lorry crane 2

BMI00027GB_0-29092008

SERVICE MANUAL 5

THE POWER OF PERFORMANCE

BA CPARTE IDRAULICA

HYDRAULIC SECTION PARTIE HYDRAULIQUE

HYDRAULIK


INSTALLAZIONE GRU E INTERVENTI TECNICICRANE INSTALLATION AND TECHNICAL OPERATIONSINSTALLATION GRUE ET OPERATIONES TECHNIQUESINSTALLATION DES KRANES UND TECHNISCHE OPERATIONEN


PARTE ELETTRICAELECTRICAL SECTIONPARTIE ELECTRIQUEELEKTRIK

PARTE IDRAULICAHYDRAULIC SECTION PARTIE HYDRAULIQUE HYDRAULIK

A

C

BB1 CONTROLBANKSB2 HOLDING VALVESB3 SUPPLEMENTARY STABILIZERSB4 FILTERSB5 HOSES AND PIPESB6 WRENCH SETTINGB7 HYDRAULIC / ELECTRO-HYDRAULIC LIMITING DEVICEB8 CONTROLBANKSB8.1 PROPORTIONAL CONTROLBANK HAWEB8.2 PROPORTIONAL CONTROLBANK SAUER-DANFOSS PVG 32B8.3 PROPORTIONAL CONTROLBANK NORDHYDRAULIC RS 210B9 F.P.I. DEVICE


�

INDEX B


B1 CONTROLBANKS1 Controlbanks on EFFER cranes ........................................................................................................................... 22 Controlbank setting ............................................................................................................................................... 7

B2 HOLDING VALVES 1 Lock valves ................................................................................................................................................................ 22 Setting the holding valves .................................................................................................................................123 Sequence valves ....................................................................................................................................................204 Sequence valve setting .....................................................................................................................................23

B3 SUPPLEMENTARY STABILIZERS1 Hydraulic plumbing (supplementary stabilizers to crane hydraulic circuit) ..................................... 2

B4 FILTERS1 Delivery filter ............................................................................................................................................................ 22 Air filter applied on the oil tank ......................................................................................................................... 6

B5 HOSES AND PIPES1 Hoses and pipes for hydraulic system ............................................................................................................. 22 Pipe fittings type UNF - JIC 37° (SAE J514) ..................................................................................................... 43 UNF flat type pipe fittings, with O-Ring - (SAE J1453) ............................................................................17

B6 WRENCH SETTING1 Torque wrench setting of hydraulic fittings .................................................................................................. 2

B7 HYDRAULIC / ELECTRO-HYDRAULIC LIMITING DEVICE1 Operating principle ................................................................................................................................................ 32 Valves and components ...................................................................................................................................... 93 Practical setting of the overload limiting device .......................................................................................154 Operating sequences to set the load limiting device ..............................................................................23

B8 CONTROLBANKSB8.0 HC-D3M Controlbank: technical improvements ................................................................................... 2


�

INDEX BB8.1 PROPORTIONAL CONTROLBANK HAWE

Operation ...................................................................................................................................................................... 71 Inlet element ..........................................................................................................................................................102 Closing element ....................................................................................................................................................173 Lever element .........................................................................................................................................................184 Troubleshooting ....................................................................................................................................................335 Variations for PSL 52-3 .........................................................................................................................................356 Coupling with DMU .............................................................................................................................................417 HAWE Proportional controlbank: variable displacement pump .........................................................44

B8.2 PROPORTIONAL CONTROLBANK SAUER-DANFOSS PVG 32Operation ....................................................................................................................................................................531 Inlet element ..........................................................................................................................................................552 Control bank element .........................................................................................................................................613 Closing element ....................................................................................................................................................734 Assembly tie rod kit ..............................................................................................................................................745 Variable displacement pump installation ....................................................................................................756 Emergency hand pump installation...............................................................................................................797 Troubleshooting ....................................................................................................................................................81

