Deutsche GROVE

GMK 3050

Outrigger System
1. General Description...............................................................................................1
1.2. Relief valve settings.........................................................................................1
2. Outrigger control box............................................................................................2
2.1 Micro relay functions......................................................................................2
3. Outrigger controls .................................................................................................4
4. Outrigger control elements ...................................................................................5
5. Diverter & direction valves...................................................................................6
6. Stabiliser cylinders ................................................................................................7
7. Malfunctions on the carrier ..................................................................................8
8. Plan view of carrier outrigger solenoid valve locations .....................................9

RC 6.1.99

GMK 3050. Training Information. Outrigger system. January 99.

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1. General Description

The outrigger system is H configuration with four horizontal sliding beams and
vertical stabiliser cylinders. Each beam has two telescoping sections. The beams are
extended and retracted by a single stage double acting cylinder.

Outrigger spread = 6200 mm for full & 4400 mm for partial extension. The distance
from the front to rear outrigger beam is 6625 mm.

Outrigger stabiliser cylinder stroke = 500 mm.

The stabiliser cylinders have integrated double check (rod & piston) valves and a rod
side, thermal protection relief valve (250 bar).

Hydraulic oil supply for the outrigger circuit is provided by diverting pump P1 when
an outrigger function is activated. Pump P1 is normally designated as a steering
pump. However, for outrigger operation the pump flow is diverted via solenoid 47-
Y9, direction control and 47-Y10, which blocks flow to the steering (see fig 2).

Oil flow is supplied to each direction control valve block of which there are four; each
mounted above the outrigger box on the opposite side to the respective
beam/stabiliser. There are two direction control solenoids on each valve block, one
for the stabiliser and the other for the beam

1.2. Relief valve settings

The maximum system working pressure is controlled by the pressure relief valve
setting of pump P1 @ 250 bar, which is located within the diverter valve module.
The diverter valve module is located below the operator’s cab (see fig 6).

Circuit relief for beam extend only = 75 bar. Location: Within the direction control
valve port block of each beam (see fig 3).

GMK 3050. Training Information. Outrigger system. January 99. Page. 1

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2. Outrigger control box

The outriggers have electric/hydraulic control from control boxes, which energise
direction control solenoid valve block modules; these are above the outrigger beams.

The outriggers are operated from control boxes on both sides of the carrier, between
axles two and three. The master control box is on the left-hand side, it contains the
printed circuit board and encapsulated micro relays. These micro relays are controlled
by toggle switches on the fascia of the control boxes. Subject to the setting of the
toggle switches, a particular sequence of micro relays will be energised to operate the
required hydraulic direction and flow diverter valves (build up pressure). There are
eleven micro relays within the master control box. Each micro relay has its own LED
to indicate that it is energised (see fig 1).

2.1 Micro relay functions

For safety reasons, the power supply within each outrigger control box is routed
through a master switch. – S1 for left and – S11 for right. This means that two
switches, the master and the selected function switch must be operated on each
control box for any outrigger function. For additional safety, it is only possible to
operate the extension beams on the visible side. This is achieved by interlocking the
power supply to the blind side via -S3 and -S31 toggle switches. Blocking diodes are
also installed to prevent inverse power supply.

K1 & K2 (Stabiliser/beams) are both controlled by toggle switches -S3 or -S31. Both
relays have double contacts = two N/C and two N/O. Subsequently, we have four
switched circuits from the N/C position to the N/O position when both relays are
energised. When de-energised, the stabiliser circuit is selected. When energised, the
extension beam circuit is selected.

K3 & K4 (Stabiliser retract/extend) are both controlled by K7, N/C. Both K3 & K4
relays have double contacts. Again, we have four switched circuits from N/C to N/O.
When de-energised, the stabiliser retract circuit is selected. When energised, the
stabiliser extend circuit is selected.

K5 & K6 (Extension beam extend/retract) are both controlled by K7, N/O. Both
K5 & K6 relays have double contacts. Again, we have four switched circuits from
N/C to N/O. When de-energised, the extension beam extend circuit is selected. When
energised, the extension beam retract circuit is selected.

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K7 (Extend/retract) is controlled by toggle switches – S2 or – S21 via diodes to

prevent inverse power supply. Relay K7 has only a single contact leg, N/C and N/O.
This gives only two switched circuits, N/C to energise K3 & K4 and N/O to energise
K5 & K6.

