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SERVICE MANUAL 5
A B C
PARTE IDRAULICA
HYDRAULIC SECTION
PARTIE HYDRAULIQUE
HYDRAULIK
BMI00027GB_0-29092008
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A
B
PARTE IDRAULICA
HYDRAULIC SECTION
PARTIE HYDRAULIQUE
HYDRAULIK
B1 CONTROLBANKS
B2 HOLDING VALVES
B3 SUPPLEMENTARY STABILIZERS
B4 FILTERS
B5 HOSES AND PIPES
B6 WRENCH SETTING
B7 HYDRAULIC / ELECTRO-HYDRAULIC LIMITING DEVICE
B8 CONTROLBANKS
B8.1 PROPORTIONAL CONTROLBANK HAWE
B8.2 PROPORTIONAL CONTROLBANK SAUER-DANFOSS PVG 32
B8.3 PROPORTIONAL CONTROLBANK NORDHYDRAULIC RS 210
B9 F.P.I. DEVICE
PARTE ELETTRICA
ELECTRICAL SECTION
PARTIE ELECTRIQUE
ELEKTRIK
INDEX
B1 CONTROLBANKS
1 Controlbanks on EFFER cranes............................................................................................................................ 2
2 Controlbank setting................................................................................................................................................ 7
B2 HOLDING VALVES
1 Lock valves................................................................................................................................................................. 2
2 Setting the holding valves..................................................................................................................................12
3 Sequence valves.....................................................................................................................................................20
4 Sequence valve setting .....................................................................................................................................23
B3 SUPPLEMENTARY STABILIZERS
1 Hydraulic plumbing (supplementary stabilizers to crane hydraulic circuit)...................................... 2
B4 FILTERS
1 Delivery filter............................................................................................................................................................. 2
2 Air filter applied on the oil tank.......................................................................................................................... 6
B5 HOSES AND PIPES
1 Hoses and pipes for hydraulic system.............................................................................................................. 2
2 Pipe fittings type UNF - JIC 37 (SAE J514)...................................................................................................... 4
3 UNF flat type pipe fittings, with O-Ring - (SAE J1453) . ...........................................................................17
B6 WRENCH SETTING
1 Torque wrench setting of hydraulic fittings................................................................................................... 2
B7 HYDRAULIC / ELECTRO-HYDRAULIC LIMITING DEVICE
1 Operating principle................................................................................................................................................. 3
2 Valves and components....................................................................................................................................... 9
3 Practical setting of the overload limiting device........................................................................................15
4 Operating sequences to set the load limiting device...............................................................................23
B8 CONTROLBANKS
B8.0 HC-D3M Controlbank: technical improvements.................................................................................... 2
INDEX
CONTROLBANKS
B1
Service Manual
Rev.
07-2008
GB
Controlbanks
B1
These controlbanks allow only one pressure setting, on the main relief -valve, with all cylinders operating at the
some max. pressure setting. Inner spools may be Open-center, Close-center, or mixed, depending from the
type of movement they are designed to control and from the type of stop valve fitted on the crane cylinders.
To fit additional controls to these types of valves, it is necessary to fit a second control bank next to the main
control bank, and to carry out a carry-over type hydraulic connection.
These controlbanks, in addition to the main pressure value, allow a pressure setting on each oil line to the
cylinder, thanks to the check-relief valves fitted on each element of the controlbank. IInner spools may be
open-centre, closed-centre, or mixed type, according to the crane movements to be checked, and the type of
lock valves fitted to crane cylinders. To fit the additional controls, you can insert further individual elements
using the new, longer tie-rods to reassemble the control bank.
semiProportional actioning controlbank
Controlbanks called semiproportional are installed on some models of crane. In spite of the fact that they do
not belong to the compensated proportional controlbank range, they are designed to allow crane movement
drive not only without load applied to the hook, but also with a medium-high load respect to the maximum
lifting capacity of the crane, simultaneously.
compensated Proportional actioning controlbank
Proportional operation control banks are also fitted by EFFER, i.e. control banks allowing the simultaneous
operation of different crane movements even at low speed, and with the maximum load applied to the hook.
These types of controlbanks are more complex than then previous ones and all technical information on this
type of controlbank are reported in the following chapters.
B1
Controlbanks
Controlbank Brand & Type
Picture
Galtech PL 25
18
28
35
30 E.P.
Dinoil DN
18
20 E. P.
38
42
Valvoil
20 E.P.
28
30 E.P.
35
40
42
55
62
65
75
80
100
Hydrocontrol HCD 10
B1
Controlbanks
Controlbank Brand & Type
Picture
95
120
140
Hydrocontrol HCD 4
110
110E
150
170
210
250
Hydrocontrol HCD 6
335
110
110 E
130
145
Nordhydraulic
Semiproportional
B1
Controlbanks
Controlbank Brand & Type
Picture
Danfoss Proportional
Hawe Proportional
165
275
305
310
325
340
370
440
470
65 (OPTIONAL)
75 (OPTIONAL)
80 (OPTIONAL)
95 (OPTIONAL)
100 (OPTIONAL)
120 (OPTIONAL)
140 (OPTIONAL)
210 (OPTIONAL)
250 (OPTIONAL)
360
430
500
535
585
680
750
860
980
100N
1150
1250
1355
1750
400
460
520
550
600
720
850
920
80N
1050
1155
1350
1550
B1
Controlbanks
Controlbank type
HYDROCONTROL HC-D3
tie rod M 8
34 Nm
HYDROCONTROL HC-D3M
tie rod M 8
34 Nm
HYDROCONTROL HC-D4
tie rod M 10
34 Nm
HYDROCONTROL HC-D6
tie rod M 10
50 Nm
HYDROCONTROL HC-D12
tie rod M 12
69 Nm
MONSUN TYSON HV 07
tie rod M 8
18 Nm
SALAMI VD 081
tie rod M 8
32 Nm
ERPOZ DN 45
tie rod M 12
49 Nm
DINOIL DNC-50
tie rod M 8
16 Nm
DINOIL DNC-50
tie rod M 10
20 Nm
tie rod M 8
30 Nm
23 Nm
9,5 Nm
HAWE - PSL 3
22 Nm
HAWE - PSL 5
46 Nm
60 Nm
tie rod M 8
23 Nm
Controlbank type
HAWE - PSL 2
DANFOSS PVG 32
B1
Controlbanks
2 - Controlbank setting
The correct controlbank setting grants the perfect operation of the crane. Therefore, it is really important to
check the setting of the controlbank valves.
NOTE: in order to perform crane overload tests, it is necessary to change and increase the controlbank setting values. When crane overload test are completed, it is necessary to set the controlbank according to
the pressure values listed in the specific hydraulic diagram of the crane configuration
When you carry out the check on crane pressures you also cancel a few small differences in setting arising from
the real oil delivery, which the hydraulic pump, fitted to the truck, supplies.
Later, we recommend to perform this check at least once a year.
When checking the setting values, the truck engine shall run at the same rpm of the crane in working condition,
with the hydraulic oil temperature in the crane oil tank at min. 20 C : any setting performed with oil at a lower
temperature will jeopardise the correct standard operation of the crane.
After this operation, all the inspected valves shall be lead-sealed and no signs of tampering must be found on
the seal. Should this occur, any warranty would be automatically denied by Effer.
Correct crane setting values are shown on the technical data sheet referred to the hydraulic diagram of the crane
configuration.
B1
Controlbanks
A correct hydraulic setting requires a reliable pressure gauge, and it is well known that pressure gauge suffer
from early wear.
If a certified pressure gauge is not available, Effer recommends to buy a sample pressure gauge to be used three
or four times a year, so as to prove the exacteness of the pressure gauges used in the workshop.
A digital and a traditional pressure gauge are shown herebelow.
To check controlbank setting, apply the pressure gauge to the controlbank, near the point of connection of the
hydraulic pump line. (See the symbol X in the diagram in the previous page).
A minipress quick coupling, with M16x2 thread, is fitted on all crane in production, in this point.
Code 8907726A
B1
Controlbanks
VG
B1
Controlbanks
check-relief valve, controlling the max. pressure value allowed during a cylinder
opening manouvre
Vp/r
check-relief valve, controlling the max. pressure value allowed during a cylinder
closing manouvre
VP/S - VP/R
VP/S - VP/R
VG
10
B1
Controlbanks
1)
320
2) 140
VG
300
Considering the setting data listed in the hydraulic diagram, youll notice that some check-relief valves are set at
a higher value than the main relief valve, while other check-relief valves are set at a lower value.
As the main relief valve controls the max. pressure allowed inside the controlbank, the aim of setting some checkrelief valves at a higher value than the main relief valve depends on the fact that it is necessary a small stream of
oil flowing out of the cylinder when the crane is subjected to sudden movements with the max. load applied.
The setting values listed in the hydraulic diagram of the controlbank mentioned above, show a check-relief valve
set at a higher value than the main relief valve.
In case of just one element or more elements set at a higher value than the main relief valve, take as a reference the element set at the highest pressure.
Pressure testing can be divided into two steps:
-
-
Apply the pressure gauge (no load shall be applied to the crane) and make a full end-stroke of the 1st boom
cylinder: the pressure value on the pressure gauge corresponds to the set value of the main relief valve, that is
300 bar.
11
B1
Controlbanks
In order to test the check-relief valves, increase the
set pressure of the main relief valve VG. To obtain
a higher pressure, keep the controlbank lever activated and turn the main relief valve adjusting
screw clockwise (screw).
Youll notice that the pressure gauge jumps up to
320 bar. As soon as pressure increase stops, release
the controlbank lever, then screw the main relief
valve adjusting screw half a turn: lock the screw in
this position.
Now test the set pressure of the check-relief valves
VP/S and VP/R located on the controlbank, by
shifting each controlbank lever and turning the
valve adjusting screws.
VG
VP/S
An additional check mush be also carried out after locking the valve adjusting screw, as the adjusting screw
tightening may lead to slight changes in the preset setting value: however, a +/- 5 bar tolerance is allowed with
respect to the pressure values shown in the hydraulic diagram.
VG
12
B1
Controlbanks
VG = 340 bar
Vp/s = 315 bar
315
340
In this case, al least one element is not equipped with main relief valve (see extension retraction).
Follow the correct procedure hereunder:
- perform a manouvre of extension retraction so as to check the pressure value of the main relief valve. If
necessary, adjust the adjusting screw.
- Check the pressure value of the main relief valves by shifting the controlbank levers, then turn the valve
adjusting screws.
The oper ator in charge of the
adjustment has the responsibility
of the re-application of lead seals.
13
Controlbanks
14
B1
HOLDING VALVES
B2
Service Manual
Rev.
07-2008
GB
B2
Holding valves
1 - Lock valves
The hydraulic system of EFFER cranes is designed in compliance with UNI EN12999: 2002/A2-2006
standards. The several safety devices required by the standards also include lock valves, often referred
to as movement control valves or hydro-piloted lock valves on crane handling cylinders.
When these valves are fitted, they allow:
A) Handling the cylinder, or the crane, only with the hydraulic pump turned on. With the hydraulic pump off, or
with the truck engine off, it is not possible to move the booms of the crane.
ST
OP
OFF
B) Ensuring that the crane is fully stopped during the intervals between the various work stages in case of any oil
leakage inside the control bank (if very worn out): hydraulic oil leaks from cylinders only when the lock valve
opens, with the hydraulic pump on, and only as a result of a manoeuvre carried out by the operator.
ST
OP
C) Preventing the load from going down unintentionally in case a hose breaks. The lock valve detects the difference
in pressure inside the hydraulic circuit caused by this breakage, and immediately closes, thus preventing the
oil from leaking out of the cylinder.
P
STO
Holding valves
B2
D) Avoiding possible breaks in case of overloads. When the oil inside the cylinder exceeds the maximum pressure
value, allowed by the project, the lock valve opens letting oil leak out of the tank, through the control bank.
If the load limiting device is not fitted, the effect is a slow descent of the applied load. When the load limiting
device is fitted, the lock valves are set to allow a maximum pressure value into the cylinder, which is higher than
the load limiting device setting value, actually having an auxiliary safety function only.
ON
E) Limiting inner pressure peaks to cylinders moving booms for effect of dynamic pressure. If the pressure peak
exceeds the valve setting value, this will cause its momentary opening. The pressure in surplus will be unloaded
onto the oil return line. The chart shows the trend of instant pressure during the different work stages carried
out with the maximum loads applied to hook; the lock valve setting value -ptar- corresponds to the max.
pressure value allowed inside the cylinder.
p (bar)
ptar (bar)
t (sec)
B2
Holding valves
There are different types of hydropiloted lock valves, EFFER uses:
1. Lock valve with direct hydropiloted opening.
c1
c2
V1
V2
c1
c2
V1
V2
This type of valves do not need to be set, like all hydropiloted valves, they are characterized by the so called piloting ratio R, this ratio of two particular oil sections inside the valve, and more precisely, it is the ratio between the
area of the section on which the setting spring pressure acts in the closing direction added to pressure exerted
by oil directly kept inside the cylinder and the section on which the piloting pressure acts.
NOTE: Since the oil leakage from cylinder is not required following an overload, the closing or opening of
cylinder (then the valve), are strictly linked to the operators will to carry out a manoeuvre.
B2
Holding valves
DIRECT OPENING HYDROPILOTED LOCK VALVE FUNCTIONAL DIAGRAM
Pcil
Fm
Ppil
Pcil
Fm
Pcil
Ppil
Piloting ratio:
R=
A1
A2
B2
Holding valves
Simple Effect
c2
c1
V2
V1
B) Double effect: the valves control both the cylinder hydraulic lines (ex: fly-jib or extension cylinder), when an
oil overflow is necessary because of a crane overload.
Double Effect
V1
V = to controlbank
C = to cylinder
V2
NOTE: These valves need a specific setting pressure value. When it is reached the valve opens, that is oil
leaks out of the cylinder.
The setting value defined by EFFER when designing the crane is such that pressure peaks generated in the cylinder by the max. load oscillations will not affect the cylinder, saving the crane structure.
B2
Holding valves
Pcil
R
Pilot Ratio
Ppil
Piloting pressure
Fm
A1
The force exerted by set spring (this is a preset setting and therefore not adjustable)
the section on which Pcil pressure acts
Fm = Ptar A1
Fm + Pcil A1 = Ppil A2
A1
by recalling that the piloting ratio R is:
R=
A2
A1
A2
it is concluded that to obtain valve opening, a Ppil pressure must be conveyed to the valve:
Ppil
Ptar + Pcil
R
In case of hidro-piloted valves with direct opening, the setting pressure is fixed and insignificant, therefore the
previous one is converted into:
PPtar
+ Pcil
cil
Ppil
pil
R R
The valve will open when, in the oil delivery line, the piloting pressure is exceeded i.e. when the pressure
is exceeded.
Pcil
R
Conclusion:
The necessary pressure value to have the opening of a hydro-piloted lock valve is influenced by the load
on the crane hook.
If lock valves with piloting ratios, other than expected, leads to have operating failures when handling
the crane.
B2
Holding valves
Since an oil leakage from cylinder is also requested these valves, the cylinder, then the valve closing or opening,
are closely linked both to the achievement of the maximum pressure allowed by the project, inside the oil line
that you want to check, and to the operators will to carry out a given manoeuvre.
P from controlbank
Pcil
Ptar
Pcil
Ppil
Fm
Pcil = Pressure caused by the
applied load
C2
C1
A2 piloting surface
on which piloting
pressure Ppil acts.
Pcil
Fm
Ppil
V1
V2
A1 surface on which the pressure
of the setting spring acts and pressure Pcil exerted by oil directly
kept into the cylinder by effect of
the load applied
B2
Holding valves
Trend of piloting pressure
The chart shows the piloting pressure required for the valve to open when the setting pressure and the cylinder
inner pressure induced by effect of the load applied to brane hook are changed.
