Section 2 ComponentID

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

Carrier

Component

Identification

Carrier

Component

Identification

Traditional Carrier

Suspension System

•

Conventional axle & hydrogas suspension

Hydrogas Suspension Principle

Pump Suspension control valve Axle blocking valve Accumulator P

Megatrak Design

Automatic gearbox

Hydraulic system

Engine

Steering

Pump drive box Outrigger

Transfer case Differential Suspension cylinder Drive

Megatrak System

•

Suspension struts & no axles

Early Suspension Struts

models 3045 - 4070 (4071 technical) all used small suspension struts • Identification by double mounting blocks • Stroke = 240 mm/9.44 inches

Large Suspension Struts

• Large struts used from 4070 (4072 technical) and on all current models

• single mounting block • Cylinder stroke is now

Large Suspension Struts

• Large struts have a single weldment

mounting with a frame dowel retained by a steel band & plastic insert

Detail of top fixing band

Large Suspension Struts

• Housing fixed to carrier

Suspension Systems

Megatrak

Suspension System Control

•

On various models suspension levelling

control solenoid valves are remote mounted,

typically above the outrigger boxes

•

Axle blocking valves are typically adjacent

to the suspension cylinders

Suspension Control System

Direction valves

Accumulators

Suspension cylinder assemblies

Blocking valve Blocking valve

Typical system layout

Suspension System Control

•

Integrated suspension levelling and axle

blocking control valves are being used on

some current, and new models

Suspension Control System

• On some current, and new models

• Axle blocking is controlled by pneumatically operated valves

• Suspension levelling is controlled by integrated solenoid valves

Large Suspension Struts

• Large struts also have integrated proximity switches for suspension control

Suspension Proximity Switches

• They look identical, but one is normally open and the other normally closed • Upper switch = N/O • Lower switch = N/C

Suspension Proximity Switches

early large struts have external proximity switches between the steering linkage within a vertical tube

Steering Geometry

Known by other terms - Wishbone or

compulsion levers. They transfer steering control to the wheels

Steering Geometry

• Steering levers are now fitted with “Swiss cheese” bushings in place of hard steel bushings

Steering Geometry

Typical standard drive steer configuration

Steering Geometry

The steering idler allows the rear axle to steer on highway or the rear two axles to steer independently of the front axles

View of all wheel steer & all wheel drive option

Steering Geometry

• Rear steering idler assembly • Used from KMK 4070 (4072

technical) - GMK 5160

• It allows highway rear wheel steering when locked and independent rear wheel steering when unlocked

Steering Geometry

• Rear steering idler assembly

• Proximity switch for locking control

• Mechanical switches for transmission and hydraulic control

Power Train

• They may look identical, but the ratio may differ! Transfer case

Power Train

•

A transfer case manufactured by MAN was

used on all GMT models with more than

three axles

•

All KMK & GMK models use a separate

Kessler transfer case on models with more

than three axles

Power Train

Kessler transfer case

Power Train

• Kessler transfer case • It divides the drive

power to the axles • It has two speeds • It also drives the

emergency steering pump

Power Train

•

All conventional drive axles are manufactured by

Kessler

•

Early Megatrak -KMK 3040 - KMK 4060 used

differentials & wheel heads manufactured by ZF

•

KMK 4070 and current models all use

differentials & wheel heads from Kessler

Power Train

Conventional axle with disk or drum brakes

Power Train

• Megatrak, Kessler differential assembly • With internal air

actuated differential cross locks

Power Train

Power Train

• Inter-axle differential gives equal power split to axles

Power Train

• Electric retarder

shown installed on the rear differential. It is also known as an eddy current brake.

• Manufacturers Kloft & Telma are used

Power Train

• Double and single joint cardan (half shafts) are used depending on application

• The assembly part number can be found here

Power Train

Fixed ring gear _{Principle of}

reduction hub 3 & 4 planet gear versions are used

Power Train

• View of reduction hub & wheel drive

• This casing is driven by internal sun & planet gears

Power Train

• It is a general rule that when replacing a

broken wheel stud -also replace the wheel stud on either side of the broken one and fit new wheel nuts

POWER TRAIN

•

Wheel studs vary in length depending on

application

•

Drive axles = 96 mm = 3.77 inches

•

Non drive axles = 88 mm = 3.46 inches

•

Double wheel drive axles = 110 mm = 4.33

inches

Power Train

• Brake design can be wedge or S cam - the latter is not used on KMK or GMK models

