Section 9

GMK Amplifier Boards

TRAINING INSTITUTE

Amp Board Layout Flip Down Extension PVR 3 - 6Y11 1

2

3

4

5

6

7

8

9

10

RVR

GLR

Swing Circuit 1

PVR 1 - P1 1

2

3

4

5

6

7

8

9

10

2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

PVR 2 - P2 1

2

3

4

5

6

7

8

9

10

Swing Down Compartment under Superstructure Dashboard

PVR Board System

Proportional Solenoid Valve Relay Board

P1

Relay Board 1

2

3

4

5

6

7

8

9

Sys Ground -

10

24 volt vdc + PVR 1 - P1

PVR Board System PVR 2 - P2 1

2

3

4

5

6

7

8

9

10

Proportional Solenoid Valve Proportional Solenoid Valve

Relay Board

P2

P1

Relay Board 1

2

3

4

5

6

7

8

9

10

High Speed Switch

Sys Ground 24 volt vdc +

PVR 1 - P1

PVR Board System Hydraulic Tank

Lift Cylinder Gravity Down Only!

Hyd Oil

Relay Board

Proportional Solenoid 6Y11 Valve

Relay Board 1

2

3

4

5

6

7

8

9

Sys Ground -

10

24 volt vdc + PVR 3 - 6Y11

PVR Board • Board Fault LEDs (2 Yellow)

• Up Directional LED (Green)

• Down Directional LED (Red) • 1.6 Amp Fuse (Board Mounted)

• Adjustable Trim Pots • Terminal Strips (10 poles)

1 2 3 4 5 6 7 8 9 10

RVR Board System Swing Brake Release

Proportional Solenoid Left Valve Proportional Solenoid Right Valve

Relay Board

Relay Board

Sys Ground 24 volt vdc +

RVR Board • • • •

Main Power LED (Green) Board Active LED (Red) Board Fault LEDs (2 Red) Right Directional LED (Yellow)

• • • •

Left Directional LED (Green) 1.6 Amp Fuse (Board Mounted) Adjustable Trim Pots Terminal Strips (16 poles)

GLR Board 1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16

H1

• H1 - H4 LED’s • R1 - R9 Trim Pots • 16 pole Terminal Strips • 1.6 Amp Fuse (Board

H2 H3 H4

Mounted)

• Main Power LED (Green)

• Pin #7 : 4.25 Volts

GMK5160 System Layout GLR 1

2 3 4 5 6 7 8

Main Hoist Joystick

9 10 11 12 13 14 15 16

Aux Hoist Joystick

Lift & Tele Joystick

Swing Joystick

Pin #7

1

r.p.m. sensor

2

3

4

5

6

7

8

9

10

PVR 1

1

2

3

4

5

6

7

8

9

10

PVR 2

1

2

3

4

5

6

7

8

9

10

PVR 3

6Y11 Throttle Position Potentiometer

1Y7 Pump 1

11Y7 Pump 2

RVR

Swing Directional Valve

GMK 5160 Amplifier Board Adjustments

PVR Board Pins Gnd. to Joystick Potentiometer

Superstr. Ground

0v - 4.25v Input from Joystick

+24 vdc Input +4.25 vdc Output

1 2 3 4 5 6 7 8 9 10

PVR Board Pins Pump Prop. Solenoid 1Y7

1 2 3 4 5 6 7 8 9 10

Current Output to Pump Solenoid

PVR Board Potentiometer Adjustment Points

P1:Time Ramp

1 2 3 4 5 6 7 8 9 10

P2:I-Max. Red P3:I-Min. Red P4:I-Max. Green

P1 P2 P3 P4 P5

P5:I-Min. Green

Direction LED’s

PVR Board Adjustments Step 1: Remove wire from pin #6

1Y7

Step 2: Connect wire to amp meter Step 3: Connect ground wire from meter to pin #6

1 2 3 4 5 6 7 8 9 10

P1P2P3P4P5

PVR Board Adjustments

Meter is now installed we are now ready to begin board adjustments

1Y7

1 2 3 4 5 6 7 8 9 10 Joystick

Relay Board

0 to 4.25v Output

P3 I-Min.