Ppil
changed
setting
modificata
Ppil, Tar
Tar
EFFER
setting
EFFER
Ppil, Tar
Tar
modificata
Changed
setting
Tar
EFFER
EFFER
setting
Ppil, min
P cil, min
Set EFFER =
Set changed =
Pcil, min =
Pcil, max, project =
Ppil, max =
Ppil, min =
P cil
Conclusions:
To open the valve, a higher piloting pressure will be required:
1)
2)
Holding valves
B2
Ppil
Ptar Pcil
R
10
Holding valves
B2
1.5 Hydropiloted Holding valve, type Overcenter: for opencenter circuits and for close-center circuits
Within the Overcenter type of holding valves, two types of valves can be found on an Effer crane, depending
on the type of hydraulic circuit provided:
A. Open-center circuits (controlbank spool designed for open
center). The controlbank lever of this spool is not activated and the
two lines from the cylinder are directly connected to the oil delivery
line, i.e. to the oil tank.
This means, in practice, that when an overcenter valve opens up due
to an overload manoeuvre, the oil flow to the tank is allowed.
This type of circuit is especially designed for extension control.
11
B2
Holding valves
The crane does not support the diagram load at the distance shown on the load
diagram and the boom is unintentionally lowered.
On the valve body, close to the ports, the following letters are punched:
V:
to controlbank
C:
to Cylinder
12
Holding valves
B2
b)
c)
electro-hydraulic powerpack, with a recommended oil
flow 6-8 l./min.
To set the valve, oil shall be sent to the port C of the valve, checking that oil starts flowing out from port V
when the required pressure value is read on the pressure gauge.
When setting one oil line of the valve, the second oil line doesnt need to be plugged.
If for example the required value is 320 bar, the setting screw on the valve shall be turned until, when reading the
value 320 on the pressure gauge, the thinnest possible stream (though continuous, not by drops) starts getting
out.
To check that setting was correct, youll then check that, at a pressure value lower by 10 bar (in the example: 310
bar), the stream stops completely, and which increasing by 10 bar compared to the setting one (in the example:
330 bar) the valve opens completely.
13
B2
Holding valves
d)
tools for lead sealing. The holding valve setting-screw must always be sealed.
37 mm l= 72 mm
30 mm l= 50 mm
14
B2
Holding valves
E) Convey oil to the valve and gradually increase the maximum pressure through the control bank main valve until
the setting value required for the lock valve is reached..
320 bar
15
B2
Holding valves
F) If there is no oil leakage:
1) unscrew the lock valve adjusting screw slightly to decrease its setting value, by shifting the control bank lever
to the opposite direction for oil to be conveyed to the clogged branch of control bank. The manoeuvre has
the only purpose to release the residual pressure inside the valve, which could alter its setting. Valve setting is
considered to be correct when you see the leakage of a small continuous drizzle of oil fromV, when the setting
pressure value is achieved.
320 bar
2) Using the control bank main valve, check that there is no oil leakage at a value of 310 bar.
3) Using the control bank main valve, check that the lock valve opens completely at a value of 330 bar.
305 bar
!!!
No oil out!
4) Fix the set screw on the valve, and check again that the settings match, both at the value of 320 bar, at the lower
value of 310 bar, and at the higher value of 330 bar.
5) Apply the seal to the part concerning the setting adjustment.
Note: a plexiglas guard should be used to protect the operator from the oil streams out of the valve.
16
Holding valves
B2
EFFER holding valves differ in the hydraulic connection, depending on the type and size. Since the 90s, effer ha
has been using holding valves named flange-coupled, i.e. holding valves connected to the cylinders by seal and
fastening screws instead of a pipe.
As previously mentioned, to do the setting work or carry out the setting check on a lock valve you must convey
hydraulic oil under pressure to the points C of the valve. In case of lock valves fitted to cylinder using a pipe or
through a fitting, for the hydraulic connection to the valve there are holes with GAS bspP -type thread with valves
fitted to the cylinder through the flanged system, you need to fit a flange to the valve, having the same size as
the flange on the cylinder on one side and a GAS bspP- type connection on the other side, for the connection to
the hydraulic power unit.
17
B2
Holding valves
Codes and drawings of the flanges are listed below, and can be ordered to effer in case of need.
EFFER part #
8866738
EFFER part #
8866739
40
10
60
8866740
M10
EFFER part #
28
40
60
EFFER part #
8866741
18
3/8 GAS
BSPP
Holding valves
B2
EFFER part #
8866742
EFFER part #
8866743
EFFER part #
8866744
EFFER part #
8866745
EFFER part #
8866746
19
B2
Holding valves
3 - Sequence valves
The sequence valves allow hydraulic oil to continue its way inside the pipes only when the pressure value exceeds
the setting value set on the valve.
Their typical application is on the extension cylinders, on which the sequence valves allow the cylinders and the
extensionsto exit in sequence.
20
Valve setting
Ex.: 200 bar
B2
Holding valves
Valve setting
Ex.: 200 bar
70 bar
100 bar
120 bar
This type of valve is used when, in the project phase, it is necessary to limit the thrust pressure inside the first
extension cylinder. When running an extension exit manoeuvre, if the pressure opens a sequence valve, this valve
requires a very limited pressure to remain opened.
Absorption of these valves is only 10 bar, corresponding to the pressure loss which occurs because oil goes through
the valve; therefore all the extension cylinders work at about the same maximum thrust pressure.
ON LINE
ON LINE
FLANGED
21
B2
Holding valves
Valve setting
Ex.: 300 bar
40 bar
20 bar
20 bar
This type of valve is used when the pressure inside the first few extension cylinders must be high for reason of
design. When running an extension exit manoeuvre, if the pressure makes a sequence valve open, this valve requires a pressure value equal to the setting value, to remain opened; therefore the first cylinders work at a thrust
pressure which is higher than the following cylinders.
22
Holding valves
B2
B) Controlbank
C) Power pack
23
B2
Holding valves
Internal
setting
Internal
setting
External
setting
External
setting
We need to set a valve at a pressure of 40 bar. We adjust the valve setting-screw until 40 bar is achieved and a
small streamof oil (not only drops) comes out.
Increase pressure to the controlbank of approx. 10 bar and check that a stream of oilcorresponding to the whole
power pack oil capacity flows out of the sequence valve.
Note: a plexiglas guard should be used to protect the operator from the oil streams out of the valve.
24
SUPPLEMENTARY
STABILIZERS
B3
Service Manual
Rev.
07-2008
GB
Supplementary stabilizers
B3
Basic crane
Supplementary stabilizers
Besides the controlbank, some line fittings allow the connection to the additional supplementary stabilizers. The
supple-mentary stabilizers must be equipped with a holding valve with faucet to select the stabilizer to operate.
When carryingout this connection, it is really important that all barrel-side and rod-side cylinders are kept separate
and directed to the two controlbank connections.
B3
Supplementary stabilizers
B) On mid and large size cranes, there is a dedicated lever on the controlbank for the stabilizers manoeuvre,
and two divertervalves (one on each side of the crane, located close to the bottomside controlbank). Thru these
diverter valves, you mayselect the stabilizer (front, rear) and the manoeuvre (outlet, down) you want to operate
by the lever on the controlbank.
After selecting the manoeuvre, move the lever to operate the stabilizer.
Pos. Outlet
1
2
3
4
A
B
C
D
Supplementary stabilizers
STOP
4
STOP
STOP
3
STOP
Basic crane
1
STOP
STOP
STOP
Pos. Outlet
1
2
3
4
A
B
C
D
STOP
3
The diverter valves incorporate also the connections for the oil outlet of additional supplementary stabilizer
cylinders. Holding valves applied to the stabilizer vertical cylinders are not equipped with oil faucet.
B3
Supplementary stabilizers
C) On the cranes where there is not a dedicated lever on the controlbank, the diverter valve incorporates also the
control for the stabilizers manoeuvre. There is one controlbank/diverter valve for each side of the crane or one
serving both sides thru a rod.
First you select by the lever which manoeuvre you want to perform, then, by pushing or pulling the same lever
you select the direction of manoeuvre (raise or lower).
The diverter valves incorporate also the connections for the oil outlet of additional supplementary stabilizer
cylinders.
Pos. Oulet
1
2
3
4
4-way diverter
4
Supplementary stabilizers
Basic crane
A
B
C
D
B3
Supplementary stabilizers
Pos. Outlet
8-way diverter
6
Supplementary stabilizers
1
2
3
4
5
6
7
8
A
B
C
D
E
F
G
H
Supplementary stabilizers
Basic crane
With hydraulic outlet
Basic crane
No hydraulic outlet
B3
Supplementary stabilizers
8866769 (QT.1)
T
V1
V2
T
Please find below the connection hydraulic diagram of the additional stabiliser safety valve.
V1
V2
150
150
V1
V2
Supplementary stabilizers
B3
IMPORTANT:
The hydraulic connection of the supplementary stabilizers must ALWAYS be made without any VALVE OR
FAUCET ordiverter left on the oil line to the cylinders rod-side.
Should this occur, the cylinder would swell as soon as it ismaneuvered.
Area A
(Piston side)
Area A-B
(Rod side)
No obstacles or obstructions on
this line !!!
Sending oil to the line indicated by blue arrow, in the upper cylinder chamber you generate a force equal
to thepressure of the oil sent multiplied by the barrel area: F = PxA
If anything (valve, faucet etc.) obstructs the oil line coloured in red, preventing the oil from flowing out to
thecontrolbank or to the oil tank, the same force presses then into the lower chamber of the cylinder and
since therethe area is much smaller than in the upper chamber, the resulting pressure will be, according to
the sameformula :
P= F / (A-B)
Since the area difference between chamber A and B is very small, the new value of pressure is then very
highand exceeds the structural design of the cylinder, with a swelling as a result.
Supplementary stabilizers
B3
FILTERS
B4
Service Manual
Rev.
07-2008
GB
Filters
B4
1-Delivery filter
The cranes not provided with proportional controlbank are equipped with an oil delivery filter as a standard, located on the lineconveying the hydraulic oil passing from the pump to the controlbank.
Correct filter servicing operations grant the reliability of the hydraulic systemcomponents.
Filter by-pass operation is shown on the clogged filter indicator: the by-pass device makes the oil flow outfrom
the filter inlet to the outlet when the cartridge is clogged by impurities.
However, the by-pass activation is allowed only for a limited period of time to finish the work, as the operation
of the by-passmakes oil pass unfiltered and there is the risk of releasing cartridge impurities due to oil delivery
pressure at the filterinlet, and of damaging the hydraulic system parts.
Please remember that the standard crane equipped with the DMU device also includes the LEPB function (see
chapter of the operator manual DMU).
This function acoustically and also visually warns if the optional panel is fitted,when the filter is clogged.
Filter cartridges are made of inert inorganic fiber. They are usually called paper cartridges so as to distinguish
them fromthe cartridges made of metallic net, having a lower fine filtering rate.
Do not clean the cartridge, neither with liquids nor with air jet. When the indicator of filter clogged lights up,
replacecartridges.
Ref. 1
**
Ref. 2
**
Ref. 3
Electric clog warning
(substitution of warning Ref. 2)
**
B4
Filters
Effer PARTS #
O-Ring: 8009000
Oil O-Ring Kit
* OilFilter
**
equipped with clog visual warning: 8919332
Ref. 1
Visual clog warning
Ref. 2
Electric clog warning
Effer PARTS #
set 8919361
* Gasket
Filter equipped with clog visual warning: 8919356
filter equipped with clog electric warning: 8919357A
filter cartridge: 8919358
Ref. 1
Ref. 2
B4
Filters
Ref. 1
Electric clog warning
Effer PARTS
Gasket set 8919364KG
B4
Filters
Ref. 1
Electric clog warning
Effer PARTS
Gasket set 8919382
Filters
B4
40 mm
3- EFFER PART #: 8916450
50 mm
4- EFFER PART #: 8916500
Filters
B4
80
80
50
80
100
38
45
65
28
B4
Filters
HOLE DIMENSION
CRANE MODEL
MODELLO GRU
GAS BSPP
DIMEN
SIONE FORO
55 - 65 - 75 - 80 - 95 - 100
20 -30 - 35- 40 - 42
18 - 28 - 38
62 - 110E
110 - 120 - 140
150 - 170 - 210
250 - 400 - 460
47
130 - 145
155-165
335 - 360 - 430
520 - 600 - 680
720 -
400 - 460 - 44N
275 - 305
310 - 325 - 340 - 370
440 - 470
500 - 550
750 - 850
860 - 920 - 980
1050 - 1150 - 1250
1155 - 1355 - 1550
1350 - 1750
80N - 100N
1 GAS
BSPP
1 GAS
BSPP
2 GAS BSPP
Service Manual
Rev.
07-2008
GB
B5
provided with an intact external rubber coating for the the protection of the metallic net. Otherwise, the metallic
net may corrode for wear-and-tear, and the factor of safety of the hoses may reduce up to the hose burst.
The metallic net shall be intact. If some metallic wires are damaged because of crashes, replace the hose immediately.
u The hydraulic fittings are applied at the tips of the flex hoses by pressing. In case of oil leaks (even of a small
quantity), replace the hose immediately as the hose pressing can not grant the reliability of the crane and its safe
operation anymore.
u Pipe condition is important likewise: crushed portions of pipes may cause hydraulic oil overheating, and reduce
the crane speed.
u Safety rules for crane design require flex hoses and pipes with a minimum safety rate between the operating
Please find the inner diameter of hoses fitted to EFFER cranes with respect of their nominal diameter:
Inner diameter
6 mm
5/16
10
3/8
12
1/2
16
5/8
19
3/4
25
B5
u The hoses shall be appropriate to bear a maximum working pressure equal to 350 bar. It follows that, since they
should have a burst safety factor which should be at least 4 times higher than the working pressure, they must
have a burst minimum pressure equal to 1400 bar.
The hoses must be appropriate to work at a working temperature ranging from -20 C to + 100 C. The following
are the reference regulations the hoses should be compliant with:
the control bank oil drain with the tank. These are referred to as low pressure. They have a maximum
operating pressure equal to 80 bar, therefore it follows that, since they have a burst safety factor which
is at least 4 times than the working pressure, they must have a minimum burst pressure of 320 bar.
NOTE: EN 12999 regulations forbid the use of hoses with reusable applied end fittings , when a working
pressure of more than 15 Mpa (150 Bar.) is used.
Outer diameter
mm
Thickness
mm
12
1,5
16
20
2,5
25
32
Material:
ST 35.4
B5
this work. All cracks, exfoliation or simple marks on the inner cone jeopardise the coupling tightness.
Tighten the coupling using a dynamometric wrench: an excessive tightening can cause the material to be squashed
in the conical part with its possible detachment on the cylindrical side of the pipeline.
BUSHING
37
NUT
PIPE
NOTE: The perfect wet seal is guaranteed by a perfect tightening of the fitting. In chapter A6 you can find
a table which shows the setting value of the torque wrench.
If it is impossible to use a dynamometric wrench, do as follows:
1) use a normal wrench, without fitting extensions,
2) tighten the fitting with the strength of your arms, without exaggerating,
3) loosen by 1/2 turn
4) tighten the fitting again, and try to bring the stopping point to a position that has to be 1/4 turn more advanced than the first tightening made.
