h.o.03.e - hydraulic setting procedures...

2012

H.O.03.E - HYDRAULIC SETTING PROCEDURES

Rev.01

WORKSHOP TOOLS

1. INTRODUCTION............................................................................................................................3

2. CONTROL VALVE SETTING ........................................................................................................4

3. SLEWING SPEED SETTING.......................................................................................................13

4. ARTICULATION CYLINDER OVERCENTER VALVE SETTING................................................16

5. LIFTING CYLINDER OVERCENTER VALVE SETTING.............................................................21

6. SEALING CHECK OF OVERCENTER VALVE ON CYLINDERS...............................................26

7. NON-CE CRANE WITH HYDRAULIC MOMENT LIMITER (LI – LIG – FHOS500) ....................28

8. CE CRANE WITH HYDRAULIC MOMENT LIMITER ( LMEQ ) .................................................30

9. CE CRANE WITH HYDRAULIC MOMENT LIMITER ( LM ) ......................................................33

10. CRANE WITH AVPS VALVE - AVPS VALVE SETTING ............................................................35

11. VERIFICATION OF CORRECT SETTINGS ................................................................................39

2

HYDRAULIC SETTING PROCEDURES

1. INTRODUCTION

This manual is intended for professionals with appropriate practical and technical skills.

The manufacturer will not be held responsible for problems, damage, or accidents resulting from failing to respect or carry out the instructions in this manual.

On the following pages we detail the procedures for complete hydraulic calibration of the crane.

3

WORKSHOP TOOLS

2. CONTROL VALVE SETTING

2.1 Install a flow meter between the pump and the crane control valve.

2.2 Turn on the truck engine and engage oil supply to the crane.

2.3 Verify that oil flow to the crane is equal to the oil flow requested on the setting table, column “portata olio max”.

An alternative to using a flow meter is to measure the time required for complete extension of the articulation cylinder, and then comparing it to the time in the setting table, column “Articol. U.”

IMPORTANT: For cranes equipped with variable displacement pumps or pressure compensated control valves (Hawe, Danfoss, Bosch LC); a flow meter MUST be used to measure the flow.

4


2.4 Connect a pressure gauge on the control valve special fitting;

Hydrocontrol Valve Shown (all other control valves use the same adapter)

2.5 Read the pressure on the pressure gauge with the oil flow to the crane but without moving

any levers. The value you read is the “back pressure”. Take note of this value, which will be needed for the next step.

2.6 Find the maximum pressure valve on the control valve according to the value indicated on

the setting table, column “valvola max generale”.

IMPORTANT: If the crane is equipped with extra functions, the maximum relief valve must be set to the value in parentheses instead (as in the example above, 275 bar instead of 325 bar).

2.7 Add the measured backpressure to the value from the table: If the back pressure measured in step 4 is bigger than 0 bar and smaller than 5 bar you must

add this value to the value given by the setting table. If the back pressure measured in step 4 is bigger than 5 bar you must add 5 bar to the value

given by the setting table. To set the valve you must move a crane movement without port relief valves up to the end of

the stroke. Once the cylinder is at the end of the stroke, press the lever of the control valve and set the maximum relief valve (screw CW to increase the pressure setting, screw CCW to decrease the pressure setting).

5

WORKSHOP TOOLS

2.8 If necessary, open the crane from the transport position. 2.9 Extend the articulation cylinder to full extension , and continue to hold the lever pressed. 2.10 With the lever fully pressed, adjust the maximum relief valve to the pressure measured

previously. 2.11 If the crane is equipped with AVPS or PB or LCS, perform the AVPS Valve Setting.

This table describes the method for adjusting each type of maximum relief valve which may be present on the crane:

Valve Type Diagram Notes

Walvoil SDM080

Loosen the lock nut with wrench 19 mm. Adjust the setting screw with allen wrench 5 mm. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting.

Walvoil SDM110


Walvoil SD5


6



Walvoil SD6


Hydrocontrol HC-D3M

Loosen the lock nut with wrench 17 mm. Adjust the setting screw with a slotted screwdriver. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting.

Hydrocontrol HC-D4


Bosch (LC)


7

WORKSHOP TOOLS


Hawe PSL2


Sauer-Danfoss PVG32

Remove the rubber cap to reveal the adjustment screw. There is no lock nut or seal Adjust the setting screw with allen wrench 4 mm. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting.

