133113925 GMK Schematic Handbook

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GMK I

Schematic Symbol Handbook

MAIN MENU SUB MENU

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GMK

Schematic Symbol

Handbook

Grove Training Institute

Second Edition

7 1 8 2 9 3 4 10 0 1

W

W 300 bar X56 2 X2 6

P

+ L -G WK 2K20 B1 A1 A2 85 86 87 87 b 30 K10 1 2 3 4 2 bl W 5 bar S62 br sw

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Introduction

The GMK schematic symbol handbook has been developed to equip a novice GMK technician with navigational skills necessary to use system schematics. The content of the handbook is intended to increase a technicians general knowledge level of GMK schematics. Schematic symbols emphasize the function and describe the operation of components and their respective circuits. An overall system schematic will show the entire machine’s circuitry on one, or in some cases, multiple pages. A technician armed with the ability to read schematics has the advantage of viewing the machine’s complete hydraulic, electrical, or pneumatic circuits. When presented with a machine fault, he can systemically eliminate possible causes, thus arriving at a solution much quicker. It is important for a technician to have a fundamental understanding of schematic symbols in order to be an effective troubleshooter . This handbook was developed based on information from ISO 1219-1 International Standard and system schematics from the GMK 5130 mobile hydraulic crane. Questions about this handbook or related material may be directed to the Grove Training Institute at:

Grove Worldwide Headquarters Grove Training Institute

1565 Buchanan Trail East Shady Grove, PA 17256 1-717-593-5316

If you wish to contact us via Email, our address is [email protected]

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GMK Schematic Symbol Handbook

Introduction

Section 1 Hydraulic Symbols

Pages 1-1 through 1-10

Section 2 Electrical Symbols

Pages 2-1 through 2-13

Section 3 Pneumatic Symbols

Pages 3-1 through 3-6

Section 4 Elan electrical schematic

Pages 4-1 through 4-15

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Section 1

Section 1 Hydraulic Symbols

This section contains a basic introduction to GMK hydraulic schematic

symbols. The information contained herein will provide a good foundation for a technician new to the GMK product line, or as a refresher for a veteran technician. Each page is laid out with the symbol on the right side of the page and the supporting text on the left side of the page. The supporting text will provide a description of the symbol and in some cases theory of operation.

Note:

This document is not intended to cover every symbol that a technician may encounter, however, it is intended to provide a starting point from which to work.

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GMK Hydraulic Symbols

Description

Symbol

Dashed line- Pilot Control, internal or

external

Continuous line - Pilot supply line,return

line, or function supply

Chain line -Enclosure of two or more

functions contained in one unit .

Double line - Mechanical connection,

( shaft, lever, piston rod) etc.

Flexible line - Hose, usually connecting

moving parts

Line size - Identification for line size

changes. Used to help locate connection points on the machine. The figures provided represent the outside diameter and the inside cross sectional area. The small line above the tie point represents a line size change.

16X2

12X1.5

1-1

line size change outside diameter

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Description

Symbol

Gate valve - Return manifolds, reservoirs, etc.

Test port - Quick disconnect style testing

point

M3

Shuttle valve - The inlet port connected to

the higher pressure is automatically connected to the outlet port, while the other port is closed. Used to direct maximum pressure to logic valves, or piston pump control, depending on the application.

W

3 bar

1S21

Hydraulic pressure switch - Senses

hydraulic pressure for the purpose of energizing electrical components, for example relay coils, indicator lights etc.

Quick disconnect - Used in the circuits of

frequently removed components, i.e. auxiliary hoist circuit lines.

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Description

Symbol

Relief Valves - Limits maximum

hydraulic pressure that can be applied to a specific circuit. Form 1 represents a normally closed valve which is shifted to the open position with pilot pressure being applied from the valve inlet. The pilot pressure acts against an adjustable spring which is represented by the spring symbol with the arrow through it. When the pilot pressure reaches 40 bar, the valve cartridge shifts and aligns the valve inlet and outlet thus routing the excess flow back to the reservoir.

Form 2 operates the same way however, it contains an additional pilot line which is a drain for the spring area adjustment point. In this case the maximum

pressure is 300 bar. When the inlet pressure reaches the maximum limit, the valve spool is shifted via pilot pressure against the opposing adjustable spring force. This action will connect the inlet and outlet of the valve spool thus permitting the excessive oil flow to be routed to tank.

W

40 bar

W 60 bar

Pressure reducing valve - Reduces

maximum hydraulic pressure that can be applied to a circuit or component. This valve symbol is slightly different than the previous example. In this case the pilot line which shifts the valve is connected to the outlet port. Additionally the valve symbol is shown in the normally open position. As a result, the valve will not shift to the closed position until the output reaches, 60bar. As the pilot line reaches the maximum limit, it shifts the spool against the adjustable spring force, shutting off the oil supply to the function. 1-3 Form 1 W 300 bar Form 2

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Description

Symbol

W

Electric solenoid - Electrically controlled

hydraulic valve, used in the normally

open or normally closed configuration. This example represents a normally open valve. The small rectangle with the diagonal line through it, represents a solenoid coil. When the coil is energized, it will shift the spool blocking oil flow through the valve.

W

Lock Valve - Pneumatically controlled

hydraulic valve normally used in carrier suspension circuits. This symbol shows a pilot line connected to a small rectangle that contains an arrow. Notice that the center of the arrow is not black, this is typically how pneumatically actuated components are shown.

X

Velocity fuse - Shifts to the closed position

when a pressure drop is sensed on the output side of the valve. This component is used to prevent loss of hydraulic oil flow in the in the event of a hose rupture in the lift circuit transducer lines.

X

W

Flow switch - Provides ground to electrical

circuit for carrier steering system. Shown in its normal position, it will illuminate an indicator light, which tells the operator the system has a fault. When operating properly, hydraulic oil flow will enter the valve and at the same time a pilot line will shift the valve spool thus opening the switch contacts and turning off the steering indicator light. This tells the operator the steering system is working properly.

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Description

Symbol

Pilot Operated control valve - Used in a

variety of forms, primarily in hoist, lift, and telescope circuits. This symbol

shows a check valve in its normal position. As pilot pressure is applied, the valve spool will shift to permit oil to flow across the restriction port, which is used to control the speed of the respective function.

Electric over hydraulic control valve -

Port X is the pilot pressure input, port Y is the drain, port A is the working port, port P is the input from the hydraulic pump, and port T is connected to the tank. The component serves as the lift control valve.

WW

T

P

Y

X

A

WW

3Way electrically operated valve

-Used to control oil flow to the logic poppets. The

arrows within the valve symbol represent the direction of oil flow in and out of the logic poppets.

WW

3-Way electrically operated valve with manual override - Used to control oil

flow to the hoist brake, and or, the hoist motor control valve. The thin rectangle with the cap is representing the manual over-ride portion of this valve.

WW

4-Way electrically operated valve - Used

to direct oil flow within a variety of circuits on the carrier and superstructure. Similar to the 3- way electrically operated valve, however it handles supply and return oil simultaneously in each position.

1-5

W

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Description

Symbol

WW

Y

WW

T P X A B

2-Way electric over hydraulic directional control valve - used to

control direction of oil flow. This 3-position, closed-center valve, is shifted via pilot pressure that is controlled by an electric solenoid. The P port is

connected to the pump outlet, and the T port is connected to reservoir. The A and B ports are connected to an actuator. The X port is connected to a pilot supply port and the Y port drains oil from the return spring area back to the reservoir.

Pilot operated directional control valve

-Open-center, 3-position directional control valve used with circuits supplied by gear pumps. Example; swing.