B8.3 PROPORTIONAL CONTROLBANK NORDHYDRAULIC RS 2101 Introduction ............................................................................................................................................................852 Main head ................................................................................................................................................................873 Lever element .........................................................................................................................................................914 Closing element ....................................................................................................................................................955 Valve block connection tie rods .......................................................................................................................966 Microswitches for DMU .......................................................................................................................................967 Mechanic microswitch adjustment and replacement .............................................................................98

B9 F.P.I. DEVICE1 Description ................................................................................................................................................................ 32 Functioning principle ............................................................................................................................................ 43 Valves ........................................................................................................................................................................... 64 Settings ....................................................................................................................................................................... 75 Tunings ....................................................................................................................................................................... 86 Operating instructions ........................................................................................................................................107 Electric connections .............................................................................................................................................118 Maintenance ...........................................................................................................................................................12

Rev. 2Service Manual GB


07-2008

B1

CONTROLBANKS

Controlbanks


�

B1 Controlbanks

1- Controlbanks on EFFER cranes1.1 Types of controlbanks DifferenttypesofcontrolbanksareusedonEffERcranes:

DirectActioningControlbank

SemiproportionalActioningControlbank

ProportionalActioningControlbank

DirecT acTioning conTrolbank

TwotypesofsuchvalvesareusedbyEffER:

Direct actioning controlbank of “monobloc type””

Thesecontrolbanksallowonlyonepressuresetting,onthemainrelief-valve,withallcylindersoperatingatthesomemax.pressuresetting.Innerspoolsmaybe“Open-center”,“Close-center”,or“mixed”,dependingfromthetypeofmovementtheyaredesignedtocontrolandfromthetypeofstopvalvefittedonthecranecylinders.Tofitadditionalcontrolstothesetypesofvalves,itisnecessarytofitasecondcontrolbanknexttothemaincontrolbank,andtocarryouta“carry-over”typehydraulicconnection.

Direct actioning controlbank of “sandwich type”

Thesecontrolbanks, inadditiontothemainpressurevalue,allowapressuresettingoneachoil linetothecylinder,thankstothecheck-reliefvalvesfittedoneachelementofthecontrolbank. IInnerspoolsmaybeopen-centre,closed-centre,ormixedtype,accordingtothecranemovementstobechecked,andthetypeoflockvalvesfittedtocranecylinders.Tofittheadditionalcontrols,youcaninsertfurtherindividualelementsusingthenew,longertie-rodstoreassemblethecontrolbank.

SeMiProPorTional acTioning conTrolbank

Controlbankscalled“semiproportional”areinstalledonsomemodelsofcrane.Inspiteofthefactthattheydonotbelongtothecompensatedproportionalcontrolbankrange,theyaredesignedtoallowcranemovementdrivenotonlywithoutloadappliedtothehook,butalsowithamedium-highloadrespecttothemaximumliftingcapacityofthecrane,simultaneously.

coMPenSaTeD ProPorTional acTioning conTrolbank

ProportionaloperationcontrolbanksarealsofittedbyEffER, i.e.controlbanksallowingthesimultaneousoperationofdifferentcranemovementsevenatlowspeed,andwiththemaximumloadappliedtothehook.Thesetypesofcontrolbanksaremorecomplexthanthenpreviousonesandalltechnicalinformationonthistypeofcontrolbankarereportedinthefollowingchapters.

Controlbanks Controlbanks


�

B1

Controlbank Brand & Type Picture Fitted on Effer Models

galtechPl 25

18283530E.P.