8


2.12 Set the port relief valve pressure of each movement on the control valve according to the

values indicated on the setting table, columns under “taratura distributore”:

Italian English

Stabilizzatori Stabilizers

Rotazione 2 o 3 motori Rotation 2 or 3 motors

Sollevamento rientro Main boom retract

Articolazione rientro Articulation retract

Sfilo gru uscita Crane extensions extend

Sfilo gru rientro Crane extensions retract

I^ - II^ Attivazione 1st and 2nd activations

Artic.ne JIB Uscita JIB articulation extend

Artic.ne JIB Rientro JIB articulation retract

Sfilo JIB uscita JIB extensions extend

Sfilo JIB rientro JIB extensions retract

For each value from the table, add the backpressure value as when setting the maximum relief valve.

To set the port relief valve, you must move the specific movement you have to set to the end of its stroke. Once the cylinder is at the end of the stroke, continue holding the lever pressed and set the port relief valve (screw CW to increase the pressure setting, screw CCW to decrease the pressure setting).

If the crane has a fixed base, use the slewing pressure from the column “Rotazione F/M” in the setting data table. (see table above)

The setting pressure of any extra function depends on the connected accessory. Set the valve in accordance with the requirements of the accessory.

Winch setting pressure is found in the setting data table, in the tab marked “ARGANI”.

9

WORKSHOP TOOLS

This table describes the method for adjusting each type of port relief valve which may be present on the crane:


Walvoil SDM080

This model of control valve does not have port relief valves.

Walvoil SDM110

Port relief valves are not adjustable. They may only be tested, and replaced if not within specification. Use a 6mm allen wrench to dismount the valve.

Walvoil SD5

Remove the cap/lock with wrench 21 mm. Adjust the setting screw with allen wrench 5 mm. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting.

Walvoil SD6


10



Hydrocontrol HC-D3M


Hydrocontrol HC-D4


Bosch (LC)

Port relief adjustments are hidden by a plate which also covers the wiring. Loosen the lock nut with wrench 10 mm. Adjust the setting screw with allen wrench 3 mm. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting. The port relief valve may be removed with a 17 mm wrench.

Hawe PSL2

Use a 12 mm wrench to remove the cap and access the adjustment screw. Adjust the setting screw with allen wrench 3 mm. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting.

11

WORKSHOP TOOLS


Sauer-Danfoss PVG32

Remove the rubber cap to reveal the adjustment screw. There is no lock nut or seal Adjust the setting screw with allen wrench 4 mm. Turn the setting screw clockwise to increase its setting. Turn the setting screw counter-clockwise to decrease its setting.

12


3. SLEWING SPEED SETTING

Set the slewing speed in order to get the operating time for 180° rotation, as indicated in the setting table, column “Velocità Rotazione” .

In the example above, slewing the crane through 180 degrees must require 22 seconds. Set the slewing speed for the CW direction and the CCW direction; each direction has its own

speed adjustment; On models with slewing bearing, the speed should be adjusted only by changing the slewing

lever stroke on the control valve.

This table defines the various types of rotation speed controls that may be present on the crane:


Inline restrictors with check valve

Each valve controls the speed in one direction of rotation. Remove the wire seal and plastic cap to reveal the adjustment screw. Adjust the setting screw with allen wrench 3 mm. Turn the setting screw clockwise to reduce slewing speed. Turn the setting screw counter-clockwise to increase slewing speed.

13

WORKSHOP TOOLS


Set screw centre-drilled with calibrated hole.

No adjustment possible. If speed is too slow, inspect for debris. If speed is too fast, ensure that the set screws are not absent.

Double overcenter valve with speed adjustment.

Each valve controls the speed in one direction of rotation. Loosen the lock nut with a wrench 13 mm. Adjust the setting screw with allen wrench 4 mm. Turn the setting screw clockwise to reduce slewing speed. Turn the setting screw counter-clockwise to increase slewing speed.


Each valve controls the speed in one direction of rotation. Loosen the lock nut with a wrench 10 mm. Adjust the setting screw with allen wrench 3 mm. Turn the setting screw clockwise to reduce slewing speed. Turn the setting screw counter-clockwise to increase slewing speed. Do not change any other adjustment screws on the valve.

14







Slewing bearing cranes with planetary motors

Each screw controls the speed in one direction of rotation. Loosen the lock nut with a wrench 10 mm. Adjust the setting screw with allen wrench 3 mm. Turn the setting screw clockwise to reduce slewing speed. Turn the setting screw counter-clockwise to increase slewing speed.

