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

EngineSteering

Pump drive boxOutrigger

Transfer case

Differential

Suspension

cylinder

Drive

Megatrak System

• Suspension struts & no axles

• Introduced in 1989

Early Suspension Struts

• Early Magatrak

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

300 mm/12 inches


• Large struts have a

single weldment

mounting with a frame

dowel retained by a

steel band & plastic

insert

Detail of top

fixing band


• Lubricating oil chamber

• Hydraulic cylinder

• Housing fixed to carrier

• Support tube turns in housing

Suspension Systems

1. Differential

2. Suspension cylinder

3. Wheel head

4. Wheel

5. Drive shaft

Megatrak

12

3 4

5

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 struts also have

integrated proximity

switches for suspension

control

Suspension Proximity SwitchesProximity 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

• All small and some

early large struts have

external proximity

switches between the

steering linkage within

a vertical tube

Steering Geometry

• Steering levers.

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 GeometryThe 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 idler

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

• Kessler transfer case

• 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

Drive from

transmission

Drive to front

axles

Drive to rear

axles

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

Megatrak axle, only with drum brakes

Power Train

• Megatrak, Kessler

differential assembly

• With internal air

actuated differential

cross locks

Power Train• Megatrack, Kessler differential with

inter-axle differential

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

Wedge S cam

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

• Pneumatic solenoids are often assembled in a

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 PumpsVarious 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

Principle of carrier remote pump drive box

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 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

• Cannon plug connections

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)

• Telemecanique - multi leg

Electrical SystemsRelay versions

BOSCH

standard micro

SIEMENS

stacking relay

SIEMENS

clear plastic

Electrical Systems

• 15 pin AMP plugs are

the most common

interface/bulkhead

plug

Electrical Systems• View of multi-pin plugs used for boom &

transmission connections

GMK Superstructures

Precision by Design

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

• Typical view

• Gate valves

• 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

• Typical view of return line filters

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

• View of A7VO bent axis piston pump

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

• H = Pilot pressure dependent

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• View of amplifiers & horsepower control circuit

board installation - Located in operators cab behind

drop down flap - Applicable to Megatrack models

5160 - 6200

PVR

RVR GLR


• 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


• 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

• Gear motors are not used

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

• Detail view of brake/motor control synchronising valve

Hydraulic Motors

• A2F bent axis motor being used to drive an

A8VOLRCH bent axis pump - GMK 4070

Hydraulic Oil Coolers

• View of oil cooler installation with electric fan

motors

GMK Crane Configurations

• Current models may use:

• Main boom

• Fixed & offset jib

• Power tilt jib

• Luffing jib


• Main boom


• Fixed jib

• The jib may also be

manually offset


• Fixed jib

• two lengths are

possible

• offset position is

obtained by

mechanical links


• Power tilt jib

• The jib angle is altered

from controls in the

operators cab by a

hydraulic cylinder on the

base of the jib


• Power tilt jib

in stowed

position

Crane Configurations• Luffing Jib

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 BoomsTelescope sections

• 3

• 2

• 1

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

section

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• Shown below is a skymaster telescope system

Telescope Cylinder Arrangement

• View of skymaster telescope cylinder

• Internal cylinder to section locking pins

Telescope Cylinder Arrangement• View of 70 tonne model telescope cylinders

S in g le t e le s c o p e c y lin d e r

C y lin d e r b o x

D o u b le t e le s c o p in g c y lin d e r

B a s e S e c t io n 1 S e c t io n 2 S e c t io n 3

S in g le t e le s c o p e c y lin d e r

C y lin d e r b o x

D o u b le t e le s c o p in g c y lin d e r

B a s e S e c t io n 1 S e c t io 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• Single stage and two

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

• EKS 83 uses digital

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• View with

compensation board

removed

• Transducers

• By-pass solenoid

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

• View showing

location of piston

transducer on the

boom lift cylinder


• 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


• View of multiple recoil drums on left side of boom


• 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


• The data transmitters are enclosed in boxes as close as

possible to the potentiometers/transducers

EKS 83 New Generation• View inside angle/length transmitter box showing:

angle potentiometer and data transmitters


• The boom length potentiometers are inside these

housings

EKS 83 New Generation• View of recoil drum potentiometer drive & slip rings

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

End of Superstructure Presentation

Section 2 ComponentID

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