Deutsche Grove GmbH Date: 09-06-06

Hydraulic System Adjustment Instructions

Adjustment Instructions for Superstructure Hydraulic System

Grove GMK 5220

Contents

1 Crane Pump 2
1.1 Adjusting the Control Difference at the Axial Piston Pump 2

2 Crane Main Control Block 3

2.1 Lower Hoist at 120 bar 3
2.2 Raise Hoist at 335 bar 3
2.3 Lower Auxiliary Hoist at 120 bar 4
2.4 Raise Auxiliary Hoist at 335 bar 4
2.5 Adjustment of the Telescoping Gear 4
2.6 Adjustment of the Control Pressure 5
2.7 Adjustment of the Derricking Gear 6

3 Compact Control Block of the Auxiliary Power Units 6

3.1 Adjustment to Lower Counterweight 7
3.2 Pressure Adjustment of Tilt Cab 7
3.3 Pressure Adjustment of Hydr. Derrickable Boom Extension 8

4 Slewing Gear 9
4.1 Pressure Adjustment at the Slewing Gear Block 9

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

Note:
It is absolutely essential that the hydraulic system is carefully bled to ensure that the
superstructure hydraulics operate correctly. This applies in particular to the following control
lines:
- Brake bleeding pipes of the slewing gear brake
- Brake bleeding pipe of the hoist brake.
Furthermore, when filling with oil, the suction pipe must be bled by loosening the screw
plug on the intake fitting of the crane pump. As soon as oil emerges, the plug must be
closed again.
The following pressure values are read on the pressure gauge. Hydraulic Circuit Diagram
03109586 applies. For measuring points indicated (M...) please refer to the circuit diagram.
The oil temperature should be approx. 40C during adjustments.

1 Crane Pump

1.1 Adjusting the Control Difference at the Axial Piston Pump

The control difference must be effected while idling without selecting any function. To do
this, connect a pressure gauge to measuring point MP and a pressure gauge to measuring
point MLs (Fig. 1). The difference between these two pressures must be 25 bar. If
necessary, any adjustment must be made at the controller (Fig. 1).
Attention: A pressure of 350 bar can occur at the measuring points, when a function is
started.

MP

Pressure cut-off MLs

Differential
pressure adjustment

Figure 1: Main crane pump P1

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

2 Crane Main Control Block

Note:
The following pressures do not have to be checked:
- DBV 1 390 bar (Primary pressure control valve)
- DBV2 45 bar (Control pressure)
- D4 (Derricking out, not in service)

2.1 Lower Hoist at 120 bar

- Connect pressure gauge to measuring point MB3 (Fig. 3).
- Remove solenoid coils Y1104/Y1105 from hoist brake control block (Fig. 2) and activate
the function Lower hoist at average engine speed.
- If necessary, adjust pressure at D6 to 120 bar (Fig. 4).
- Reassemble solenoid coils.

Y 1104/1105

Figure 2: Hoist brake control block

2.2 Raise Hoist at 335 bar

- Connect pressure gauge to measuring point MA3 (Fig. 3).
- Activate Raise hoist at average engine speed. During this, only move the control
lever slightly, as otherwise the diesel engine could stall.
- If necessary, adjust pressure at D3 to 335 bar (Fig. 4).

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

2.3 Lower Auxiliary Hoist at 120 bar

- Connect pressure gauge to measuring point MB1 (auxiliary hoist section).
- Remove solenoid coils Y1204/Y1205 from hoist brake control block (auxiliary hoist) and
activate the function Lower auxiliary hoist at average engine speed.
- If necessary, adjust pressure at D4 to 120 bar (the lower one on the auxiliary hoist
section).
- Reassemble solenoid coils.

2.4 Raise Auxiliary Hoist at 335 bar

- Connect pressure gauge to measuring point MA1 (auxiliary hoist section).
- Activate Raise auxiliary hoist at average engine speed. During this, only move the
control lever slightly, as otherwise the diesel engine could stall.
- If necessary, adjust pressure at D1 to 335 bar (the upper one on the auxiliary hoist
section).

MA1
MB1

MA2

MA3

MB3 MB2

Figure 3: Crane main control block

2.5 Adjustment of the Telescoping Gear

- A laptop with the service software is required to adjust the pressures of the telescoping
gear!
- Lock telescope 1 in 50%.
- Connect pressure gauge to MA2 and MB2 (Fig. 3).
- In the service software, select the menu item to adjust the pressure or go into
emergency operation.
- Retract telescoping cylinder in the locked condition.

