GKD 1S Series User manual

SLEW LIMITER
M1000008 V1.4 - 11/2021
COPYRIGHT NOTICE
Intended audience: This document contains sensitive
information. It may not be shared with other parties without
the express written permission of GKD Technologies Ltd.
INSTALLATION MANUAL

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CONTENTS
Page
1 INTRODUCTION 4
1.1 Overview 4
1.2 Display mounting 4
2 SLEW MODULE MOUNTING 5
2.1 Motion cut solenoids 5
3 PROXIMITY SWITCHES (TOOTH COUNTING) 6
3.1 Proximity Switch Installation - clearance 6
3.2 Tooth Count Proximity Switch Spacing 7
3.3 Reset proximity switch 7
4 SYSTEM LAYOUT 8
5 SLEW MODULE CONNECTION TABLE 9
6 SLEW MODULE CONNECTIONS 10
6.1 +V and 0V Supply to slew module 10
6.2 Motion cut solenoid valve connections 10
6.3 Proximity sensor connections 10
7 TESTING THE INSTALLATION 11
8 CHECKING THE TOOTH COUNT SEQUENCE 12
9 CALIBRATION 13
10 GUIDE TO KEY SWITCH / LED MODES 14

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1 INTRODUCTION
This manual contains the installation instructions for the Series 1-S slew limiting system.
Installation should only be carried out by competent and trained sta as this product is a
safety product.
During installation it is assumed that industry standards will be observed and all cabling will
be protected against damage either from the movement of the machine or from collisions
that may occur during normal operations ( trees & branches, etc.).
All welding or bare metalwork should be treated to ensure that rust does not form.
1.1 Overview
Series 1-S is a stand alone slew limiter intended for use on hydraulic excavators and similar
machines where an upper structure rotates relative to the base structure, and where slew
limits are required.
Series 1-S monitors the slew position of the machine by means of counting of the teeth on
the slew ring, and limits the slew movement of the machine to between two slew points
which are set by the machine operator.
Pre-emptive stop algorithms will monitor the speed of approach to the limit and will
progressively apply the motion cut earlier the faster the speed of approach, ensuring the
machine stops before the limit is breached.
The Series 1-S system consists of an in cab display mounted at the operator station and
external slew module.
Communication between the slew module and the display is by means of a 4 connection
CAN cable with 12mm screw connectors at each end.
The slew module has two 12 way Deutsch connectors for connection to +V and 0V, three
proximity switches (slew ring tooth counting and reset), and two motion cut outputs for
connection to solenoid valves to motion cut the slew left and slew right controls.
1.2 Display mounting
The in cab display should be mounted at the operator station in direct line of sight of the
operator and should be positioned so the machine operator can easily reach the device.
A RAM type swivel mount is provided to enable the device to be orientated towards the
operator. Mount the bracket to a firm surface in the cab, bearing in mind the loads likely to
be imposed on the mount by vibration and movement.
Ensure that no machine controls are obscured, and that windows, doors and access panels
can be opened and closed without fouling the Series 1-S display..

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2 SLEW MODULE MOUNTING
The slew module should be mounted in a position where it is protected from direct rainfall
and jet washing etc, and where it is unlikely to be damaged mechanically. It is useful if the
LEDs within the module can be seen to assist in setup and fault finding. The slew module
may be mounted in any orientation. Ideally it should be fixed to a suitable panel using the
two mounting lugs and suitable 6mm bolts.
2.1 Motion cut solenoids
Two motion cut solenoid valves are typically used, to cut motion to the slew left and slew
right circuits. The motion cut valves are typically mounted in the pilot circuit between the
hydraulic controls of the machine and the main valve block, and should cut pilot pressure to
the valve block when not energized, and allow normal operation when energized.
The solenoid valves should be installed in the pilot control line to the slew left and slew right
hydraulic circuits, and should connect the control levers to the valve block when energized.
When not energized (motion cut) the supply from the control levers must be blocked and
the line to the high pressure valve block must be connected to tank to dump any residual
pressure, thus cutting motion.
Solenoid Energized (Motion Allowed)
Solenoid NOT Energized (Motion Cut)
From Control Lever
Pressure Dump to Tank
To Main Valve Block
From Control Lever
Pressure Dump to Tank
To Main Valve Block

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3 PROXIMITY SWITCHES (TOOTH COUNTING)
Two proximity switches must be installed in such
a way as to count the movement of the upper
structure against the slew ring teeth. The teeth are
typically accessed through an inspection hatch,
and it is usually possible to mount the proximity
switches into the inspection plate so that they
are able to detect the slew ring teeth as they
pass beneath. It is possible that a custom bracket
may need to be fabricated to hold the proximity
switches in a position where the slew ring teeth
may be counted. Where no access to the slew ring
teeth is possible, an external toothed ring may be
fitted as a register.
It may also be possible to count the bolts holding
the slew assembly together, although this solution
generally provides a lower count resolution,
which is less desirable.
3.1 Proximity Switch Installation - clearance
The proximity switches must be installed so that
the clearance between the sensor head and the
target being detected is approximately 5mm. The
proximity switches have a maximum detection
distance of 8mm.
Clearance between
proximity switch
head and target
approx. 5mm
Min
spacing
20mm
between
teeth
Proximity
switch
position
When determining the position for
installation of the two tooth counting
sensors, ensure that there is at least
20mm of clear space between teeth
as they are seen by the proximity
switches. This clearance is important
because the proximity switch needs to
have a period between teeth where no
tooth is detected