B5
Pipe mm
Hose
Coupling thread
1/4
12
3/8
16
1/2
20
3/4
25
32
1 1/4
B5
2.1 EFFER codes of pipe fittings, UNF - JIC 37 - SAE J514 type
F1
Effer code
F1
9300601
22,5
8,5
9300602
18
12
9300603
20
16
9300604
23
20
9300500
41
29,5
NUT - JIC 37
Pipe outer mm
Effer code
A UNF
9320800
12
9320900
16
93201000
20
93201100
25
93201200
32
93201300
B5
Bushing
Pipe outer mm
Effer code
F mm
9321600
12
9321700
12
16
9321800
16
20
9321900
20
25
9322000
25
32
9322100
32
Reduction - JIC 37
1 Pipe
2 Pipe
Effer code
A UNF
C UNF
12
9333400
9333500
9333600
9333700
9333800
9333900
25
9334000
16
9334100
32
20
9334002
1 5/8
1 1/16
38
32
9334001
1 7/8
1 5/8
16
20
25
32
12
16
20
THE POWER OF PERFORMANCE
B5
Pipe outer mm
Effer code
A UNF
9335100
12
9335200
16
9335300
20
9335400
25
9335500
32
9335600
Pipe outer mm
Effer code
A UNF
9334300
12
9334400
16
9334500
20
9334600
25
9334700
32
9334800
B5
Joint - JIC 37
Pipe outer mm
Effer code
A UNF
9322400
12
9322500
16
9322600
20
9322700
25
9322800
32
9322900
Pipe outer mm
Effer code
A UNF
9324000
12
9324100
16
9324200
20
9324300
25
9324400
32
9324500
B5
90-bend - JIC 37
Pipe outer mm
Effer code
A UNF
9331000
12
9331100
16
9331200
20
9331300
25
9331400
32
9331500
10
Pipe outer mm
Effer code
A UNF
9323200
12
9323300
16
9323400
20
9323500
25
9323600
32
9323700
B5
Pipe outer mm
Effer code
A UNF
9335900
12
9336000
16
9336100
20
9336200
25
9336300
32
9336400
Pipe outer mm
Effer code
A UNF
9332600
12
9332700
16
9332800
20
9332900
25
9333000
32
9333100
11
B5
Pipe outer mm
Effer code
A UNF
9331800
12
9331900
16
9332000
20
9332100
25
9332200
32
9332300
12
Pipe outer mm
Effer code
A UNF
B GAS BSPP
12
9320000
3/8
16
9320100
1/2
20
9320200
3/4
25
9320300
9320400
1/4
12
9320500
1/2
16
9320101
3/8
B5
Pipe outer mm
12
16
20
Effer code
A UNF
9325600
1/4
9325700
3/8
9339601
1/8
9325800
1/4
9325900
3/8
9326000
1/2
9326200
3/8
9326300
1/2
9326400
3/4
9326600
1/2
9326700
9326900
9327000
9327200
3/4
1
3/4
1
1
9327100
32
1/2
9325610
9326800
25
B GAS BSPP
9327300
1 1/4
1 1/2
13
B5
B
Pipe outer mm
Effer code
A UNF
B GAS BSPP
9327600
1/4
33
9327700
1/4
34
9327800
3/8
36.5
9327900
1/2
42.5
9328811
3/8
34
9328000
1/2
42.5
9328100
1/2
48.5
9328200
3/4
48.5
9328300
3/4
51.5
9328400
51.5
9328700
3/4
48.5
9328800
1/2
79
9328812
1/2
36
9328813
3/8
39.5
12
16
20
25
16
14
B5
Pipe outer mm
Effer code
A UNF
B GAS BSPP
16
9329000
1/2
20
9329100
3/4
12
9329400
1/2
16
9329510
3/8
16
9329511
3/4
Pipe outer mm
Effer code
A UNF
B GAS BSPP
12
9330300
3/8
16
9330400
1/2
20
9330500
3/4
25
9330600
15
B5
Union tee - 2 male connectors JIC 37 / GAS BSPP in line - 1 JIC 90-male
connector
Pipe outer mm
Effer code
A UNF
B GAS BSPP
12
9329600
3/8
16
9329700
1/2
20
9329800
3/4
25
9329900
12
9330200
1/4
9329601
1/4
16
Effer code
B GAS
D GAS
9337000
3/4
3/8
9337200
1/2
9337300
3/4
9337400
1 1/4
3/4
9337600
1 1/2
B5
BUSHING
90
NUT
PIPE
As said above, tightening can be carried out without the use of particular equipment; when the O-Ring joint is
deformed the pipe and the fitting collide on the front thus not allowing the nut to be screwed up.
In case of oil leaks, replace the O-Ring joint (see table below).
Thickness
Hose
Coupling thread
5/16
10
5/16
12
1.5
1/2
14
1/2
16
1/2
16
5/8
20
2.5
3/4
22
2.5
25
32
1 1/4
17
B5
18
Pipe outer
mm
Effer code
F thread
UNF O-Ring
D
mm
B
mm
8 - 10
9342600
11/16-16
9.25
1.78
12
9342601
13/16-16
12.42
1.78
14 16
9342602
1-14
15.60
1.78
18 - 20
9432603
1 3/16-16
18.77
1.78
22 - 25
9342604
1 7/16-12
23.52
1.78
28 32
9342605
111/16-12
29.87
1.78
35 - 38
9342606
2-12
37.82
1.78
B5
3.1 EFFER codes of pipe fittings, type UNF front O-Ring -SAE J1453
F1
Pipe outer mm
Effer code
F UNF O-Ring
F1
12
9340146
13/16-16
25
12
14 16
9340147
1-14
33,5
16
18 - 20
9340148
1 3/16-16
37,5
20
22 - 25
9430112
111/16-12
42
25
Pipe outer mm
Effer code
F UNF O-Ring
12
9340507
14 16
9340522
18 - 20
22 - 25
F1
26
9,6
1-14
33,5
22,5
9340505
1 3/16-16
37,5
25
9430506
111/16-12
42
30
13/16-16
Raccordi speciali
19
B5
Pipe outer mm
Effer code
F UNF - O-Ring
10
9341100
11/16-16
12
9341101
13-16-16
14 - 16
9341102
1-14
20
9341103
1 3/16-12
25 - 22,5
9341104
1 7/16-12
28 - 32
9341105
1 11/16-12
35 - 38
9341106
2 -12
20
Pipe outer mm
Effer code
10
9341150
10
12
9341151
12
14
9341152
14
16
9341153
16
20
9341154
20
22
9341156
22
25
9341155
25
F mm
B5
Pipe outer mm
Effer code
F UNF - O-Ring
8- 10
9342500
11/16-16
12
9342501
13/16-16
14 16
9340136
1-14
18 - 20
9340137
1 3/16-12
22 - 25
9340138
1 7/16-12
28 - 32
9342502
1 11/16-12
35 - 38
9342503
2 -12
Pipe outer mm
Effer code
F UNF O-Ring
L mm
B mm
8- 10
9342400
11/16-16
19,5
19
12
9342401
13-16-16
22
22
14 16
9340120
1-14
26
27
18 - 20
9340121
1 3/16-12
27,5
32
22 - 25
9340122
1 7/16-12
28
38
28 - 32
9342402
1 11/16-12
28
46
35 - 38
9342403
2 -12
28
55
21
B5
F1
22
Pipe outer mm
Effer code
F1 UNF O-Ring
8 - 10
9341800
1/4
11/16-16
8 - 10
9341801
3/8
11/16-16
8 - 10
9341802
1/2
11/16-16
8 - 10
9341803
3/4
11/16-16
12
9341804
1/4
13-16-16
12
9341805
3/8
13-16-16
12
9341806
1/2
13-16-16
12
9341807
3/4
13-16-16
14 - 16
9341808
3/8
1-14
14 - 16
9341809
1/2
1-14
14 - 16
9341810
3/4
1-14
14 - 16
9341811
1-14
18 - 20
9341812
1/2
1 3/16-12
18 - 20
9341813
3/4
1 3/16-12
18 - 20
9341814
1 3/16-12
18 - 20
9341815
11/4
1 3/16-12
22 - 25
9341816
3/4
1 7/16-12
22 - 25
9341817
1 7/16-12
B5
F1
Pipe outer mm
Effer code
F1 UNF O-Ring
22 - 25
9341818
11/4
1 7/16-12
22 - 25
9341819
11/2
1 7/16-12
F1
Pipe outer
1 mm
Pipe outer
2 mm
Effer code
F UNF O-Ring
F 1UNF O-Ring
8 - 10
8 - 10
9341900
11/16-16
11/16-16
10
10
9341901
11/16-16
9/16-18
12
12
9340145
13/16-16
13/16-16
12
12
9341902
13/16-16
11/16-16
14 -16
14 -16
9341903
1-14
1-14
16
9341904
1-14
13/16-16
18 - 20
9340127
1 3/16-12
1 3/16-12
20
9340139
1 3/16-12
1-14
22 - 25
9340128
1 7/16-12
1 7/16-12
25
9340129
1 7/16-12
1 3/16-12
16
18 - 20
20
22 - 25
25
23
B5
F1
Pipe outer mm
Effer code
F UNF - O-Ring
F1 UNF JIC 37
8 - 10
9341818
11/16-16
9/16-18
12
9341819
13/16-16
1 7/16-12
14 - 16
9341802
1-14
7/8-14
18 - 20
9341803
1 3/16-12
1 1/16-12
22 - 25
9341804
1 7/16-12
1 5/16-12
24
Pipe outer mm
Effer code
F UNF - O-Ring
8- 10
9342200
11/16-16
12
9342201
13/16-16
14 16
9342202
1-14
18 - 20
9342203
1 3/16-12
22 - 25
9342204
1 7/16-12
28 - 32
9342205
1 11/16-12
25 - 38
9342206
2 -12
B5
F1
Pipe outer mm
Effer code
F1 UNF O-Ring
8 - 10
9341700
1/4
11/16-16
8 - 10
9341701
3/8
11/16-16
8 - 10
9341702
1/2
11/16-16
12
9341703
3/8
13-16-16
12
9341704
1/2
13-16-16
14 - 16
9341705
3/8
1-14
14 - 16
9341706
1/2
1-14
14 - 16
9341707
3/4
1-14
18 - 20
9341708
3/4
1 3/16-12
18 - 20
9341709
1 3/16-12
22 - 25
9341710
3/4
1 7/16-12
22 - 25
9341711
1 7/16-12
22 - 25
9341712
1 1/4
1 7/16-12
25
B5
F1
Pipe outer mm
26
Effer code
F O-Ring
F1 UNF O-Ring
10-8
9342100
11/16-16
9/16-18
12-6
9342101
13/16-16
9/16-18
12-10
9342102
13/16-16
11/16-16
16-12
9342103
1-14
13/16-18
20-12
9342104
13/16-12
13/16-16
20-16
9342105
13/16-12
1-14
25-16
9342106
17/16-12
1-14
25-20
9342107
17/16-12
13/16-12
32-20
9342108
111/16-12
13/16-12
32-25
9342109
111/16-12
17/16-12
38-25
9340130
2-12
17/16-12
38-32
9340105
2-12
111/16-12
B5
Pipe outer mm
Effer code
F UNF - O-Ring
10
9341400
11/16-16
12
9341401
13/16-16
14-16
9341402
1-14
18-20
9341403
1 3/16-12
22 - 25
9341404
1 7/16-12
F1
L1
F1
Pipe outer mm
Effer code
F UNF - O-Ring
8-10
9341500
11/16-16
12
9341501
13/16-16
14-16
9341502
1-14
18-20
9340140
1 3/16-12
22 - 25
9340102
1 7/16-12
28 - 32
9341503
1 11/16-12
35 - 38
9340103
2 -12
27
B5
L1
F1
28
Pipe outer mm
Effer code
F UNF - O-Ring
8-10
9341500
11/16-16
12
9341501
13/16-16
14-16
9341502
1-14
18-20
9340140
1 3/16-12
22 - 25
9340102
1 7/16-12
28 - 32
9340503
1 11/16-12
35 - 38
9340103
2 -12
B5
Effer code
F
GAS BSPP
9342702
1/4
9342703
1/4
9342704
1/4
9342705
1/4
9342706
1/4
Effer code
F1
GAS BSPP
9341102
11/16-16
9341103
13/16-16
9341104
1-14
9341105
1 3/16-12
9341106
1 7/16-12
29
B5
3.2 UNF front flat seal terminals, with O-Ring (SAE J1453 to be
welded)
It may be required to carry out repairs without the availability of a pipe that is an EFFER original spare part.
BUSHING TO BE WELDED
NUT
PIPE
Pipe outer
(A) mm
Bushing code
Nut code
10
9341080
9341000
12
9341081
9341001
14
9341082
9340116
16
9341083
9340116
20
9341084
9340117
22
9341085
9340118
25
9341086
9340118
NOTE: It is obvious all the above will be required to carry out the first repair.
30
It is understood that then it will be necessary to fit the original spare part as soon as possible.
B5
u All surfaces to be joined and the zones close to them must be previously cleaned in order to remove all traces
of dirt, grease, paint, superficial oxides, zinc coating, etc. To do so it is necessary to degrease and grind, with the
utmost care, and by means of an abrasive cloth, the pipe outer surfaces and the surfaces inside the ogive in the
coupling areas indicated in the figure 1. Grinding is essential to round the corners and to make the surfaces rough
in order to improve the weld.
Fig. 1
u Position the ogive and the pipe with the axis of the vertical joint vertically on a support surface made up of
refractory material to avoid any loss of heat. Preheat in width and in depth with a neutral or slightly carburazing
flame without directing the flame to the joint opening. For the 20- and 25-mm diameter pipe preheat the pipe to
a greater extent. As soon as the deoxidizer liquefies (material colour will be dark red) and flows freely, melt the tip
of the stick, remove a drop of filler metal and position it on the joint (figure 2).
Fig. 2
Filler metal deposit area
31
B5
Blowpipe inclination 30-45 and blowpipe end at 1-2 cm. from the surface. During melting of the filler metal, make
the stick turn slowly between your fingers and avoid overheating the piece.
Make the metal flow along the joint with a continuous movement of the flame. Deposit other filler material until
it comes out of the lower side of the ogive.
u After finishing welding, with the piece still hot (300C maximum), dip the brazed area of the pipe in warm
water in order to eliminate the residues of deoxidier. If necessary, clean the surfaces using a brush made up of
hard silks.
Safety at workplace
u Welding should be carried out in a well-ventilated place to avoid inhaling the gases/vapours exhausted while
welding and getting in contact (with your skin or your eyes) with the deoxidizer paste. Comply with the recommendations of the supplier of the brazing materials.
32
WRENCH SETTINGS
B6
Service Manual
Rev.
07-2008
GB
Wrench settings
B6
Pipe diameter
Nm
26
12
58
16
95
20
130
25
200
32
260
38
330
Wrench settings
B6
Hose diameter
Nm
31
3/8
61
95
130
190
Thread
Nm
31
3/8
61
95
160
230
Wrench settings
B6
1.4 Torque wrench setting of fittings with thread type UNF, flat
front seal with O-Ring-(SAE J1453)
As already explained in section A5.3, for a correct torque wrench setting of these types of fittings, a dynamometric
wrench is not necessary.
During tightening, the O-Ring deformes , the two metallic surfaces get in touch and it turns to be impossible to
continue fitting tightening.
Moreover, please note that it is useless and harmful to continue the tightening operation, using various tools
instead of usual wrenches operated with the force of the arms.
Hydraulic / electro-hydraulic
limiting device
B7
Service Manual
Rev.
07-2008
GB
B7
B7
1 - Operating principle
INTRODUCTION
u The overload limiting device fitted to the EFFER cranes has been designed according to the EN 12999 A2
rules. The aim of EFFER is to supply a safety device which, instead of penalizing the user of the crane, makes the
operators work safer according to the features indicated in the load diagrams, avoiding the risk of damaging
people and things.
A crane with the overload limiting device correctly set grants the user a safe and reliable use in the time.
LTHE EUROPEAN STANDARD EN 12999 A2, UNDER POINT 5.6.1.1, provides for the presence of
the load limiting device on those cranes that have even only one of the following
requirements:
-
Cranes with lifting capacity equal to or greater than 1000 KG, indicated in the load diagram.
-
Cranes whose maximum net lifting moment is higher than or equal to 40.000 Nm (4T x m).
The load limiting device fitted to the crane must have three different functions:
1)
avoiding overloads in the frame
2)
avoiding the risk of overturning the vehicle
3)
avoiding dangerous movements of the load
u The same set of standards, under point 5.6.4, provides for the worker is acoustically warned when the crane
reaches 90% of its maximum lifting capacity, and when 100% of its maximum lifting capacity is achieved, a
different warning signal noise is emitted.
u Under point 5.6.7 of the same set of standards it is reported that on the cranes with a radio control to handle
the booms, or a horizontal outreach of more than 12 metres, an acoustic alarm device must be provided, for
example, a KLAXON, operable by the worker from any control station used.
