process for adjusting the sensor technology of cranes with light display en

EKS 5 Technical Description“Process for Adjusting the Sensor Technology of Craneswith Light Display”TK4/Training Centre 01.02.2005

EKS 5 Technical Description

“Process for Adjusting the Sensor Technology of

Cranes with Light Display”


Table of Contents

1. EKS 5 Adjustment Instructions ...........................................................................................................3

2. Process for Adjusting the Main Boom Angle ......................................................................................6

3. Process for Adjusting the Length Sensor Inner Drum ........................................................................9

4. Process for Adjusting the Length Sensor Outer Drum .....................................................................11

5. Process for Adjusting the Pressure Sensor Lower Chamber ...........................................................12

6. Process for Adjusting the Pressure Sensor Upper Chamber ...........................................................14

7. Process for Adjusting the Slewing Angle Sensor (Slewing Range) ..................................................16


1. EKS 5 Adjustment Instructions

General Note

All of the drive units of the crane must be functioning. The hydraulics, ECOS and RCI control systems arepre-adjusted with standard values.

Connecting the change-over box

• Switch off ignition

• Unscrew protective cover on the right at the bottom of the crane operator’s cab.

• Connect change-over box (part No. 03056586) to the 15-pin (EKS/RCI) diagnostic plug connection inthe crane operator’s cab.

Fig. GROVE�� change-over box in crane operator’s cab

Attention! Pay attention to the description of the diagnostic plugs in older cranes!

As the RCI is not functioning during the adjusting process, particular care is required whenoperating the crane. Pay particular attention to the hoist limit switch and outrigger and ensure thatthe counterweight is sufficient.


• Turn RS232 switch to “3+4”.

• Switch on ignition

• Release write protection via interface (position the toggle switch in position “1” on the change-overbox).

Fig. GROVE�� change-over box


Adjustment: PIN input

Fig. EKS 5 light display

For the connection of the change-over box see EKS 5 Adjustment Instructions “General Notes”

Entering the programming mode

• Activate keys + for the PIN input prompt.

INFO display flashes!

• Input PIN via Num. Block keys to and confirm with <ENTER>

• The input + is required to release the sensor equalisation

Rigging mode display flashes!

• Enter address with Num. Block and confirm with <ENTER> key.

INFO display flashes!

• The current value is displayed which is to be altered to

• Confirm with <ENTER>


2. Process for Adjusting the Main Boom Angle

• Adjust the base section to 0.0° using an electronic spirit level.

Fig. Electronic spirit level with base section adjustment 0°

Adjustment: starting value for angle sensor

• Teach starting value with , . The display is automatically set to 0.0°.

• Display:


• Only when process is being carried out with a pendulum potentiometer! If the process is beingexecuted with a digital angle sensor, this 80° adjustment process is not required.

• Using an electronic spirit level adjust the base section to 80.0°.

Fig. Electronic spirit level with base section adjustment 80°

Adjustment: end value for angle sensor

• Check address 224 � value 800

• Teach end value with , . The value is automatically adjusted to 80.0°.

• Display:


A list of all of the types of cranes with the relevant adjustment data is given below for the main boomangle:

Type of crane (GMK)

GMK

2035

GMK

3050

GMK

3050_1

GMK

3055

GMK

4075

GMK

4075_1

GMK

5100

GMK

5130

GMK

5200

GMK

6200

GMK

6220

GMK

6221

Starting

value1300 1300 1300 0 1250 0 1250 0 1280 1280 1280 1200

End

value4900 4900 4900 800 4800 800 4800 800 4850 4850 4850 4800

Stroke 800 800 800 800 800 800 800 800 800 800 800 800

Type of crane (GMK)

GMK

6250

GMK

6300

GMK

7450

Starting

value1300 1300 1300

End

value4800 4800 4800

Stroke 800 800 800

Table: GMK main boom adjustment data

Note:The starting and end values in the table are not fixed values and are therefore just a guide!


3. Process for Adjusting the Length Sensor Inner Drum

Please comply with the sequence!

Attention: This adjusting process can only be carried out after the telescope lengths have been adjustedin the ECOS (ESX) system!