15

WORKSHOP TOOLS

4. ARTICULATION CYLINDER OVERCENTER VALVE SETTING 4.1 Connect the pressure gauge on the special fitting on the overcenter valve on articulation

cylinder in order to read the pressure inside the articulation cylinder;

4.2 Close the hydraulic extensions of the crane; 4.3 Open completely the articulation cylinder;

4.4 Close the articulation very slightly (a few millimeters is enough) in order to reduce the

pressure accumulated inside the cylinder; 4.5 Connect a test load to the crane, equal to the value from the setting data table, column

“carico di prova”.

16


4.6 Lift the load using the main boom of the crane until the 2nd boom is near horizontal;

4.7 Slowly extend the 2nd boom of the crane until the pressure inside the articulation cylinder is

equal to the pressure indicated in the setting table, column “valvola articolazione”;

*IMPORTANT* If the value appears between asterisks (**), this indicates that the valve is preset

by its manufacturer.

17

WORKSHOP TOOLS

4.8 Unscrew the overcenter valve on the articulation cylinder until the 2nd boom begins to move

down slowly.

This table defines the technique of adjusting the various types of valve that may be present on the articulation:

Valve Type Notes

Adjustment is fixed. It is only possible to check for normal operation.

Adjustment of the maximum pressure in the piston end of cylinder. Loosen the locknut with a 13mm wrench, and use a 4mm allen wrench to make the adjustment. Turn the setting screw clockwise to increase the valve pressure setting. Turn the setting screw counter-clockwise to decrease the valve pressure setting.

Adjustment of the overcenter setting in rod end of cylinder. Not used in this procedure.

18


Valve Type Notes


Adjustment of the overcenter valve setting in the rodi end of the cylinder. Not used in this procedure.

Adjustment of the overcenter valve setting in the piston end of the cylinder. Not used in this procedure.


Adjustment of the overcenter valve setting in the rod end of the cylinder. Not used in this procedure.

Adjustment of the maximum pressure in the piston end of cylinder. Loosen the locknut with a XXmm wrench, and use a XXmm allen wrench to make the adjustment. Turn the setting screw clockwise to increase the valve pressure setting. Turn the setting screw counter-clockwise to decrease the valve pressure setting.

Adjustment of the overcenter valve setting in the rod end of the cylinder. Not used in this procedure.

19

WORKSHOP TOOLS

Valve Type Notes


4.9 Retract the extensions of the crane completely, open the articulation cylinder, and extend

the crane again in order to check that the cylinder begins to close at the correct setting pressure;

20


5. LIFTING CYLINDER OVERCENTER VALVE SETTING 5.1 Connect a pressure gauge to the gauge port at the piston end of the cylinder. If the quick

connector is not attached directly to the overcenter vave, then it will be connected to the sensing line, on or close to the load limiting device (see examples below):

5.2 With all extensions closed, attach a test weight to the hook that is equivalent to the test load

indicated in the setting data table in column ”carico di prova”.

21

WORKSHOP TOOLS

5.3 Open the lifting cylinder until the main boom reaches an angle near 45°. 5.4 Move the articulation (second boom) into a horizontal position.

5.5 Extend the extensions slowly until the pressure indicated on the gauge is equal to the

pressure setting indicated in the setting data table, in column “valvola sollevamento”.

*IMPORTANT* If the value appears between asterisks **, this indicates that the valve is preset by its manufacturer and must not be adjusted. If the crane has extra activations, the value

appearing between parentheses () must be used instead.

22


5.6 Reduce the setting of the overcenter valve until the main boom slightly begins to lower.

*CAUTION* In cases where the overcenter valve is preset, then no adjustment can be made, or

in some cases a special procedure must be followed. Refer to the table below for more information.

This table defines the various types of valve that may be present on the crane:

Valve Type Notes

Adjustment for pressure in piston end of cylinder. Loosen the locknut with a 13mm wrench, and use a 4mm allen wrench to make the adjustment. Turn the setting screw clockwise to increase the valve pressure setting. Turn the setting screw counter-clockwise to decrease the valve pressure setting.


23

WORKSHOP TOOLS

*IMPORTANT* This valve is preset by its manufacturer. Do not adjust it unless directed to do so by the crane’s manufacturer.

Adjustment of the overcenter valve. It is preset at factory. Loosen the locknut with a 13mm wrench, and use a 4mm allen wrench to make the adjustment. Turn the setting screw clockwise to increase the response time of the piloting. Turn the setting screw counter-clockwise to decrease the response time of the piloting.


*IMPORTANT* This valve is preset by Hawe. Do not adjust it unless directed to do so by the crane’s manufacturer.

If adjustments are necessary, please refer to procedure: “H.O.01.E-CALIBRATION OF OVERCENTER VALVE HAWE LHDV

24


*IMPORTANT* Do not adjust this valve unless directed to do so by the crane’s manufacturer.


