Deutsche GROVE GmbH

Adjustment Instructions Hydraulic System GMK 6250

1. Hydraulic System Carrier (FHG781)

Note: Given measuring points (M...) see attached schematic 3005207 Bl. 1 / 2

• Adjustment of the control settings at the axial – piston pump P1 for the steering circuit I.
Connect two pressure gauges @ 60 bar to the measuring points M1 & M4.
With idle speed, the pressure at M4, without selecting a function , must be 14 bar
higher than at M1. To make any adjustments, the adjusting screw for the differential pressure
at pump P1 must be adjusted. For adjusting screw detail, see page 3.
Attention!! Do not operate the steering wheel during the above checks, higher pressures
occur, which could destroy the pressure gauges.

• Check the adjustment (300 bar) of the pressure build – up valve =47-Y9. Connect a
pressure gauge of 400 bar to the measuring point M4 and activate the function “Retract
outrigger beam”. First, the pressure regulator control at the axial-piston pump P1 must be
adjusted to a higher value (appr. 320 bar). The pressure regulator is integrated on pump P1,
see page 3. Check pressure of the pressure build – up valve (300 bar + 5 bar tolerance). A
correction can be made with the adjusting screw, see page 4.
Afterwards, the pressure control regulator on P1 is to be readjusted to 280 bar (tolerance +5
bar). The pressure can be read via a pressure gauge at the measuring point M1.

• Check the adjustment 75 bar at the valves for the function “Extend outrigger beam”
(44Y11,21,31,41). Connect pressure gauge (250 bar) to the measuring points M7 - M10 and
activate the function (in idle speed). The allowable tolerance amounts to +5 bar. Otherwise,
the adjustment of the pressure control valve of the respective outrigger valve block is to be re-
adjusted.
(The valve block is always located at the opposite side of the respective outrigger
beam!!).

• Check the pressures in the steering system. These pressures can be checked via a pressure
gauge at the measuring points M1 + M2. With inoperative steering, the gauge should not
display more than 20 bar (rpm 1800 min-1). When steering against blocked wheels (not normal
full lock), the pressures of both steering circuits should be 150 bar. The allowable tolerance
amounts to ± 10 bar.

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• The all wheel steering is to be adjusted as follows:

-- All wheel steering axle 3/4. Check the adjustment of 180 bar at the proportional valve.
Connect a 250 bar pressure gauge to the measuring point MA4 and activate the function “All
wheel steering”. First, the plug of the solenoid valve (=47-Y11) is to be disconnected and
connected to a separate (spare) solenoid. (Otherwise, the ESX cuts off). At the steering limit
of the wheels (rpm 1800 min-1), the pressure must be 180 bar (tolerance + 5 bar). Otherwise
a correction at the pressure valve in the proportional (vertical) valve block between axle 4 and
5 is to be made.

-- All wheel steering axle 5/6. Two pressure gauges @ 250 bar are to be connected to a
steering cylinder of axle 5 or 6. and the function “all wheel steering left resp. right” is to be
activated (Valve =47-Y2,Y3). At the steering limit of the wheels (Engine RPM 1800 min-1), the
pressure must be 150 bar (tolerance + 5 bar). Otherwise, a correction of the adjustment at the
pressure control valve is to be made in the (horizontal) direction control block between axles 4
& 5.

After checking/adjusting the all wheel steering pressure of axle 5 and 6, the pressure
sequence valve is to be adjusted to 130 bar.
1. Screw in the sequence valve adjuster at least two complete turns.
2. Connect 250 bar pressure gauges to to the measuring points MA3 and MA4. Any registered
pressure on MA4 must be less than 150 bar.
3. Reconnect the previously removed solenoid plug (=47Y11) and turn out the adjustment screw
on the (LS) pressure control valve (adjacent to the solenoid) at least two complete turns.
4. Start the engine and increase the (LS) pressure control until the pressure at MA3 is 130 bar.
5. With constant pressure of 130 bar at MA3, carefully turn out the previously turned in adjusting
screw on the sequence valve until the pressure gauge at MA4 shows 130 bar
(rpm 1800 min-1 , tolerance + 5 bar)
6. Connect a 250 bar pressure gauge to the measuring point M1 and re-adjust the (LS) pressure
control valve to 150 bar with the function “all wheel steering” activated
(tolerance + 5 bar).

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• Check the adjustment 190 bar at the Cooling fan drive pump P3 (Mercedes). Connect a 250
bar pressure gauge at the measuring point ML. The ball valve before the thermostatic valve is
to be closed. With rpm 1800 min-1 , the pressure must be 190 bar (tolerance + 5bar ) . If the
adjusted value is incorrect, the pressure is to be reset via the adjusting screw of the priority
valve. The priority valve is mounted at the gear pump P3. For adjusting screw detail see below.

Adjusting screw for

Differential pressure Adjusting screw for
pressure regulator

Axial piston pump P1 and P2

for the steering circuit I/II

View of the drive shaft

Adjusting screw of pressure

control valve

Gear pump P3 with priority valve

for the fan operation

Priority valve Gear pump

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Pressure build – up valve (=47-Y9)

Adjustment screw for pressure control valve

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2. Hydraulic System Superstructure (FHG 786)

For the proper function of the superstructure hydraulic system, careful bleeding of the
superstructure hydraulic system is imperative. In particular, the following lines:

-- Bleeding the release line of the slewing gear brake

-- Bleeding the release line of the hoist brake

Note: : The following pressure values are read at the laptop resp. at the Pressure gauge.
Mentioned measuring points (M..) see attached schedule 3005201

• Check the adjustment 25 bar at the charge pump P5/6. Connect a 40 bar pressure gauge to
the measuring points MA or MB (slewing gear pump or hoist pump) With rpm @ 800 min-1
25 bar must be measured. When increasing the rpm to 1800 min-1 , a maximum of 30 bar
should be measured.