• Lock telescoping cylinder with telescope section 1 (telescope position 0 – 0 – 0 – 0 – (0) ), derrickboom up to approx. 80°.

Adjustment: starting value for length sensor inner drum

• Teach starting value with , .

• Extend telescope section 4 to 100% and lock (or the maximum level, e.g. GMK3055 tele. 5).

Adjustment: end value for length sensor inner drum

• Check address 264� enter the appropriate stroke (see table on next page; e.g..: for GMK3055 � 732)

• Teach end value with , .


A list of all of the types of cranes with the relevant adjustment data is given below for the length sensorinner drum:

Type of crane (GMK)

GMK

2035

GMK

3050

GMK

3050_1

GMK

3055

GMK

4075

GMK

4075_1

GMK

5100

GMK

5130

GMK

5180

GMK

5200

GMK

6200

GMK

6220

GMK

6221

Starting

value1044 1044 1044 1049 1044 1044 1044 1044 1044 1044 1044 1044 1044

End value 3200 3200 3200 2635 2800 2970 3250 3150 3150 3150 3150 3150 3550

Stroke 666 707 707 732 887 887 1042 1054 1054 1054 1054 1054 1254

Type of crane (GMK)

GMK

6250

GMK

6300

GMK

7450

Starting

value1044 1044 1044

End value 3500 3500 3500

Stroke 1247 1247 1247

Table: GMK length sensor inner drum adjustment data



4. Process for Adjusting the Length Sensor Outer Drum


• Retract all telescope sections to (0 - 0 - 0 – 0) (fully retract telescopic boom), derrick up to approx. 80°.

Adjustment: starting value for length sensor outer drum


• Extend all telescope sections fully and derrick boom up to approx. 80°.

Adjustment: end value for length sensor outer drum

• Check address 234 � enter value from the following table; e.g.: GMK3055 � 3334

• Adjustment: Teach end value with , .

A list of all of the types of cranes with the relevant adjustment data is given below for the length sensorouter drum:

Type of crane (GMK)

GMK

2035

GMK

3050

GMK

3050_1

GMK

3055

GMK

4075

GMK

4075_!

GMK

5100

GMK

5130

GMK

5180

GMK

5200

GMK

6200

GMK

6220

GMK

6221

Starting

value1044 1044 1044 1044 1044 1044 1044 1044 1044 1044 1044 1044 1044

End value 2800 3600 3600 3875 3900 3750 3350 4000 4000 4000 4000 4000 4650

Stroke 2016 2828 2828 3334 3200 3200 3820 4650 4650 4650 4650 4650 5650

Type of crane (GMK)

GMK

6250

GMK

6300

GMK

7450

Starting

value1044 1044 1044

End value 3900 3900 3900

Stroke 4454 4454 4454

Table: GMK length sensor outer drum adjustment data

Note:The starting and end values inthe table are not fixed valuesand are therefore just a guide!


5. Process for Adjusting the Pressure Sensor Lower Chamber


Adjustment: Starting value of the pressure sensor lower chamber

• Lower boom onto the boom support

• Make pressure sensor lower chamber pressureless via the bleeder screw of the safety lowering valve.

Fig. bleeder screw; Example: GMK3055 safety lowering valve on the derricking cylinder

• Adjustment: Teach starting value with , .

• Read physical value on Info Display � must be less than 1.5 bar

Note:If the value exceeds 1.5 bar, then unscrew the sensor and tighten again with a torque wrench or if thevalue stays the same (over 1.5 bar)� replace sensor.

Check: end value for pressure sensor lower chamber

• Check address 204 � value 350 (bar) (see table on next page)

• The end values are not taught but are preset

• Read starting value for address 200 and 201 e.g. 1024 + 4096 (stroke) = 5120 (end value for address202 or 203)


A list of all of the types of cranes with the relevant adjustment data is given below for the pressure sensorlower chamber:

Type of crane (GMK)

GMK

2035

GMK

3050

GMK

3050_!