DinoilDn

1820E.P.3842

Valvoil

20E.P.2830E.P.354042

HydrocontrolHcD 10

55

62

65

75

80

100

Controlbanks


�

B1 Controlbanks


HydrocontrolHcD 3-M

95

120

140

HydrocontrolHcD 4

110110E150170210250

HydrocontrolHcD 6 335

nordhydraulicSemiproportional

110

110E

130

145



�

B1


Danfoss Proportional

165275305310325340370440470

Hawe Proportional

65(OPTIONAL)75(OPTIONAL)80(OPTIONAL)95(OPTIONAL)100(OPTIONAL)120(OPTIONAL)140(OPTIONAL)210(OPTIONAL)250(OPTIONAL)

36040043046050052053555058560068072075085086092098080N100N10501150115512501350135515501750

Controlbanks


�

B1 Controlbanks

1.2 Torque wrench setting of controlbank tie rods

DirecT acTioning anD SeMiProPorTional conTrolbankS:

Controlbanksof“Sandwichtype”areequippedwithgasketstoensurecorrectpartsealing.Therefore,itisreallyimportant to provide tie rods with correct torque wrench setting as a wrong setting may cause oil leaks orpreventcontrolleversmoothness.Controlbanktierodsarebuiltwithspecialhighresistancesteel:theuseoftierodswithfeaturesdifferentfromthegenuineones,mayjeopardisethecorrectoperationofthecontrolbank.Thecorrecttorquewrenchsettingoftierodsisreportedbelow,togetherwiththecontrolsfittedonEffERcranesinthepast.

ProPorTional acTioning conTrolbank

Controlbank type Tie rod diameter Torque wrench setting

HYDROCONTROLHC-D3 tierodM8 34Nm

HYDROCONTROLHC-D3M tierodM8 34Nm




MONSUNTYSONHV07 tierodM8 18Nm

SALAMIVD081 tierodM8 32Nm

ERPOZDN45 tierodM12 49Nm

DINOILDNC-50 tierodM8 16Nm

DINOILDNC-50 tierodM10 20Nm

HYDROIRMAHDS130 tierodM8 30Nm

Controlbank type Tie rod diameter Torque wrench setting

HAWE-PSL2 nr.2tierodsM8

nr.1tierodM6

23Nm

9,5Nm

HAWE-PSL3 nr.1tierodM8

nr.2tierodM10

22Nm

46Nm

HAWE-PSL5 nr.3tierodM12 60Nm

DANfOSSPVG32 tierodM8 23Nm



�

B1

Afterthisoperation,alltheinspectedvalvesshallbelead-sealedandnosignsoftamperingmustbefoundontheseal.Shouldthisoccur,anywarrantywouldbeautomaticallydeniedbyEffer.Correctcranesettingvaluesareshownonthetechnicaldatasheetreferredtothehydraulicdiagramofthecraneconfiguration.

PliersEffERpart#2008006

LeadsealsEffERpart#2008005(1kg)

(1Kg=240leadseals)

� - Controlbank settingThe correct controlbank setting grants the perfect operation of the crane.Therefore, it is really important tocheckthesettingofthecontrolbankvalves.

noTe: in order to perform crane overload tests, it is necessary to change and increase the controlbank set-ting 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

Whenyoucarryoutthecheckoncranepressuresyoualsocancelafewsmalldifferencesinsettingarisingfromtherealoildelivery,whichthehydraulicpump,fittedtothetruck,supplies.

later, we recommend to perform this check at least once a year.

Whencheckingthesettingvalues,thetruckengineshallrunatthesamerpmofthecraneinworkingcondition,withthehydraulicoiltemperatureinthecraneoiltankatmin.20°C:anysettingperformedwithoilatalowertemperaturewilljeopardisethecorrectstandardoperationofthecrane.

Controlbanks


�

B1 Controlbanks

Acorrecthydraulicsettingrequiresareliablepressuregauge,andit iswellknownthatpressuregaugesufferfromearlywear.Ifacertifiedpressuregaugeisnotavailable,Efferrecommendstobuya“sample”pressuregaugetobeusedthreeorfourtimesayear,soastoprovetheexactenessofthepressuregaugesusedintheworkshop.Adigitalandatraditionalpressuregaugeareshownherebelow.

