133113925 GMK Schematic Handbook

GMK I Schematic Symbol Handbook

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X2 6

GMK

X56 2

Schematic Symbol Handbook

P 3

2

4

1

W

2 K10 86

87

85

30

87 b

W 7

300 bar S62

5 bar

1

8

2

9

01

W br

3

bl

sw

2K20

4

B1

A1

10 +

L -

G

WK

A2

Grove Training Institute Second Edition

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]

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

Index

GMK Schematic Symbol Handbook

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.

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.

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.

GMK Hydraulic Symbols

outside diameter

12X1.5

Flexible line - Hose, usually connecting moving parts

line size change

16X2

Wall thickness

1-1

Description

Symbol

Gate valve - Return manifolds, reservoirs, etc.

Test port - Quick disconnect style testing point

M3

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

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

3 bar 1S21

Quick disconnect - Used in the circuits of frequently removed components, i.e. auxiliary hoist circuit lines.


1-2


40 bar

Form 2

300 bar

60 bar W

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. 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.

Form 1

W

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.

Symbol

W

Description

1-3

Description

Symbol

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.

W

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.

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.


X

W

X

1-4

Description 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.

Symbol

W

X

Y

WW WW P

3-Way 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.

T

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.

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.

A

WW

WW

1-5 GMK Hydraulic Symbols

Description 2-Way electric over hydraulic directional control valve - used to control direction of oil flow. This 3position, 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.

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.


Symbol X

Y

A

B

WW

WW P

T

WW

WW

A

T

W

X

WW

P1

P2

1-6

Description 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.

Single acting cylinder - Used as boom section locking cylinder. Also equipped with mechanical release and air bleeder.

Symbol

X

WW

WW

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.


1-7

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.

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.

Bi-directional 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.


P3

T

Form 1

DFR

Form 2

P2

LRCH

T1

T2 1-8

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.

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.

Swing brake control pedal - Used by the operator to control the application of the swing brake.

f

b ec

a a

P

d

T

5 - 30 bar

A

B

T

Connected to swing brake

T P


1-9

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.

Symbol

W

Description

B A

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.


1-10

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: 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.

1

Symbol +BE 550

Description of Location

+BE 540

.UR1

V8

.UR2

.UR3

.AK2 V5 V4

.UR4

.UR5 V2 V1

.UM1

.UM2

.UM3

.UM4

.UL1

V9 .UL2

.UL3

V7 V6 .AK1 .UL4

.UM5

V3 .UL5

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.

GMK Electrical Symbols

2-1

Symbol

Carrier Cab +BE 550

Dash Panel?Enclosures .A1 .A2 .A3 .A4 .A5 Steering .LS Wheel

.A6 .A7 .A8

.S1

.A9 .A10

.A11 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.


2-2

Symbol +BE660

+BE600.R

X34

V13 V14

V34

+BE620

V2 V3

+BE600.M +BE600.L

+BE630 VB2

VB3 VB1

.A7 .S2

.A3

.A2

.S1

-A100

.A1

.KR

.A5 .K

.KL

.A4

GMK 5130 Superstructure Grid Locator Map

.A6

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.


2-3

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.

etc.

Grid #1

4 3 2 1

Grid #2

etc.

Grid #3

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.

Symbol

Grid #4

Description

Title Block

Connector Module

.A9

Pin #

X1

13

4.15 Sheet #

Grid #

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.


2-4

Description

Symbol Form 1

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.

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.

Connector 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

Pin number within a connector X26 6 +BE550 .S1

Locator Identifier

Ground - Frame ground


2-5

Description

Symbol

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.

X1

3

V6

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.

1

2

3

4

X1

1

.S1

2

10 A

A


7

3

10A

B

4

10 A

C

1 . 21

-F5

.A4

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.

6

5

Fuse Bank - Made up of six 10-amp fuses.

5

Grid

5

6

10 A

D

Sheet

10 A

E

10 A

F

2-6

Description

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.