GMK

3055

GMK

4075

GMK

4075_1

GMK

5100

GMK

5130

GMK

5180

GMK

5200

GMK

6200

GMK

6220

GMK

6221

Starting

value1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024

End value 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120

Stroke 350 350 350 350 350 350 350 350 350 350 350 350 350

Type of crane (GMK)

GMK

6250

GMK

6300

GMK

7450

Starting

value1024 1024 1024

End value 5120 5120 5120

Stroke 350 350 350

Table: GMK pressure sensor lower chamber adjustment data



6. Process for Adjusting the Pressure Sensor Upper Chamber


• Lower boom onto the boom support

• Make pressure sensor upper chamber pressureless via the bleeder screws of the cylinder.

Fig. Cylinder bleeder screw for pressure sensor upper chamber

Adjustment: starting value for pressure sensor upper chamber (concerns cranes with pressuresensor upper chamber)


• Read physical value on Info display � must be less than 1.5 bar

Note: If the value exceeds 1.5 bar, then unscrew the sensor and tighten again with a torque wrench, or ifthe value stays the same (over 1.5 bar)� replace sensor.

Attention: No pressure sensor upper chamber exists for the GMK 3055 crane!

Adjustment: end value for pressure sensor upper chamber (concerns cranes with pressure sensorupper chamber)

• Check address 214 � value 350 (bar)

• The end values are not taught, but are preset

• Read starting value for address 210 e.g. 1024 + 4096 (stroke) = 5120 (end value for address 212)

General NoteWhen changing the new pressure sensors with a screw cap and in the case of new cranes, the pressuresensors must be configured with EasyCAN.If the pressure sensors are detected by EasyCAN, they must also be configured.See also EKS adjustment list Address 206, 207 and 216 Status must be on “2”.


A list of all of the types of cranes with the relevant adjustment data is given below for the pressure sensorupper chamber:

Type of crane (GMK)

GMK

2035

GMK

3050

GMK

3050_1

GMK

3055

GMK

4075

GMK

4075_1

GMK

5100

GMK

5130

GMK

5180

GMK

5200

GMK

6200

GMK

6220

GMK

6221

Starting

value1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024

End value 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120 5120

Stroke 350 350 350 350 350 350 350 350 350 350 350 350 350

Type of crane (GMK)

GMK

6250

GMK

6300

GMK

7450

Starting

value1024 1024 1024

End value 5120 5120 5120

Stroke 350 350 350

Table: GMK pressure sensor upper chamber adjustment data



7. Process for Adjusting the Slewing Angle Sensor (Slewing Range)


• The crane is rotated to the back and locked in the 0.0° position.

Adjustment: starting value for slewing angle sensor


• Info display:

• The crane is locked forward in the 180.0° position (not in the case of the 5130)

Note: Slew right check of 0.0° must display a positive (+) value � left negative (-).

Adjustment: end value for the slewing angle sensor

• Check address 272 � value 180 (°) see table on next page (stroke)

• Teach end value with , .

• Info display:

Note:

* In the case of ATTO-CANOpen sensors, the sensor must first be configured with EasyCAN.During adjustments, only the position 0° locked to the back is operated and taught. Theposition 180° forwards does not have to be taught.


A list of all of the types of cranes with the relevant adjustment data is given below for the slewing anglesensor:

Type of crane (GMK)

GMK

2035

GMK

3050

GMK

3050_1

GMK

3055

GMK

4075

GMK

4075_1

GMK

5100

GMK

5130

GMK

5180

GMK

5200

GMK

6200

GMK6

220

GMK

6221

GMK

6250

Starting

value2048 2048 2048 2048 2048 2048 2048 2048 2048 2048 2048 2048 2048 2048

End value 2377 2377 2377 2377 4096 3848 4096 4096 4096 4096 6144 6144 6144 6144

Stroke 180 180 180 180 180 180 180 180 180 180 180 180 180 180

Type of crane (GMK)

GMK

6250

GMK

6300

GMK

7450

Starting

value2048 2048 2048

End value 6144 6144 4096

Stroke 180 180 180

Table: GMK slewing angle sensor adjustment data


process for adjusting the sensor technology of cranes with light display en

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