Power Train

•

Brake drums and brake linings also vary in

width depending on axle location

•

The term “simplex or duplex” is used to

indicate single or double air actuators on

wedge brake applications

•

Disk brakes were only used on

pre-Megatrak AT models up to 70 tonnes

Pneumatic Systems

• View of Wabco air dryer. The desicant cartridge should be changed at least every two years

Pneumatic Systems

sandwich block

Pneumatic Systems

•

The cooling coil between the compressor &

air dryer is copper pipe

•

Coloured plastic air pipes are not used, they

are all black plastic

•

In addition to the olive (compression ring)

plastic pipes need an internal reinforcing

sleeve

Hydraulic Pumps

Various pump drive methods are used

•

Engine crankshaft

•

Engine auxiliary drive

•

Drive box between engine & transmission

•

PTO from transmission

•

Drive from transfer case for steering backup

pumps

Hydraulic System

Engine

Superstructure hyd motor/pump

Pump drive box

Hyd swivel

Transmission

Hydraulic Systems

• View of hydraulic pump drive box for GMK 4070 (4072 technical)

Hydraulic System

•

View of remote hydraulic pump drive box

Through drive

Engine to transmission Hydraulic pump

Hydraulic Pumps

• View of Chelsea transmission mounted PTO for hydraulic pump drive & live pump drive on a GMK 3050 - both are left & right mounted to the Allison world series

Swivel - Hydraulic

• Multi port hydraulic swivels are used on current models upto 70 tonnes

Hydraulic Systems

• Outriggers are H configuration and controlled by electric solenoid direction valves

Swivel - Electric

• The electric swivel (if used) is mounted directly to the carrier or mounted on top of the hydraulic swivel as shown

Electrical System

• Any model with plastic junction boxes no longer has a traditional chassis harness. It has now been

replaced with multi core cables & junction boxes

Electrical Systems

Electrical Relay Suppliers:

•

Bosch - single & double leg (standard).

Single leg (micro)

•

Siemens - multi leg (stacking). Double or

triple leg (clear plastic)

Electrical Systems

Electrical Systems

the most common interface/bulkhead plug

Electrical Systems

transmission connections

GMK Superstructures

Hydraulic Systems

The typical open circuit system consists of :

•

1. A separate reservoir

•

2. A gear or piston hydraulic pump

•

3. A direction control block

•

4. An actuator - cylinder or motor

Hydraulic Reservoir

• Temperature sensor • Drain point

Hydraulic Reservoir

•

The reservoir is open to atmosphere via a

breather element

•

The return line hydraulic filter is integrated

into the reservoir

•

Suction filters are not used

Hydraulic Reservoir

Hydraulic Systems

•

All models 50 tonnes & below use the carrier

engine to drive the hydraulic pumps

•

GMT 60/70 & some KMK 70 tonne models

(pre-Megatrak) used a superstructure engine

•

All Megatrak & current GMK models up to 70

tonnes use the carrier engine

•

All larger models use a superstructure engine

Hydraulic Systems

•

All models 50 tonnes & below use a

transmission power take off for the pump

drive

•

KMK 60/70 (Megatrak) and current GMK

70 tonne models use a remote mounted

pump drive box between the engine &

transmission for pump drive

Hydraulic Systems

•

GMT & KMK models up to 35 tonnes used

gear pumps for all functions

•

Larger models used axial piston pumps for

primary crane functions

•

All current GMK models use axial piston

pumps for primary crane functions

Hydraulic Pumps

•

There are two basic types of piston pumps

used for crane functions

•

1. Swash plate, this can have through drive

and be in combination (piggy back).

•

2. Bent axis, this can not have through drive

and is only a single unit or double side by

side unit in a common housing

Hydraulic Pumps

• View of A10VO swash plate piston pump

Hydraulic Pumps

Hydraulic Pumps

• Typical view of

A8VO bent axis piston pump

• This has two bent axis pumps in one housing

Hydraulic Pumps

• Installed view of

A8VO bent axis piston pump

• Mounted directly to engine

• Auxiliary drive for gear pumps

Hydraulic Pumps

•

The hydraulic pumps are controlled by pilot

pressure from the hydraulic control

joysticks in the operators cab

•

Current GMK models from 5160 - 6200 use

electric pump control via electric joy stick

controls and amplifier boards

Hydraulic Pumps

•

Pump identification codes e.g.

•

A8VO107LR3CH

•

A = Axial. 8 = Series. V = Variable

•

O = Open circuit. 107 = displacement

•

LR = Constant horsepower. 3 = 3rd input

•

C = Cross sensing

Hydraulic Pumps

•

Pump identification codes e.g.

