Work instruction no.

55 Page: 1 of 13
Wilhelmshaven

Adjusting instructions for

the hydraulic systems UW (carrier) Index: A

GMK 5170/5170C/5220/5220C

Created by: Date: Checked: Date: Released: Date:

Gerold Schüßler 03.02.10 T. Held 15.03.10 C. Kien 19.03.10

Field revision: R Chester April 2010

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Deutsche GROVE GmbH Wilhelmshaven Adjusting instructions for

the hydraulic systems

GMK 5170/5170C/ 5220/5220C UW (carrier)

1. Hydraulic system UW (carrier)

For the measuring points (M…) and adjustment values, see circuit diagram.

Note: All pilot lines and work lines must be bled to achieve the correct adjustment.

Any oil added to the system should be pre-filtered until the oil purity category < ISO 18/16/13 or NAS 7 is
reached.
If there should be any doubt about system oil contamination it should be analysed to confirm compliance and if
necessary carry out corrective measures and use a flushing/filtration device to achieve the required oil purity
< ISO 18/16/13 or NAS 7.

1.1 Set up the flushing/filtration device.

Typical illustration of flushing/filtration device

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1.2. Check the differential pressure on the axial piston pump P1.

To do this, a portable measuring instrument with two 200 bar sensors is required. Before the measuring equipment
is connected, the two sensors must be connected to the measuring equipment and calibrated to 0 bar.

The sensors are calibrated to 0 bar

using the F2 key.

Steering pump for circuit 1: connect

sensor 1 to measuring point M1.

Connect sensor 2 to pressure build-up

valve M5.

Start the engine.

The pressure dp (see circuit diagram) must be set at an engine speed between 1400 – 1800 rpm. Indicated in the
display, third line. A correction is made by using the adjusting screw for the differential pressure
on pump P1.

Important: If the steering wheel is operated, higher pressures occur - this must be prevented.
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Undo the counter nut of the adjusting

screw and perform the adjustment.
Important: After the adjustment is
made, hold the adjusting screw and
tighten the nut at the same time.

The pressure can be checked

under dp1.
Note: The character (-) has no
meaning.

Important: After the adjustment is made, the engine speed should briefly be brought to idling speed and
then run back up to 1400 – 1800 rpm so that the adjustment can be checked again.

1.3. Check the differential pressure on the axial piston pump P2.

The adjustment must be checked as described under section 1.1.

Steering pump for circuit 2: connect

sensor 1 to measuring point M2.
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Steering pump for circuit 2: connect

sensor 2 to measuring point MP.

Undo the counter nut of the adjusting

screw and perform the adjustment.
Important: After the adjustment is
made, hold the adjusting screw and
tighten the nut at the same time.

1.4. Check the pressure setting for the pressure build-up valve = 47-Y9

To do this, a 400 bar (Kl.0.6) pressure gauge must be connected to measuring point M5 and the retract extension
cylinder function must be activated. For this, the pressure regulator on the variable displacement pump P1 must
firstly be set higher. If the adjustment value (see circuit diagram) is incorrect, this must be rectified by using the
adjusting screw of the pressure build-up valve. Then the pressure regulator must be set back to the old adjustment
value (see circuit diagram). The pressure can be checked via a pressure gauge at measuring point M1.

Measuring point M5 on the

pressure build-up valve
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Screw in the adjusting screw on

pressure
regulator P1 approx. 1.5 turns.
After the pressure has been set for
the pressure build-up valve, the old
adjustment value (see circuit
diagram) must be reset.

Adjusting screw on the pressure build-up

valve

Activate the retract extension cylinder

function using the outrigger controls.
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Connect the pressure gauge to measuring

point M5 and M1.

1.5. Check the pressure setting for extending the extension cylinder.

Carry out the check (see drawing) on the valves for the extend extension cylinder function 44Y11, 21, 31 and 41.
To do this, a pressure gauge must be connected to measuring point M7 to M10 and the extend extension cylinder
function must be activated with increase in speed. A correction must be made using the pressure valve for the
applicable port block.
Note: The port block is always located on the opposite side of the extension cylinder.

Measuring point M7 to M10

Pressure valve for extending

the extension cylinder

1. 6. Adjustment of the hydraulic steering limit stops

Before adjusting the hydraulic steering limit stops, the hydraulic and mechanical steering must be
checked or adjusted.