X W

WW

P1

P2

A

T

Standby priority valve - Used to

provide back up steering system supply in the event of a main hydraulic pump failure. This symbol contains two main components, the priority valve, and a flow switch. Notice the chain, or enclosure lines, that surround the two items. The port identification is as follows: P1 is connected to the primary pump outlet and P2 is connected to the back up or ground driven pump. The A port is connected to the carrier steering circuit and the T port is connected to the reservoir.

WW

W

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Description

Symbol

WW

X

Single-acting cylinder - Used as the hoist

brake, this symbol also includes a plugged port for pressure checking. As oil enters the rod side of the brake cylinder, it retracts the rod and compresses the spring. This action allows the hoist to rotate. This action must take place for hoist up, and hoist down.

WW

Single acting cylinder - Used as boom

section locking cylinder. Also equipped with mechanical release and air bleeder.

Filter Assemble - Used primarily in the

hydraulic reservoir, in some cases will be used with a pressure switch and check valve.

Oil cooler assemble - Used primarily in return

lines of hydraulic system, may also be used in conjunction with check valves to ensure cooler is kept full of oil.

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Description

Symbol

Fixed displacement pump - Used to supply

hydraulic oil in superstructure or carrier applications, the pump may have, two,

three, or four sections. Mechanical connected as one unit.

T1

T2

LRCH

P2

Variable displacement piston pumps -

Used to provide a proportional amount of hydraulic oil supply. Their primary advantage over a gear pump is operating efficiency. They only produce oil when there is a requirement. Form 1 uses a DFR to control the output of the pump, this type pump control utilizes a load sense signal from the system to control the pumps output.

Form 2, also a piston pump, utilizes an LRCH to control the output of the pump. This type pump control uses proportional pilot pressure from the joysticks in the operator’s cab to control the output of the pump. There are several other signals

connected to the LRCH, which all play a part in the control of the pump, depending on the operating configuration of the machine.

Bidirectional fixed displacement motor

-Two directions of rotation. Hydraulic oil is

supplied to either side to control the direction of rotation, used in hoist and swing applications. The T1 and T2 ports are provide to permit cooling and lubricating oil to flow through the motor case. 1-8

DFR

T

P3

Form 1 Form 2

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Description

Symbol

Pump/motor unit - Fixed displacement, two

directions of rotation. This component can act as a pump or a motor. It is normally used in swing circuits.

T

P

a

b

c d

a

e

f

Joystick control - Used by the operator to

control the amount of pilot pressure sent to various crane functions, joystick movement is directly proportional to the speed of the function. The a, b, e, and f ports are connected to control valves and or actuators. The P port is connect to a regulated pilot supply.

Speed control - Used to regulate the

amount of pilot pressure that is supplied to the swing directional valve. The A and B ports are connected in parallel to the pilot lines that shift the directional control spool for the swing circuit. The relief valve symbol contains an adjustable spring symbol which represents an adjustment knob. The

operator can regulate the amount of pilot pressure which is allowed to pass through the relief valve by increasing or decreasing the amount of tension on the spring.

T

P

Swing brake control pedal - Used by the

operator to control the application of the swing brake.

1-9

5 - 30 bar

A B T

Connected to swing brake

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Description

Symbol

Logic valve

-Combines flow from pumps to increase function speed. This symbol is used on the GMK 5130 to combine oil flow from two different piston pump. This is

accomplished by controlling the pilot line at the top of the symbol. The pilot line is connected to the top surface of the logic valve. The top portion of the logic valve has twice the surface area

as ports A or B. The top pilot line is connected to port A via a solenoid valve, which is not part of this symbol. When the solenoid valve is de-energized, the logic valve will remain closed thus separating the flow in the A and B ports. When the solenoid valve is energized the pilot line will be connected to tank thus the logic valve will open and permit the flow from ports A and B to

combined. Although the function speed will increase, the amount of functions that can be operated at one time will be severely limited.

1-10

W

A

B

Accumulator - used to store hydraulic

energy. Typical application is the carrier suspension circuit. The accumulator

absorbs pressures spikes in the suspension circuit to provide a smoother ride. The

superstructure swing circuits also incorporate accumulators to ensure the swing brake remains released when in the trailing boom configuration.

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1

Section 2

Section 2 Electric Symbols

This section contains a basic introduction to GMK electric schematic symbols. This information will provide a good foundation for a technician new to the GMK product line or a refresher for a veteran technician. The first three pages explain the description of location information found on the title page of the schematic. It also provides tips that will help a technician navigate from page to page within a machine schematic. The remaining body of the this section is laid out with the electric symbol on the right side of the page and the

supporting text on the left side across from the symbol.

Note:

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GMK Electrical Symbols

Symbol

Description of Location

+BE 540

+BE 550

.UM4 .UM5 .UM3 .UM2 .UM1

.UL1 .UL2 .UL3 .UL4 .UL5

.UR1 .UR2 .UR3 .UR4 .UR5

V5 V4 .AK2 .AK1 V3 V2 V1 V6 V7 V8 V9

Description

Located on each electrical schematic is an illustration that provides information to aid in

the location of electrical components on the carrier. The following is a general description of how to use this information.

The electrical schematic description of location provides the technician with a grid map of the carrier. The carrier is divided into two major areas: +BE550 which is the locator for the cab: and +BE540 is the locator for the carrier frame. The frame is broken down into three sections, each with five sub sections. The left side of the machine is designated as .UL1 -.UL5. The middle of the machine is designated as .UM1 - .UM5, and the right side is designated as .UR1 - .UR5. The outrigger control boxes are identified as .AK1 and .AK2. They are located on each side of the carrier. The terminal boxes are designated as. V1 -.V9, and are located in various areas throughout the machine.

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Symbol

+BE 550

.A1 .A2 .A3 .A4.A5 .A6 .A7 .A8 .A9 .A10

.LS

.S1

.A11

Carrier Cab

?

Steering Wheel

Dash Panel Enclosures

Drivers Seat

_{Relay Box}

Description

The cab is broken down into 13 areas. Each area is designated with an identifier to aid the technician with the location of electrical components. The designation .A1 - .A13 is used to identify all dash panel enclosures. All electrical components housed within a dash panel enclosure will be represented schematically within an enclosure line on the schematic. For example, if you are looking for the carrier ignition switch on the electrical schematic, from the illustration and your knowledge of the machine you can see the switch is housed in dash panel enclosure .A4. To find the schematic representation of the ignition switch we must look for the enclosure identifier .A4 with the locator +BE550.

The . A4 enclosure will show all components that are housed within that dash panel. The designation .S1 represents the fuse panel, all fuse banks are located within this compartment. The .LS designation represents all components that are within the steering wheel/column area.

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Symbol

Description

The superstructure is broken down into eight areas . A grid locator map is

provided to aid the technician with the location of electrical components. There are eight major areas identified on the grid map. +BE600.R is the locator for the superstructure right side. +BE600.M is the locator for the middle of the

superstructure, and +BE 600.L is the locator for the left side. The engine compartment uses +BE 660 and the auxiliary hoist is identified with the +BE620 designation. Valve Block assemblies are located at various areas on the machine, and use the VB1 - VB3 designation. Terminal boxes use the locator

designation V, as does the carrier.

The operator’s cab locator is +BE630. Within the operator’s cab are several

identifiers to aid the technician with locating specific areas in the cab. The operator’s seat uses .K to identify this area of cab. The left and right armrest use .KL and .KR respectively. The identifiers .A1 - . A7 represent modules or dash panel enclosures within the cab.