N.B: Note that the KLAXON function on the cranes operated by the radio control and without the DMU
load limiting device, is assigned to truck klaxon electrical connections; such connection is carried out by
the crane installer.
u It may occur that the crane tip, when the maximum load that can be lifted is applied to the hook, yields, or
u THE EUROPEAN STANDARD EN 12999 A2, under point 5.6.2, indicates the maximum tolerance which the
load limiting device can have: this varies according to the length of the crane and the load applied to the hook.
The load limiting devices fitted to EFFER cranes are very accurate devices: it is not necessary to refer to tolerance
allowed by the standards to consider the device operation appropriate.
All EFFER cranes are able to handle the loads indicated in the table.
B7
u The principle governing the hydraulic /electro-hydraulic limiting device fitted to the EFFER cranes is to auto-
matically inhibit certain crane movements when inside a lifting cylinder the maximum pressure value allowed
by the project is reached. This pressure value is dependent on the load applied.
Therefore, some movements are inhibited when the crane achieves its maximum performance.
NOTE: The following instructions deal with the winch and the supplementary jib: as they are optional
parts, they may be not fitted to your crane.
u a - Crane with slewing mechanical limitation (operating by 180 on the truck body: working area A):
The following manoeuvres are locked:
- all boom descents,
- the outer boom and the fly-jib rise,
- all the hydraulic extension exits,
- the winch rise.
Inhibited movements
B7
u b - Crane with slewing mechanical limitation and proportional controlbank: (operating by 180 on the
truck body: working area A):
Ref. X
Inhibited movements
B7
c- Crane with slewing electrical limitation: the truck body working area A is surrounded by electrical sensors.
This crane version allows obtaining the maximum operation on the truck body working area A, and reduced
operation over 180 in the front of the truck cab working area B. The operation depends on the stability of the
truck/crane combination.
Slewing control systems:
Ref. X
Inhibited movements
B7
If the overload limiting device is operated in this working area, as a result of a slewing manoeuvre you may:
1
2
Standard working
Area in which the overload
limiting device operated
B7
c3- Overload limiting device operation during crane slewing passing from the working area A to the working
area B
If the overload limiting device is operated as a result of a slewing manoeuvre to enter the 180 area in front of
the cab, the inverse manoeuvre is allowed automatically.
B7
Ref.
Connections
Connection to the oil tank, without passing through the drain filter. The valve drainage oil comes out
of this hole.
It is connected to the pipe connecting the hydraulic pump to the crane controlbank.
P1
The hydraulic pipe is connected here. This pipe conveys the pressure value to the valve inside the cylinder/s on which the device detects the pressure value: when the allowed maximum value is achieved,
then the device is operated.
RS
The hydraulic pipe is applied here. It connects to the extension element inlet conveying oil to the extension cylinderduring the return manoeuvre. This signal inhibits, for a while, the load limiting device, that,
however, comes into operation again if the conditions causing its operation persist. You may benefit
from this manoeuvre when you have to release the crane from the device operation as a result of a
limit stop manoeuvre carried out with the first boom cylinder or when the device comes into operation
further to a swinging of the load.
Oil comes out of this hole when the load limiting device comes into operation to feed the cylinders
preventing the operation of some of the controlbank functions.
A pipe connection point connected with the first boom element inlet conveying oil to the first boom
cylinder during this boom descent manoeuvre. This hydraulic connection optimises the load limiting
device operation further to the boom descent manoeuvre, by correcting the effect of the friction existing on the crane pins (Not fitted on some smallmiddle range cranes).
IF
A hydraulic pipe connection point connected with the first boom element inlet conveying oil to the
first boom cylinder during this boom rise manoeuvre.
Register for the valve setting value change. For the correct operation sequence, please see the
following sections.
Tap, lead coated by EFFER. This tap overrides the load limiting device. When overload tests are to be
performed, the operation of the load limiting device has to be blocked momentary. This override has
to be performed when the device is not turned on due to the crane max. performance. NOTE: Said
tap must be always sealed. If found unsealed, the crane warranty decays.
Electrical microswitch- EFFER part # 9394704. When the load limiting device comes into operation,
a small piston inside the valve, operates the microswitch, conveying the signal to the crane electrical
component.
A pipe connection point connected with the controlbank element inlet : the first boom descend - jib
rise (if fitted) - (inlet marked with M ed N)
P
ipe connection point to send a pressure signal to the
load limiter valve to delay the operation (inlet
marked with P)
Connection point
for a pressure switch, if mounted.
Connection point
for cylinder pressure signals activating the load limiting device.
2.2 Components
EFFER part # 8865717
rs
p1
m
p1
rs
e
10
B7
B7
RS
M
p1
IF
P
T
rs
p1
11
p1
Z
L
12
B7
Flip-Flop valve
B7
+
EFFER part # 8866707
Pressure swicth
13
B7
Electric microswitch
S2
bn
bk
Proximity
S2
+
bu
14
Gauge
B7
15
B7
d1 m 7,8
P1 kg 4800
m 10 d2
kg 3400 P2
- The result is that our crane can lift a load of 3800 kg at a max. outreach of 9.4 m from the slewing axis.
NOTE: In order to set correctly the point of intervention of the overload limiting device, see the
instructions of the following chapter.
16
B7
f
f
+2 4
NOTE: The load diagrams show the angle that the 1st boom must reach, to get the maximum distance f.
Rest the crane 2nd boom in horizontal position. Perform a manoeuvre of extensions out at the max. speed, avoid
oscillating the load. It is advisable to apply ropes or chains as short as possible to lift the load.
When the test of the point of intervention is completed, rise the 1st boom cylinder to lift the load
(manoeuvre 2).
17
B7
?
The stabilty calculations provide a new load diagram (to be applied to the crane control post). Now, following the
instructions of the previous section , you can determine the point of intervention of the overload limiting device
according to the loads available.
NOTE: In order to set correctly the point of intervention of the overload limiting device, see the instructions
of the following chapter.
NOTE: In this configuration, after the intervention of the overload limiting device (see chapter A7 - 1.1- C2),
the load can not be lifted by the crane booms.
18
B7
MAX.
- (2 3)
NOTE: This test does not affect the basic crane test,
since the overload limiting device receives the pressure signal directly from the jib cylinder.
OFF
19
B7
32 m
Fig.1
83
30
28
26
24
22
20
18
16
14
12
10
1760 Kg
1170 Kg
670 Kg
880 Kg
2800 Kg
530 Kg
6
4
12
1000 Kg
16.01 m
10
12
740 Kg
19.98 m
560 Kg
24.09 m
665 Kg
845 Kg
17.98 m
21.98 m
16
18
20
22
14
480 Kg
26.20 m 0
24
26 28m
6S+JIB 4S
0
10
12
14
16
18
20
Fig.2
22 m
85
230
29.78
kg
170
m
31.81
24
22
20
2080
920
530
9.70 13.50 17.30
kg
670
1430
m
11.60 15.40
18
16
14
12
10
kg
1430
670
920
2080
20
530
6
4
kg
m
510
385
295
20.14 23.94 27.74
435
325
22.04 25.84
2
0
B7
You should lay down a load diagram concerning the jib, which is independent of the crane: as if the additional
jib was..... kept in hand.....
kg
After finding the values relating to the maximum loads that can be moved by the jib, you have to identify
distances: these data are essential to apply the mathematical formula that determines the load limiting device
proper point of operation.
m
1
kg
m
21
B7
3.6 Conclusion
u
In the configuration of horizontal crane and jib, with basic crane extensions completely out, the max. lifting
capacity of the supplementary jib is controlled by the overload limiting device connected to the basic crane.
u
In the configuration of basic crane extensions completely retracted, the max. lifting capacity of the supplementary jib is controlled by the overload limiting device connected to the supplementary jib cylinder.
22
NOTE: In this working configuration, the crane can operate with loads -applied to the jib- higher than
those shown in the load diagram (as regard the horizontal configuration).
B7
Please find below the operating sequence to be followed to set the load limiting device,
in case the crane referred to is a basic crane.
- from 4.1 to 4.10 -
NOTE: A basic crane means that the crane is not provided with the equipment for the additional hydraulic
jib.
For the operating sequence to be followed to set the load limiting device, in case the crane
referred to is a basic crane with additional hydraulic jib, please refer to page 29.
from 4.11 to 4.21 -
23
B7
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder. When
the overload limiting device operates, the pump oil is conveyed directly to the tank, and the crane stops.
Setting points
Valve ref. 1 controls overload limiting device
operation.
NOTE: valve fig.2 has a standard setting,
according to its design, and can not be
modified. This valve has the function to
lock the overload limiting device during the 1st boom rise manoeuvre. If an
increase of the standard value setting
is performed, the max lifting values
listed in the table can not be lifted.
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder.
Setting points
Valve ref. 1 controls overload limiting device operation.
24
B7
of the work area behind cabin: the crane can operate in the cabin work area, according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder.
Setting points
1st test: operation of the overload limiting device in the
front work area. Valve concerned ref. 1.
2nd test: operation of the overload limiting device in the
rear work area. Valve concerned ref. 2.
The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd
boom cylinder ref. 2. The max. pressure value is the same for both the cylinders.
Setting points
The valve ref. 3 controls the operation of the overload
limiting device.
2
1
25
B7
of the work area behind cabin: the crane can operate in the cabin work area, according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd boom
cylinder ref. 2. A higher pressure value inside the 2nd boom cylinder is allowed, respect to the 1st boom cylinder:
valve ref. 3 operates to compensate pressure values.
2
Setting points
1st test: operation of the overload limiting device in
the front work area. Valve concerned ref. 4.
2nd test: operation of the overload limiting device in
the rear work area. Valve concerned ref. 5.
3rd test: valve setting ref. 3. This is a fixed setting. To
check the setting value, remove the valve and test
it at the test bench. This test may be necessary
when the overload limiting device releases during
a manoeuvre of max. opening of the 2nd boom
without load applied.
The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd
boom cylinder ref. 2. The max. pressure value is the same for both the cylinders.
2
Setting points
1st test: operation of the overload limiting device in
the rear work area. Valve concerned ref. 3.
26
B7
can operate in the cabin work area, according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder.
Setting points
1st test: operation of the overload limiting device in the
front work area. Valve concerned ref. 1.
2nd test: operation of the overload limiting device in the
rear work area. Valve concerned ref. 2 with FPI device
OFF.
3rd test: operation of the overload limiting device with
FPI device ON. Valve concerned ref. 3.
of the work area behind cabin: crane operating capacity in the cabin area is set by
a pressure switch
The crane can operate in the cabin work area, according to
the special setting . The overload limiting device operates
when the max. pressure value is reached
1
Setting points
1st test: operation of the overload limiting device in the
front work area. Valve concerned ref. 1.
27
B7
and electrical limitation of the work area behind cabin: crane operating capacity in
the cabin area is set by a pressure switch
The crane can operate in the cabin work area, according to the special setting .
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder.
Setting points
1st test: operation of the overload limiting device in the
front work area. Valve concerned ref. 1.
4.10 Basic crane with proportional controlbank, with device F. P. I., and
electrical limitation of the work area behind cabin: crane operating capacity in the
cabin area is set by a pressure switch. The crane can operate in the cabin work area,
according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd
boom cylinder ref. 2.
A higher pressure value inside the 2nd boom
cylinder is allowed, respect to the 1st boom
cylinder: valve ref. 3 operates to compensate
pressure values.
2
Setting points
1st test: operation of the overload limiting device in the front work area. Valve concerned
ref. 4.
2nd test: operation of the overload limiting device in the rear work area. Valve concerned
ref. 5 with FPI device OFF.
28
B7
Please find below the operating sequence to be followed to set the load limiting device,
in case the crane referred to is a basic crane with additional hydraulic jib.
4.11a Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, operating in the rear work area only
The operation of the overload limiting device of the basic crane takes place when the max. pressure value is
reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. The overload limiting device operates also
when the max. pressure value is reached inside the jib
2
cylinder ref. 3.
3 JIB
Setting points
1st test: operation of the overload limiting device of the
supplementary jib: Valve concerned ref. 4.
2nd test: operation of the overload limiting device of
the basic crane (supplementary jib not fitted): Valve
concerned ref. 5.
1
5
4.11b Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, operating in the rear work area only
The operation of the overload limiting device of the basic crane takes place when the max. pressure value is
reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. The overload limiting device operates also
when the max. pressure value is reached inside the jib
cylinder ref. 3.
3 JIB
Setting points
1st test: operation of the overload limiting device of the
supplementary jib: Valve concerned ref. 4.
29
B7
4.12 Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, and electrical limitation of the work area behind
cabin: the crane can operate in the cabin work area, according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first ref. 1or the 2nd
boom cylinder ref. 2. A higher pressure value inside the 2nd boom cylinder is allowed, respect to the 1st boom
cylinder: valve ref. 4 operates to compensate pressure values. The overload limiting device operates also when the
max. pressure value is reached inside the jib cylinder ref. 3.
Setting points
3 JIB
1
5
6
Setting points
1st test: operation of the overload limiting device of the
supplementary jib: Valve concerned ref. 3.
2nd test: operation of the overload limiting device of
the basic crane (no supplementary jib applied): Valve
concerned ref. 4.
30
B7
can operate in the cabin work area, according to the special setting
2 JIB
Setting points
1st test: operation of the overload limiting device
in the front work area (no supplementary jib
applied). Valve concerned ref. 3.
5
1
2 JIB
Setting points
1st test: operation of the overload limiting
device of the supplementary jib: Valve
concerned ref. 3.
2nd test: operation of the overload limiting
device of the basic crane (no supplementary jib applied): Valve concerned ref. 4.
31
B7
4.16 Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, operating in the rear work area only
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1
or inside the jib cylinder ref. 2.
Setting points
2 JIB
can operate in the cabin work area, according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref.
1 or inside the jib cylinder ref. 2.
2 JIB
Setting points
1st test: operation of the overload limiting device
in the front work area (no supplementary jib
applied). Valve concerned ref. 3.
2nd test: operation of the overload limiting device
in the rear work area (supplementary jib not
fitted). Valve concerned ref. 4.
5
1
3
4
32
B7
2 JIB
Setting points
1st test: operation of the overload limiting device
in the front work area (no supplementary jib applied). Valve concerned ref. 3.
2nd test: operation of the overload limiting device in
the rear work area (supplementary jib not fitted).
Valve concerned ref. 4 with FPI device OFF.
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref.
1 or inside the jib cylinder ref. 2.
2 JIB
Setting points
1st test: operation of the overload limiting device of the
supplementary jib: Valve concerned ref. 3.
2nd test: operation of the overload limiting device in the
rear work area (no supplementary jib applied). Valve
concerned ref. 4.
3rd test: operation of the overload limiting device in the
front work area (no supplementary jib applied). Valve
concerned ref.5.
1
3
4
33
B7
jib, and electrical limitation of the work area behind cabin: crane operating capacity
in the cabin area is set by a pressure switch
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref.
1 or inside the jib cylinder ref. 2.
Setting points
1st test: operation of the overload limiting device
of the supplementary jib: Valve concerned ref.
3.
2nd test: operation of the overload limiting device in the rear work area (no supplementary
jib applied). Valve concerned ref. 4 with FPI
device OFF.
3rd test: operation of the overload limiting device
with FPI ON (no supplementary jib applied).
Valve concerned ref. 5.
4th test: operation of the overload limiting device
in the front work area (no supplementary jib
applied). Valve concerned ref. 6.
2 JIB
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref.
1, the 2nd boom cylinder ref. 2, and the jib cylinder ref. 3. A higher pressure value inside the 2nd boom cylinder is
allowed, respect to the 1st boom cylinder: valve ref.4 operates to compensate pressure values.
