GMK II

Superstructure
Hydraulics
GMK 5160 S/S Hydraulics

M M
M

Monoblock Swing Counter Weight

Control Removal System

Swing Brake Release

Piston Motors

Tank

Gear Motors
To P1 & P2
P4

To Rexroth
Mono-Blk.
P3.2 40 Bar

P3.1

To Swing
Directional Valve

GMK 5160 Gear Pumps

Mono-Blk. Mono-Blk.
Drain 5 Bar 5 Bar Drain

Drain Line

3 Bar OS55

Optional
Coolers

To Pumps

GMK 5160 Hydraulic Tank

TRAINING INSTITUTE

A8VO...Superstructure Pump Assembly

GMK A8VO Pump (5160)

Y1 A1 A2 Y1

R2 X 1Y7 11Y7 X R1

P1 P2

23S1 23S1

3 bar 3 bar
GMK A8VO Pump (5160)

Y1 A1 A2 Y1

R2 X 1Y7 11Y7 X R1
200-600 mA

P1 P2

23S1 23S3
OK11
OK12

3 bar 3 bar
Rexroth
Monoblock
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
TRAINING INSTITUTE

Rexroth Mono Block

Pump P4
40 Bar Pilot Pressure
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P1 Ramping Up
Main Hoist Only
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P2 Ramping Up
Tele or Lift Only
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P1 & P2 Ramping Up
Main Hoist and Tele or Lift
40 Bar

23Y11 23Y12 P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
M

Pump P1 Ramping Up
Main Hoist
40 Bar

23Y12 P4
P4
23Y11

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P2 Ramping Up
Telescope
40 Bar

23Y11 23Y12 P4
P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
Pump P2 Ramping Up Direct
Lift Up (only) to
40 Bar Tank

23Y11 23Y12 P4
P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
M
Auxilary Hoist

Pump P1 Ramping Up
Aux Hoist
40 Bar

23Y11 23Y12 P4
P4

Main Hoist Aux. Hoist Telescope Lift

P1 P2
Concept Drawing Only
GMK 5160 Lift Circuit
Raising Boom
1 2 3 4 5 6 7 8 9 10

6Y11

3 Bar
PVR 3
23S4 Board

40
Bar
5 Bar

Lift
Rexroth P4
Joystick
TANK Mono-Blk. 300
Bar
0 - 4.25
Volts

1 2 3 4 5 6 7 8 9 10

P2
P2
PVR 2
6Y2 Lift Large Board
Current
GMK 5160 Lift Circuit
Lowering Boom
1 2 3 4 5 6 7 8 9 10

6Y11
Large
Current

3 Bar
PVR 3
23S4 Board
0 - 4.25
40 Volts
Bar
5 Bar

Lift
Rexroth P4
Joystick
TANK Mono-Blk. 300
Bar

1 2 3 4 5 6 7 8 9 10

P2
PVR 2
6Y2 Lift Board
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

1 2 3 4 5 6 7 8 9 10

Micro 40
Switch
Bar
320 TANK
Bar

P4
Rexroth
Mono-Block

P1

Hoist Down
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar

P4
Rexroth
Mono-Block

P1

Hoist Down
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar
Large
Current P4
Rexroth
Mono-Block

P1

Hoist Down
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar
Large
Current P4
Rexroth
Mono-Block

P1

Hoist Down
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

1 2 3 4 5 6 7 8 9 10

Micro 40
Switch
Bar
320 TANK
Bar

P4
Rexroth
Mono-Block

P1

Hoist Up
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar
Large
Current P4
Rexroth
Mono-Block

P1

Hoist Up
1Y12 1Y11
Main Hoist Hoist Brake

Circuit

1Y1 1Y2
Main
Hoist
Joystick

0 - 4.25
Volts
11 22 33 44 55 66 77 88 99 10
10

Micro 40
Switch
Bar
320 TANK
Bar
Large
Current P4
Rexroth
Mono-Block

P1

Hoist Up
1Y12 1Y11
T1 Tele Section
Pin Locking
System
Section T1 Pins Locked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
I 60 bar
Section

φ2 φ0.6
P2

Base Section

P4
Section T1 Pins Locked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I
Pins Locked Indicator
T1Lamp
The control panel has a T1Boom
Boom
I 60 bar Section Pinned indicator lamp.
Section
When illuminated the operator
confirms the boom section is pinned.
φ2 φ0.6
P2

Base Section

P4
Section T1 Pins Locked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
I 60 bar
Section