+BE630 V3 V14 V13 +BE660 V2 _V34 +BE600.R +BE600.M +BE600.L .S2 .K .A5 .A4 .KR .KL .A7 .A6 .A2 -A100 .A1 .A3 .S1

GMK 5130

Superstructure

Grid Locator Map

VB2 VB3 VB1

X34

+BE620

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Description

Symbol

Title Block 1 2 3 4 etc. Grid #1 Grid #2 Grid #3 Grid #4 etc.

Grid lines - Each page of a schematic

has numbers across the top and bottom from right to left. These rows of numbers form zones which are known as grids. These grids are used to help with schematic navigation. The grids start with #1 on the right side and continue through #24. This information is vital when tracing a circuit.

Circuit tracing - Information is provided

on wire lines that will aid in schematic navigation. In this example, the

information tells a technician where this particular circuit continuation can be found on the overall schematic. The first

number represents the dash panel or module the circuit is continuing on to. The next number represents the plug or connector that this particular circuit can be found within on the .A9 module. The last number represents the pin number within the connector where this circuit will be found.

The bottom set of numbers also provide additional information concerning the continuation of this circuit. The

continuation will be found on sheet # 4, within grid # 15. When moving to page # 4, a techncian must first look for the .A9 module, then within grid # 15 he should be able to find the X1 connector and pin # 13.

.A9 X1 13

4.15

Pin # Connector Module Sheet # Grid # 2-4

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Description

Symbol

Form 1

Form 2

Conductors - Conductors or wires that

cross but do not intersect are represented in form 1. Conductors or wires that cross and intersect are represented in form 2.

Female socket - Female portion of a pin

connection found on a wiring harness plug or component.

Male plug - Male portion of a pin

connection found an a wiring harness plug or component.

Ground - Frame ground

Terminal connections - The numbers

provided at wire connections give the location of the connection point as well as the plug numbers and the pin numbers.

X2 8 X26 6

+BE550 .S1

Connector Pin number within

a connector

Locator

Identifier

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Description

Symbol

X1 3

V6

Terminal strip connection - The numbers

provide the following information: V6 indicates a terminal box located on the carrier. X1 represents the wiring harness going to the V6 terminal box. The

number 3 indicates the terminal strip number within the V6 terminal box.

1 2 3 4 5 6 7

Terminal strip connections - Terminal

strips can also be drawn horizontally with spaces in between the terminal connections. This symbol may spread over several grids on one sheet.

Fuse Bank - Made up of six 10-amp fuses. The -F5 designation indicates the fuse bank number with each fuse being numbered 1 through 6. The fuse bank is located in module or enclosure .S1 within the carrier cab. The fuse bank receives power from module .A4 harness plug X1, pin number 5. The origin of the power supply is found on schematic sheet number 1, grid number 21.

-F5

_.A4 X1 5 1 . 21

.S1

A 1 2 3 4 5 6 B C D E F 10 A 10A 10 A 10 A 10 A 10 A Sheet Grid 2-6

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Description

Symbol

Pressure switch - Used to monitor

pressure within hydraulic and other fluid power systems. These switches are normally used to trigger an electrical relay chain to energize a variety of solenoid valves and other electrical components.

P

T

Temperature switch - Used to monitor the

temperature of fluid within power units for example, hydraulic oil, transmission fliud, and engine coolant etc...

Toggle switches - Used in a variety of

applications, serves as a single pole “on-off” switch.

Momentary toggle switches - Used in

a variety of applications, serves as single pole “on-off” switch. It must be held in the “on” position.

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Description

Symbol

br bl sw Form 1 br bl sw Form 2

Proximity switch - These switches are used

in a variety of applications, for example the boom, suspension, rear steer lock etc. Form 1 is the schematic representation of a normally closed proximity switch. Form 2 represents a normally open switch. The “br” represents the supply voltage, the “bl” represents the ground, and “sw” represents the signal wire.

Single-pole switch - This style switch is also provided with an indicator light, all switches carry the “S” designation, as well as a number. The light will illuminate when the switch is activated.

0 1 1 9 5 10 7 1 8 2 9 3 4 10 0 1

Double-pole double-throw switch - Used

in a variety of locations within both cabs. This particular example also provides a light which indicates when the switch is activated. Also notice the normally open and normally closed contacts. This type switch is used many different ways.In some cases the open contacts may not be connected to any circuits and in other cases they may be used. It is vital that the technician pay close attention to the particular circuit connections he is working with.

2-8

S1

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Description

Symbol

Form 1 Form 2

Diode - Diodes will be represented in

three different forms, form 1 is used to illustrate a blocking diode, form 2 and form 3 are used to illustrate an L.E.D., or Light Emitting Diode, which are used as troubleshooting indicators.

Form 3

Swivel slip-ring - used to represent the

connection of an electrical slip-ring within a swivel assembly. This symbol is often mistaken for a diode symbol, the difference between the two symbols is the width of the arrow . The slip-ring symbol is more narrow then the diode.

Solenoid valve - Solenoid valves will

be shown in two different forms, form1 illustrates a valve without an arc suppression diode.

Form 2 represents a solenoid valve with an internal diode to prevent arcing of switch contacts.

Form 1 Form 2

M

3 2

Lubrication pump - used to represent

an automatic lubrication system pump assembly.

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Description

Symbol

P _Q

Form 1 _{Form 2}

Sending units - There are a variety of

sending unit symbols used on GMK schematics, these two forms illustrate examples of what can be encountered. Form 1 represents a pressure sending unit with an indicator light. Form 2 represents a fuel quantity sending unit without an indicator light.

Gauges - These are examples of gauge

symbols that are used on GMK schematics. Form 1 illustrates a gauge with a internal indicator warning light as well as an analog indication. This particular example also has a light for illumination of the gauge. Form 2 is similar but it does not have an internal warning light.

+ L -G WK + L -G Form 1 Form 2

+

-24V 12V S SW BR GE

DC to DC converter - This is an example

of a converter which transforms 24 volts DC to 12 volts DC.

G 3

U

Dynamo/Alternator - This is the symbol

used to illustrate a alternator or as it is referred to on the GMK schematics, a dynamo.

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Description

Symbol

Relay Identification - The letter K is used

to designate a relay. The prefix number identifies which circuit the relay is used in and the last number is used as

identification of a specific relay within a circuit.

Superstructure Relay Identification -Without any prefix - Safe load indicator,

hoist limit, and or engine control With prefix 0 = Pump Control With prefix 1 = Main hoist With prefix 2 = Auxiliary hoist

With prefix 3 = Telescope/Derricking

2K5

Circuit Prefix

Relay identification

number

Relay - In this example, the relay coil

is shown as a separate symbol on the schematic. The contacts for the relay are drawn on the same page within the same enclosure module, but they are not connected with a line. When tracing a circuit it is important to make sure you are looking at the correct set of relay

contacts. A technician must always

look for the relay identification number.

Coil 85 86 K50 K50 30 87 87 b Contacts K10 85 86 87 87 b 30

Relay - The same basic component can

also be represented schematically as shown in this example. The major difference is that a line connects the coil of the relay to the contacts of the relay. The theory of operation for these two symbols is exactly the same.

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Description

Symbol

Relay - Multiple contact relays are

commonly used on GMK machines. This is an example of how a four contact relay will be represented on an

electrical schematic. The numbers provide a great deal of information that is necessary for navigating through the various circuits. The numbers on the left side of the contacts represent the location of the contacts on the schematic. A single number indicates the contacts are on the same page as the relay coil and can be found in grid 15. The next example shows two numbers with a period between them. The

first number represents the page number the contacts can be located on and the second number represents the grid on that page. When a period is found beside the contacts, this means the contacts are not used in this circuit.