Setting points
1st test: operation of the overload limiting device
of the supplementary jib: Valve concerned
ref. 5.
2nd test: operation of the overload limiting device in the rear work area (no supplementary
jib applied). Valve concerned ref. 6 with FPI
device OFF.
3rd test: operation of the overload limiting device
with FPI connected (no supplementary jib applied). Valve concerned ref. 7.
4th test: operation of the overload limiting device
in the front work area (no supplementary jib
applied). Valve concerned ref. 8.
34
3 JIB
4
1
8
7
6
CONTROLBANKS
B8
Service Manual
Rev.
07-2008
GB
Controlbanks
B8
We adopted the solution of decreasing the contact surface between elements (push area, reduced by 40% as
compared to the previous area) and of creating two channels connected to the drain branch so that those small
amounts of oil that the mechanical coupling of elements may eject, can flow out.
Controlbank modification:
B8
Controlbanks
If an element has to be added to a controlbank or an element has to be replaced, you may have to deal with the
following cases:
- A new element is fitted to an old controlbank: this is not advantageous for the problem in question nor does it
create problems of any type.
- An old element is fitted to a new controlbank: this eliminates the benefit of the reduction in the push area only
on the applied element. The other elements still benefit from the modifications that have been made.
Oil leakage on the element lower plug
The following modifications have been made to solve the problem relative to oil leakage from the plug applied
to the element lower part:
- the material has been modified to be able to tighten it with a higher torque wrench setting
- an o-ring with a composition more suitable for higher temperatures has been applied
- the position of the o-ring on the plug has been modified along with its seat on the controlbank element
- the plug threaded portion has been increased to prevent it from being unintentionally unscrewed because of
dilatations.
previous
version
new
version
Both the Manufacturer and EFFER, are convinced that the technical solutions which have been found lead to the
elimination of oil leakages: before making these modifications, a prototype has undergone a test cycle at 350 bar,
consisting in the execution of 280, 000 working cycles lasting 1 second each. At the end of the test, the controlbank
did not have any leakage.
P.S. Since the beginning of April 2000 the manufacturer has also modified the closing plugs of the special
valves and the general valve.
Such modification has also been made on the HC-D4controlbank. The new plugs are interchangeable with the
previous plugs and vice versa.
Controlbanks
B8
Proportional controlbank
HAWE
B8.1
Features:
420 bar
420 bar
100 lt/min.
200 lt/min
24 volt
24 volt
12 volt
12 volt
Controlbanks
B8.1
Controlbanks
B8.1
Operation
u When activating the hydraulic pump, the oil direct to the controlbank enters the first section, and if no lever
is selected, the oil exits to return into the oil tank, so preventing the hydraulic oil from passing through the controlbank.
u When moving a controlbank lever, only the quantity of oil required (depending on the design features arranged
for that specific function or on the shift of the lever performed by the operator) is delivered to the selected element. The exceeding quantity of oil always returns into the tank.
u This feature is guaranteed by the element compensator and by the inlet compensator. By moving two or
more levers of the controlbank simultaneously, the compensator of each element sends its request of oil to the
inlet compensator, which operates so as to deliver the total amount of oil required, until the port flow available
from the pump is consumed.
u When moving many levers simultaneously, so as to make the inlet compensator demand an oil flow higher
than the quantity the pump can deliver, the priority of operation is given to the functions that require a lower
working pressure.
u This function allows to fit pumps with an oil flow higher than the data specified for the crane, thus increasing
the operating speed remarkably and still without increasing the oil temperature, which turns to be insignificant
with respect to the usual systems. (Ask the EFFER Technical Department about the max. pump size you may fit to
a given crane model equipped with Hawe controlbank).
u The most remarkable operational advantage lies in the fact that different manoeuvres can be performed at very
reduced speed but at the max. pressure allowed for each movement, differently from the usual controlbank.
NOTE: any operation carried out on the controlbank must be performed in the cleanest possible environment. Make sure impurities do not enter the controlbank. Even touching the components with very dirty
hands may jeopardise the correct operation of the controlbank.
B8.1
Controlbanks
2- Closing element
758-2
757-2
3- Lever element
761-2
760-2
762-2
THE POWER OF PERFORMANCE
B8.1
Controlbanks
763-3
763-2
760-3
761-3
765-2
765-3
B8.1
Controlbanks
1 - Inlet element
1.2 -
Inlet compensator
1.3 -
1.4 -
1.5 -
1.6 -
- An additional gasket (2) - type O-Ring 15x2 EFFER code # 8182271 - is located inside the valve.
To adjust the max. pressure, loosen the counternut then turn the cap screw (3). Turn the screw clockwise to increase
the setting value, and counterclockwise to decrease it.
NOTE: It is advisable to turn the screw slightly, taking care of checking the setting value achieved as remarkable changes of the setting value can be obtained with small adjusting shifts.
Should the valve be removed, when reassembling it, it is not necessary to apply Loctite as previously.
In order to make the mounting of the valve easier, we recommend that you loosen the pressure adjusting screw
completely. In this way, the inner spring will not affect the assembly. Obviously, it is necessary to set the valve
when the assembly is completed. Tighten with torque wrench, set to 100 Nm.
10
B8.1
Controlbanks
CAUTION: Always clean the components carefully before mounting the parts.
Fig. 1
1
Fig. 2
Since 2007 the vibration damper (X) shown in fig.1 was modified inside the element body as in fig. 2. In addition
to vibration damper (Y) , a spring (A) and a pin (B) were fitted to grant constant max. pressure to the main valve.
All parts can be supplied as a whole spare part with EFFER code # 8990920 (complete main valve).
11
B8.1
Controlbanks
2
4
(cod.1932893H)
(cod.1932893)
5 l = 5,8 cm
(cod.8991268)
12,2 mm
2
4
5 l = 6,8 cm
(cod.8991972)
*
4
17,3 mm
l = 5,8 cm
(cod.1932893)
(cod.8991268)
l = 6,8 cm
(cod.8991972)
(cod.1932893H)
* Version for changing control bank feed with fixed displacement pump to variable displacement pump
(or viceversa), by turning screw (see section 7).
12
Controlbanks
B8.1
Coil input:
24 Volt = 1,1 A
12 Volt = 2,2 A
13
B8.1
Controlbanks
uThis screw with gauged inner ports for oil flow, is meant to shift the compensator towards the closing position,
avoiding fluid hammers in the hoses connecting the controlbank to the oil tank.
u The cranes manufactured in the years 98 and 99 -approx.- are provided with a screw A as shown in the photo,
in alternative to the more recent units, fitted with a screw B (in use now) as shown below.
u A clogged port in the screw may cause a reduction of the crane operating speed, or a lower max. pressure value,
and even the total crane outage.
u When the replacement of the controlbank or of an inlet element is necessary, make sure that the original screw
type A keeps being fitted on the replacement part.
CAUTION: Always clean the components carefully before mounting the parts.
NOTE: It is advisable to avoid mounting screws type B on a controlbank supplied with screws type A (the
type A of screw may generate a peak in the truck engine RPM , peak which wont last anyway more than
few seconds at the very beginning of the lever operation, and which grants a much more constant boom
operation).
A
B
773
14
535
THE POWER OF PERFORMANCE
Controlbanks
B8.1
u That letter indicates the point suitable for the application of a pressure gauge to detect the pressure values
inside the controlbank.
However, it is necessary to point out some data related to the pressure gauge readings:
A- When oil starts flowing to the controlbank, the pressure value on the pressure gauge is 15-18 bar. This is
a standard value, indicating the pressure value necessary for the inner operation of the controlbank. Such
value must not be added to the values listed in the crane set tables (i.e.: set at the values actually read on the
gauge!)
B- When performing a crane movement, the pressure gauge shows the pressure value necessary for that
movement, until the max. setting value is reached. If the lever movement is interrupted, the pressure gauge
indicator goes down slowly if compared to a traditional controlbank. Such fact is normal.
C- If you need to set a check-relief valve with a setting value much lower that the main relief valves, you know
already that youll first have to make a full end-stroke of the cylinder you are going to set, before proceeding
with the setting. In doing this, youll notice that the pressure gauge first jumps to the setting value of the
main relief valve (max.) and then starts dropping down to the setting value of the check-relief valve (See the
photos). This fact is normal. Moreover, note that the value initially shown by the gauge is only a reading, while
in reality such a pressureAdid never occur in the circuit related to the check-relief valve being set.
772
15
Controlbanks
B8.1
X = 7 mm
Y) Pressure-reducing valve complete with gaskets: for crane supplied with DMU ,
EFFER code # 8991470.
CAUTION: Always clean the components carefully before mounting the parts.
Y = 18,5 mm
776776
775
16
B8.1
Controlbanks
2- Closing element
u The closing element of the controlbank is meant for closing the controlbank but also for collecting the drain
758-2
17
Controlbanks
B8.1
3 - Lever element
The main parts of the lever element are listed hereunder, with notes for each of them:
3
1
5
18
Controlbanks
B8.1
Lever:
EFFER code # 8990896
8
6
19
Controlbanks
B8.1
One or more elements can be fitted in the controlbank to activate different hydraulic functions: this type of controlbank can have max. 10 lever elements.
u In case of modifications, we recommend to always use original tie rods, as tie rods made up with unsuitable
material might cause oil leaks or worst break down.We list herebelow the code # of the tie rods, according to the
different diameter and the number of element bodies of the controlbank:
No. elements
bodies
Tie rod M 10
Tie rod M 8
8991068
8991072
8991069
8991073
8991070
8991074
8991071
8991075
8991097
8991098
8991220
8991219
10
8991222
8991221
PSL2
PSL5
Tie rod M 10 40 Nm
NOTE: The tightening torque shall be applied or checked only when the controlbank temperature is below
30C after operation.
Hydraulic sealing of the different body elements is assured by gaskets type O-ring:
20
Size
EFFER Code
4,47 X 1,78
8000500
13,94 X 2,62
8005600
14 X 1,78
8001500
17,12 X 2,62
8006000
B8.1
Controlbanks
u The cranes equipped by an FPI device, are provided on some functions/levers - with an element featuring a
port (diameter 1/8 GAS) to connect it to the FPI device. It may happen that the same element body is fitted on
cranes not supplied with the FPI device: in that case, the port is sealed with a plug.
Should be necessary to replace an element body, we recommend to replace the whole lever element. For this
spare part, you have to notify EFFER of the crane serial number and the function for which the lever element is
intended, in addition to different element configurations, depending upon the type of inner spool. Three types
of element body are available:
- arranged with two check relief valves on port A and B.
- arranged with one check relief valve on port A and B.
- without check-relief valves
In the first case, see additional information in section 3.7. In the second case, the max. pressure value measured
at both ports of the elements shall be equal to the setting value for the main relief valve.
CAUTION: Always clean the components carefully before mounting the parts.
control bank
without DMU
*
control bank
for DMU
NOTE:
NB: Allinterno
di questo
c una
sfera
A FLIP-FLOP
ball isblocchetto
located inside
the block.
FLIP-FLOP. Se unimpurit impedisce lo stscorriIf impurities prevent ball sliding, the crane 1 boom
mento della sfera, il primo braccio della gru non
can
not rise.
esegue
la manovra di salita.
Note: On some crane models, a screwed block is fitted under the control bank element with 4 screws removable by a 6mm-socket head wrench -. This block is fitted to the elements enabled to those cylinders
that require the presence of valves discharging pressure peaks in a timely way. These pressure peaks are
caused by the movement of the crane in a poor progressive way.
The regulating valve is set to a single value, higher than the setting of the special valves fitted to the hawe control
bank element.
In case of supply of the block as a spare part, the regulating valve above is supplied already set, and the register
is sealed with lead.
- The hydraulic tightness between the block and the control bank element is guaranteed by two gaskets.
- In case the block has to be removed, it is recommended to lock the screws using a dynamometric wrench: torque
wrench setting 9,5 Nm.
WARNING: always clean the components with care before assembling.
THE POWER OF PERFORMANCE
21
B8.1
Controlbanks
keeping the cursor of the element in central position (neutral) when the control lever is idle, both in Manual and
Radio-remote operation, and also at limiting the stroke of the cursor.
Unscrew the four cap screws (1), with a 4-mm Allen wrench, to remove the cover of the rod return device.
u When the device cover is removed for any reason, before refitting it, grease the spring carefully: any break of
partial corrosion of the spring may damage the operation of the device.
u Hydraulic sealing between the element body and the cover is assured by a gasket (2) EFFER code # 8002800
type O-ring 34,65 x 1,78.
Complete rod return device: EFFER code # 8990657.
CAUTION: Always clean the components carefully before mounting the parts.
2
1
22
Controlbanks
B8.1
Inside the lever support two additional gaskets (3) type O-ring 12,42 x 1,78 are located Code # EFFER 8001400.
u As explained in section 3.2, the max. flow allowed to a given function of the crane and to each of the element ports
is determined by Effer Technical Dept. while designing the matching of a controlbank to a given crane model.
u Therefore, on the lever element, two adjusting screws (4) are located so as to reduce the mechanical stroke
of the lever (5), in case you wish to reduce furtherly the oil flow given to an element of to one direction only of a
movement on a crane.
To adjust the screws, dismount the control lever (5), and loosen the lock pins (6).
Fasten the adjusting screws (4) to reduce the oil flow to the corresponding port of the lever element.
In order to act on the lock pins and on the adjusting screws, use a 3-mm Allen wrench.
Complete lever support: EFFER code # 8991263.
CAUTION: Always clean the components carefully before mounting the parts.
789
23
B8.1
Controlbanks
u Different types of cursors are available also, depending on the max. rate of oil flow designed for the ports a
and B.
When you need to replace an inner cursor, ask to effer s.p.a. for the exact type of spool used. The type of spool
applied is marked on the spool head (fig. X). Otherwise, it is vital to mention in your order the crane serial number
and also which crane movement is controlled by the specific cursor you want to replace. The mark identifies the
open centre (O), the closed centre (L), 1/2 open centre / 1/2 closed centre (B), and oil ports flows.
u The cursor shall slide freely inside the element body. In case the cursor has scratches due to impurities in the
oil, the smooth sliding of the cursor is jeopardised and it may be necessary to replace the cursor, or as we recommend, the whole lever element. If the cursor is removed from the inside of the element body, before fitting it, it is
necessary to follow these indications: CURSOR (1) WITH LONGITUDINAL GROOVES:
The grooves must be turned towards the closing element.
CURSOR (2) WITH TWO LONGITUDINAL PORTS:
The two ports must be turned towards the opposite side of the
controlbank ports. (ports A and B).
CAUTION: Always clean the components carefully before mounting the parts.
O = Oper Centre
O 80 140
o
L 80 140
0
PORT
A / B
80 14 0
L = Closed Centre
Code
PORT
A / B
24
POTR
A / B
Code
O-10/10
O-16 / 16
O-25 / 25
O-40 / 40
O-63 / 63
O-80 / 80
8990921
8991099
O-16 / 25
8991228
O-25 / 40
O-40 / 63
8991111
8991112
O-40 / 80
O-25 / 16
8991110
8991229
O-40 / 25
8991150
O-63 / 40
O-80 / 40
8991230
8991231
8991233
2
A
Code
B = 1/2
1/2 Closed centre
A
THE POWER OF PERFORMANCE
Controlbanks
B8.1
the inlet element. Since the inlet element has to deliver as much oil as it is required by each single compensator,
the hydraulic signals shall be conveyed to one internal line only. Each element is fitted with a flip-flop valve, meant
to select the input signals inside the channel leading then to the inlet compensator.
The flip-flop valve is supplied as spare part withe EFFER Code # 8991947.
An O-ring 6.07x1.78 EFFER Code # 8000700 is located on the plug.
780
u The correct operation of the compensator is achieved when it runs smoothly along its seat and no major grooves
are scratched on its surface.
This part is available as spare part, however the replacement of the sole compensator with deep scratches is
unadvisable, as inevitably the seat is damaged too.
