4.3. Telescoping Gear – Adjust Imax – Extend Telescope Function ...................................... 12
5. Derricking Gear ............................................................................................................................ 13
5.1. Derricking Gear – Adjust Imin – Derrick Out Function ..................................................... 13
5.2. Derricking Gear – Adjust Imin – Derrick In Function ........................................................ 15
5.3. Derricking Gear – Adjust Imax – Derrick Out Function..................................................... 15
5.4. Derricking Gear – Adjust Imax – Derrick In Function........................................................ 17
6. Slewing Gear ................................................................................................................................ 18
6.1. Slewing Gear – Adjust Imin – Slew Right Function........................................................... 18
6.2. Slewing Gear – Adjust Imin – Slew Left Function ............................................................. 20
6.3. Slewing Gear – Adjust Imax – Slew Right Function .......................................................... 20
6.4. Slewing Gear – Adjust Imax – Slew Left Function ............................................................ 20
6.5. Slewing Gear Brake – Adjust Imin & Imax.......................................................................... 21
7. Tilt Cab Control System, Adjust Imin & Imax ........................................................................... 22
8. Counterweight Control System.................................................................................................. 23

GMK 4075 Imin & Imax Training Information April 2002

 Deutsche GROVE GmbH

1. General Description
The ECOS controls the proportional valves with the relevant current signals:

- Imin for starting the function

- Imax for achieving the maximum performance/speed.

The window is to be closed (“Close”) each time the parameters are adjusted using “Set”.

The following valves are controlled:

Valve Drive unit

Y2108 Derricking gear
Y2107 Telescoping gear
Y1107 Main hoist
Y1207 Auxiliary hoist
Y2301 Slew left
Y2302 Slew right
Y2308 Slewing gear
brake
Y2120 Derrick out

The activated valves control the control pressure for the appropriate direction valves at the
superstructure control block proportional to the current signal. See hydraulics circuit diagram OW
03057302.

2. Necessary Preparations for the Adjustments

a) Preheat hydraulic oil to approx. 400C.
b) Bleed hoist control hydraulic system and all pilot (spool) end caps on the control block.
c) Connect laptop to GMK 4075 service program
d) Prepare an electronic pressure gauge (manometer) with a 60 bar probe
e) Stop watch

Note: The adjustments must only be carried out by trained specialist staff!!

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3. Main Hoist

3.1. Main Hoist – Adjust Imin – Raise Function

Note: The adjustment should be carried out with reeving of up to a maximum of 4 parts of line.

a) The speed adjustments are to be activated on the display.

Activate

Set hoist speed to 1%.

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b) Start GMK 4075 service program & click on Main Hoist Drive Unit
Open the throttle, move the joystick as far as it will go towards “Raise” (without high-speed!).
then move back to set value of 0.5% and hold.

Move set value

to 0.5% and hold

Left click on

c) Left click on ‘speed control main hoist’

Set Imin such that the hoist raises

quite slowly. The speed must be
slow enough that the HDRI can
be heard “ticking” every 4 - 5
seconds.

Empirical value approx. 300 –

330mA

d) Move joystick to 0.3% Æ main hoist must stop

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3.2. Main Hoist – Adjust Imin – Lower Function

a) The speed adjustment of 1% holds good (Raise function).

Click on Main Hoist Drive Unit

Move set value to

0.5%

Left click on

Set Offset Imin to 10

mA first.

b) Set Imin offset to 10mA.

Open the throttle, move joystick as far as it will go towards “Lower” (without high-speed), then
move back to set value of 0.5 and hold.

c) Set offset such that the hoist lowers quite slowly. The speed must be slow enough that the HDRI
can be heard “ticking” every 4 - 5 seconds. The offset value can be between –5 and +12.

d) Move joystick to 0.3 Æ main hoist must stop.

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3.3. Main Hoist – Adjust Imax – Raise Function

a) Set speed on the active display (see Imin, raise function) to 100%.

b) Connect pressure gauge (manometer) to the control block (right side of superstructure) at
measuring point MC.

c) Left click on ‘Speed control main hoist’ to activate PWM parameters

Click on

d) Open the throttle, operate joystick to maximum position, and activate high-speed.