Temperature switch - Used to monitor the temperature of fluid within power units for example, hydraulic oil, transmission fliud, and engine coolant etc...

Symbol

P

T

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.


2-7

Description 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.

Symbol

Form 1

Form 2 represents a normally open switch. The “br” represents the supply voltage, the “bl” represents the ground, and “sw” represents the signal wire.

sw

Single-pole switch - This style switch is also

bl

1

9

5

10

01

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.


br

sw

S1

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.

Form 2

bl

br

S5 7

1

8

2

9

01

3

4

10

2-8

Description 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.

Symbol Form 1

Form 2

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.

Form 2

Lubrication pump - used to represent an automatic lubrication system pump assembly.


2

Form 1

3

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.

M

2-9

Symbol

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.

Form 1

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.

Form 1

P

Q

Form 2

+

L -

+

G

WK

G

+

L -

GE

BR

DC to DC converter - This is an example of a converter which transforms 24 volts DC to 12 volts DC.

Form 2

SW

Description

S

-

24V 12V

Dynamo/Alternator - This is the symbol used to illustrate a alternator or as it is referred to on the GMK schematics, a dynamo.


G 3 U

2-10

Description

Symbol Circuit Prefix

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.

2K5

Relay identification number

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 K10

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.


87

85

30

87 b

Contacts K50 K50

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.

86

30 85 87 87 b 86

Coil

2-11

Description

Symbol Relay Identification

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.


Coil terminals 2K5

A1

Grid number

Page & Grid #

A2 15 13

14

4.8 21

22

33

34

43

44

.

10

Contacts not used

Normally closed

21

Second set of contacts First set of contacts

22 Normally open

13

14

2-12

Description

Symbol 2K4

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.

A1 A2

12

13

14

12

23

24

10

33

34

8

43

44

4.17

53

54

4.20

63

64

4.15

73

74

4.16

83

84

2K20 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.


B1

A1

A2 15

18

2-13

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.


1

Description 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.

Symbol Tubing wall thickness

Outside diameter

12 X 1.5

Control line - Used to illustrate control pressure.

Ventilation line - Used to illustrate air exhaust from the system.

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.

S62

5 bar

W

Test port

Air reservoir - Used to store supply air volume. Also represented are a manual drain valve and test port.

40 l V1

X

Manual drain valve

GMK Pneumatic Symbols

3-1

Description

Symbol

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

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.


3/4 NPT

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

1

6 bar

W 2

3-2

Description

Symbol

Single-acting cylinder - Used to actuate various mechanical components via air pressure. i.e., inter axle diff locks, or cross axle diff locks.

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.

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.


WW

3

2

4

1

2

41

42 3

2

2 1

3-3

21 W

6 bar

W

6 bar

5.5 bar

24

22

1-2

2


23

W

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.

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.

5.5 bar

1

W

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.

Symbol

W

Description

1

21 21 11 21 3 22 22 22

12 3

3-4

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.

Symbol

22

1 3

21

W

Description

Service Brake Chamber - Used primarily on the front axle to apply brakes when air air volume is supplied to the inlet port.

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.


WW

11

WW

12

WW

3-5

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.


Symbol

WW

Description

8.1 bar

W

1

21 W

W

4

3

22

3-6

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.


1

Symbol “Elan” Schematic structure Location Map Page 1 Carrier

Location Map Page 2 Upper

Section 01 Title Page

Section 01 Contents

Print 1 Page 1-X


Section 02 Contents

Print 1 Page 1-X


Section 03 Contents

Print 1 Page 1-X

Description 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

Elan Electrical Schematics

4-1

D

Symbol Fur diese UnterLogan behalten wir uns alls Reichts vor, auch fur den Fell der Potenterteilung oder Gebrauchemusteintragung. Sie darf ohne unsre vorherige schriftliche Zustimmung weder vervielfaltigt noch sorestwie benutzt, noch Dritten zuganglich gemacht werden.