• Check the control pressure. First, the pressure setting of the priority valve at the pump P7 is
to be set to a higher value. Afterwards, connect an 60 bar pressure gauge to the measuring
point MSt. Without operating any functions, 40 bar should be measured. If the adjusted value is
incorrect, it must be adjusted at the adjusting screw of the pressure control valve on the sub-
plate. Then, the previously adjusted pressure setting of the priority valve is to be readjusted with
rpm 1800 min-1 to 30 bar . For pressure adjustment to the priority valve see page 8.

• Check the adjustment 50 bar at the fan motor . Connect an 250 bar pressure gauge to the
measuring point ML. Emergency operation of the thermostatic valve is to be selected with an
SW4 Allen Key. With rpm @ 1800 min-1, the pressure must be 50 bar . If the pressure value
is incorrect, the pressure is to be adjusted at the adjusting screw of the thermostatic valve
relief valve.
Any additional oil cooler must be disconnected during the measurement.
Note: Do not forget to reset the thermostatic valve to normal operation.

• Crane Control. Following valves are to be checked (with rpm 1200 min-1):

-- Primary valve 330 bar in the inlet section of the logic block. First, the pressure valve
(pressure cut – off) at the pump P1 is to be set to a higher value. With the function
“derricking in/boom raise” against the bottomed out cylinder, 330 bar must be shown at the
laptop. Any corrections can be carried out with the adjusting screw, see page 8. After
checking resp. correcting, the pressure valve at the pump is to be readjusted to 300 bar.
See crane pump P1.

Note: The adjusting screw at the pressure valve is to be turned out a few turns, after that,
turn in slowly up to the required pressure.

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--Secondary valves telescoping gear. For this, the respective function is to be fully
retracted / extended to its end. Read the adjusted value at the laptop.

Tele cylinder extending (100%) 155 bar

Tele cylinder extending ( 60%) 210 bar
Tele cylinder retracting 250 bar

--Secondary valve derricking gear. Booming down in rapid motion with boom totally
down. At the laptop, 120 bar should be measured.

• The pressure adjustment Lock Counterweight is checked at the connection MA2 by pressure
gauge. At rpm 1200 min-1 100 bar must be measured. Any pressure adjustments can be
made at the pressure control valve in the counterweight control block.

• The pressure adjustment Lock Turntable is checked at the connection MA2 by pressure
gauge. At rpm 1200 min-1 75 bar must be measured. Any pressure adjustments can be made
at the pressure control valve in the turntable pinning/cab elevation control block.

• Check the adjustment 100 bar and 10 bar at the control block for the telescope cylinder
locking system. In order to control the pressure adjustments, connect a pressure gauge to
the connection MV.

--- Activate the function “extend cylinder”. At the pressure gauge 10 bar must be read. The
allowable tolerance amounts to +3 bar. Any pressure adjustments can be made at the
pressure control valve of the cylinder sub-plate (left side of frame behind operator’s cab).

--- Activate the function “unlock cylinder”. At the pressure gauge 100 bar must be read. The
allowable tolerance amounts to + 5 bar. . Any pressure adjustments can be made at the
pressure control valve of the cylinder sub-plate (left side of frame behind operator’s cab).

• Slewing gear pump P2 Check the pressure adjustment (pressure cut – off) 400 bar. Slew left
resp. right with the slewing brake engaged. At the laptop 400 bar should be read. Corrections
are to made at the pressure control valve of the pump. For details see page 7.

• Hoist pump P3 and P4 Check the pressure adjustment 400 bar (pressure cut - off) and 135
bar (lowering).

-- Pressure valves raising (400 bar). First, remove solenoid valve plug at the solenoid control
block for the hoist brake (Y1104,Y1105 Main hoist or Y1204,Y1205 auxiliary hoist ). Select
the function “Raise hoist ” (normal speed). 400 bar must be read at the laptop. Corrections are
to made at the pressure control valve on the pump. For details see page 7.
After checking/adjustments, the previously removed solenoid valve plug is to be reassembled.

-- Pressure valves lowering (135 bar). First, remove solenoid valve plug at the solenoid control
block for the hoist brake (Y1104,Y1105 main hoist or Y1204,Y1205 auxiliary hoist ).
Afterwards, the function “Lower hoist ” is to be selected. 135 bar must be read at the laptop.
Corrections are to made at the pressure control valve on the pump. For details see page 7.
After checking/adjustments, the previously removed solenoid valve plug is to be reassembled.

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Crane pump P1
Pressure valve
300 bar

Pressure
Slewing gear pump P2 valve
(400 bar)

Pressure valve
(400 bar)
Hoist gear pump P3 & P4

Pressure valve
(135 bar)

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Control Block

Y2101 Y2102 Y2103 Y2104 Y2105

Y2107 Y2106

330 bar 120 bar 250 bar 210 bar 155 bar
Main Lift cylinder Telescope cylinder Telescope cylinder Telescope cylinder
Relief Rod side Rod side Piston side, subject Piston side, subject
to length to length

Pressure Control, pump P7

Adjustment screw for pressure control

Priority Valve Gear Pump

Enclosure: Schematics for carrier and superstructure