Tocheckcontrolbanksetting,applythepressuregaugetothecontrolbank,nearthepointofconnectionofthehydraulicpumpline.(SeethesymbolXinthediagraminthepreviouspage).A“minipress”quickcoupling,withM16x2thread,isfittedonallcraneinproduction,inthispoint.

Code8907726A



�

B1

Vg

2.1 Monoblok type controlbank: pressure adjustment

ThehydraulicdiagramofaMonobloktypecontrolbankisshownbelow:

As already mentioned, all the cylinders of a craneequippedwithmonoblocktypecontrolbank,workatthesamepressurevalue.Therefore,onlyonepressuresettinghastobeperformedonthevalvecalled“mainvalve”–Vg-.

Applyapressuregaugetothevalve.Noloadshallbeappliedtothecrane.Thenraiseorretractacylindertothefullstroke.Thepressurevalueonthegaugewillshowthesettingvalueofthemainvalve.

If the pressure value on the pressure gauge is not inaccordance with the crane hydraulic diagram, adjustthe valve setting screw: with the controlbank leveractivated, turnthesettingscrewclockwise (screw)toincreasepressure,andviceversaturnthesettingscrewanticlockwise(unscrew)todecreasepressure.When the correct pressure value is obtained, releasethecontrolbanklevertolockthesettingscrew.After locking the valve setting screw, carry out anadditionaltestasscrewingmayaffectsetting:ashiftof+5barcomparedtothepressurevalueshowninthehydraulicdiagramisallowed.

THe oPeraTor in cHarge of THe aDjuSTMenT H a S T H e r e S P o n S i b i l i T y o f T H e r e -aPPlicaTion of leaD SealS

Vg= 265 bar

Controlbanks


10

B1 Controlbanks

2.2 Multiple element controlbank: pressure adjustment

Vp/s 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

Multipleelementcontrolbanksallowcheckingthepressurevalueoneachhydrauliclineconnectingthedifferentcranecylinders.Twopressureadjustingvalves,orjustone,ornovalveatallmaybefittedonacontrolbankelement.Ifnopressureadjustingvalveisfitted,themax.pressurevalueinthehydrauliccircuitwillbethesameofthesetmainreliefvalve–Vg –locatedatthecontrolbankinlet.Valvesappliedtothecontrolbankelementsarecalledcheck-reliefvalvesandareclassifiedinto:

Vg

VP/S - VP/rVP/S - VP/r



11

B1

a) exaMPle of conTrolbank SeTTing WiTH cHeck-relief ValVe SeT aT a HigHer PreSSure THan THe Main relief ValVe

Consideringthesettingdatalistedinthehydraulicdiagram,you’llnoticethatsomecheck-reliefvalvesaresetatahighervaluethanthemainreliefvalve,whileothercheck-reliefvalvesaresetatalowervalue.Asthemainreliefvalvecontrolsthemax.pressureallowedinsidethecontrolbank,theaimofsettingsomecheck-reliefvalvesatahighervaluethanthemainreliefvalvedependsonthefactthatitisnecessaryasmallstreamofoilflowingoutofthecylinderwhenthecraneissubjectedtosuddenmovementswiththemax.loadapplied.Thesettingvalueslistedinthehydraulicdiagramofthecontrolbankmentionedabove,showacheck-reliefvalvesetatahighervaluethanthemainreliefvalve.In case of just one element or more elements set at a higher value than the main relief valve, take as a refer-ence the element set at the highest pressure.

PreSSure TeSTing can be DiViDeD inTo TWo STePS:

- Testofcheck-reliefvalvepressure- Testofthemainreliefvalvepressure

Applythepressuregauge(noloadshallbeappliedtothecrane)andmakeafullend-strokeofthe1stboomcylinder:thepressurevalueonthepressuregaugecorrespondstothesetvalueofthemainreliefvalve,thatis300 bar.