K8 (Front left) is controlled by switch – S7 or – S71. K8 has only a single contact

leg. Only the N/O contact is used to energise solenoid 47 – Y10 (build up pressure)
and supply power to – S1 & - S11 terminal 5 for increase in engine speed if selected.

K9 (Front right) is controlled by switch – S6 or – S61. K9 has only a single contact

leg. Only the N/O contact is used to energise solenoid 47 – Y10 (build up pressure)
and supply power to – S1 & - S11 terminal 5 for increase in engine speed if selected.

K10 (Rear left) is controlled by switch – S5 or – S51. K10 has only a single contact
leg. Only the N/O contact is used to energise solenoid 47 – Y10 (build up pressure)
and supply power to – S1 & - S11 terminal 5 for increase in engine speed if selected.

K11 (Rear right) is controlled by switch – S4 or – S41. K11 has only a single
contact leg. Only the N/O contact is used to energise solenoid 47 – Y10 (build up
pressure) and supply power to – S1 & - S11 terminal 5 for increase in engine speed if
selected.

Note: Although the respective LED may be illuminated, that in its self does not prove
that the corresponding solenoid is energised.

The left - hand master control box has the schematic designation +BE503.AK1.
The right hand control box has the schematic designation +BE503.AK2

The schematic group = 44 Outriggers should be consulted for details of the electrical
circuit.

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3. Outrigger controls

Electrical schematic outrigger group designation: = 44. Component designation

= + BE503. AK1

1 = Control box lighting

2 = Toggle switch for beams/stabiliser

3 = Toggle switch for front left outrigger

4 = Toggle switch for front right outrigger

5 = Toggle switch for rear right outrigger

6 = Toggle switch for rear left outrigger

7 = Toggle switch for extend/retract

8 = Central toggle switch with speed control

To X1

Printed circuit Encapsulated

board fixed to micro relays
K7 K8 K9 K10 K11 K1 K2 K4 K3 K5 K6
rear of control with LED
box

Diode
block

To front &
X2 rear solenoid
X1 X3 Valves from X4
Input from X4
right hand
control box
to X2

Power supply &

engine speed control

Figure 1: View of left-hand master control unit with control panel removed

GMK 3050. Training Information. Outrigger system. January 99. Page. 4

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4. Outrigger control elements

Table 1 indicates the necessary micro relay and solenoid valves that must be energised
for the selected function.
Table 1

Function Micro relays Solenoids

Extension

K10
K11
K1
K2
K3
K4
K5
K6
K7
K8
K9
Pressure Direction
Beams

F/L extend X X X X O O O X O O O *47-Y10 44-Y11

F/L retract X X O O X X X X O O O *47-Y10 44-Y51
F/R extend X X X X O O O O X O O *47-Y10 44-Y21
F/R retract X X O O X X X O X O O *47-Y10 44-Y61
R/L extend X X X X O O O O O X O *47-Y10 44-Y31
R/L retract X X O O X X X O O X O *47-Y10 44-Y71
R/R extend X X X X O O O O O O X *47-Y10 44-Y41
R/R retract X X O O X X X O O O X *47-Y10 44-Y81

Stabiliser
Cylinders

F/L extend O O X X O O O X O O O *47-Y10 44-Y1

F/L retract O O O O X X X X O O O *47-Y10 44-Y5
F/R extend O O X X O O O O X O O *47-Y10 44-Y2
F/R retract O O O O X X X O X O O *47-Y10 44-Y6
R/L extend O O X X O O O O O X O *47-Y10 44-Y3
R/L retract O O O O X X X O O X O *47-Y10 44-Y7
R/R extend O O X X O O O O O O X *47-Y10 44-Y4
R/R retract O O O O X X X O O O X *47-Y10 44-Y8

X = Energised. O = De-energised

* In addition to 47-Y10 being energised, it is also necessary for 47-Y9 to be

energised to enable pump flow to be directed to the outrigger circuit (see fig 2). The
power supply to 47-Y10 is from the output of the micro relays to the solenoid via
relay 41-K41 interlock. 47-Y9 is energised from the carrier/super switch 41-S10 via
relay 47-K33 interlock. Please see page 3 in schematic group 47 for details.