The numbers on the contacts also provide information. The first number represents the order the contacts are arranged on the schematic. The second number tells you if the contacts are normally open or are normally closed. If you examine the other sets of contacts, you should be able to see this pattern. Contacts not used Second set of contacts A1 A2 2K5 4.8 13 14 33 34 43 44 21 22 15

.

10 Coil terminals Relay Identification Grid number Page & Grid #

13

14

22

21

Normally closed Normally open First set of contacts 2-12

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Description

Symbol

A1 A2 2K4 13 14 23 24 33 34 43 44 53 54 63 ₆₄ 73 ₇₄ 83 ₈₄ 12 12 10 8 4.17 4.20 4.15 4.16

Relay - This is the schematic representation

of a relay with eight sets of contacts. This particular example is using all normally open contacts. Notice the contact location

information on the left side of the symbol. The first four sets of contacts are located on the same page and the last four sets of contacts will be found on page number four in there respective grid areas.

2K20 _B1 _A1

A2

15 18

Time Delay Relay - Time delay relays

are used to keep a circuit energized for a short time after power has been removed from the control circuit. They are used in a variety of applications. The first noticeable difference is the coil

symbol. There are three wires connected to the coil unlike the previous examples. Also notice the coil symbol has a black box on the left side of the symbol also unlike the previous examples.

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1

Section 3

Section 3 Pneumatic Symbols

This section contains a basic introduction to GMK pneumatic schematic symbols. Each page is laid out with the symbol on the right side of the page and the supporting text on the left. The supporting text will provide a

description of the symbol, where the component is normally used, and in some cases a theory of operation.

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GMK Pneumatic Symbols

Description

Symbol

Working line - A solid line represents

a working section of the circuit. The numbers shown above indicate the outside line diameter and the cross section of the inner diameter.

Outside diameter Tubing wall

thickness 12 X 1.5

Control line - Used to illustrate control

pressure.

Ventilation line - Used to illustrate

air exhaust from the system.

W

5 bar

S62

Pressure switch - Used to close

electric contacts when the air system reaches a predetermined value. Each switch is assigned a number, which will aid in locating the

switch on the electrical schematic

.

40 l V1

X

Manual drain valve Test port

Air reservoir - Used to store supply

air volume. Also represented are a manual drain valve and test port.

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Description

Symbol

3/4 NPT Air compressor - Generates air supply

for the system. A control line is provided from the air dryer to control the

output of the compressor.

Port identification - This list of numbers

is used to represent the corresponding type port. A second digit is to be provided if there are several similar connections. For example: 21 - energy output to energy storage device ( air reservoir 1 ) and 22 - energy output storage device ( air reservoir 2 ). If one connection can fulfill several functions, it must be identified by two ( first ) digits. These are to be separated from each other by means of a dashed line. For example: 1-2

energy input or energy output

0 - Intake connection 1 - Energy input

2 - Energy output ( not to atmosphere ) 3 - Connection to atmosphere

4 - Control connection or pilot inlet on component

5 - Not used 6 - Not used

7 - Antifreeze connection

8 - Lubrication oil Connection on compressor

9 - Coolant connection on compressor

W

1

2

6 bar

Pressure reducing valve - Limits system

pressure to 6 bar is this case. Also notice the port identification. The 1 indicates energy input and the 2 indicates energy output, as listed above.

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Description

Symbol

WW

Single-acting cylinder - Used to actuate

various mechanical components via air pressure. i.e., inter axle diff locks, or cross axle diff locks.

1 2 3 4

2

Relay valve - used to control air volume

to service brake chambers. Port

identification is as followings: port #1 is the input supply directly from the air reservoir. Port #2 output air supply to brake chambers when relay is triggered. Port #3 releases air to atmosphere when control pressure signal has been removed. Port #4 control pressure from service brake pedal, and triggers actuation of relay valve.

1

41 42

2 2

3

Anti compounding valve - In the event

the parking brake and the service brake are applied at the same time, this valve

prevents possible damage to the brake drums by metering air into the maxi brake chambers thus compressing the parking brake spring tension.

Port identification is as follows,

Port #1 is the supply from air reservoir, Port #2 is the output supply to the maxi brake chambers, Port #41 is the control pressure input signal from the service brake pedal, Port #42 is the control pressure signal from the parking brake hand valve.

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Description

Symbol

W W W W ₂₃ 24 22 21 1 5.5 bar 5.5 bar 6 bar 6 bar

Circuit Protection valve - Used to isolate

individual circuits in the event of

a system failure. This valve will prevent a complete loss of system air volume if one of the circuit lines rupture. The port identification is as follows: Port #1 is the input supply from the air dryer, Port # 21 supplies, in this case brake circuit number one. Port #22 supplies brake circuit number two. Port #23 supplies brake circuit number three, and Port #24 supplies brake circuit number four.

1-2

W

1 2

Tire inflator valve - Used to inflate tires

or provide an external air supply. Port identification is as follows: Port #1 is the supply from the air compressor, Port #2 is the output supply to the quick disconnect and Port # 1-2 is the source for the external supply.

11 12 3 3 21 21 21 22 22 22

Service brake valve - used by the

operator to meter air volume to the service brakes. Port identification is as follows: Ports #11&12 are the supply ports from the number 1 & 2 brake circuits, respectively. The Ports numbered 21 & 22 are output control lines to various relay valves, and the ports numbered 3 are representing air exhaust to the

atmosphere.

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Description

Symbol

W

3 1

21 22

Parking brake hand valve - This valve

is used to control brake release air volume to the maxi brake chambers. It has three possible positions: as shown, the valve would supply control air volume to release the maxi brakes. The next position would permit the operator to bleed off release air to slowly apply the maxi brakes. The last position would exhaust the

release air volume completely, thus applying the parking brake. The port identifications would follow the same pattern as the previous symbols.

WW

Service Brake Chamber - Used primarily

on the front axle to apply brakes when air air volume is supplied to the inlet port.

WW

_WW

11 12 Maxi brake chamber - Used for

two primary purposes: applying air to Port # 12 will release the parking brake

and allow the machine to move. If air volume is applied to Port # 11, the service brakes will be applied, thus stopping or

slowing the machine.

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Description

Symbol

3-6

Air dryer - The air dryer is provided to

remove moisture from the system. It also serves as a governing device to limit the maximum amount of air pressure the system can achieve. The port identification is as follows: Port #1 is the inlet supply from the air compressor, Port #21 is the output line which supplies air volume to the pressure protection valve. Port #22 is connected to the regeneration tank, which purges the system when the maximum pressure is reached. The two-position valve at the top of the symbol is set at 8.1 bar. This device serves as the pressure limiting component for the system.

W W WW W 8.1 bar 21 22 3 1 4

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1

Section 4

Section 4 Elan Electrical Schematics

This section contains a basic introduction to GMK Elan schematic structure and symbols. The information contained herein will provide a good

foundation for a technician new to the GMK product line, or as a refresher for a veteran technician. This section will began with a general description of Elan, followed by several pages laid out in two different manners. The first several page will have examples at the top of the page and the supporting text at the bottom. This will be followed by several pages with the schematic symbols on the right side of the page and the supporting text on the left. The supporting text will provide a description of the symbol and in some cases theory of operation.