P1P2P3P4P5

Move joystick until the LED just lights, then make current adjustment Using a small technicians screwdriver adjust the P3 pot. till it reads 200ma (Counterclockwise=Decrease Clockwise=Increases

Red LED lights when P3 Min threshold is reached

PVR Board Adjustments

1Y7

1 2 3 4 5 6 7 8 9 10 Joystick

Relay Board

0 to 4.25v Output

P1P2P3P4P5 P2 I-Max. Move joystick to full span, then make current adjustment Using a small technicians screwdriver adjust the P2 pot. till it reads 600ma (Counterclockwise=Decrease Clockwise=Increases

Red LED will stay on during this adjustment

PVR Board Adjustments

1Y7

1 2 3 4 5 6 7 8 9 10 Joystick

Relay Board

0 to 4.25v Output

P5 I-Min.

P1P2P3P4P5

Move joystick until the LED just lights, then make current adjustment Using a small technicians screwdriver adjust the P5 pot. till it reads 200ma (Counterclockwise=Decrease Clockwise=Increases

Green LED lights when P5 Min threshold is reached

PVR Board Adjustments

1Y7

1 2 3 4 5 6 7 8 9 10 Relay Board

Joystick

0 to 4.25v Output

P1P2P3P4P5 P4 I-Max. Move joystick to full span, then make current adjustment Using a small technicians screwdriver adjust the P4 pot. till it reads 600ma (Counterclockwise=Decrease Clockwise=Increases

Green LED will stay on during this adjustment

PVR Board Adjustments Full Deflection Joystick Joystick

1Y7

1 2 3 4 5 6 7 8 9 10 Relay Board

0 to 4.25v Output

P1P2P3P4P5

P1 Time Ramp Adjust the time required for the current to fall from I-Max. to I-Min.

Fully deflect Joystick and release. Observe needle sweep return on analog meter. Adjust P1 pot. to .6 sec. return

** Special Note: Repeat this step as required **

PVR Board Adjustment Values 1Y7

1 2 3 4 5 6 7 8 9 10

PVR 1 & 2 Hoists, Lift & Tele I-Min I-Max Time Ramp

LED

200mA 600mA

.6 Sec.

Green

200mA 600mA

.6 Sec.

Red

P1 = Time Ramp P2 = I-Max. Red P3 = I Min. Red P4 = I-Max. Green P5 = I Min. Green

P1P2P3P4P5

PVR Board Adjustment Values 6Y11

PVR 3 Lift Down I-Min I-Max Time Ramp

LED

250mA 700mA

.6 Sec.

Green

250mA 700mA

.6 Sec.

Red

1 2 3 4 5 6 7 8 9 10

P1P2P3P4P5

P1 = Time Ramp P2 = I-Max. Red P3 = I Min. Red P4 = I-Max. Green P5 = I Min. Green

Pin #15 S/S Ground

Pin #8 - 13.2 vdc output supply to swing Joystick

R1 R2 R3 R4 R5 R6 R7 R8

1 2 3 4 5 6 7 8 9 101112131415 16

Pin #16 +24vdc Supply

RVR Board Pin Identification

Pin #7 - 13.2 to 0 vdc input from swing joystick

Pin #6 - Ground for swing joystick potentiometer

Swing Fine Speed Control Potentiometer

4.7 K

Supply from RVR

3 Output Signal 2

Ground to RVR 1 2 3 4 5 6 7 8 9 101112131415 16

RVR Board Pin Identification

R1 R2 R3 R4 R5 R6 R7 R8

1

Swing Joystick Potentiometer

Pin #6 RVR Ground

Joystick

Pin #8 -13.2 vdc Supply

RVR Input Signal Pin #7

1 2 3 4 5 6 7 8 9 101112131415 16

RVR Board Pin Identification

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

Swing Proportional Directional Solenoids

4Y3

RIGHT

4Y4

Swing Right 1 2 3 4 5 6 7 8 9 101112131415 16

Pin #13 Output

RVR Board Pin Identification

R1 R2 R3 R4 R5 R6 R7 R8

Swing Proportional Directional Solenoids

Swing Left Pin #12 Output

LEFT

4Y3

RIGHT

4Y4

1 2 3 4 5 6 7 8 9 101112131415 16

RVR Board Pin Identification

R1 R2 R3 R4 R5 R6 R7 R8

RVR Board Adjustments 1 2 3 4 5 6 7 8 9 101112131415 16

R1 I-Max. Left R2 I-Min. Left R3 I-Max. Right R4 I-Min. Right R5 DO NOT ADJUST Board Frequency R6 Special Switching Function R7 Ramp Time #1 R8 Ramp Time #2 R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments Install Amp meter in-line between wires and Pin #14