1

2

3

FAHRERHAUS +BE550 driverscabin

4

5

6

7

8

FAHRERHAUSE

UNTERWAGEN +BE 506 carrier

+BE550

driverscabin

A

A

.A1

.A2

.S1

.A3 .A6

.LS .UR1

B

.UR2

.AK2 .NK2 .V4 .V5

.UR3

.UR4

B

.UR5 .A4

Microfilm

Freigabe: 25.04.95

CAD - ZEICHNUNG

GROVE MOBILKRANE GmbH

.V9 .V7 .V8

C

.UM1

.UM2

.UM3

.SR

.UL1

.UL2

.UL3

.V6 .V10 .AK1 .NK1

.V2 .V3 .V1

.UM5

.UL4

C

.UL5

FUR SEPARATLENKUNG for separate steering FAHRGESTELL

FAHRERHAUS

carrier

driverscabine +BE 550

+BE 506 D

E

.V1 - .V8

VERTEILERKASEN

terminalboxes

.A1 - .A4

MODULE

panel modules

.UL1 - .UL5

SEKTIONEN KRANTRAGER LINKS

section carrier left

.AL

KABINENELEMENTE

cabinelements

.UM1 - .UM5

SEKTIONEN KRANTRAGER MITTE

section carrier middle

.LS

LENKSAULE

steeringcolumn

.UR1 - .UR5

SEKTIONEN KRANTRAGER RECHTS

section carrier right

.S1

SCHNITTSTELLE

connections

.SR

SCHLEIFRINGKORPER

sliprings

.AK1

ABSTUTZEINHEIT LINKS

stabilizing unit left

.AK2

ABSTUTZEINHEIT RECHTS

stabilizing unit right

.NK1

NEIGUNGSAZEIGE LINKS

angle status display left

.NK2

NEIGUNGSAZEIGE RECHTS

angle status display right

.B1/.B2

STObSTANGE VORNE/HINTEN

carrier lights front/rear

D

E

F

F

Datum Name A Zust.

.UM4

841070 Anderungs- Nr.

0 Anz ahl

17.03.98

1

pos Name

07.01.97

Plotdatum

Ges. Plot

04.05.98

GMK

SKS

Urspr.

2

Ers.f.

3

Er s.d.

4

B e nenn u ng

A u ftra g s - N r.

K e nwo rt

AnLagenkennzeichung

Zeic hnu n gs - N r.

Ortskennzeichen UW 5

FHG

6

800

Abt.

F 3

TK 4 7

Blatt 1 8 Bl.

8

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. Elan Electrical Schematics

4-2

Developed by Grove Training Institute


1

2

3

4

5

6

7

8

+BE630

+B E600

.AL

.V7 .V2 .VB2 .VB1 .V1 -M 1 -V3 .GZR

A

A

-A103 -A102 .A1 .A2 .A3 .A4

B

B

+B E620

.KL

.K5

.KR

Freigabe: 25.04.95

CAD - ZEICHNUNG

GROVE MOBILKRANE GmbH

.A5

C

C

-X201,202

-A114 -A111

.V6

-X101,102 .V5 .GZL.V4 -X203

-101

-A104

DRE HT IS C H TUR NTA BLE +B E 600

HIFLSH UB TRA GE R A UX IL IARY HO IST +B E 620

K RA NK AB INE C RA N E DR IV E RS CA BIN +B E 630

TE LE S KO PA US LE G ER B OO M S +B E 700 D

D

V ERTE ILE R K A STE N

.G ZR

G EG N GE W IC HTS ZYL. CO UN TERW EIG HTCY L. RIG HT

RE CHT S

.A1 - .A 8

M O DU LE

PAN ELM O DULE S

-A 102

DRU CK AU FNE HME R

P RE SS URE S E NSE R

.KR

K R A NS ITZ

CRA NE DR IV E R S EAT -A 103

DRU CK AU FNE HME R

P RE SS URE S E NSE R

R E CHT S

RIG HT

K R A NS ITZ

CRA NE DR IV E R S EAT

-A 104

W INK LE / LANG E

A NG LE / L ENG H T

LIN KS

LEFT

-A 111

K AB E LTR OM M E L

CA B LE DRU M

.KS

K R A NS ITZ

CRA NE DR IV E R S EAT

.AL

K AB INE N E LE ME NTE

-A 114

K AB E LTR OM M E L

G EG N GE W IC HTS ZYL. CO UN TERW EIG HTCY L.