A plug complete with O-ring 13x1.5 -EFFER Code # 8991264 is located on the other side of the compensator.
780
25
B8.1
Controlbanks
u Under the cylindrical-head nut, a screw (1a) adjustable by a 3-mm Allen wrench, has the function of pressing
the tapered pin (3a) against the body seat, so as to prevent the oil from flowing towards the drain line. In order
to remove the pin from its seat use a M3 screw.
For correct operation of the controlbank, make sure the screw is tightened strongly.
External hydraulic sealing is assured by copper washers (4) of the following size: 8 x 12 x 2 code # 8990983.
CAUTION: Always clean the components carefully before mounting the parts.
Y
792
791
4
4
1a
3a
790
26
2
1
3
B8.1
Controlbanks
u When one of the levers of the controlbank is moved by the radio remote control, on the opposite side of the
manual control lever a double electric solenoid is fitted (of proportional type).
12-volt Solenoid EFFER code # 8991215
24-volt Solenoid EFFER code # 8990569
A sole double-coil solenoid allows driving the lever in both directions: forward and backward.
The solenoid is connected electrically to three wires: the connection at the point 1 is common to the two movements of the lever, with negative polarity.
NOTE: HAWE controlbank is electrically powered, therefore, for any check, fit an ammeter on connecction
2 or 3. The ammeter values will depend on the manupilator stroke.
Connections to the points 2 and 3 refer to the different movements of the lever, and have polarity inverse to the
one designed for a.m. point 1.
he solenoid is fitted by three cap screws (1), removable by an Allen wrench, 4 mm.
Hydraulic sealing between the solenoid and the element body is assured by two gaskets (2) type O-ring 12,42 x
1,78 EFFER Code # 8991474.
As mentioned above, the sole solenoid controls the shift of the lever in both directions. Therefore, on the element
body there are two ports, where two valves (3) are housed. These valves turn the proportional shift of the solenoid
into a proportional shift of the lever of the controlbank, corresponding to a crane movement accordingly.
code # corresponds to a complete kit including : solenoid , gaskets, fastening screws, connector,
*andThethefollowing
parts to be fitted inside the lever body (valves for the proportional shift of the lever of the controlbank).
uTo remove the valves (3) extract the inner part of the valve (4) (yellow) and unscrew the valve body with a
screwdriver.
CAUTION: Always clean the components carefully before mounting the parts.
NOTE: The inner valve (4) shall run smoothly, under the pressure of the spring. Manually check the correct
operation of the inner valve.
2
3
2
1
793
27
B8.1
Controlbanks
u For reasons of standardisation, or due to special requests when ordering the crane, it may happen that the
controlbank is not equipped with the solenoid for the radio remote controls, although it has been pre-arranged
for the fitting of the solenoid .
Cap covering the port of the radio remote control solenoid
894
28
B8.1
Controlbanks
etc., require to lock some crane movements. hawe controlbank can neutralize some movements, thanks to the
fitting of L.S. solenoids on the lever element.
u A sole double-coil solenoid locks the operation of a lever element, for just a single function port A or B or for
both the functions - both ports A and B -.
Said solenoid is of actively safe type, i.e. in case of electric power shortage, the solenoid prevent the hydraulic oil
from flowing out of the lever element.
Coil 12 volt
code # 8991284
Coil 24 volt
code # 8990589
The solenoid is fitted to the lever element by three cap screws (1), removable by a 4-mm Allen wrench.
Hydraulic sealing between the solenoid and the element body is assured by two gaskets (2) type O-ring 6,86 x
1,78 Code # EFFER 8990983.
A gasket (3) mm. 3 x1.50 is fitted inside the element.
800
798
A
THE POWER OF PERFORMANCE
B
29
B8.1
Controlbanks
The lever element has two ports: port A and port B.
The lever element can be locked in three ways:
2 = port B inhibited
1 = port A inhibited
The movement to be locked (and its direction) is determined by Effer when designing the matching of a controlbank to a given crane model.
The electric connections to the solenoid are the following:
u When the solenoid is electrically activated, a pin (3) comes out the solenoid and drives a piston (4/5) inside
the lever element. Only when that piston is pushed, may the hydraulic oil run out the ports of the lever element.
u If both the ports of the controlbank are to be controlled, two pistons (4) are to be fitted, whereas if just one port
of the controlbank has to be controlled, a pin (5) shall then be fit into the seat of the corresponding port NOT to
be controlled, instead of the piston.
NOTE: On controlbanks fitted to cranes delivered until the end of 1999, it may happen that the pin (3) fitted into
the solenoid, is worn out at both its ends, due to the electric signal induced by constant ON-OFF switching.
The deformation will cause a slowdown of the movement. Therefore, we recommend that you check the pin length
at least once a year.
A
4
5
3
799
3
Copper gasket
12x16x1,5
800
3
5
17,517,6
803
30
B8.1
Controlbanks
u When extracting the piston or the pin from their seat, it is essential to remove the gasket (6) type O-ring first. In
order to avoid damaging it, use a small nail to remove it from its seat. With sharp-nose pliers, extract the pistons
(4-5) from the seat.
u The solenoid is fitted with two pins having a cylindrical point in the centre. If the solenoid is not activated
electrically, by pushing that point with a shaped tool, or simpler with a nail, the solenoid acts as if it was powered,
and allows the oil to run out the port of the controlbank when the control lever is activated manually.
882
Copper gasket
12x16x1,5
31
Controlbanks
B8.1
u For some lever elements, according to the Effer design, the L.S. solenoid may be not provided. In such a case the
corresponding ports are sealed by a plate secured by three Allen screws adjustable by a 8-mm open wrench.
Two pins are located under the plate, and their hydraulic sealing is assured by two gaskets, type O-ring, similar
to the gaskets mentioned above.
EFFER code # 8991224 sealing plate complete with fastening screws, gaskets and pins.
798
802
805
32
B8.1
Controlbanks
4 - Troubleshooting
1 / Trouble
2 / Cause
3 / Remedy
1 A - No crane motion is 2.1- Inlet compensator stuck in 3.1- See section 1.2 regarding the indications
possible, although the
closed position because of
for the removal of the inlet compensator,
hydraulic pump operimpurities.
and its working
ates perfectly.
2.2 - No electric supply to the inlet 3.2- To check the operation of the solenoid
solenoid valve.
valve, supply voltage to the valve by connecting it to a wire applied directly to the
truck batteries. In this way, you find out if
the trouble comes from the electric connection of the crane or from the coil of the
solenoid valve.
2.3 - Solenoid valve coil burnt
2.4 - The gauged screw to eliminate 3.4 - Remove the gauged screw and clean the
pressure peaks on the drain line
ports with an air jet. For additional informais clogged.
tion, see section 1.4.
1 B -The crane does not per- 2.1- The pin fitted to the L.S. sole- 3.1- Check pin size according to the instructions
form a specific movenoid is damaged.
in section 3.9; if necessary, make a test by
ment, when activating
removing a pin from another solenoid.
the lever of controlbank. The L.S. solenoid
is fitted on the lever 2.2- The L.S. solenoid controlling 3.2- Connect a cable to the batteries of the
a specific movement does not
truck, with negative polarity applied to point
element.
get any electric supply.
1, and positive polarity to points 2 and 3.
Then, verify if the trouble comes from the
electric connection of the crane or from the
solenoid.
2.3- The L.S. solenoid controlling 3.3 - If the solenoid is faulty, in order to perform
the inhibited manoeuvre so as to fold the
a specific movement is damaged.
crane, press the cylindric point in the centre
of the solenoid, as described in section 3.9.
2.1- The inlet compensator doesnt 3.1- Damaged compensator or seat, not allow1 C - All crane movements
perform a complete stroke.
ing the compensator to slide smoothly, see
are slow
section 1.2.
2.2- Gauged screw to eliminate 3.2- Remove the pressure gauged screw and
hammers in the drain line, parclean the ports with an air jet. For additional
tially clogged.
information, see section1.4.
33
B8.1
Controlbanks
1 / Trouble
2 / Cause
3 / Remedy
1 D - A crane movement 2.1- Flip-flop valve related to that 3.1- Remove the flip-flop valve and clean the
can be performed at low
specific lever element does not
seat with an air jet. For additional informaspeed only
slide smoothly in its seat.
tion, see section 3.4.
1 E- A lever of the control- 2.1- The fault may come from a 3.1- Replace the electric connection of the
trouble in the electronic system
solenoid related to the movement not
bank does not move
when activated by the
of the radio remote control, or
performed, with a connection related to
radio remote control
the solenoid of the controla working movement: if the trouble is still
bank. .
present, replace the remote control activator - see section 3.8 -. If the lever works, the
cause may be in the radio remote control
system or in the wire.
1 F - The crane does not 2.1- The pressure reducing valve 3.1- Remove the pressure reducing valve, clean
is stuck
with an air jet, then fit it.
operate by the radio remote control, but only
For additional information, see section 1.6.
in manual.
1 G - The max. pressure 2.1- The main relief valve is dirty 3.1- Remove the main valve - see section 1.1or faulty
and check that the small semispheric-head
valve can not be depiston is free from impurities or surface
tected anymore by the
scores. Otherwise, fit a new valve.
controlbank.
34
B8.1
Controlbanks
245
The elements of the PSL 52-3 control bank, as well as the connecting rods of the joining elements and the closing
element are the same as those used for the PSL 41-3 version.
EFFER code # 8991626 : Complete inlet element of size 5 fitted to inlet elements of size 3
EFFER code # 8991790 : Complete inlet element of size 5 fitted to inlet elements of size 3
5.8 - Plug
5.2
5.9
5.8
5.7
5.1
5.4
5.6
249
5.5
248
35
B8.1
Controlbanks
4
2
792
1
3
u The check-relief valve can be easily identified by the presence of a cylindrical-head nut, adjustable by a 12-mm
Allen wrench, and of a counternut adjustable by a 13-mm Allen wrench -.
Inside the valve there is a spring (1): act on the screw (2) that pushes the spring, by a 3-mm Allen wrench, so as to
change the valve setting value. During working, if the valve set pressure is reached, the tapered pin (3) under the
spring moves so as to let the oil flow towards the drain line, interrupting the crane movement.
u External hydraulic sealing is assured by copper washers (4) of the following size: 8 x 12 x 2 code # 8991234.
CAUTION: Always clean the components carefully before mounting the parts.
36
Controlbanks
B8.1
controlbank is equipped with solenoids for radio remote control, or when it is prearranged for the solenoids. In
case of manual operation only, a closing pin is located under the plug A.
NOTE: on crane equipped with DMU, pressure inside the control lever circuit is 40
Bar (pressure not detected by the pressure gauge).
X = 7 mm
Pressure-reducing valve complete with gaskets: for standard crane, EFFER code #
8991262.
Pressure-reducing valve complete with gaskets: for crane supplied with DMU , EFFER
code # 8991470.
CAUTION: Always clean the components carefully before mounting the parts.
Y = 18,5 mm
775
37
Controlbanks
B8.1
771
5.5 Plug
u This plug is required for the execution of the works on the inlet element. The hydraulic tightness in outer part
is guaranteed by an ERMETO G1/4 gasket, Effer code # 8991476.
38
Controlbanks
B8.1
5.6 LS connection
u The hole located under to this plug is related to the hydraulic connection of the LS pipeline, which is pro-
vided in case a pump is fitted to a variable delivery pump. The hydraulic tightness in outer part is guaranteed by
an ERMETO G1/4 gasket, Effer code # 8991476.
is screwed into the hole. The hydraulic tightness in outer part, - when the pressure gauge quick socket Millimes
is not fitted - is guaranteed by an ERMETO G1/4 gasket, Effer code # 8991476.
39
Controlbanks
B8.1
5.8 Plug
u This plug is required for the execution of the works on the inlet element. The hydraulic tightness in outer part
is guaranteed by an ERMETO G1/4 gasket, Effer code # 8991476.
NOTE: The pressure exerted by the inner spring (3) on the plug makes the plug move
by loosening the screws. We recommend that you hold the plug in its position with your
hand, so as to avoid damaging it or making it fall out.
The compensator (2) shall run freely in its seat, and the ports for oil flow shall be free
from impurities. Piston (6) operates as a spring guide.
External oil-hydraulic sealing is assured by a gasket (4) type O-ring 17.17x1,78 EFFER
code # 8991468.
It is not necessary to tighten the four screws fastening the plug by a torque wrench.
The correct operation of the compensator is achieved when it slides freely in its seat,
and when there are no deep scratches or grooves on its surface.
The inlet compensator is supplied as a spare part - EFFER Code # 8991223. However
the replacement of the sole compensator when heavily scratched is unadvisable, as
inevitably the seat is damaged too.
1
4
CAUTION: Always clean the components carefully before mounting the parts.
5
40
Controlbanks
B8.1
located on the control bank. The function of this microswitch is to transmit a signal to the DMU when the lever
of the control bank is operated in one of the two directions: according to the configuration of the crane load, the
DMU will provide - or wont provide - the validation to the solenoid valve located at the control bank inlet to convey
the oil to the control bank element, thus allowing - or not allowing - the execution of the manoeuvre.
237
236
The microswitch is positioned inside a cylinder, fitted to the control bank body through 4 socket head screws 4mm screw socket head -.
241
41
Controlbanks
B8.1
NOTE: To check the exact centering of the lever zero position, it is necessary to keep the two buttons PROG
and ON pressed checking to press the button PROG first.
42
Controlbanks
B8.1
The microswitch is operated by a magnetic rod, connected to the control bank spool.
IMPORTANT:
The amagnetic rod loses its magnetic characteristics if put in contact with metallic bodies.
To disassemble the rod, which is necessary in order to remove the cursor from the element, a socket wrench 10mm wrench hexagon, made with amagnetic material is required. (This socket wrench Effer code # 8991472 is
available from Effer).
N.B. When the rod is disassembled, the position of the nut must not be changed with respect to the amagnetic
rod, to avoid losing rod centering with respect to the microswitch.
In case the element spool has to be replaced, apply the magnetic rod on the crane to the new spool.
43
B8.1
Controlbanks
a)
The inlet compensator comes with a spring inside - see section 1.2 -. This spring is removed in the version of controlbank for variable displacement pump and replaced by a pin of the size shown in the drawing below.
Cylinder EFFER Code # 1932893
36,7 36,8 mm
54,7 54,8 mm
10,6 10,7 mm
10,6 10,7 mm
r =1mm
r =1mm
steel
acciaio
44
LS
B8.1
Controlbanks
u Control bank type PSL 52-3 (elements of size 3)
In the version of control bank setup for operation with fixed delivery pump, a plug A1 located under the screw
A.
- The hydraulic tightness toward the outer part is guaranteed by a copper washer having the following size:
M8x12x2 mm, Effer code # 8991234
To perform the transformation of a control bank type PSL 52-3 from operation with fixed delivery pump into
operation with variable delivery pump, proceed as follows:
1) Unloosen the screw ref. A and remove the inner screw A1.
2) Under the screw B, fit the screw A1.
3) Under the screw A, apply the screw C Effer code # 8991430 (with central hole 0,6).
Required material: number 1 Code 8991430
A1
C
A1
LS
45
B8.1
Controlbanks
u Control bank type PSL 52-5 (elements of size 5)
In the version of control bank prearranged for operation with fixed delivery pump, a dowel B is placed under the
screw A.
To convert a control bank from operation with fixed delivery pump to operation with variable delivery pump,
proceed as follows:
B
2) Under the screw A place the dowel C EFFER code
8991430, with central hole 0.6.
D
B
46
B8.1
Controlbanks
A hydraulic connection marked L.S. - diameter 1/4 Gas - is also located on the inlet element.
The line to this connection goes to the variable displacement pump. We recommend a diameter of the line of 1/4
GAS-type. The L.S. signal from the controlbank is meant to call from the pump only that portion of oil flow required
by the levers being activated from the operator. The max. oil flow remains of course the max. one available from
the pump. When no of the controlbank is activated, no pressure will be found on this circuit.