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e) Set a control pressure of 20 bar with Imax

parameter.

Empirical values: Imax 700 – 720mA

ATTENTION:
The control pressure must also be checked for the Lower function. It must not fall below 20 bar. If
necessary, adjust Imax – even if the pressure for the Raise function is rather higher.

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3.4. Lower Main Hoist – Checking and Correcting the Starting Time & Starting
Value Parameters
Parameters

Click on

Main hoist
Adjust if necessary
Empirical values: 700 – 900 ms
3–5%

Auxiliary hoist shown

without adjustment

a) Set main hoist speed to 100% (active display).

b) Move joystick as in normal operation towards Lower (without high-speed at average speed)

c) Following the adjustment, the Lower function must start without any undue delay and without any
jerky movements. If necessary, correct the starting time and starting value.

Note:

This adjustment is reminiscent of the setting of the throttle on the safety lowering valve.

The auxiliary hoist is adjusted in the same way as the main hoist

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4. Telescoping Gear
4.1. Telescoping Gear – Adjust Imin – Retract Telescope Function

a) Extend telescope 4 to 100% and lock it

b) Unlock the telescoping cylinder and partially retract it to 2000 – 3500 mm.
The adjustment should be carried out in mid range at a length of approx. 2000 – 3500mm to avoid
the braking ranges of the ECOS program.

Activate speed adjustment

Set speed to 1%

Check length here on the

ECOS display

c) Open the throttle. Move joystick as far as it will go (retract) then move back to a set value of 0.5%
and hold.

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d) Observe the length of the telescoping cylinder on the ECOS display (on the instrument panel).
Measure a change in length of 10mm (e.g. from 2270 to 2280) with a stopwatch.

Set value to
0.5% and
hold

Left click on

e) Adjust Imin such that a change in length of 10mm occurs every 3 seconds. This corresponds to a
telescoping cylinder speed of 10mm/3 secs. (= 3.3mm/sec.).

Empirical value:
Imin 310 – 340 mA

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4.2. Telescoping Gear – Adjust Imin – Extend Telescope Function

a) Extend telescope section 4 to 100% and lock it

b) Unlock the telescoping cylinder and partially retract it to 2000 – 3500mm and then extend slightly.
The adjustment should be carried out in mid range at a length of approx. 2000 – 3500mm to avoid
the braking ranges of the ECOS program.

Activate
Set speed to 1%

Check length
here on ECOS
display

c) Open the throttle. Move the joystick as far as it will go (extend) then move back to a set value of
0.5% and hold.

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d) Observe the length of the telescoping cylinder on the ECOS display (on the instrument panel).
Measure a change in length of 10mm (e.g. from 2270 to 2280) with a stopwatch.

Set value to
0.5% and
hold

Click on

e) Adjust Imin offset such that a change in length of 10mm occurs every 3 seconds. This
corresponds to a telescoping cylinder speed of 10mm/3 secs. (= 3.3mm/sec.).

Imin offset adjustment

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4.3. Telescoping Gear – Adjust Imax – Extend Telescope Function

a) Connect pressure gauge (manometer) to the control block (right side of superstructure) at
measuring point MB.

b) Set telescoping gear speed on the display to 100%. Left click on PWM parameter ‘Speed control
telescoping’
Push joystick right forward, open the throttle and activate fast speed. Adjust Imax such that the
control pressure is 20 bar.

Empirical values:
Imax 600 – 700 mA

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5. Derricking Gear
5.1. Derricking Gear – Adjust Imin – Derrick Out Function

The adjustments should be carried out with just base section or maximum of 1x telescope and with a
boom angle of approx. 700 .

a) Set speed to 1%

Activate
Set speed to 1%

b) Left click on speed control derricking down for PWM parameter window.

Move set
value to 0.5%
and hold

Click on

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c) Open the throttle. Move the joystick as far as it will go (derrick down) then pull back to set value of
0.5% and hold. Adjust Imin such that the boom derricks out very, very slowly. At 0.3% it must stop.