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3.2 Tooth Count Proximity Switch Spacing
The tooth counting proximity switch spacing is important, as by the sequence of switches
detecting teeth, the Series 1-S is able to determine the direction of slew.
The proximity switches must be
mounted 90 degrees out of phase, or
in other words, the spacing between
the two switches should be 75% of
the full tooth spacing, as shown in the
diagram alongside.
The detection of teeth by the
switches can be monitored by looking
at the LEDs within the slew module
associated with Input 1 and Input
2. These LEDs can be seen through
the orange translucent cover of the
module.
When registered on the slew module LEDs (input 1 and input 2) as the machine slews, there
must be a period when both prox switch LEDs are OFF. One LED should come on, then the
second (both ON together) then first one o, then second one o (both OFF together). This
sequence is important, if necessary adjust the spacing between the two proximity switches
to achieve this sequence.
3.3 Reset proximity switch
The third proximity switch is a Reset switch. The reset switch should be mounted in such
a way as to be momentarily triggered by a suitable target as the machine passes over 0
degrees of slew (upper structure in line with the undercarriage over the front end)..
Prox switch
spacing =
3/4 of full
tooth spacing
Tooth spacing -
1 full tooth

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4 SYSTEM LAYOUT
RED: = +V Ignition switched
BLACK = 0V (Chassis)
YELLOW = Not used
GREEN = Not used
BLUE = Not used
+V IN, 0V IN
Proximity Switches
Motion Cut Valve Outputs
(see separate connection table)
CAN bus lead between
display and module
Display Tooth Counting
Proximity Switches
Reset Proximity
Switche
Slew
Module
Slew Left
Motion Cut
Valve
Slew Right
Motion Cut
Valve

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5 SLEW MODULE CONNECTION TABLE
Grey Black Function
1 Not used
2 Not used
3 Not used
4Slew proximity switch 2 Slew tooth count proximity switch 2 input
5 Not used
6 Not used
7Slew Reference switch Slew reference proximity switch input
8 Not used
9 Not used
10 Slew proximity switch 1 Slew tooth count proximity switch 1 input
11 POS +24V supply OUT +V out for proximity switches
12 0V OUT 0V out for proximity switches
1 Not used
2 Not used
3Slew Motion Cut Left +V output to solenoid valve
4POS +24V supply IN Switched by ignition and protected by a 5A Fuse
5POS +24V supply OUT +V out for proximity switches
60V OUT 0V out for proximity switches
7 Not used
8 Not used
9POS +24V supply IN Switched by ignition and protected by a 5A Fuse
10 Slew Motion Cut Right +V output to solenoid valve
11 Travel Allow Output +V output. Cuts travel when slew limits are active
12 0V IN 0V input, connect to chassis (ground)
GREY BLACK

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6 SLEW MODULE CONNECTIONS
6.1 +V and 0V Supply to slew module
The slew module internal electronics are powered through the 12mm CAN bus connector
from the display. The solenoid valves driven from the slew module derive their power from
the +V inputs into the slew module deutsch connectors (black connector, pins 4 and 9).
If the total current draw of the two solenoid valves is less than 5A it is not necessary to
connect both pins 4 and 9 to +V, only one (either one of the two) needs to be connected.
The external power supply to the module should be connected to an ignition switched
supply, and fused. A 5A fuse is recommended on a 24V machine, a 10A fuse will be required
for a 12V machine.
The black connector, pin 12 should be connected to 0V, a direct connection to the vehicle
chassis is recommended.
6.2 Motion cut solenoid valve connections
The two motion cut valves are connected to the Slew module as per the table on the
previous page. The slew module provides +V out to the solenoids when slew movement is
allowed, and cuts the +V output to each valve individually when motion cut is required.
The 0V connection to each motion cut solenoid should be directly to the vehicle chassis.
6.3 Proximity sensor connections
The cables from the proximity switches should have their insulation removed at the
connection end to expose the internal coloured wires.
For each switch the brown, blue and black wires are used, the white wire is not used and can
be cut back.
> BROWN = +V
> BLUE = 0V
> BLACK = SIGNAL
The BROWN wires from all three sensors should be combined and powered from an ignition
switched power source. This can be from the same power source as the +V input to the
module.
Alternatively, the proximity switches can be powered from GREY pin 11 and BLACK pin 5 on
the slew module deutsch connectors. Please note that the power source from the module
(grey 11 / black 5) is a low current power source, do not connect anything else to these pins.
The BLACK wires from the three proximity switches should be connected individually to the
appropriate inputs on the Slew module deutsch connectors, as per the connection table on
the previous page.
The BLUE wires from all three sensors should be combined and connected to an external
chassis ground, or alternatively to GREY pin 12 and BLACK pin 6 on the slew module
deutsch connectors.