1. Lower the crane, insert the axle locking and jack it up with the outriggers.
2. Completely unscrew the steering stop screws of the first axle.
3. Turn the steering to the axle stop of the first axle.
4. Unscrew the steering stops of the second and third axles to the stop on the steering levers.
5. Connect the pressure gauge on the steering circuits 1 and 2 (P1 and P2).
6. Turn the steering wheel until approx. 80 bar is displayed on the pressure gauges.
7. Hold the steering wheel in this position (e.g. fasten it with a cable binder).
8. Check if the steering cylinders are connected correctly.
9. Turn the steering completely against the steering stop. A pressure of 150 bar must be displayed.
10. Then adjust the steering stops of the first, second and third axle such that the steering wheel can be turned
3.06 rotations *).
Setting the hydraulic steering limit stops for a turn to the right
11. Turn the steering wheel until approx. 100 bar is reached. Hold the steering wheel in this position.
12. Screw in the set screws 1R and 2R until the pressure falls to approx. 50 to 60 bar.
Screwing in the set screws reduces the steering stop with hydraulic support; unscrewing them increases it.
1R = steering circuit 1; turn to the right. 2R = steering circuit 2; turn to the right
13. When the steering wheel is then pulled against the right stop, the pressure on both circuits must be
between 50 and 60 bar.
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Setting the hydraulic steering limit stops for a turn to the left
14. The steering limit stops for a turn to the left are set analogously to a turn to the right.
15. The set screws are designated 1L and 2L.
1L = steering circuit 1; turn to the left. 2L = steering circuit 2; turn to the left
* ) corresponds to: 3 steering wheel rotations measured + 85 mm on the steering wheel.

2R 2L

1L R1

1.7. Check the steering circuits 1 and 2.

Checking the pressures in the steering system.

These pressures can be checked using a pressure gauge at measuring points M1 + M2. To do this, the crane has to
be standing on its wheels (straight ahead position) and the footbrake fully applied When the steering is not
being operated, the pressure gauges should not indicate more than 20 bar (diesel engine running at 1800 rpm).
When the steering is turned, the pressures in both steering circuits must be (see circuit diagram). The permissible
tolerance is ± 10 bar. It is not allowed to check the steering pressure with the crane on outriggers and with
spacers inserted between the lock stops. A correction to the setting is not possible, since the pressure is set
permanently.

1.8. Check the charging of reservoirs on the left and right side.

A laptop with the appropriate software connected as shown below is required to do this.

Connect the SBW service cable TN Connect the USB CAN dongle Connect the service cable to the
03125031 to the diagnostic to the service cable. USB CAN dongle on the laptop
interface (UW (carrier) – interface
in the driver's cab).
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Switch on the ignition and open the SBW service software.

First, the “CAN status” window must be opened via the menu bar.

Various information about the two controls of the SBW system is available
in the “CAN status” window.
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The two controls must be put into service mode with the buttons “ “Activate service mode” When the two controls
are in service mode, the buttons are greyed out and the “Service mode” point
is marked “On”

Next, the “Reservoir loading” window has to be opened via the menu bar.
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To check the working pressure, the reservoirs on the left and right side have to be charged. The control of the side
to be charged can be selected in the “Unit” field.

Using the button “Maintenance mode on”, the control activated in the “Unit” field is switched into maintenance
mode and afterwards the text “Maintenance mode off” appears in the button. If the maintenance mode for the
control is active, then the button “Reservoir loading on” is enabled.
The working pressure can be adjusted or checked. If the adjustment value is not correct, this must be corrected
using the adjusting screw of the steering control block (right and left side).
The pressure can be checked via measuring point M11 (left side), M12 (right side) or via the laptop.
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After the reservoir of the selected control (left or right) has reached the working pressure (see drawing),
you can deactivate the procedure again using the “Maintenance mode off” button.
This procedure must be performed with the left and right control. So now click in the “Unit” field,
“right”. And then, just as in the same way for the left control, activate the maintenance mode etc.
using the “Maintenance mode on” button (see photo below).
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Measuring point M 11
and M12

Adjusting screw of the

steering control block (right
and left side).

Note: The setting for the steering cylinders is described in the “Steer by wire” service software setting for
production.