Imin adjustment

Note: this is a very precise adjustment and boom movement must be closely observed!

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5.2. Derricking Gear – Adjust Imin – Derrick In Function

a) Set speed to 1% (see Derrick Out Imin)

b) Left click on ‘Speed control derricking’ for PWM parameter window.

Imin Adjustment

c) Open the throttle. Move the joystick as far as it will go, then pull back to set value of 0.5% and
hold. Adjust Imin such that the boom derricks in very, very slowly. At 0.3% it must stop.

5.3. Derricking Gear – Adjust Imax – Derrick Out Function

a) Set speed to 100%.

b) Connect pressure gauge (manometer) at measuring point MX to the derricking cylinder holding
valve.

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c) Left click on ‘Speed control derrick down’ for PWM parameter window

Empirical values Imax 680 –

730mA.

d) Push joystick right forward, open the throttle. Adjust Imax such that the control pressure is max.
21.5 bar.

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5.4. Derricking Gear – Adjust Imax – Derrick In Function

a) Set speed to 100%.

b) Connect pressure gauge to the control block (right side of superstructure) at measuring point MA.

c) Left click on ‘Speed control derricking’ for PWM parameter window.

Empirical value for

Imax is approx. 680 –
710mA.

d) Move joystick to max position for Derrick in, open the throttle and activate high-speed. Adjust Imax
such that the control pressure is 20 bar.

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6. Slewing Gear

6.1. Slewing Gear – Adjust Imin – Slew Right Function

a) The turntable must be adjusted so that it is not affected by wind and it is not carrying any load.

b) Set speed to 1%.

Activate and
set to 1%

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c) Left click on slewing right for PWM parameter window.

Increase set
value to
0.5% and
hold

Left click on

Empirical values for Imin are approx.

310 – 360mA.

d) Open the throttle. Move joystick to right as far as it will go, then pull back to set value of 0.5% and
hold. Adjust Imin such that the slewing gear slews very slowly to the right. At 0.3% it must stop.

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6.2. Slewing Gear – Adjust Imin – Slew Left Function

Here again the turntable has to be adjusted so that it is not affected by wind and it is not carrying any
load.

The adjustments for the Slew left function are identical to those for the Slew right function.

Exception:

Left click on ‘Slewing left’ for PWM parameter window (instead of Slew right).

6.3. Slewing Gear – Adjust Imax – Slew Right Function

a) Set speed to 100%.

b) Click on PWM parameter Slew Right Speed (see Imin).

c) Adjust basic value of 600mA Imax.

Move joystick hard right, open the throttle and measure the slewing speed. Move Imax continually
upwards in 10mA stages until the crane has reached a slewing speed of 26-28 seconds for 1
revolution. Reduce Imax by 10mA and then close the window.

Empirical values are 350 – 360mA higher than for Imin

6.4. Slewing Gear – Adjust Imax – Slew Left Function

The adjustments for the Slew Left function are identical to those for the Slew Right function.

Exception:

Click on PWM parameter Slew Left (instead of Slew Right).

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6.5. Slewing Gear Brake – Adjust Imin & Imax

a) Connect pressure gauge to mini measuring point

b) Left click on ‘slewing brake control pressure’ for PWM parameter window.

Adjust Imin to 150mA

(basic adjustment)

Adjust Imax
(see description
below)

C) Description:

- Engine idling
- Release slewing brake (deadman must be set via joystick or seat switch)
- Press slewing gear foot brake pedal right down and then fully release brake pedal
- Adjust Imax such that the control pressure is 28 bar
- Complete the adjustment using “set” and “close”

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7. Tilt Cab Control System, Adjust Imin & Imax

a) Adjust Imin
Set Cab Lower ramp value to 0.1%

b) Left click on Speed control of auxiliary drives

c) Tilt cab with the button (lower), adjust Imin such that the
cab lowers very slowly (start of movement).

d) Then adjust Imax: Imin + 275 mA.

e) Adjust ramp values to 2% + 1% if required.

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8. Counterweight Control System

Imin & Imax values are input as standard values and should not be changed. Any changes are only
permitted by arrangement with GROVE.

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