The micro relays can be found by removing the control panel from the outrigger
control box on the left-hand side of the carrier. Each relay is numbered and has its
own LED.

( Bear in mind, that although the LED is illuminated, this does not guarantee that
the relevant solenoid is energised.

GMK 3050. Training Information. Outrigger system. January 99. Page. 5

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5. Diverter & direction valves

To superstructure

P1 To carrier steering To susp/outriggers

rear steering
A1 A2 B2

25 L/min

47Y11 47Y9
47Y10 T

250 bar

P
To carrier
steering

Transmission P1 P2
PTO

Figure 2: Actual and schematic view of diverter valve

To stabiliser cylinder To extension beam cylinder

Figure 3: Actual and schematic view of typical direction valve arrangement

GMK 3050. Training Information. Outrigger system. January 99. Page. 6

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6. Stabiliser cylinders

As any stabiliser cylinder creep could affect the stability of the crane, the stabiliser
cylinders are all fitted with double check valves to ensure that the cylinder is leakfree
at any desired standstill position (fig.4.4). The double check valve is integrated into
the barrel of the stabiliser cylinder.

The typical schematic view of a double check valve installation is a simplified symbol
(fig. 4.1). A detailed schematic view can be seen in (fig.4.2). In order to guarantee
the safe closing of both valve poppets, both user ports (A & B) must be connected to
the tank in the neutral position (fig.4.3).

As the cylinder is completely closed and leakfree, should the oil be heated (sun etc.)
and expand. The difference in surface area ratio would generate destructive pressure
in the rod side. The thermal protection relief valve (250 bar) is integrated into the
cylinder barrel, rod side circuit, to protect against excessive pressure intensification.

A B

A B
Thermal relief valve

250 bar

A1 B1

Figure 4.1
A1 B1

Figure 4.2

A B
A B

A1 B1

A1 B1

Figure 4.4

Figure 4.3

Figure 4: View of double check and thermal protection valve installation

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7. Malfunctions on the carrier

The respective solenoid valve groups (1) are located

above the outrigger beam on the opposite side of the
carrier, i. e. the solenoid valve groups for the left beam /
outrigger functions are located on the right side of the
carrier. Manual operation is possible by pushing the
buttons (2) on the end of the solenoid valve (fig 5).

Figure 5: View of solenoid location

Procedure in the event of malfunctions:

Accident risk! Make sure personnel are clear of outriggers prior to operation.

Table 2

Item Function Schematic Graphic

Symbol
1 Extend / retract front left outrigger cylinder =44 Y1 =44 Y5
2 Extend / retract front left beam =44 Y11 =44 Y51
3 Extend / retract front right outrigger cylinder =44 Y2 =44 Y6
4 Extend / retract front right beam =44 Y21 =44 Y61
5 Extend / retract rear left outrigger cylinder =44 Y3 =44 Y7
6 Extend / retract rear left beam =44 Y31 =44 Y71
7 Extend / retract rear right outrigger cylinder =44 Y4 =44 Y8
8 Extend / retract rear right beam =44 Y41 =44 Y81

Emergency operation of the solenoid valves:

Accident risk! Use extreme caution and only operate valves when in a safe
position to prevent being trapped by movement of the chassis or outriggers.

Locate the required direction valve according to the illustration (fig 6) and table 2, and
then push the manual override button on the end of the valve. For complete electrical
failure, it will also require an extra person to manually operate the pressure solenoid
47-Y10 & 47-Y9. This valve is under the carrier cab (see figure 6).

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8. Plan view of carrier outrigger solenoid valve locations

Front

47Y9 Diverter 47Y11

Ext 44Y21 Ret 44Y61
Beam
4 47Y10
Stabiliser 3

Ret 44Y6 Ext 44Y2

Ret 44Y5 Ext 44Y1

Stabiliser
1
Beam 2

Ext 44Y11 Ret 44Y51

Ret 44Y81 Ext 44Y41
Beam
8
Stabiliser 7

Ext 44Y4 Ret 44Y8

Ret 44Y7 Ext 44Y3

Stabiliser
5
Beam 6

Ext 44Y31 Ret 44Y71

Figure 6: View of outrigger solenoid locations, and item identity numbers

GMK 3050. Training Information. Outrigger system. January 99. Page. 9