Note:

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Elan Electrical Schematics

Symbol

Description

4-1 Section 01

Title Page Section 01Contents Page 1-XPrint 1

Section 02

Section 03

Location Map Page 2 Upper Location Map Page 1 Carrier

“Elan” Schematic structure

The Elan schematic structure begins with several pages depicting graphic views of major sections of the crane. All major sections are called assembly groups, which are given an identity or location code. For example: Carrier Chassis +BE 505,

Carrier Cab + BE 550, Turntable + BE 600, Superstructure cab +BE 630, and Telescopic boom + BE700.

The major assembly groups are then divided into functions groups.

The function groups are given an identity number. The function groups are made up of a title page, table of contents page, and finally the actual Elan schematic pages. For example: Carrier frame, 02 = Diesel Engine Chassis 41 = Drive unit Chassis, 47 = Steering Chassis, Superstructure 11 = Main hoist, 23 = slewing gear and, 37 = safety equipment

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Elan Electrical Schematics D

Symbol

Description

This is an example of a function group location map. This map represents the carrier and the drivers cab, the drivers cab is designated as +BE550 and the carrier frame is

designated as +BE 506. The carrier frame is subdivided into specific location areas with individual identification /location codes. For example UR1, UM3, these designations will aid a technician with the location of electrical components much like the location maps provided on single sheet electrical schematics. Additional component identification /locations are also given to enclosures with abbreviated identification/location, and a listed description. The list of codes is located under each of the respective maps. This information will direct a technician to specific areas of the machine, thus aiding in component location when

troubleshooting. 4-2 Mi cr o fil m F rei ga be : 2 5. 04 .9 5 C A D - Z E ICH N U N G G R O V E M O BI LK RANE G m b H F ur di es e U nt er Lo gan beh al ten w ir uns al ls R ei cht s vor , auc h f ur d en F el l d er P ot en ter tei lu ng ode r G ebr au che -m us tei nt ragu ng. S ie da rf o hne un sr e v or her ige sc hr ift lic he Z us tim m ung w eder v er vi el fa lti gt no ch s or es t-w ie be nut zt , no ch D rit te n z uga ngl ic h ge m ac ht w er den. F E D C B A 1 2 3 4 5 6 7 17.03.98 pos Datum Name Ges. Plot A 841070 0

Zust.Anderungs- Nr.Anz ahl Name

07.01.97 Plotdatum 04.05.98 SKS Urspr. Ers.f. GMK Er s.d. Benennung AnLagenkennzeichung Ortskennzeichen UW FHG800 Abt. TK 4 Auftrags - N r. Kenwort Zeic hnungs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 1 8 Bl. F E D C B A +BE 506

.UR1 .UR2 .UR3 .UR4 .UR5

.UL1 .UL2 .UL3

FUR SEPARATLENKUNG for separate steering

.UL5

.UM1 .UM2 .UM3 .SR .UM4 .UM5

+BE550 .A6 FAHRERHAUS driverscabin FAHRGESTELL carrier +BE 506 FAHRERHAUS driverscabine +BE 550 .V1 - .V8 .UL1 - .UL5 .UM1 - .UM5 .UR1 - .UR5 .SR .AK1 .AK2 .NK1 .NK2 .B1/.B2 terminalboxes section carrier left section carrier middle section carrier right sliprings stabilizing unit left

carrier lights front/rear stabilizing unit right angle status display left angle status display right VERTEILERKASEN

SEKTIONEN KRANTRAGER LINKS SEKTIONEN KRANTRAGER MITTE SEKTIONEN KRANTRAGER RECHTS SCHLEIFRINGKORPER ABSTUTZEINHEIT LINKS STObSTANGE VORNE/HINTEN ABSTUTZEINHEIT RECHTS NEIGUNGSAZEIGE LINKS NEIGUNGSAZEIGE RECHTS .A1 - .A4 .AL .LS .S1 panel modules cabinelements steeringcolumn connections MODULE KABINENELEMENTE LENKSAULE SCHNITTSTELLE FAHRERHAUSE driverscabin .A3 .A2 .A1 .S1 .A4 .LS .V9 .V7 .V8 .AK2 .V4 .NK2 .V5 .V6 .AK1 .V10 .NK1 .V2 .V3 .V1 +BE550 UNTERWAGEN carrier .UL4

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Developed by Grove Training Institute

Symbol

Description

This is an example of the superstructure locator map. As in the previous

example, it provides the technician with identification / location codes that will aid in determining the location of components on the machine. The superstructure is identified as +BE600 and the superstructure cab is designated as +BE630. Terminal boxes, counterweight cylinders , valves, and other components are identified in the lists located under the respective map.

Within the Operator’s cab are several identifiers to help a technician locate specific items inside the cab. The seat is identified as K5, and the left and right armrest use KL. And KR. respectively. The identifiers .A1 -.A5 represent modules or dash panel enclosures within the cab.

4-3 1 2 3 4 5 6 7 1 9 .0 9 .9 4 p o s p o s p o s D a tu m N a m e G e s . P lo t A 3 4 48 4 3 Z us t. A n d e ru n g s -N r. A n z a h l N a m e P O S IM A p o s tm a P lo td a tum 1 9 .0 9 .9 4 SKS U r s p r. Ers.f. GMK E r s .d . B en en nu ng AnLagenkennzeichnung Ortskennzeichen OW F H G800 A b t. TK 4 A uf tr ag s - N r . K en w o r t Z e ic h nu ng s - N r. F 3 B la tt 2 2 B l. Mi cr o fi lm F rei ga be: 25 .04 .95 CA D - Z E ICHN UNG GROV E M O B ILK R A N E G m b H F ur di es e U nte rLoga n behal ten w ir uns al ls R e ic hts v or , auc h f ur den F el l der P ot ent er tei lung oder G ebr auc he -m us te int ragung. S ie d ar f oh ne uns re v or her ige sc hr ift lic he Z us tim m un g w ede r v er vi e lfal tigt no ch sor e st-w ie ben ut zt , no ch D rit ten z ugang lic h gemac ht w erden . F E D C B A 1 2 3 4 5 6 7 8 8 F E D C B A HIFLSH UBTRAGE R AUXILIARYHO IST +BE 620 -A103 +BE600 .V7 .V2 .VB2 .VB1 .V1 -M 1 -V3 .GZR -A102 .VB3 .V6 -101 -X101,102 .V5 .GZL.V4 -X203 +BE620 .V8

-A114 -A111 -A104

+BE630 .AL

.A1.A2.A3

.A4 .KR .A5 .KL .K5 -X201,202 DREHT ISCH TUR NTA BLE +BE 600

K RANK ABINE CRANEDR IVERS CABIN +BE 630 TELESKO PAUSLEG ER B OO M S +BE 700 .A1 - .A8 .KR .KL .KS .AL MO DU LE KRANSITZ RECHT S KRANSITZ LIN KS KRANSITZ KAB INENELE ME NTE

PAN ELMODULES

CRA NEDR IVERSEAT RIG HT

CRA NEDR IVERSEAT LEFT

CRA NEDR IVERSEAT

CABIN ELEMENTS -A102 -A103 -A104 -A111 -A114 -X201,202

DRU CKAU FNEHME R

WINKLE / LANG E

KABELTR OM MEL TELE 1 KABELTR OM MEL TELE 2 - 4 STECKVE RBER BING UN G

PRE SSURE SENSER

ANG LE / LENG H T CAB LEDRU M T ELE 1 CAB LEDRU M T ELE 2 - 4 CO NN ECTO RS .V1 - .V8 .G ZR .G ZL .VB 1 - .VB3 -A101 X101, 200 - 300 -M 1 VERTEILERKASTEN GEG N GEW IC HTSZYL. RECHT S

GEG N GEW IC HTSZYL. LIN KS VEN TILBLOCKE MESSW E RTSENDER STECKVE RBINDUNG OLKUH LE R TERMINALBOXE S CO UN TERW EIGHTCYL. RIGHT CO UN TERW EIGHTCYL. LEFT VALVES PLU GS O ILRADIATO R A A A

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Symbol

Description

This is an example of a title page for a function group. Each function group begins with the same basic cover sheet.