LS
V. max. PUMP
47
B8.1
Controlbanks
V. max. (A)
V. max. pump
48
B8.1
Controlbanks
ADDITION OF HYDRAULIC USERS ON A HYDRAULIC CIRCUIT WITH VARIABLE DELIVERY PUMP
The previous chapters explained that the variable delivery pump conveys oil to crane hydraulic control, then to
the various cylinders that handle the crane, only when it receives a signal by the control bank.
Otherwise, the pump conveys only a small oil amount, at a very low pressure value that does not allow the crane
to be handled.
The application of more users on a hydraulic circuit supplied by a variable delivery pump, requires a signal of oil
demand to be sent to the pump whenever you want to operate the added user.
The diagram below shows the application of a user:
In addition to diverter (1) whose task is to divert oil to the added control bank, you must fit a FLIP-FLOP valve (2)
and a flow regulator (3)
The function of the flow regulator is to send to the pump, through the connection carried out on LS hydraulic line
with the application of the flip-flop valve, a signal that determines the pump displacement , that is the maximum
oil delivery that you want the added user to have at its disposal:
the more the flow regulator is closed, the less oil will reach the added user.
The above is true in case the control bank of the added user is not proportional, that is when you do not have the
LS signal at disposal.
In this specific case, during the use of the added user, the variable delivery pump turns into a fixed delivery pump,
losing the advantages of self-adjustment according to the demanded oil amount.
L.S.
Flip-flop valve
Oil diverter tap
added use
49
Controlbanks
50
B8.1
Proportional controlbank
DANFOSS - PVG 32 B8.2
PVG 32
Features:
Maximum working pressure 350 bar, continuous work
Inlet maximum oil flow rate:
Controlbanks SAUER-DANFOSS
52
B8.2
Controlbanks SAUER-DANFOSS
B8.2
Operation
u As soon as the hydraulic pump is operated, the oil conveyed to the control bank enters the first section and,
if no control lever is operated, it goes out of the section and goes back to the oil tank. Therefore the hydraulic oil
does not pass through the control bank.
u When a control bank lever is operated, only the demanded amount of oil (amount which is demanded either
by the project data established by EFFER for that specific function, or by the displacement of the lever set by the
operator) is deviated towards the operated element. The surplus part of oil always goes back to the tank without
passing through the control bank.
u This functionality is ensured by the element compensator and by the inlet compensator. If two or several
control bank levers are operated at the same time, the various compensators of the single elements send their oil
demand to the inlet compensator: the compensator positions itself so as the sum of the demanded oil continues
until the whole pump oil flow rate is ended. In case several levers are operated at the same time, demanding the
inlet compensator for more oil than the pump can supply, the functions requiring less operational pressure will
be operated in priority.
This functionality allows fitting pumps whose displacement is able to convey an oil amount that is higher than
the one recommended by EFFER on the specifications of the various cranes; it also raises the operating speed
considerably and creates an increase of oil temperature that is however irrelevant compared to a traditional system.
(Contact the Technical Service for the data item concerning the maximum oil flow rate that can be conveyed to
the control bank, according to the crane type).
u The most important operating advantage is that, unlike what occurs with a traditional control bank, it is possible to perform several manoeuvres at the same time, also at very reduced speed, but at the maximum pressure
allowed for the single movements.
u Does not require oil drain hoses.
NB: All operations carried out on the control bank must be performed under perfectly clean conditions. Make
sure not to make impurities enter the control bank. In case of deposit of impurities if you only touch the
control bank components with very dirty hands, the control bank correct operation may be jeopardized.
53
B8.2
Controlbanks SAUER-DANFOSS
1
3
4
4
54
4
THE POWER OF PERFORMANCE
B8.2
Controlbanks SAUER-DANFOSS
1- Inlet element
Complete inlet element (EFFER Code 8991453)
The following main components are fitted to the inlet element:
1.1 - Maximum pressure control valve generally referred to as main valve.
1.2 - Inlet compensator
1.3 - Unloading solenoid valve
1.4 - Additional pressure gauge connection
1.5 - L.S. hydraulic connection
1.6 - Pressure reducing valve to supply electro-hydraulic controls
1.1
1.4
1.2
1.6
1.3
1.4
1.5
1.3
1.1
1.6
1.2
1.5
55
Controlbanks SAUER-DANFOSS
B8.2
u If it has to be disassembled for maintenance or to carry out adjustments of the setting value, act on the hexagon. The hexagon is 6 mm in size.
The hydraulic sealing towards the outside is ensured by a 9x2 O-ring type seal. EFFER cod 8991567 Ref. 1.
The adjustment of the maximum pressure value is carried out by acting on the cheese-headed screw Ref. 2.
If the screw is turned clockwise the setting value increases, if it is turned counterclockwise the setting value
decreases.
1 complete turn increases the setting value by 100 bar. Maximum setting allowed by the control bank: 350 bar.
WARNING: The increase of the setting beyond the project values is an operation that may entail serious
hazards for safety.
NB: It is recommended to carry out small movements of the screw while keeping the achieved setting value
constantly monitored.
WARNING: Always clean the components carefully before assembly.
u A filter is fitted inside the element, under the main valve. A 6-mm socket wrench is required to disassemble this
filter. This filter Ref. 3, does not require special maintenance: it is recommended to clean it only in case of serious
troubles such as the truck pump breaking.
1.1
2
1
56
Controlbanks SAUER-DANFOSS
B8.2
It is possible to remove the compensator only after removing the tie rod spacer Ref. 1. Please note that this spacer
has a tapered shape and can be removed towards the control bank side.
Therefore to disassemble the compensator it is necessary to disassemble the head from the control bank.
u Using a M6 screw the bushing complete with the O-ring type seal Ref. 2 can be removed.
Please note that a considerable force must be applied to remove the Ref. 5.
NB: Pressure that the internal spring exerts on compensator causes the compensator to move when loosening the screws. It is therefore recommended to keep the plug in its position this operation can be carried
out with the pressure of a hand - to avoid that the plug is damaged or falls to the ground.
u The compensator has to flow freely inside the seat, and the small oil holes have to be free from impurities.
The compensator perfect operation is achieved when it flows freely inside its seat, and when it is free from significantly deep marks on the surface.
u The dowel Ref. 4 is screwed inside the compensator Ref. 3. This is a special dowel, with a small 1-mm hole in
its center. A 3-mm setscrew wrench is required to disassemble this dowel. It is recommended to disassemble this
dowel if a through cleaning of the compensator is required, because of its malfunction. If the malfunction is caused
by impurities that clog oil passage, this may cause all crane movements to be slowed down until the entire crane
stops.
u The compensator Ref. 3 cannot be supplied as a single spare-part: we recommend replacing the whole inlet
element in case it has deep marks, as its seat will be certainly damaged too.
u The only case when disassembling, cleaning or replacing the compensator can be useful, is to cope with an
emergency that may arise temporarily on the field.
WARNING: Always clean the components carefully before assembly.
1.2
3
4
2
5
57
Controlbanks SAUER-DANFOSS
B8.2
24 Volt = 0.78 A
12 Volt = 1.55 A
Note: when the unloading solenoid valve is not fitted, the hole on the control bank inlet element is closed
with a special plug EFFER code 8865777 Ref. 3.
In old solenoid valves, just press the pusher to carry out the by-pass.
1
1
2
58
1.3
B8.2
Controlbanks SAUER-DANFOSS
1.4
1.5
59
Controlbanks SAUER-DANFOSS
1.6
60
B8.2
B8.2
Controlbanks SAUER-DANFOSS
2.6
2.8
2.2
2.1
2.7
2.6
2.6
2.3
2.4
2.5
THE POWER OF PERFORMANCE
61
B8.2
Controlbanks SAUER-DANFOSS
insert one or several elements in the control bank to operate several hydraulic functions: this type of control bank
can have a maximum of 10 lever elements.
The hydraulic sealing between the various elements is ensured by a series of O-ring type seals:
N. 2
O-RING 5 X 2
N. 4
O-RING 16 X 2.5
N. 1
O-RING 10 X 2.5
N.B: With the Effer Code 8990717 a kit including all seals fitted to the element is supplied.
u In case you need to replace a control bank element we recommend fitting a complete lever element. For this
spare-part, communicate the crane serial number and the function for which the lever element is intended to
EFFER.
Two types of pressure control valves can be fitted to the element body:
a) valve that controls the pressure maximum value sent inside the cylinder - active pressure.
b) valve that controls the pressure maximum value allowed inside a cylinder, due to crane performance increase
carried out with any movement - passive pressure.
In the light of the above, three element types can be supplied:
- element prearranged for two maximum pressure adjusting valves on A and B ports (n. 2 valves a).
- element prearranged for two maximum pressure adjusting valves on A and B ports and two shockproof/anticavitation valves (n. 2 valves b)
- element not prearranged for pressure adjusting valves (n. 2 valves a) + n. 2 valves b)
WARNING Always clean the components carefully before assembly.
62
2.1
A
a
b
THE POWER OF PERFORMANCE
B8.2
Controlbanks SAUER-DANFOSS
2.2
3
4
3
2
5
4
63
B8.2
Controlbanks SAUER-DANFOSS
u There are also different types of spools as to the maximum oil flow rate they have to make pass through port
A and port B.
u In case you need to replace an inner spool, it is necessary to ask EFFER for the exact type of spool fitted.
The type of spool fitted is stamped on the hooking tooth of the spool Ref. 1. Otherwise, it is compulsory to communicate the crane serial number to EFFER and also specify the movement that the specific spool controls.
The spool has to flow freely inside the element body. If there are marks on the spool due to the use of the crane
with impurities in oil, this may hinder the spool free sliding: if this is case, it is necessary to replace it; for replacement we recommend fitting a complete element.
The following parts are fitted to the two ends of the spool: a plug on one side, and a stem return device on the
other.
The drawing shows the mechanical composition of the completely assembled spool.
Ref. 2: Stem return spring.
WARNING: Always clean the components carefully before assembly.
2.3
Z
2
1
64
Controlbanks SAUER-DANFOSS
B8.2
Listed below are the Effer codes of the spools that are mainly fitted to the cranes:
EFFER Code
Code
Description
8991568
157B7002
8991569
157B7021
8991570
157B7022
8991571
157B7024
8991486
157B7135
5-l/min. Spool in open center con pressure control on ports A and B (PC
-> AB)
8991572
157B7062
40-l/min. Spool in closed center with pressure control on port A (PC -> A)
and flow rate control on port B
8991573
157B7072
40-l/min. Spool in closed center with pressure control on port B (PC -> B)
and flow rate control on port A
8990469
157B7121
8990442
157B7122
8990443
157B7123
8991574
157B7172
40-l/min. Spool in open center with pressure control on port B (PC -> B)
and flow rate control on port A
8991575
157B7421
8991576
157B7502
8991577
157B9505
8991578
157B9591
8991579
157B9592
157B9641
8991580
65
B8.2
Controlbanks SAUER-DANFOSS
2.4
2.5
66
B8.2
Controlbanks SAUER-DANFOSS
b
4
67
Controlbanks SAUER-DANFOSS
68
EFFER Codes
Setting
8990151
125
8990152
140
8990329
150
8990330
160
8990150
210
8990328
250
8990149
280
8990147
300
8990148
320
B8.2
Controlbanks SAUER-DANFOSS
B8.2
2.7
69
B8.2
Controlbanks SAUER-DANFOSS
2.8
2
2
Radio control electric
connection
DMU electric
connection
(Black connector)
DMU
70
V bat V bat +
Controlbanks SAUER-DANFOSS
B8.2
Note: When turning off the radiocontrol, if a movement of the control bank lever is noticed (movement
related to the mechanical zero) act on the regulation placed in the coil rear part, using a 2.5-mm setscrew
wrench.
The correct adjustment is obtained when the control bank lever maintains its position if an ON-OFF is executed
on the radiocontrol.
71
Controlbanks SAUER-DANFOSS
B8.2
HPCO SPOOL
fixed delivery pump
HPCO SPOOL
Crane
This control bank element has an inner slider which can have three positions:
1)
It conveys oil to the control bank, to allow crane to be handled
2)
It conveys oil outside, to feed the hydraulic system of the stabilisers
3)
This is a neutral position: the oil is conveyed to drainage, and inhibits any hydraulic handling
During the normal work of the crane, the operation of the slider inside the element is carried out electrically. The
electric module code 8991920 has two electrical coils inside. When these coils are electrically energized, they move
the slider to one direction or to another.
72
Controlbanks SAUER-DANFOSS
B8.2
Note 1:
If the crane, where the HPCO function is provided, is also equipped with the DMU3000, it is not equipped with the unloading solenoid valve (NEM) connected to the operating stops imposed by DMU
Note2:
If the crane, where the HPCO function is provided, is also equipped with a radio control, it is not provided with the unloading solenoid valve connected to radio control operation.
Nota3:
If you want to fit a variable delivery pump to the crane where the HPCO function is provided, a spool
must be placed inside the element (code 8991934 ) along with a single pipe between control bank connection LS and the hydraulic pump connection LS.
In addition to what mentioned above, it is necessary to carrry out the operation of 5.
73
Controlbanks SAUER-DANFOSS
B8.2
to insert one or several elements in the control bank to operate several hydraulic functions: this type of control
bank can have a maximum of 10 lever elements.
In case of changes, we do not recommend fitting non original tie rods: the use of tie rods built with unsuitable
material can cause oil leaks or their breaking. Listed below are the tie rod codes according to different diameter
and the number of element bodies the control bank is equipped with:
N. of elements
Tie rod Code Kit
8991561
8990439
8990440
8990441
8990492
8991562
10
8991563
Torque wrench setting necessary for the control bank correct operation: 22Nm
N.B.: A tie rod kit includes the supply of:
3 tie rods
6 nuts
6 washers
74
B8.2
Controlbanks SAUER-DANFOSS
LS
0,8 1 mm
Note:
In case of use of a variable displacement pump, a
non constant movement of the cylinders operating
the crane booms, called pendulum effect, may occur;
please note that this can result from the instability of
the tilted pump plate.
In case of troubles as described above, a pipe fitting
has to be connected to the end of the hose connected
to the control bank LS connection, on the connection
side with the hydraulic pump; the pipe fitting oil
passage must be 0.8 1 mm.
75
Controlbanks SAUER-DANFOSS
B8.2
1
Variable displacement pump
76
B8.2
Controlbanks SAUER-DANFOSS
VARIABLE DISPLACEMENT
pump version
In case in addition to the crane control bank, another
control bank has to be supplied by the variable displacement pump, (i.e.: for crane stabilizers) also the
valve Ref. A and Ref. B has to be installed as shown
in the diagram of the following page.
LS
Flow regulator
EFFER Code 8853750
are
77
Controlbanks SAUER-DANFOSS
B8.2
When you fit a variable delivery pump to a crane, the maximum operating pressure value of the crane is
adjusted by the maximum pressure valve fitted to the pump.
The variable delivery pump has two adjusting points:
1)
STAND-BY pressure
2)
MAXIMUM WORKING pressure
1) STAND-BY pressure
Even when no crane control lever is operated, the variable delivery pump, conveys a little oil amount to the crane
hydraulic circuit. When one control bank lever is operated, this oil amount is conveyed by the control bank to the
pump to move the inner plate so that there is the required oil amount in the crane hydraulic circuit to handle the
crane.
If the pressure gauge is fitted to the LS hydraulic line (joining the LS connection to the control bank with the LS
junction on the pump) a setting value relating to the pressure inside this pipe is detected.
By way of example, manufacturers of variable delivery pumps recommend setting the pressure at a value of 30-35
bar. Please note that this pressure value, although very low, creates an increase in hydraulic oil temperature when
no control bank lever is operated.
Having said that, the proper setting value is the minimum value at which the crane movements respond quickly
to the displacement of the control bank lever.
2) MAXIMUM WORKING pressure
a variable delivery pump feature is that it automatically does not convey oil anymore to the crane circuit when the
provided maximum pressure value is reached thus preventing oil from overheating.