Joystick

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Step 1: Remove wire from pin #14 Step 2: Connect wire to Ammeter Step 3: Connect Ammeter to Pin #14

Important Caution! R1 R2 R3 R4 R5 R6 R7 R8

Pin #15 is hot with 24V (fused power) Shorting Danger

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Swing Left Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R2 I-Min. Swing Left Move joystick slightly until Green LED just lights Deflect Joystick Slightly Green LED lights Output begins R2, I-Min Adjust to 360 mA Counter Clockwise Decrease Output Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Full Deflection Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R1 I-Max. Swing Left Move joystick full deflection left Green LED on bright Deflect Joystick Full Green LED lights Output Full R1, I-Max Adjust to 750 mA Counter Clockwise Decrease Output Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Swing Right Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R4 I-Min. Swing Right Move joystick slightly until Yellow LED just lights Deflect Joystick Slightly Yellow LED lights Output begins R4, I-Min Adjust to 360 mA Counter Clockwise Decrease Output Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Full Deflection Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R3 I-Max. Swing Right Move joystick full deflection right Yellow LED on bright Deflect Joystick Full Yellow LED lights Output Full R3, I-Min Adjust to 750 mA Counter Clockwise Decrease Output Clockwise Increase Output

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Full Deflection Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R7 Time Ramp #1 Adjust the time required to go from I-Min to I Max to 0 Sec. R7, Ramp Time Observe Analog Needle Adjust to Smooth Sweep (Repeat as required)

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Swing Right Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R8 Time Ramp #2 Ground Pin 1, adjust the time required to go from I-Max to neutral Adjust to 2 Sec. Deflect Joystick Full Connect Grounding Wire to Pin #1 (note ground to superstructure)

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Swing Right Joystick

1 2 3 4 5 6 7 8 9 10111213141516

R8 Time Ramp #2 Ground Pin 1, adjust the time required to go from I-Max to neutral Adjust to 2 Sec.

R1 R2 R3 R4 R5 R6 R7 R8 R1R2R3R4R5R6R7R8

Release Joystick and Observe Needle Sweep Adjust R8 to approx. 2 sec. sweep

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R6 Special Swing Brake Release. Connect Ohmmeter to Superstructure Ground Connect Pin #11 to Ohmmeter

R1 R2 R3 R4 R5 R6 R7 R8

LEFT

4Y3

RIGHT

4Y4

RVR Adjustments

Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R6 Special Swing Brake Release. Turn R6 Observe Needle Sweep Adjust to full sweep absolute ground Turn Counter Clockwise until Ohmmeter reads No Resistance (meter pegged)

R1 R2 R3 R4 R5 R6 R7 R8

Then, Turn Clockwise 1/4 turn to Set

LEFT

RVR Adjustments

RIGHT

4Y3

4Y4

Joystick

1 2 3 4 5 6 7 8 9 101112131415 16

R5 Board Frequency

Do not Adjust

R1 R2 R3 R4 R5 R6 R7 R8

4Y3

4Y4

1 2 3 4 5 6 7 8 9 101112131415 16

RVR Adjustment Summary

Direct. Left Right

I-Min I-Max Ramp

LED

360mA 750mA

#1 = 0 Sec. #2 = 2 Sec

Green

360mA 750mA

#1 = 0 Sec. #2 = 2 Sec

Red

R1 =I-Max. Left - Green R2 =I-Min. Left - Green R3 =I-Max. Right - Red R4 =I-Min. Right - Red

R5 =DO NOT ADJUST R1 R2 R3 R4 R5 R6 R7 R8

R6 =Special Func. Swing Brake Release R7 = Time Ramp #1 R8 = Time Ramp #2