4-4 Mi cr of ilm F re iga be : 20 .04 .98 C A D ZE IC HNUN G F ur di es e U nt erL ogan beh al ten w ir un s al ls R ei cht s vo r, auc h fur de n F e ll der P otent er te ilung ode r G ebr auc he -m us tei nt ragun g. S ie da rf oh ne uns re v or her ig e sc hr ift lic he Z us tim m ung w ed er v er vi el fa lti g t noc h so re st -w ie be nut zt , noc h D rit te n z uga n gl ic h ge m a ch t w er den . F E D C B A 1 2 3 4 5 6 7 17.04.98 pos Datum Name Ges. Plot A 841078 0

Zust.Anderungs-Nr.Anzahl Name

07.01.97 Plotdatum STR Urspr. Ers.f. Er s.d. B en en nu n g PLAN, E-SCHALT-DIESEL-MASCHINEN-ANLAGE UW FHG800 Abt. TK 4 Au ftra gs - N r. Ke nwort Zeic hn un gs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 1 17 Bl. F E D C B A =02 GROVE CRANE 

=02

Diesel-Maschinen

Anlage UW

diesel engine

installation chassis

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Symbol

Description

4-5 Mi cr of ilm F rei ga be : 20 .04. 98 C AD - Z E ICHNUNG F u r di e se U n te rLog an beh alten w ir u ns al ls R ei cht s vo r, a uc h fu r de n F el l de r P ot en ter te ilung ode r G e br auche-m us tei nt ra gun g. S ie dar f ohne unsr e v o rher ig e sc hr ift lic he Z us tim m ung w eder ver vi el fa lti g t noch sor est -w ie ben ut zt , noc h D rit te n z uga n gl ic h ge m acht w er d en. F E D C B A 1 2 3 4 5 6 7 17.03.98 pos Datum Name G es. Plot A 841070 0

Zust.Anderungs-Nr.Anzahl Name

05.01.98 Plotdatum 04.05.98

SKS

Urspr. Ers.f. Ers.d.

Be nenn un g AnLagenkennzeichung Ortskennzeichen UW + OW FHG800 Abt. TK 4 A uftrag s - N r. Ke nwort Zeic hn un gs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 8 8 Bl. F E D C B A GROVE CRANE 

The example above illustrates a table of contents page that outlines each page or (Blatt) within a function group. The remarks section on the right side of the page gives a brief explanation of what portion of the electrical circuit is covered

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Symbol

Description

4-6 Once you have a good understanding of the Elan structure, it is important to learn

how to navigate for page to page and from function group to function group. Circuits that continue to other pages are given identification of the continuation by group/page and grid line as required; there may be a signal number with a +BE code and a destination terminal reference. The signal number is for continuation identification only; it is not a wire number. On later GMK models the Elan schematics have less signal numbers. They give the wire termination with module/insert/terminal box identification, and the function group, page & grid reference numbers. The next several examples will illustrate how to move within the Elan schematic document.

Mi cr of ilm Fr ei ga be: 2 0 .04. 98 C A D - Z E IC HN UN G Fur d ies e U nterL ogan be ha lte n w ir un s alls Rei chts vor, au ch fur d en Fell d er P otent erteilun g oder Gebr au che-mus tei ntragu ng. Sie d arf o hne uns re v orher ige sc hriftlic he Z ustim m un g wede r v ervielfa ltigt noc h s orest -wie b enu tzt, n oc h D ritten z uga ngl ich ge mach t w er de n. F E D C B A 1 2 3 4 5 6 7 17.04.98pos Datum Name Ges. Plot A 841078 0 Zust.Anderungs-Nr.Anz ahl Name

07.01.97 Plotdatum 04.05.98 Urspr. Ers.f. Ers.d.

B enennung FHG800 Abt.TK 4 Auftrags - N r. Kenwort Zeic hnungs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 3 17 Bl. F E D C B A GROVECRANE  STR PLAN, E-SCHALT-DIESEL-MASCHINEN-ANLAGE UW Postma =02+BE550.S1 1 2 3 4 5 6 7 8 9 10 Batterie 2 X 12V Battery 2 X 12V Batteriehaupt-schlater battery master switch Anlasser starter Lichtsmachine alternator Fogeschaden-schultz high voltage protection No. < > 15 7 /15. 1 + B E 50 6.U M 2 -A 1 5 0 S1 /3 0 /5 .1 6 2 95 2 2, 5 2 16 2 95 2 47 /17.6 +BE506.UL4 -A2 : 95 2 2,5 2 M G 3 U 16 2 D-D+ - F11 +BE503.UM2 D+ B+W - G3 +BE506.UM2 - M1 +BE506.UM2 50 30 6 2 95 2 -X2+13 = -F9 20A 1 2 +BE506.UL2 -G1 +BE506.UL2 -53 +BE506.UL2 -G2 +BE506.UL2 + + _ _ < 4 > < 3 > < 1 > < 2 > < 5 > -X5 1 = -F7 50A 1 2 +BE506.UL2 = -F6 50A 1 2 +BE506.UL2 /10. 6 -F 6/ 6 6 31 B-70 2 2, 5 2 4 8 /5 .7 +-K 5 3 0 /6 .1 -F 1/ 1.1 S 1/ R30/5.1 6 2 2, 5 2 6 2 6 2 -X2 12 21 /16. 4 -A 1 1 1 /3 3 /5 .4 -K 5 8 6 1 =4 4/ 4 .1 PLUS 1 MINUS 1 Kundenwunnsch customers request X) 6 2 95 2 Mi cr of ilm F rei ga be: 20. 04. 98 C AD - Z E ICHNU NG Fur dies e U nte rLog an be ha lten w ir uns a lls R eicht s vo r, au ch fu r d en Fell de r Pote nter teilun g ode r G ebr auch e-m ustei nt ragu ng . Sie da rf oh ne un sre v or herig e sc hrift liche Zustim mung w eder v er vielfal tigt no ch s orest -wie be nu tzt, noc h D ritte n z uga ng lich ge mach t werden . F E D C B A 1 2 3 4 5 6 7 17.04.98pos Datum Name Ges. Plot A 841078 0 Zust.Anderungs-Nr.Anz ahl Name