•

A8VO107EP

•

The last two letters (EP) indicate that this

pump is (E) electric (P) proportional and

would only be used on a GMK 5160

Hydraulic Pump Control

• Cabin electric joystick with pancake

potentiometer

• The potentiometer type & value will differ on model type

Hydraulic Pump Control

board installation - Located in operators cab behind drop down flap - Applicable to Megatrack models 5160 - 6200

PVR

RVR GLR

Hydraulic Pump Control

•

There are two amplifier types:

•

PVR for open circuits (smallest boards)

•

RVR for closed loop control (swing)

•

The amplifiers convert the joystick signal

voltage into a milliamp output to control the

hydraulic pump output

Hydraulic Pump Control

•

The GLR board is used to regulate the

hydraulic pumps output according to the

available engine power

•

Replacement PVR, RVR & GLR boards

must all be calibrated on the crane - contact

Service Department

Control Block

•

The control block is used to control the

direction of the oil flow to the actuator

•

The block is of modular design

•

spool switching control is by integrated

electric solenoids

•

Spool switching control by pilot pressure

was used on pre-Megatrak models - except

the KMK 5100 AT

Control Block

• Typical view of modular control block

Control Block

• Logic valves are similar to direction valves

• They are integrated within the control block and are controlled by solenoids

Control Block

• Main pressure and

circuit relief valves are often integrated into the control block • Direction control

solenoid valves

Hydraulic motors

•

Most motors are bent axis piston motors

-used on hoist & swing box drives

•

Some vane motors are used on swing box

drives

•

Orbital motors are used on some 3050 PTJ

applications for extending the jib

Hydraulic motors

• Typical view of A2F bent axis piston motor

Hydraulic Motors

• Two A2F bent axis motors in parallel drive - GMK 5130 application

Hydraulic Motors

• A2F bent axis piston motor - application in main hoist drive

• Brake release solenoids • Motor control valve • Brake/motor control

synchronising valve

Hydraulic Motors

Hydraulic Motors

A8VOLRCH bent axis pump - GMK 4070

Hydraulic Oil Coolers

GMK Crane Configurations

•

Current models may use:

•

Main boom

•

Fixed & offset jib

•

Power tilt jib

•

Luffing jib

GMK Crane Configurations

GMK Crane Configurations

• The jib may also be manually offset

GMK Crane Configurations

• two lengths are possible

• offset position is obtained by

GMK Crane Configurations

• The jib angle is altered from controls in the operators cab by a

hydraulic cylinder on the base of the jib

GMK Crane Configurations

• Power tilt jib in stowed position

Crane Configurations

Pendent - Steel links

A Frames or

Back masts

Main hoist controls hook Auxiliary hoist controls jib angle via bridle

GMK booms

• The boom lift/derricking cylinder is often referred to as a luffing cylinder

GMK Booms

•

Boom telescoping sections are identified by

numerical reference counting from the base

section

•

The base section is not included in the

numerical reference

GMK Booms

GMK Booms

•

On current models from KMK//GMK 4080

and higher, one or more boom telescope

sections are mechanically pinned

•

All models that only pin the first telescope

section are hydraulic control

•

All other models are pneumatic control

GMK Booms

• On large cranes - GMK 6200, the right hand side of the boom carries pneumatic hose reels

GMK Booms

• On various models boom sections are locked by mechanical pins - View of KMK 6140

GMK Booms

• Several models use hydraulic boom

pinning, only on the first telescope section

GMK Booms

• Several models from 70 to 130 tonnes all use a retaining clamp to hold the head section

• Belville washers provide the clamping force

GMK Booms

• For safety, the boom and locking pin positions are monitored by either

proximity or micro switches • Locking pin micro switches • Boom proximity switches

GMK Booms

• The left hand side of the boom base section carries electrical recoil drums for the LMI/SLI/RCI and boom pinning functions if applicable

GMK Booms

• Large cranes with a luffing jib also carry an electrical recoil drum on the right side of the boom base