φ2 φ0.6
P2
Mechanical Spring Closed
Base Section
When hydraulic pressure is released
the pins are mechanically engaged.
They will only trip the proimity
switch when fully engaged or locked.
P4
Section T1 Pins Locked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
I 60 bar
Section

φ2 φ0.6
P2
Pins Locked
When the pins are in a locked
Base Section
position they trip proximity
switches. These switches will not
trip if the pins are transitioning or
not in position.
P4
Section T1 Transitioning

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
I 60 bar
Section

f2 f0.6
P2

Base Section

P4
Section T1 Transitioning

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
I 60 bar
Section

f2 f0.6
P2

Base Section

P4
Section T1 Transitioning

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
II 60 bar
Section
Pins Moving; Lamp Flashing
The control panel has a T1 Boom
f2 f0.6
P2 Section Unlocked indicator lamp.
When flashing the operator confirms
the pins are moving.
Base Section

P4
Section T1 Transitioning

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
I 60 bar
Section

f2 f0.6
P2

Both Proximity Switches Off

Baseand
The pins are transitioning Section
not in
a safe condition. Once they have
acknowledged fully unlocked the
boom will be free to move.
P4
Section T1 Transitioning
Circuit is regulated to 60 bar
The pinning circuit is protected by a

Unpinned

Unpinned
Pinned

Pinned
60 bar relief. This insures smooth,
controlled release of the pins.
5Y10
I

T1
Boom
I 60 bar
Section

f2 f0.6
P2

Base Section

P4
Section T1 Pins Unlocked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
III 60 bar
Section
Pins Unlocked; Lamp On

The control panel has a T1 Boom

f2 f0.6
P2 Section Unlocked indicator lamp.
When on solid the operator confirms
the pins have moved and are
completely unlocked. Base Section
The boom is
now ready to move.

P4
Section T1 Pins Unlocked

Unpinned

Unpinned
Pinned

Pinned
5Y10
I

T1
Boom
II 60 bar
Section

f2 f0.6
P2

Unpinned Proximity Switches On

Base
The pins are unlocked and are ready to Section
allow the boom to move.

P4
Staged Monton
Telescope Cylinder
System
5Y13
5Y11

5Y12

GMK5160

Staged
Monton Cylinder
P2 System
5Y13
5Y11

Hydraulic Directional Valve

5Y12

This valve is the directional control valve

mounted on the Mono-Block which controls
direction of the telescope circuit. Pump P2 is
shown here which is the primary pump. High
speed can be engaged by pressing the floor
switch which adds pump P1 . GMK5160

Staged
Monton Cylinder
P2 System
5Y13
5Y11
Cylinder #1
5Y12
This cylinder is a two stage
cylinder that acts similar to the
domestic Grove “Trombone”
Cylinder.

It also has transfer tube that

GMK5160
runs through cylinder #1 to
feed cylinder #2

Staged
Monton Cylinder
P2 System
5Y13
5Y11

5Y12
Cylinder #2

This cylinder is a single stage

cylinder that entends section T3

Section T4 is cable extended

sychronized to the T3 section GMK5160

Staged
Monton Cylinder
P2 System
5Y13
5Y11

Holding Valves
5Y12
These valves directly hold the
cylinder oil while extended. Both are
pilot operated and shifted when a
cylinder is to be retracted.

GMK5160

Staged
Monton Cylinder
P2 System
5Y13
5Y11

5Y12

GMK5160
Logic Valve
This logic or poppet valve directs
oil to cylinder #2 which controls
section T3 & T4. This opens or Staged
closes based on oil control on
topside of cylinder. Monton Cylinder
P2 System
5Y13
5Y11

5Y12

GMK5160
Logic Cartridge Valve

This logic or poppet cartridge valve

Staged
directs oil to the different stages of
cylinder #1 which controls boom
Monton Cylinder
sections T1 & T2. This valve opens or
closes the different passages based on
P2 System
oil from the 3 solenoid control valves.
5Y13
5Y11

5Y12

GMK5160
Logic Control Valves

Staged
These valves directly hold the
cylinder oil while extended. Both are
Monton Cylinder
pilot operated and shifted when a
cylinder is to be retracted.
P2 System
5Y13
5Y11

5Y12

Shuttle Valve GMK5160

Allows the highest pressure to the
back side of the cartridge valve and
permits smooth opening and closing.
Staged
Monton Cylinder
P2 System
5Y13
5Y11

5Y12

Section T1
Extending
Cylinder #1
P2
5Y13
5Y11

5Y12

Section T1
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Section T1
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Section T1
T1
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Section T2
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y11