.G ZL

E

TE RM INA L BO X E S

.V1 - .V 8

LIN KS

LEFT

.VB 1 - .V B3

V EN TILB LO C K E

VALV ES

-A 101

M E S SW E RTS E ND E R

X 101, 200 - 300S TE CKV E RB IN DUNG

.KL

E

TE LE

P LU GS O ILRA DIATO R

O LK UH LE R

-M 1 Microfilm

.VB3

.V8

A

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

1 9 .0 9 .9 4

pos pos

D a tu m Nam e

P O S IM A

pos

G e s. P lo t

p o s tm a

Nam e

1

T ELE

2 - 4 F

TE LE

P lo td a tum

2 - 4

A 1 9 .0 9 .9 4

GM K

SKS

U r s p r.

2

Ers.f.

3

E r s .d .

4

A

B en en nu ng

A u f tr a g s - N r .

K en w o rt

AnLagenkennzeichnung

Z e ic h n u n g s - N r.

Ortskennzeichen OW 5

1

CA B LE DRU M

-X 201,202 S TE CKV E RB ER BING UN GCO NN ECTO RS

CA B IN EL E M E NTS F

T ELE

1

FHG

6

800

A b t.

F

TK 4

3

7

B la tt

2

2 B l.

8

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

Freigabe: 20.04.98

CAD - ZEICHNUNG

7

8

A

B

B

=02 Diesel-Maschinen Anlage UW

C

diesel engine installation chassis

D

Microfilm

6

A

C

D

E

E

F

F

Datum Name A Z ust.

5

841078 Anderungs-Nr.

0 Anzahl

17.04.98

pos Name

07.01.97

Plotdatum

Ges. Plot

1

B en en nu n g

STR

Urspr.

2

Ers.f.

3

GROVE  CRANE

Au ftra gs - N r.

4

Ke nwort

PLAN, E-SCHALT5

=02

Zeic hn un gs - N r.

DIESEL-MASCHINEN-ANLAGE UW

Er s.d.

F HG

800

Abt.

F

TK 4

6

3

7

Blatt

1

17 Bl.

8

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


Symbol

Microfilm

Freigabe: 20.04.98

CAD - ZEICHNUNG

Fur diese UnterLogan behalten wir uns alls Reichts vor, auch fur den Fell der Potenterteilung oder Gebrauchemusteintragung. Sie darf ohne unsre vorherige schriftliche Zustimmung weder vervielfaltigt noch sorestwie benutzt, noch Dritten zuganglich gemacht werden.

1

2

4

5

6

7

8

A

A

B

B

C

C

D

D

E

E

F

F

Datum Name A Zust.

3


0 Anz ahl

17.03.98

pos Name

05.01.98

Plotdatum

G es. Plot

1

04.05.98

2

Be nenn un g

SKS

Urspr.

Ers.f.

3

GROVE  CRANE

A uftrag s - N r.

4

Ke nwort

AnLagenkennzeichung


Ortskennzeichen UW + OW

Er s.d.

5

FHG

6

800

Abt.

F

TK 4

3

7

Blatt

8

8 Bl.

8

Description 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 on the respective page.