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

- Adjust pressure at D2 to 210 bar (Fig. 4).

- Carefully extend telescoping cylinder in the locking pin hole.
- Connect pressure gauge to measuring point MA6 on the compact control block (Fig.
7).
- Carefully lower the telescoping cylinder again in the hole (Retract telescope).
- Create a pressure build-up by activating the boom section unlocking device.
- The process can be repeated by activating the boom section locking device and then
the boom section unlocking device. The pressure build-up always only occurs for a
few seconds.
- Adjust the pressure on the DBV compact control block to 100 bar (Fig. 7).
- If an adjustment has been made with the aid of emergency operation, leave this again
by restarting the engine and by re-entering the current telescope status (in the Ecos).
- The pressurising valve Y2115 can only be adjusted via the service software.
- If the pressure cannot be adjusted to greater than approx. 150 bar, valve Y2115 is not
energised. In this case, there must presumably be an error in the control system.

DM
DBV1

D1
Y2115

D2 D6

D3

Figure 4: Crane main control block

2.6 Adjustment of the Control Pressure

- Connect pressure gauge to measuring point MSt (Fig. 5).
- Activate a function (pump pressure greater than 50 bar) and adjust the pressure at DM
to 35 bar (Fig. 4).

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

MST

Figure 5: MSt on the crane main control block

2.7 Adjustment of the Derricking Gear to 305 bar

- Connect pressure gauge to MA1 (Fig. 3).
- Carefully derrick in the derricking cylinder at average engine speed against the stop.
During this, only move the control lever slightly.
- If necessary, adjust the pressure at D1 to 305 bar (Fig. 4).

3 Compact Control Block of the Auxiliary Power Units

Note:
The pressure values which are read at measuring point MLs (Fig. 7) must be 5 bar higher
than the values indicated in the circuit diagram. The speeds must be preset. The set
pressure changes with the volume adjustment!

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

3.1 Adjustment to Lower Counterweight

- Ensure that Imin and Imax are already memorised.

- Connect pressure gauge to measuring point MP (Fig. 6).
- Carefully derrick in the derricking cylinder at average engine speed against the stop.
During this, only move the control lever slightly and hold.
- Adjust the pressure at the pressure reducing valve to 300 bar. To do this, adjust DM
(Fig. 6) first to a lower pressure (approx. 250 bar), then raise the pressure to 300 bar.
- Lower counterweight against the stop.
- Adjust pressure at DBV to 100 bar (Fig. 7), pressure at MLs: 105 bar.

MP

DM

Figure 6: Measuring point MP

3.2 Pressure Adjustment of Tilt Cab

- Check speed of the cab.
- Connect pressure gauge to MLs (Fig. 7).
- Move cab into its lower end position and adjust pressure at DBV to 50 bar (Fig. 7),
pressure at MLs: 55 bar.
- Move cab into its upper end position and adjust pressure at DBV to 90 bar (Fig. 8),
pressure at MLs: 95 bar.

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

3.3 Pressure Adjustment of Hydr. Derrickable Boom Extension (Customer Option)

- Connect pressure gauge to MLs (Fig. 7).
- Derrick out luffing jib up to the stop, then adjust pressure at DBV to 100 bar (Fig. 7),
pressure at MLs: 105 bar.
- Derrick in luffing jib up to the stop, then adjust pressure at DBV to 280 bar (Fig. 7),
pressure at MLs: 285 bar.

MA6 (concealed)

DBV 90 bar DBV 55 bar DBV 100 bar MLS (concealed)

DBV 280 bar

DBV 300 bar

(concealed)

DBV 100 bar

Figure 7: DB valves on the compact control block

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Deutsche Grove GmbH Date: 09-06-06
Hydraulic System Adjustment Instructions

4 Slewing Gear
4.1 Pressure Adjustment at the Slewing Gear Block
- If the pressure cannot be adjusted via the software, proceed as follows:
- Connect pressure gauge to measuring point MP (Fig. 8).
- Pull valve plug Y2307 for enabling the mechanical slewing gear brake (Fig. 9).
- Move the control lever completely to the left or right. Only hold it for a brief time, in
order to read the pressure.
- If a pressure of 200 bar is not displayed, the DBV (Fig. 9) must be adjusted.
- After adjusting the pressure, reinsert the valve plug.

MP

Figure 8: MP slewing gear block

DBV 200 bar

Y2307

Figure 9: Valve plug 2307 & DBV slewing gear block

[NB: DBV = pressure control valve]

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