05.01.98 Plotdatum STR Urspr. Ers.f. Er s.d. Ben ennung FHG800 Abt.TK 4 A uftrag s - N r. K enwort Zeic hnu ngs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 5 17 Bl. F E D C B A GROVECRANE  Pos tma ihnen PLAN, E-SCHALT-DIESEL-MASCHINEN-ANLAGE UW =02 +BE550.A3 1 Zuendschalter ignition switch 2 3 4 5 6 7 8 9 10 AnLasssperre starter interuption No. < > R15 15 +BE550.LS 50 P30 R30 -X94 P30 +BE550.LS -X941 5 +BE550.LS -X94 15 +BE550.LS -X941 8 +BE550.LS S1/15 /7.1 -X94 50 +BE550.LS -X941 7 +BE550.LS /15.1 +BE550.S1 -X1 8 -X43 4 + -X43 3 + /16.5 +BE550.S1 -A1 11/5 -X43 5+ -K330 87 5 = 2 22 -K12 4 3 =41 5 +BE550.S1 =41/7.6 -X94 R15 +BE550.LS -X941 3 +BE550.LS /9.1 S1/R15 -S1 -X941 6 -X94 30 +BE550.LS -X941 4 -X94 R30 +BE550.LS 30 +BE550.LS +BE550.LS /3.2 S1/R30 /3.2 S1/30 2, 5 2 6 2 2,5 2 6 2 -X43 2 + -X43 3 -K5 87 30 85 +BE550.S186 OHNE DIODE without diode -K386 +BE550.S185 OHNE DIODE without diode -H1 1 GE 2 RT 87a 7 1 87 30 87a 2 /3.5 +BE550.S1 -X2 12 S1 27 /1 2.1 -P 6 + /4.7 F3: 1/2 /8.2 -K530 87 5 = +BE550.S1 8 /3 .3 10 /1 0.1+BE5 50 .S1 -F6 /1 1 6 2 6 2 Ladekontrolle charge control < 3 > < 1 > < 2 >

Navigating “Elan” Schematics

Function Group= 02/3.2=Sheet, Grid

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Description

Symbol

Grid lines - Each page of an Elan Schematic has numbers across the top and bottom from left to right. These rows of numbers form zones which are known as grids.

These grids are used to help with schematic navigation. The grids start with #1 on the left side and continue through #8. This information is vital when tracing a circuit. The schematic drawing extends from grid 1-7. Grid 8 is reserved for component description and has vertical numerical reference 1-10. Component functions that require a

description are contained within numbered brackets < > on the schematic. The

brackets number is then referred to in the description column for its particular

function.

4-7

Page identification – The component Identification /location area code is shown on the bottom right corner of the page, directly beneath the function group. Should a component have another location the Identification/location codes are listed Beside the component item on the Schematic drawing; these codes can be used to locate the

components on the crane relative to the assembly locator map.

=02

+BE550.S1 Blatt 3

20 Bl Page 3_{of 20}

Function group: =Diesel Engine Install

Location: + Carrier cab Connection .S1 Mi cr o fil m Fr ei ga be : 20 .0 4. 98 C A D Z E ICHN UN G Fur di ese U nter Logan beh al ten w ir uns al ls R eicht s vo r, auc h fur den Fel l der Potent ertei lung ode r Gebr auc he-m ustei ntragun g. Sie da rf oh ne unsr e v or her ige sc hriftlic he Z us tim mung weder v erviel faltigt noc h s or est -wie benu tz t, noc h D ritten z ug ang lic h gem ac ht w erden . F E D C B A 1 2 3 4 5 6 7 17.04.98pos Datum Name Ges. Plot A 841078 0 Zust.Anderungs-Nr.Anz ahl Name

Ben ennu ng F HG800 Abt.TK 4 Auftrags - N r. Kenwo rt Zeic hn un gs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 3 17 Bl. F E D C B A GROVECRANE  STR PLAN, E-SCHALT-DIESEL-MASCHINEN-ANLAGE UW Pos tma =02 +BE550.S1 1 2 3 4 5 6 7 8 9 10 Batterie 2 X 12V Battery 2 X 12V Batteriehaupt-schlater battery master switch Anlasser starter Lichtsmachine alternator Fogeschaden-schultz high voltage protection No. < > 15 7 /15. 1 + B E50 6.U M 2 -A1 50 S1 /3 0 /5.1 6 2 95 2 2, 5 2 16 2 95 2 47 /17.6 +BE506.UL4 -A2 : 95 2 2, 5 2 M G 3 U 16 2 D-D+ - F11 +BE503.UM2 D+ B+W - G3 +BE506.UM2 - M1 +BE506.UM2 50 30 6 2 95 2 -X213 + = -F9 20A 1 2 +BE506.UL2 -G1 +BE506.UL2 -53 +BE506.UL2 -G2 +BE506.UL2 + + _ _ < 4 > < 3 > < 1 > < 2 > < 5 > -X5 1 = -F7 50A 1 2 +BE506.UL2 = -F6 50A 1 2 +BE506.UL2 /1 0. 6 -F6 /6 6 31 B-70 2 2, 5 2 4 8 /5 .7 +-K 5 3 0 /6 .1 -F 1/ 1 .1 S1 /R 30/5.1 6 2 2, 5 2 6 2 6 2 -X212 21 /16. 4 -A 1 1 1 /3 3 /5 .4 -K 5 86 1 = 44/4 .1 PLUS 1 MINUS 1 Kundenwunnsch customers request X) 6 2 95 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Grid 8 - Description area

The bottom of the schematic is were the bracketed numbers will be located

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Description

Symbol

Circuit continuation – Form 2

The numbers provided at the

top of the line determine the function group number, the page, and grid number for this particular circuit.

Located on the underside of the

wire is the location identifier with the

module number. Followed by the connector number and the pin number for the respective circuit. The signal line is used to help guide the user to the correct area of the schematic on the Following page.

4-8

Circuit continuation – Form 1

Information will be provided at the end of each line. When no function group is provided the circuit

continuation is within the same

function group, in this example, page 12 Grid 1.

The number 20 represents a signal wire # that can be used to help ensure you are following the correct line on the following page.

The information at the bottom of the line provides the location on the crane as well as the module, plug, and pin number. Signal line /12.1 +BE550 .A2 – X40 3 20 No function group information prior to the page number indicates that the continuation is within the same function group; in this example, page 12 grid 1.

Location = Carrier cab

Module = .A2 – Connected to Plug/terminal –X40 pin3

Form 1

= 01/3.2 +BE600 A5 X22 9

4 Function group number,

Page and Grid Number

Location and module number Connector number 22 and Pin 9 within that connector

Signal line Form 2

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Description

Symbol

Special prefix symbols – There are basic symbols that are used within Elan to illustrate information application.

The( =) symbol is used to represent a function group. The (+) symbol is used to represent the location of a particular

component. The (–) symbol is used to illustrate a component.

Prefix letters – There are various abbreviations and prefixes used within Elan schematics, the list on the right

outlines a few examples. .

4-9 Function Group (=)

Example: =03 is lighting on the carrier Location of component (+)

Example: +BE550 .S1 is carrier cab connections. Component (- ) Example: - K1 is a relay B = Sensors E = White lights G = Battery/Generator H = Warning lights K = Relay M = Motor R = Resistor S = Switch

X = Terminal/Plug followed by a pin # Y = Solenoid

F = Fuse J = Joystick V = Diode

P = Pressure switch

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Description

Symbol

Component prefix – On later model GMK

machines, the switch, relay, and solenoid valve prefix numbers are the same as the function group number, for example; in form 1, solenoid valve” Y2130” is shown, The letter Y represents a solenoid and the next two numbers “21”, represent function group 21 or the telescope circuit. The last numbers are the identification number of the solenoid valve.

In form 2, a switch is illustrated, the

identification number of the switch is “S2304” The letter S represents a switch, and the first two numbers “23” , represent the slewing gear or swing circuit. The last two numbers are the identification number for this particular switch within the swing circuit.

4-10 Form 1 Y2130 7 1 8 2 9 5 6 10 0 1 Form 2 S2304

Elan layout – The schematic is drawn

in principle with the power supply path beginning at the top of the page and the ground path at the bottom. Later Elan schematics have dedicated pages for both power supply and ground terminations. Terminal boxes prefix (V) and PVC multi-core cables are now used instead of a traditional wiring harness. Cables of 2, 3, 5, 7, 12, 15, 25, & 55 core are used. The cables have wire numbers and all cables other than two core, have one brown wire that is used as ground.