From this you may understand that the setting of the crane maximum working pressure is assigned to the main
overpressure valve fitted to the pump.
If a pressure gauge is fitted to control bank connection P, the maximum overpressure valve setting value is detected.
NOT KNOWING if this value is limited by the control bank valve operation, or by the valve fitted to the pump, the
first step is, when the truck engine is not started yet, to increase the main valve setting by around 35-40 bar: you
can have this increase by screwing up the adjuster by a half turn.
In this way the valve fitted to the control bank is used only as a further safety, and you must set the overpressure
valve fitted to the pump at the value indicated on the specific crane hydraulic diagrams.
LS
78
B8.2
Controlbanks SAUER-DANFOSS
u a) Automatic system
You need to buy a special fitting EFFER code 8991498, Ref. 1 and insert it into the M hole located on the control
bank inlet element.
A hose recommended gas diameter Ref. 2-, has to be applied to this fitting. On oil delivery coming from
truck pump and from the emergency hand pump, there must be some check valves Ref. 3 and to the oil deliveries
of the truck pump Ref. 4 and of the emergency hand pump Ref. 5 .
N.B. The flip-flop valve, fitted to the hydraulic branch that connects the truck pump to the control bank,
must have a size to ensure that the whole oil capacity is conveyed by the truck pump.
2
3
3
4
79
B8.2
Controlbanks SAUER-DANFOSS
u b) Manual system
You need to buy a special tap EFFER code 8991541, Ref. 6 and insert it into the control bank connection M.
Check valves Ref. 7 have to be located on the oil delivery coming from the truck pump and on the delivery
coming from the emergency hand pump.
- To operate the crane using the hand pump the tap must be closed.
- To operate the crane using the truck pump the tap must be open.
N.B. The flip-flop valve, fitted to the hydraulic branch that connects the truck pump to the control bank,
must have a size to ensure that the whole oil capacity is conveyed by the truck pump.
6
6
LS
80
Controlbanks SAUER-DANFOSS
B8.2
7 - Troubleshooting
1 / Problems
2 / Causes
3 / Solutions
1A. The crane does not 2.1 Main valve locked by impurities. 3.1 See paragraph 1.1 for main valve disasexecute any movement
sembly and reset.
although it is certain that
the hydraulic pump is per2.2 Inlet compensator locked in its 3.2 See paragraph 1.2 for its disassembly
fectly working.
closed position by impurities.
and operation. Moreover check that the
special dowel is free from impurities.
2.3 Unloading solenoid valve not 3.3 To check the solenoid valve operation,
powered or burnt.
it can be powered using a cable connected to the batteries. In this way, you
will see if the problem is in the crane
connection or in the coil. To be able to
refold the crane, operate the mechanical emergency applied on the coils as
described in paragraph 1.3.
1B. The crane does not ex- 2.4 If fitted, special pressure adjusting 3.4 See paragraph 2.4 for its disassembly
ecute a specific movement
valve clogged by impurities.
and operation.
although it is certain that
the control bank levers
and inner spool are not
2.5 The flip-flop valve does not pres- 3.5 To clean the flip-flop valve refer to chaplocked mechanically.
surise the signals because of the
ter 2.4, concerning disassembly..
presence of impurities.
1C. It is no longer possible 2.6 Electrical problem in the module 3.6 Module replacement. For replacement
to operate a movement
relative to a movement.
refer to chapter 2.8.
using the radiocontrol.
1D. It is no longer possible to 2.7 Pressure reducing valve clogged 3.7 Clean the pressure reducing valve
operate movements using
by impurities.
and replace. For disassembly refer to
the radiocontrol but it is
chapter 1.5.
working manually.
81
Controlbanks SAUER-DANFOSS
82
B8.2
RS 210
Controlbanks Nordhydraulic
84
B8.3
B8.3
Controlbanks Nordhydraulic
1 - Introduction
u Even if this hydraulic valve block is not a compensated proportional valve block, it is particularly appreciated
for its motion sensitivity.
Specifications:
it is a modular valve block, max. 10 elements, suitable for hydraulic oil operation with temperatures from -15 C
to +80 C.
94
37
A
G 1/2
A
G 1/2
T2
G 1/2
113
56,5
90
9(4X)
37
25
50
42
70
35
45
T1
G 1/2
27
B
G 1/2
B
G 1/2
22
39,5
43
43
43
43
36,5
Specifications:
85
B8.3
Controlbanks Nordhydraulic
When the truck is operating and once the hydraulic pump has been operated, only a 25 l/ oil delivery circulates
inside the valve block elements.
The oil in excess with respect to this value returns to the oil tank.
As a consequence, during small movements of the crane booms, the element spool shall paralyse only a small
quantity of oil, thus obtaining optimum operating sensitivity.
In case the lever shifting or different simultaneous movements require an oil delivery higher than 25 l, the compensator sends the required oil delivery up to the maximum level sent by the pump.
All element spools have a pre-set maximum delivery: this value is pre-set by Effer during design.
A
A
B
86
Controlbanks Nordhydraulic
B8.3
2 - Main head
u The type of main head used by Effer requires the coupling for the oil sent by
the pump (P1 = GAS) and the coupling for the connection to the oil tank (T4
= GAS).
On this type of head it is not possible to carry out a carry-over connection in order
to feed another valve block.
The main head is provided with the following components:
2.1 master valve
2.2 compensator
2.3 unloading solenoid valve
2.3
2.1
2.2
The main head is provided with the pressure gauge coupling, in the position shown by the arrow.
87
Controlbanks Nordhydraulic
B8.3
88
2.1
Controlbanks Nordhydraulic
B8.3
2.2 Compensator
u The compensator does not need any adjustment. It can
be easily removed in order to carry out inside cleaning
operations that are necessary, in case the crane does not
move at maximum speed.
2.2
89
Controlbanks Nordhydraulic
B8.3
90
2.3
B8.3
Controlbanks Nordhydraulic
3 - Lever element
The Effer cranes are provided with the lever elements shown below, i.e. with both closed and opened centre.
The single spools positioned inside the different elements are custom-made for the specific functions. The elements can be provided with one or two pressure reducing valves (also called anti-shock or special valves).
3
Consequently, each lever element has a specific order Effer code: this code corresponds to the basic supply, without
the microswitch that activates the DMU 2000 load control device.
91
B8.3
Controlbanks Nordhydraulic
Element
Cod. Effer
3.1
92
Controlbanks Nordhydraulic
B8.3
u In case you want to disassemble the inside components of the pressure reducing valve, loosen the adjusting device completely, extract it by means of long
nose pliers.
93
B8.3
Controlbanks Nordhydraulic
3.2
94
B8.3
Controlbanks Nordhydraulic
The above valves can be disassembled only after removing the valve block element and after removing the
lever support and the stem return device.
To remove the non return valve use a M5 screw to be
used as an extractor.
3.4
3.4
4 - Closing element
The closing element, complete with gaskets, has Effer code 8991507.
4
THE POWER OF PERFORMANCE
95
Controlbanks Nordhydraulic
B8.3
Cod. Effer
8991500
8991501
8991502
8991503
8991504
6
u The sensor applied to the element cursor is provided
96
Controlbanks Nordhydraulic
B8.3
97
B8.3
Controlbanks Nordhydraulic
load limiting device is fitted, signal the positioning of the inner slider
to the DMU.
- electronic microswitch: Effer code 8991508 (refer to paragraph 6).
- mechanic microswitch: Effer code 9395656KN.
a
b
98
B8.3
Controlbanks Nordhydraulic
3)
Grease the two O-rings located on the bushing (c) and
insert it in the slider and in the special housing on the rod return
device cap.
c
4)
Introduce the cam (b) in the microswitch support (a),
ensuring the proper position (the grooved side facing up and the
slider housing hole on the insertion side). Now push the cam until
it is against the support edge.
5)
Put a drop of Loctite 222 on the two M6x6 dowels and
on the M5X10 dowel and insert them in the appropriate housings
located on the cam. Slightly screw the dowels, making sure they
do not obstruct the slider housing hole.
6)
Fix microswitch support (a) to the control bank with suitable washers and socket head screws using a 5-mm Allen wrench
and extension to provide a higher torque wrench setting. The use
of washers is advisable but not biding. After the mechanic microswitch is secured to the block it will have an angulated position
of approximately 30 on the left side with respect to the vertical
axis
b
a
M6
M5
2) First, position the cam (b) in the central area with respect to
the two microswitches: neutral point. With the cam correctly positioned in the neutral point, the two pilot lights are turned on.
To adjust the cam position better with respect to the two microswitches, you can use the dowel fitted to the cam rear end. Obviously, when adjusting, always apply a slight pressure on the cam
in the direction of the control bank to avoid any contact between
the adjusting dowel and the cam support shaft. After having carried out this first centring, slightly tighten the two dowels which
lock the cam to the centring pin.
THE POWER OF PERFORMANCE
99
B8.3
Controlbanks Nordhydraulic
3) Do small movements with the control lever in the two directions: the
two pilot lights are turned off when the relative microswitch is operated
by the cam. If the two pilot lights do not turn off symmetrically with
respect to the central position of the cam, change the position of the
cam with respect to the microswitches by acting on the rear dowel (by
screwing or unscrewing it).
4) When the symmetry of the cam with respect to the two microswitches
is achieved, check the stroke, the control bank slider the and the cam
do before the two pilot lights are turned off . If they turn off too early a
signal may be conveyed to the DMU that a lever of the control bank is not
positioned in the central area. Therefore a faulty state occurs. If they turn off
too late a flow of oil occurs inside the hydraulic cylinders without the proper
initial proportionality, and therefore the movement will start abruptly
To ease the work of the control bank inner springs, check that nothing can prevent double control rods from sliding, and lubricate the control lever connecting pins on both the control bank side and the double control side.
100
F.P.I. DEVICE
B9
Service Manual
Rev.
07-2008
GB
F.P.I. Device
B9
F.P.I. Device
B9
1 - Description
The F.P.I device referred to is fitted only to certain crane models and has an electro-hydraulic operation.
The operation of this device is intentional, that is it is the worker who decides when using it. The operation may
take place either by operating the key switch, placed near the manual control station or through a switch on the
button panel of the radio control. In both cases the operation of the device is accompanied by lighting of a warning light, placed next to the two switches described above.
The use of F. P. I. device involves:
a reduced crane boom handling speed, (first boom, second boom and jib if fitted)
Crane performance features that are consistent with the reported data in load diagrams .
This type of device is present only in combination with HAWE-type proportional control banks.
F.P.I. Device
B9
2 - Functioning principle
u
The F.P.I. device works by reducing the dynamic effects on crane structure due to load movements. The
valve Ref. 1 deducts a portion of the oil sent to the compensators of each controlbank element (for those elements
controlling the crane booms), thus reducing the internal stroke of the spool inside the element, which results in
the end in a limited operating speed of the crane. The solenoid valve applied on the unit is electrically powered
when the F.P.I. device turns ON.
Ref. 1
F.P.I. Device
B9
B9
F.P.I. Device
3- Valves
3.1 F.P.I. valve
SPEED
ADJUSTING
SCREW
PRESSURE
ADJUSTING
SCREW
SPEED
ADJUSTING
SCREW
SPEED ADJUSTING
SCREW
B9
F.P.I. Device
PRESSURE ADJUSTING
SCREW
4 - Settings
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The holding valves on booms cylinders of F.P.I. cranes have a specific setting, obviously higher than
the one designed for the same crane model without F.P.I., since they must keep the oil inside the barrel with
a higher load (i.e.: pressure) applied to the crane..
u
As explained above, when the F.P.I. is switched on, a higher pressure is available in the crane circuit. The
working pressure is controlled: by the F.P.I. valve (when the F.P.I. is off ), while the (higher) pressure value is controlled
by the main relief valve of the controlbank when the F.P.I. is on.
Setting points
F.P.I. Device
B9
5 - Tunings
5.1 F.P.I. valve tunings
u
Any fine tuning of the crane circuit shall always be carried out with the F.P.I. switched on and with an oil
temperature of at least 25 C (by lower temperatures, the booms speed might be much slower).
Crane operational speeds, with the F.P.I. switched on, shall correspond to the values listed in the hydraulic diagrams
of the corresponding crane model.
Note: when willing to increase the cylinder outlet speed, unfasten the register screw on the F.P.I. valve
while to decrease the speed fasten the same.
We recommend to fasten the registers screws by fine tunings since even a small portion of revolution generates
big speed changes.
ELECTRIC CONNECTOR
ADJUSTING SCREW
STANDARD CRANE
GENERAL PRESSURE
E50
ADJUSTING SCREW
OUTER BOOM SPEED
ADJUSTING SCREW
MAIN BOOM SPEED
ADJUSTING SCREW
FLY-JIB SPEED
u
After having verified the stroke times of the booms cylinders, we recommend to carry out a complete
movement until the cylinder end-stroke for each of the set cylinders so as to verify that the check-relief valves are
set according to the tables.
F.P.I. Device
B9
ELECTRIC CONNECTOR
E51
u
Turn the screw clockwise to increase pressure and crane operating range. Otherwise, turn the screw counterclockwise to decrease pressure and to reduce crane operating range.
In order to change the load limiting device operation point, we recommend you to read chapter 4 for the correct
operating sequence.
F.P.I. Device
B9
6 - Operating instructions
As already explained, the F.P.I. device can be activated by turning the key switch near the manual control table
or through the radio remote control board. On both cases, when activated, the yellow lamp on the main electric
board lights up.
Important
The device can be switched OFF only by the same unit of activation. So, if you switch it on from the radiocontroller, you may switch it off only from the radio-controller again.
u
The F.P.I. device can be activated only if the crane boom operates within the 180 max. stability area (rear
side of truck cab). The device can not be activated when the crane operates in the 180 truck front area.
u The F.P.I. device will cut out automatically if the crane slewing reaches the front work area, and will cut in
automatically
when the crane slewing to operate again in the rear work area.
u The F.P.I. device switched on through the radio remote control, will cut out automatically if the crane electric
system is turned OFF.
u
The F.P.I. device can be switched ON/OFF even during crane operation, with or without load applied.
u
The lifting capacity of the crane with the F.P.I. device OFF cuts by 10% restect to the load diagram. It means
that, with the same load applied, the crane outreach at the moment of the Overload Safety Device operation will
be less than the value reported on the crane load diagram.
u
If the Overload Safety Device operates with the F.P.I .device ON, crane movements controlled by the Overload Safety Device will stop. In order to perform any manoeuvre, it is necessary:
b - to start a manoeuvre of extension retraction until the Overload Safety Device alarm stops sounding.
c -At this step, the crane lifting capacity has increased and you may keep on manoeuvring, with more
lifting capacity available.
u
When activating the function SNAIL with the F.P.I. device switched ON, crane boom movements slow
down further. If the SNAIL speed has been set very slow this could actually make the whole crane not move at
anymore. We reccommend you do not use this function with the F.P.I. device switched ON.
u
The F.P.I. device can control the decrease of the boom working speed correctly only when oil temperature
in the hydraulic circuit reaches at least 25 C. By lower temperatures, the booms speed might be a bit faster.
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B9
F.P.I. Device
7 - Electric connections
The following instructions refer to some relevant electric connections.
ply).
Relay for the activation of the F.P.I. device energized by the radio
signal. The relay is electrically energized by the wire connected
to clamp 38.
K 50
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Clamp 38: the electric wire connecting the radio control
receiver is attached to one side of the clamp 38.
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Clamp 50: two electric wires activating the two F.P.I. device
solenoid valves are attached to one side of this clamp..
The electric connectors of the two solenoid valves are marked with
the numbers of the following parts:
E51: solenoid valve for Overload Safety Device pressure
increase.
E 50
E 51
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F.P.I. Device
B9
8 - Maintenance
The F.P.I. valve doesnt need any specific maintenance: the filters on the inlet of the specific controlbank elements
are designed for 100 microns and therefore should never be obstructed considering that the crane circuit has a
25 microns high-pressure filter.
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