Adjustment for overcenter valve, preset at factory. Loosen the locknut with a 27mm wrench, and use a 6mm allen wrench to make the adjustment.

Adjustment for pressure in piston end of cylinder. Loosen the locknut with a 13mm wrench, and use a 4mm allen wrench to make the adjustment. Turn the setting screw clockwise to increase the valve pressure setting. Turn the setting screw counter-clockwise to decrease the valve pressure setting

5.7 Repeat the retract/extend operation to verify correct setting of the valve. 5.8 Lock the setting of the overcenter valve.

25

WORKSHOP TOOLS

6. SEALING CHECK OF OVERCENTER VALVE ON CYLINDERS 6.1 With extensions closed, attach a test weight to the hook that is equivalent to the test load

indicated in the setting data table, in column “Carico di PROVA”.

6.2 Extend the lifting cylinder until the main boom reaches an angle near 45° above horizontal. 6.3 Move the second boom to a position near horizontal.

6.4 Turn off the hydraulic supply or press the emergency stop button. 6.5 Activate each lever of the control valve in both directions, and confirm that no crane

movement takes place. 6.6 Re-engage the hydraulic supply or release the emergency stop button.

26


6.7 Lower the second boom to a 45° angle below horizontal.


movement takes place. 6.10 Re-engage the hydraulic supply or release the emergency stop button. 6.11 Close the crane into a position approximately like the diagram below:


movement happens.

27

WORKSHOP TOOLS

7. NON-CE CRANE WITH HYDRAULIC MOMENT LIMITER (LI – LIG – FHOS500) 7.1 Connect a pressure gauge to the gauge port at the piston end of the cylinder. 7.2 With extensions closed, attach a test weight to the hook of the weight indicated in the

setting data table, in column “Carico di PROVA”.



pressure setting indicated in the setting data table from the column “Press.LM GRU”.

28


*IMPORTANT* If the crane has extra activations, the value appearing between parentheses () must be used instead.

7.6 Unscrew the setting on the moment limiter until, in pressing the lever to extend the

extensions, you hear the limiter engage (oil returns to tank and all functions are blocked, except for retraction of extensions). Loosen the locknut with a 19mm wrench, and perform the adjustment with a 17mm wrench.

7.7 Perform a retraction/extension of the extensions to confirm that the setting pressure of the

limiter is reached simultaneously with limiter engagement and a stoppage of movement. Readjust if necessary.

7.8 Verify the repeatability of the limiter intervention, and verify that the correct functions are blocked:

Rotation: both directions blocked Lifting: blocked Articulation: blocked Jib Articulation: blocked Extensions crane/jib: extend blocked, retract allowed Winch: blocked

29

WORKSHOP TOOLS

8. CE CRANE WITH HYDRAULIC MOMENT LIMITER ( LMEQ ) 8.1 Connect a pressure gauge to the gauge port at the piston end of the cylinder. 8.2 With extensions closed, attach a test weight to the hook that is equivalent to the test load in

the setting data table, in column “Carico di PROVA”.


8.5 Unscrew the restrictor on the signal line to the moment limiter, which will cause the limiter to

have an immediate response time.



30


8.7 Unscrew the setting screw on the moment limiter until a blocking of the levers is triggered.

Loosen the locknut with a 19mm wrench, and perform the adjustment ( ) with a 17mm wrench.

8.8 Screw the signal line restrictor ( ) to a more closed setting so that the limiter

engagement is not very sudden. Ensure that it still responds in a reasonably short time. If this screw is too tight, it will exclude the load limiting device.

8.9 Perform reentry and exit of extensions to verify that setting pressure of the limiter is reached simultaneously with limiter engagement and a stoppage of movement. Readjust if necessary.

31

WORKSHOP TOOLS

8.10 Verify the repeatability of the limiter intervention, and verify that the correct functions are

blocked: Rotation: both directions allowed Lifting: lowering blocked, unable to raise boom, but not blocked. Articulation: blocked Jib Articulation: blocked Extensions crane/jib: extend blocked, retract allowed Winch: raising blocked 8.11 Test the reset function of the limiter; with the crane unloaded, raise the main boom

completely until it causes the lmeq to engage. Confirm that holding the main boom lever in the lowering position and making several quick presses on the reset button will cause the limiter to disengage.

32


9. CE CRANE WITH HYDRAULIC MOMENT LIMITER ( LM ) 9.1 Connect a pressure gauge to the gauge port at the piston end of the cylinder. 9.2 With extensions closed, attach a test weight to the hook that is equivalent to the test load in

the setting data table, in column “Carico di PROVA”.