Mi cr of ilm F re iga be : 20 .0 4 .9 8 C A D ZE IC HN UN G Fur di es e U nter Logan be halten w ir un s al ls R eicht s vo r, au ch fu r den Fel l der Pot ent erte ilung oder G ebr auc he-m uste intragun g. S ie dar f ohn e un sre v orher ig e sc hrift liche Zust im mung weder verviel faltigt noc h s orest -wie benut zt, no ch Drit ten z uga ngl ich ge mac ht w erden . F E D C B A 1 2 3 4 5 6 7 17.04.98pos Datum Name Ges. Plot A 841078 0 Zust.Anderungs-Nr.Anz ahl Name

Ben ennu ng F HG800 Abt.TK 4 Auftrags - N r. Kenwo rt Zeic hn un gs - N r. F 3 8 1 2 3 4 5 6 7 8 Blatt 3 17 Bl. F E D C B A GROVECRANE  STR PLAN, E-SCHALT-DIESEL-MASCHINEN-ANLAGE UW Pos tma =02 +BE550.S1 1 2 3 4 5 6 7 8 9 10 Batterie 2 X 12V Battery 2 X 12V Batteriehaupt-schlater battery master switch Anlasser starter Lichtsmachine alternator Fogeschaden-schultz high voltage protection No. < > 15 7 /1 5.1 + B E 506.U M 2 -A 1 50 S1 /3 0 /5.1 6 2 95 2 2, 5 2 16 2 95 2 47 /17.6 +BE506.UL4 -A2 : 95 2 2,5 2 M 3G U 16 2 D-D+ - F11 +BE503.UM2 D+ B+W - G3 +BE506.UM2 - M1 +BE506.UM2 50 30 6 2 95 2 -X213 + = -F9 20A 1 2 +BE506.UL2 -G1 +BE506.UL2 -53 +BE506.UL2 -G2 +BE506.UL2 + + _ _ < 4 > < 3 > < 1 > < 2 > < 5 > -X5 1 = -F7 50A 1 2 +BE506.UL2 = -F6 50A 1 2 +BE506.UL2 /1 0. 6 -F6 /6 6 31 B-70 2 2, 5 2 4 8 /5 .7 +-K 5 3 0 /6 .1 -F 1/ 1 .1 S1 /R 30/5.1 6 2 2, 5 2 6 2 6 2 -X212 21 /1 6.4 -A 1 1 1/3 3 /5 .4 -K 5 86 1 =4 4/ 4.1 PLUS 1 MINUS 1 Kundenwunnsch customers request X) 6 2 95 2 Power supply Ground Path

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Description

Symbol

Relays – Relays from Bosch, Siemens & Telemecanique are used.

Telemecanique has been used to replace Siemens in later models because it is power rated at 28 volts, socket mounted, and has better utilization & increased capacity. Bosch relays only have a single leg contact configuration drawing, only the application used will be drawn in the Identification for Bosch.

Form 1 is a typical Bosch relay. Terminal 86 depicts the power input and 85

represents the ground side of the coil. Terminal 30 is the common with 87a as the normally closed and 87 as the normally open terminal. The number 2 to the left of the contacts, represents the grid line in which the contacts will be shown in the schematic.

Form 2 is a typical example of a Bosch Micro Relay. Terminals A1 & A2 are the Power and ground terminals respectively.

In this case terminal 3 is common with 4 being normally closed and 5 being normally open. 4-11 4 3 5 A1 A2 Form 2 85 86

Form 1

87a 30 87 2

The contact configuration is drawn at the bottom of the page. This formation will denote that the actual contact can be found in grid line 2 of the same page.

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Description

Symbol

Relay – Siemens relays have only one function per contact leg, either N/O or N/C. The contact configuration may vary depending on requirements, and can be 4 or 8 contact sets per relay. As the relays have multiple contacts it is not possible to draw the schematic and keep the complete set of contacts associated with the actuating coil together. Subsequently, you will see the drawing of the actuating coil with the complete contact configuration drawn at the bottom of the page, beneath or adjacent to the actuating coil. The contact configuration contains location information that will allow you to find the actual contacts that are now drawn as single items within the schematic. The system is

bi-directional and against any set of contacts there will be location information to locate the actuating coil.

A1 A2 13 ₁₄ 33 34 43 44 21 22 4-12 The first digit of

the contact number only indicates the numerical reference of the relay contact leg. For example,

1,2,3 &4

The second digit of the contact number indicates the contact status For example; 3 & 4 = N/O 1 & 2 = N/C 13 ₁₄ 33 34 43 44 21 22 2 3 =33/3.4 /4.1 The information preceding the contacts is the location guide for the contacts in the schematic. For example;

2 = Grid 2 on the same page 33/3.4 = Group 33, page 3, grid 4

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Description

Symbol

A1 A2 K1102

Relay – Telemecanique relays are used in a 4 contact configuration with the availability of dual functions per contact leg; both N/O & N/C. The logic for locating the contacts is the same as the Siemens examples on

the previous page. Schematically, the major difference between the two types of relays is that the Telemecanique relay has three terminals per contact set, and the Siemens relay, only has two, which are N/O or N/C.

4-13 12 11 21 31 41 14 22 24 32 34 42 44 12 11 21 31 41 14 22 24 32 34 42 44 5 /5.2 /6.6 =47/4.3 The information preceding the contacts is the location

guide for the contacts in the schematic The first digit of the contact number only indicates the numerical reference of the contact legs

The second digit Of the contact Number indicates The contact status;

1 & 2 = N/C 1 & 4 = N/O

For example;

5 = Grid 5 on the same page

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Description

Symbol

Time Delay Relay - Time delay relays are used to keep a circuit energized for a short time after power has been removed from the control circuit. They are used in a variety of applications. The first noticeable difference is the coil

symbol. There are three wires connected to the coil unlike the previous examples. Also notice the coil symbol has a black box on the left side of the symbol also unlike the previous examples. The B2 terminal servers as the trigger for the timer, the B1 terminal is a constant 24 volt supply. with the A2 terminal serving as the ground. Another difference is the arc located

above each contact set. This symbol represents special contacts, and in the case, the special is referring to the time delay feature of this relay.

4-14

- K1103

_B2 _B1 A2 t = 1 sec 12 11 21 31 41 14 22 24 32 34 42 44

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2. Exam p le p a g e of ELAN la y out

Grove Training Institute

Elan Electrical Schematics

Developed by

133113925 GMK Schematic Handbook

GMK I

Schematic Symbol Handbook

GMK

GMK

Schematic Symbol

Handbook

Grove Training Institute

Second Edition

W

P

Introduction

Table of Contents

Introduction

Section 1

Hydraulic Symbols

Pages 1-1 through 1-10

Section 2

Electrical Symbols

Pages 2-1 through 2-13

Section 3

Pneumatic Symbols

Pages 3-1 through 3-6

Section 4

Elan electrical schematic

Pages 4-1 through 4-15

Section 1

Section 1

Hydraulic Symbols

Note:

Description

Description

Symbol

Symbol

Description

Description

Symbol

Symbol

M3

W

3 bar

Description

Description

Symbol

Symbol

Description

Description

Symbol

Symbol

W

W

X

X

W

Description

Description

Symbol

Symbol

WW

WW

T

P

Y

X

A

WW

WW

WW

W

Description

Description

Symbol

Symbol

WW

WW

WW

P1

P2

A

T

_{Relay Box}