4-5


Symbol Navigating “Elan” Schematics

6

8

2

B

PLUS 1

MINUS 1

4

3

4

5

6

7

8 No. <>

A

2,5

S1/R30 /3.2

2

1

8

F3: 1/2 /8.2

2

-X941 4

-X941

+BE550.LS

+BE550.LS

2

S1 /4.7

6

Zuendschalter ignition switch

/3.3

6

S1/30 /3.2

A

AnLasssperre starter interuption

2

starter

6

2

6

Anlasser

12

2

6

2,5

2,5

2

2

13 -X2

+

2

A

6

3

-X5 1

1

Batteriehauptschlater

27

2

2 X 12V

/12.1 -P6 +

Battery

battery master switch

-X2 B

Batterie 2 X 12V


3

1

21

/5.4 -K5 86

1

=44/4.1

15 /15.1 -A1 50

A

7 N o. < >

/16.4 -A1 11/3

8

5

+BE506.UM2

4 S1/R30 /5.1

S1/30 /5.1

/10.6 -F6/6 6


4

/5.7 +-K5 30

3

/6.1 -F1/1.1

2

7

1

-X94 R30 -X94 30

Lichtsmachine

-S1

+BE550.LS

3

+BE550.LS

Ladekontrolle charge control

R30

alternator

30

-X43 1

B

B

+BE550.LS

= -F9

C

+BE506.UL2

2

= -F7

1

+BE506.UL2 2

2

1

+BE506.UL2

50A

50A

5

R15

Fogeschadenschultz

15

50

P30

C

-X94 R15 -X94 50

high voltage protection

-X94 15 -X94 P30

+BE550.LS

+BE550.LS

+BE550.LS

-X941 3

-X941 7

-X941 8 -X941 5

+BE550.LS

16

2

20A

= -F6

1

4

95

2

5 6

C

2

+BE550.LS

+BE550.LS

+BE550.LS

-K5

+BE550.LS

OHNE DIODE without diode

2

70

+BE506.UL2

D 2

5

86

OHNE DIODE without diode

86

+BE550.S1

1

-H1

85

2

C

-K5 30 5 87 +BE550.S1

RT

GE

4

-K12

S1/R15 /9.1

7

=41

=

-K3

85

6

3

=41/7.6

+BE550.S1

2

B-

_

9

6

6

2

2

2

95

2

D-

95 Microfilm A Z ust.

<

841078 Anderungs-N r.

0 Anz ahl

17.04.98

pos Name

1

Datum Name Ges. Plot

2 1

2

>

F

10 >

07.01.97 Postma

< Plotdatum

04.05.98

Ers.f.

3

>

<

4

>

B e nen n un g

STR

Urspr.

2

3

GROVE  CRANE

4

<

5

5

X)

>

Au ftra g s - N r.

Ke n wo rt

PLAN, E-SCHALT-

Ze ic hn u n gs - N r.


Ers .d.

F HG

6

800

Abt.

Kundenwunnsch customers request +BE550.S1 F 3

7

22

/16.5 +BE550.S1 -A1 11/5

5

2

6

-X43 -X43 4 +

2

E

8

/15.1 +BE550.S1 -X1 8 S1/15 /7.1

3

2

/3.5 +BE550.S1 -X2 12

-X43

87a 7

Blatt

7

+

=02

TK 4

Function Group= 02/3.2=Sheet, Grid

Description

30 87

5

16

<

=

-K3 E

U

31

-G2

8

/10.1 +BE550.S1 -F6/1 1

95 +

B+W D+ - F11 +BE503.UM2 G 3

Freigabe: 20.04.98

2

- G3 +BE506.UM2

CAD - ZEICHNUNG

50

M

87

3

+

30

8

E

9

87a 2 87

30

17 Bl.

Microfilm

30

+BE506.UM2

D

+

10

95 - M1

_

+BE506.UL2

F

-X43 3

D

D+

-G1 +BE506.UL2

E

2,5

+

Freigabe: 20.04.98

CAD - ZEICHNUNG

2

6

+BE550.S1

2

47

6

/17.6 +BE506.UL4 -A2 :

2,5

2

2,5

D

-53

A Zust.

F

<

2

<

841078 Anderungs-Nr.

0 Anz ahl

17.04.98

1

>


05.01.98 Pos tma

>

<

Plotdatum

2

Ers.f.