9.3 Open the lifting cylinder until the main boom reaches an angle near 45°. 9.4 Move the articulation (second boom) into a horizontal position. 9.5 Extend the extensions slowly until the pressure indicated on the gauge is equal to the


33

WORKSHOP TOOLS

9.6 Uncrew the locknut to release the setting screw, then unscrew the setting screw ( ) on

the moment limiter until a blocking of the levers is triggered. Tighten the locknut again to hold the setting.

9.7 Perform reentry and exit of extensions to verify that setting pressure of the limiter is reached

simultaneously with limiter engagement and a stoppage of movement. Readjust if necessary.

9.8 Adjust the pressure switches to engage the warning lights at 90% and 100%, respectively. 9.9 Verify the repeatability of the limiter intervention, that the correct functions are blocked, and

that the warning lights activate correctly.

Rotation: both directions allowed Lifting cylinder up: allowed over horizontal, blocked below horizontal. Lifting cylinder down: blocked over horizontal, allowed below horizontal. Articulation cylinder up: allowed over horizontal, blocked below horizontal. Articulation cylinder down: blocked over horizontal, allowed below horizontal. Jib articulation up: allowed over horizontal, blocked below horizontal. Jib articulation down: blocked over horizontal, allowed below horizontal. Extensions crane/jib: extend blocked, retract allowed Winch: raising blocked

34


10. CRANE WITH AVPS VALVE - AVPS VALVE SETTING 10.1 Disconnect electrical power to the solenoid valve on the AVPS valve.

10.2 Set the maximum pressure on the crane control valve (see maximum relief valve setting). 10.3 Check and if necessary set the port relief valves on the main control valve (see port relief

valve setting). 10.4 Set the flow divider based on the opening time of the articulation hydraulic cylinder, as

indicated in the setting data table, in column “Apertura Mart. Articolazione (AVPS)”.

10.5 Remove the cap using a wrench 14mm, and loosen the locking nut with a wrench 17mm. 10.6 Adjust the setting screw using an allen wrench 4mm. Turn the screw clockwise to reduce

the speed, or counterclockwise to increase it.

35

WORKSHOP TOOLS

10.7 Retighten the locking nut and replace the cap.

10.8 Reconnect electrical power to the AVPS solenoid valve. 10.9 Set the pressure relief valve on the AVPS valve as indicated in the setting data table in

column “Pressione Max AVPS”.

10.10 Loosen the locking nut with a wrench 14mm and adjust the setting screw using an allen

wrench 6mm. 10.11 Operate the articulation to the completely open position and continue to hold the lever

pressed. 10.12 Turn the screw clockwise to increase the pressure, or counterclockwise to decrease it. 10.13 Retighten the locking nut and replace the cap.

36


10.14 Move the pressure gauge from the control valve to the gauge port at the piston end of the

cylinder (as instruction attach a test load to the machine, equal to the weight test load in the setting data table, in column “Carico di PROVA”.

10.15 Open the lifting cylinder until the main boom reaches an angle near 45°. 10.16 Move the articulation to a horizontal position.

10.17 Set the AVPS engagement pressure as indicated in the setting data table in column

“Press Intervento AVPS”.

37

WORKSHOP TOOLS

10.18 Extend the extensions slowly until the indicated pressure is reached.

10.19 Remove the cover screw with a blade-type screwdriver to reveal the adjustment screw. 10.20 Use a very small blade screwdriver to turn the adjustment screw; turn it clockwise to

increase the pressure setting or counter-clockwise to reduce it. Adjust the AVPS pressure switch until it barely activates AVPS.

10.21 Retract the boom and repeat the above movement to verify correct engagement of the

AVPS valve.

38


39

11. VERIFICATION OF CORRECT SETTINGS 11.1 Apply a load to the crane equal to full capacity at maximum reach. 11.2 Move the articulation boom to a horizontal position and the main boom to the same position

as in the load diagram. 11.3 Extend the extensions completely. 11.4 Confirm that the crane can lift the load slowly, and that this happens without continuous

engagement of the load limiting device.

ATTENTION : All lifting operations must take place not starting from a position on the ground, but instead with the second boom horizontal.

ATTENTION : If, as a result of anomalies in the hydraulic circuit, a backpressure exceeding 5bar is present, the setting of the maximum relief valve must be overset by the value of the

backpressure until setting procedures are finished. Once the setting procedures are finished, the maximum relief valve must be set to a value not more than 5bar over the standard setting

pressure noted in the setting data table, in column “Valvola Max Generale” (see maximum relief valve setting).

h.o.03.e - hydraulic setting procedures...

Documents