GMK Booms

• Skymaster & 6250 booms also have

internal cable drums to monitor cylinder

position and control solenoids

BoomWear Pads

• Top rear wear pads are often machined to suit the particular boom section

• New top pads may need machining to specification from the machine file

Telescope Cylinder arrangements

•

1. Telescope cylinders & manual section

•

2. Telescope cylinders for all sections

•

3. Telescope cylinders & power pin section

•

4. Telescope cylinders & cable

synchronized sections

•

5. Travelling telescope cylinder for all

sections

•

6. Static, pin & push telescope

cylinder for all sections

Telescope Cylinder Arrangement

Telescope Cylinder Arrangement

• Internal cylinder to section locking pins

Telescope Cylinder Arrangement

S i n g l e t e le s c o p e c y l i n d e r C y l i n d e r b o x D o u b l e t e l e s c o p i n g c y l i n d e r B a s e _{S e c t i o n 1} S e c t i o n 2 S e c t io n 3 S i n g l e t e le s c o p e c y l i n d e r C y l i n d e r b o x D o u b l e t e l e s c o p i n g c y l i n d e r B a s e _{S e c t i o n 1} S e c t i o n 2 S e c t io n 3

Telescope cylinders

•

The cylinders have internal transfer tubes to

supply oil to themselves and other cylinders

- a power -track arrangement is used on

travelling cylinders

•

Hydraulic hose reels are not used

Telescope Cylinders

stage cylinders are often used in

combination

• Shown is a two stage cylinder with

integrated solenoid valve control

• Cable routing is up body of cylinder

Telescope cylinders

• View of cylinder head with control by integrated solenoid valves

• The solenoids are

mounted at the head of the cylinder along with the holding/logic valves

EKS LMI/SLI/RCI Indicators

•

There are four types of system in current use

•

1. EKS 83 uses a Kruger transducer box & single

boom recoil drum

•

2. EKS 83 new generation uses Dynisco

transducers & has multiple boom recoil drums

•

3. EKS 3 with softpad interactive faceplate - This

system also uses Dynisco transducers & multiple

recoil drums

•

4. EKS 4 with softpad interactive faceplate - This

system is being used ECOS technology.

EKS 83

switches on the faceplate

• This is known as the central unit

EKS 83

•

There are several central unit software

versions that may be fitted to early cranes

•

Only one type (D) is now available as a

replacement

•

Please seek Service Department advice for

correct configuration

EKS 83

• View of central unit with cover removed showing location of main fuse = 3.15 amps • NOTE: a larger fuse

will destroy the unit

EKS 83

• View of central unit with cover removed showing location of Data Bus fuse

= 1.25 amps

• NOTE: a larger fuse will destroy the unit

EKS 83

• View inside Kruger transducer box, it is mounted on the lift cylinder

• Two transducers are left & right behind compensation board

EKS 83

• Compensation board -resistors must be

changed to suit model type

EKS 83

EKS 83

•

NOTE: the compensation board part

number is for a standard board

•

The standard board may need some

resistors changed to suit the particular

model

•

Please contact the Service Department for

advice

EKS 83

•

Cranes that have Kruger transducers only

have a single boom length recoil drum on

the left side of the boom

•

The single recoil drum is a very good way

to identify the original version of EKS 83 &

only applies to pre-Megatrak models

EKS 83

• View of boom

length/angle drum on left side of main boom • There are two length

cable sizes up to 70 tonnes = 2.5 mm. All larger cranes = 4.0 mm

EKS 83

•

It is very important to supply the correct

diamater boom length cable

•

2.5 mm part no = 0553323

•

4.0 mm part no = 1374345

EKS 83 New Generation

location of piston transducer on the boom lift cylinder

EKS 83 New Generation

• View of transducer on the rod side of the lift cylinder

EKS all versions

• A load pin or load strap is used on luffing jibs to measure the load signal

• View of load pin - This is fitted in the centre of the hoist rope top sheave on the boom head

• The load strap is used in the rope anchor

EKS 83 New Generation

• View of multiple recoil drums on left side of boom

EKS 83 New Generation

•

Many of the models now use 8 core cable

on the recoil drums = part no 1924065

•

The correct diamater & length is critical

•

Housed inside & driven by the drum are

potentiometers, these give a length signal to

the data transmitters

EKS 83 New Generation

• The data transmitters are enclosed in boxes as close as possible to the potentiometers/transducers

EKS 83 New Generation

EKS 83 New Generation

housings

EKS 83 New Generation

EKS 3

• EKS 3 uses softpad switches on the

interactive faceplate • This is known as the

central unit

EKS 3

• Rear view of central unit showing fuse locations

• F1. Main fuse = 3.15 amps

• F2. Data bus fuse = 1.25 amps

• F3. Data bus fuse = 1.25 amps

EKS Generic Compatability

All models use the same:

•

Boom length potentiometers

•

Boom angle potentiometers

•

Data transmitters