3

3

>

Ben ennung

STR

Urspr.

ihnen

F

10

1

pos Name

GROVE  CRANE

A uftrag s - N r.

4

5

+BE550.A3 F 3

Zeic hnu ngs - N r.


Er s.d.

=02

K enwort

PLAN, E-SCHALT-

FHG

6

800

Abt.

TK 4 7

Blatt 5 17 Bl.

8

Section =02/5.1=Sheet, Grid

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.


4-6


Description

Symbol Grid 8- Description area

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.

7

6

8

1

3

Batterie 2 X 12V

1

=44/4.1

21

A

8

7 No. <>

/5.4 -K5 86

8

6

5

+BE506.UM2

4 S1/30 /5.1

S1/R30 /5.1

5

4

/5.7 +-K5 30

7 /10.6 -F6/6 6


4

3

15

3

2

/15.1 -A1 50

2

1

/16.4 -A1 11/3

1

Battery

Anlasser

13 -X2

+

12 starter

2

2

6

6

2,5

6

2

2

2

2,5

A

battery master switch

-X2

B

PLUS 1

-X5 1

2 X 12V


2

3

B

MINUS 1

Lichtsmachine

4

alternator

= -F9

C

+BE506.UL2

= -F6

1 2

= -F7

1

+BE506.UL2

2

50A

1

+BE506.UL2

50A

Fogeschadenschultz

5

C

2


16

2

20A

2

6

2

95 70

2

2,5

D

-53

/17.6 +BE506.UL4 -A2 :

+BE506.UL2

47

D 2

7

2

95

2,5

+

D+

-G1

- M1

_

+BE506.UL2

30

+BE506.UM2

95 +

B+W D+ - F11 +BE503.UM2 G

8

3

M

E

U

31

-G2 +BE506.UL2

- G3

50

+BE506.UM2

2

B-

_

9

2

6

2

95

95

2

D-

6

E

2

Freigabe: 20.04.98

CAD - ZEICHNUNG

2

6

16 Microfilm

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.

/6.1 -F1/1.1

Grid lines - Each page of an Elan

A Zust.

F

< <


0 Anz ahl

17.04.98

1

1

pos Name


2

2

>

1

F

10 >

07.01.97 Pos tma

< Plotdatum

04.05.98

2

2

Ers.f.

3

3

>

<

4

>

B en ennu ng

STR

Urspr.

3

GROVE  CRANE

4

4

5

X)

>

A uftrags - N r.

5

5

+BE550.S1 F 3


F HG

800

Abt.

TK 4

6

7

6

7

Kundenwunnsch customers request =02

K enwo rt

PLAN, E-SCHALTDIESEL-MASCHINEN-ANLAGE UW

Ers.d.

<

Blatt 3 17 Bl.

8

8

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

Function group: =Diesel Engine Install

=02 +BE550.S1 Blatt 3 20 Bl

Page 3 of 20

Location: + Carrier cab Connection .S1


4-7

Description 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.

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.


Symbol

Form 1 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. /12.1 +BE550 .A2 – X40 3

20 Signal line

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

Form 2 Function group number, Page and Grid Number

= 01/3.2 +BE600 A5 X22 9

4 Signal line

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


4-8


Description 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.

.

Symbol 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 W = Electric swivel slip ring


4-9


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.

Form 1 Y2130

Form 2 S2304

7

1

8 2

5

6

9

01

10

Power supply


6

8

3

1

21

/5.4 -K5 86

1

=44/4.1

15 /15.1 -A1 50

A

7 No. <>

/16.4 -A1 11/3

8

5

+BE506.UM2

4 S1/R30 /5.1

S1/30 /5.1

/10.6 -F6/6 6


4

/5.7 +-K5 30

3

/6.1 -F1/1.1

2

7

1

13 -X2

+

2

6

6


A

Anlasser

12 starter

2

2

6

2,5

2

2

2,5

2 X 12V

battery master switch 3

B

PLUS 1

-X5 1

Batterie 2 X 12V Battery

2

-X2 B

MINUS 1

4

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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 multicore 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.