Section T2
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y11

T2
Section T2
Extending
Power 5Y32
Cylinder #1
P2
5Y13
5Y11

5Y12

Section T3 & T4
Extending
Power 5Y32
Cylinder #2
P2
5Y13
5Y11
T3
& 5Y12
T4

Power 5Y12 & 5Y13

Section T3 & T4
Extending
Power 5Y32
Cylinder #2
P2
5Y13
5Y11
T3
& 5Y12
T4

Power 5Y12 & 5Y13

Section T3 & T4
Extending
Power 5Y32
Cylinder #2
P2
5Y13
5Y11

5Y12

Section T1
Retracting
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T1
Retracting
Power 5Y42 Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T1
Retracting
Power 5Y42 Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T1
T1
Retracting
Power 5Y42 Cylinder #1
P2
5Y13
5Y11

5Y12

Section T2
Retracting
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

5Y12

Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

5Y12

T2 Power 5Y13

Section T2
Retracting
Power 5Y42
Cylinder #1
P2
5Y13
5Y11

5Y12

Section T3
Retracting
Cylinder #2
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2
5Y13
5Y11

5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2
5Y13
5Y11

T3 5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2
5Y13
5Y11

T3 5Y12

Power 5Y12

Section T3
Retracting
Power 5Y42
Cylinder #2
P2
GMK 5160 Operating Principle
R
P of Telescoping System When section 2 is in the fully
extended position it is then
5Y11 pinned / bolted.
A

Section 1
A
Section 2
5Y10
B

5Y12 Extend
A Retract
B Solenoid Control Table
5Y11 5Y12 5Y13
Cyl 1 section 2 ext 0 0 0
R Cyl 1 section 1 ext X 0 0
P
Cyl 2 section 3/4 ext 0 0 X
CYLINDER 1 Cyl 1 section 2 ret 0 X 0
5Y13 Cyl 1 section 1 ret 0 0 X
A
Cyl 2 section 3/4 ret 0 X 0

0 = Solenoid de-energized
X = Solenoid energized

CYLINDER 2
Swing System
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

275
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
Swing Brake Pedal

This brake control is primarily Swing

Joystick
used as a holding brake. It is
proportionally controlled.
275
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
Swing Control Valve
GMK 5160 Swing System
This assembly/enclosure controls
the hydraulic oil flow to the swing circuit.
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

275
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
Dual Gear Pumps

These gear pumps P3.1 and P3.2 Swing

are driven through the same shaft. Joystick

Two pumps are provided to create

the needed volume.
275
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

RVR Amp Board Swing

Joystick

This board controls the Min, Max

and275
Ramping Functions of the
P3.2 Swing
Bar circuit. Time delays
prevents back checking and shock
4Y4
loading.

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
40 Bar Pilot Pressure

The 40 bar pilot pressure is created Swing

Joystick
by gear pump P4.

275 In this diagram P4 is not shown

P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
Single Swing Motor
Older Generation GMK’s have Swing
single large capacity swing motors. Joystick

New Generation GMK’s have

275
P3.2 smaller multiple motor systems
Bar
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Joy Stick Control

Swing
Joystick
The Joy Stick Control sends signal
directly to the RVR board. The
275
RVR then controls the swing
P3.2 Bar
components .
4Y4

P3.1
1.4mm RVR
4Y10
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
4Y1 Solenoid Valve

This valve permits release of the Swing

Joystick
swing brake and is electrically
activated with 4Y10 valve.
220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

4S1 Brake Release Indicator

220
P3.2 Bar Switch is activated when the
The 4S1
hydraulic line sees a 1 bar4Y4
signal. The
yellow indicator light in the cab goes out
indicating the brake is released. When no
P3.1 pressure is present, the light is on.
1.4mm RVR
4Y10

40 Bar
GMK 5160 Swing System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
4Y10 Solenoid Valve

This valve permits control of the Swing

swing brake control valve and is Joystick

electrically activated with 4Y1 valve.

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
GMK
System
5160
Pumps
SwingFlowing
System
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
Releasing the Brake
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
Swing Left
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3
0- 750 ma
Current

Swing
Joystick

6.3 - .75 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
Swing Right
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar
Swing Right
40 Bar 4S1
4Y1
Pilot 1Bar
Press.

4Y3

Swing
Joystick

6.3 - 12.6 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar 0- 750 ma
Current
Applying the Brake
40 Bar
Foot 4S1
4Y1
Pilot
Pressure 1Bar
Press.

4Y3

Swing
Joystick

6.3 - 12.6 Volts

220
P3.2 Bar
4Y4

P3.1
1.4mm RVR
4Y10

40 Bar 0- 750 ma
Current