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Description 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.

Symbol

Form 1

86 85

87a 2 30

87

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.

Form 2

A1

A2 4

5

3


4-11


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

21

22

33

34

43

44

The first digit of the contact number only indicates the numerical reference of the relay contact leg. For example, 1,2,3 &4

The information preceding the contacts is the location guide for the contacts in the schematic.

The second digit of the contact number indicates the contact status For example; 3 & 4 = N/O 1 & 2 = N/C

2

13

14

3

21

22

=33/3.4

33

34

43

44

/4.1

For example; 2 = Grid 2 on the same page 33/3.4 = Group 33, page 3, grid 4 Elan Electrical Schematics

4-12

Description 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.

Symbol K1102


A1 A2

12 14

11

22 24 32

21

34

31

42 41

44

The second digit Of the contact Number indicates The contact status; 1 & 2 = N/C 1 & 4 = N/O

The first digit of the contact number only indicates the numerical reference of the contact legs

5 The information preceding the contacts is the location guide for the contacts in the schematic


12 14

11

22 /5.2 /6.6 =47/4.3

24 32

21

34

31

42 44

41

For example; 5 = Grid 5 on the same page =47/4.3 = Function Group 47, page 4, grid 3

4-13


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.

- K1103

t = 1 sec

B2

B1

A2

12 14

11

22 24

21

32 34

31

42 44

41


4-14


Example page of ELAN layout

4-15


2.

Index A Accumulator 1-10 Air compressor 3-2 Air dryer 3-6 Air reservoir 3-1 Anti compounding valve 3-3

B

D Dash panel enclosure 2-2 Dashed line 1-1 DC to DC converter 2-10 Description of location 2-1 Diode 2-9 Double-pole double-throw switch 2-8 Double line 1-1 Dynamo/ Alternator 2-10

Bi-directional fixed displacement motor

C Chain line 1-1 Circuit protection valve 3-4 Circuit Tracing 2-4 Conductors 2-5 Continuous line 1-1 Control line 3-1

E Electic over hydraulic control valve 1-5 Electric solenoid 1-4

F Female socket 2-5 Filter assemble 1-7 Fixed displacement 1-8 Flexible line 1-1 Flow switch 1-4 Fuse bank 2-6

G Gate valve 1-2 Gauges 2-10 Grid lines 2-4 Grid map locator 2-3 Ground 2-5

H

P Parking brake valve 3-5 Pilot operated control valve 1-5 Pilot operated dieectional contro valve 1-6 Port identification 3-2 Pressure reducing valve 1-3, 3-2 Pressure switch 2-7, 3-1 Proximity switch 2-8 Pump/motor unit 1-9l

Hydraulic pressure switch 1-2

J

Q

Joystick 1-9 Quick disconnect 1-2

L Line size 1-1 Lock valve 1-4 Logic valve 1-10 Lubrication pump 2-9

M Male plug 2-5 Maxi brake chamber 3-5 Momentary toggle switch 2-7

O Oil cooler assemble 1-7

R Relay 2-11, 2-12, 2-13 relay identification 2-11 Relay valve 1-3, 3-3

S Sending units 2-10 Service brake chamber 3-5 Service brake valve 3-4 Single-pole switch 2-8 Single-acting cylinder 1-7, 3-3 Solenoid valve 2-9 Speed control 1-9 Standby valve 1-6 Swing brake control pedal 1-9 Swivel slip-ring 2-9

T Temperature switch 2-7 Terminal connections 2-5 Terminal strip connections 2-6 Test port 1-1 Time delay relay 2-13 Tire inflator valve 3-4 Toggle switch 2-7

V Variable displacement piston pump 1-8 Velocity fuse 1-4 Ventilation line 3-1

W 2-Way electric over hydraulic directional control valve 1-6 3-Way electrically operated valve 1-5 3-Way electrically operated valve with manual override 1-5 4-Way electrically operated valve Working line 3-1

133113925 GMK Schematic Handbook

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