300

140320

Vg

1) 2)

Vg= 300 bar1st boom cylinder1)Vp/s = 320 bar2) Vp/r = 140 bar

Controlbanks


1�

B1 Controlbanks

Vg

VP/S

Inordertotestthecheck-reliefvalves,increasethesetpressureofthemainreliefvalveVg.Toobtainahigherpressure,keepthecontrolbankleveracti-vated and turn the main relief valve adjustingscrewclockwise(screw).You’llnoticethatthepressuregauge jumpsupto320 bar.Assoonaspressureincreasestops,releasethe controlbank lever, then screw the main reliefvalveadjustingscrewhalfaturn:lockthescrewinthisposition.Nowtestthesetpressureofthecheck-reliefvalvesVP/S and VP/r located on the controlbank, byshifting each controlbank lever and turning thevalveadjustingscrews.

AftercheckingthesetpressureofthevalvesVP/Sand VP/r according to the hydraulic diagram, setthemainreliefvalveVgto300bar.

Makeafullend-strokeofthe1stboomcylinder:thepressurevalueonthepressuregaugecorrespondstothesetvalueofthecheckreliefvalve(320bar).

Keepthecontrolbankleveractivatedandturnthemain relief valve adjusting screw anticlockwise– unscrew it- up to obtain a setting value slightlylower than the main valve value shown in thediagram, then turn the adjusting screw clockwise(screwup)untilthedesiredvalueisachieved(300bar).

Vg

An additional check mush be also carried out after locking the valve adjusting screw, as the adjusting screwtighteningmayleadtoslightchangesinthepresetsettingvalue:however,a+/-5bartoleranceisallowedwithrespecttothepressurevaluesshowninthehydraulicdiagram.



1�

B1

b) exaMPle of conTrolbank SeTTing WiTH cHeck-relief ValVe SeT aT a loWer PreSSure

THan THe Main relief ValVe

Inthiscase,alleastoneelementisnotequippedwithmainreliefvalve(seeextensionretraction).followthecorrectprocedurehereunder:

-performamanouvreofextension retractionsoas tocheck thepressurevalueof themain reliefvalve. Ifnecessary,adjusttheadjustingscrew.

-Checkthepressurevalueof themainreliefvalvesbyshiftingthecontrolbank levers, thenturnthevalveadjustingscrews.

THe oPer aTor in cHarge of THe aDjuSTMenT HaS THe reSPonSibiliTy of THe re-aPPlicaTion of leaD SealS.

Vg = 340 bar

VP/S = 315 bar

340

315

Controlbanks


1�

B1


Service Manual GB

B2

HOLDING VALVES

07-2008 Rev. 3

Holding valves


2

B2 Holding valves

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.

1 - Lock valvesThe 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.

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.

OFF

STOP

STOP

STOP

Holding valves Holding valves


�

B2D) 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.

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.

ON

t (sec)

p (bar)

ptar (bar)Max. pressure value allowed inside the cylinder

Holding valves


�

B2 Holding valves

There are different types of hydropiloted lock valves, EFFER uses:

1. Lock valve with direct hydropiloted opening. 2. “Overcenter” hydropiloted lock valve.

1.1 Lock valve with direct hydropiloted opening

This type of valve does not lets oil flow to the cylinder after an overpressure has been reached but only after a piloting internal pressure signal caused by the manoeuvre carried out by the operator.

They are divided into two categories:

A) Simple effect: they control a single hydraulic line and are fitted to those cylinders where the effect of the applied load generates an internal pressure on one side (e.g. stabilizers)

B) Double effect: they control the two hydraulic lines of cylinder.

Double effect

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 operator’s will to carry out a manoeuvre.

Simple effect

Oil Passage Legend

V = to controlbank

C = to cylinder

This type of valves do not need to be set, like all hydropiloted valves, they are characterized by the so called “pilo-ting 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.

c1 c2

V1 V2

c1 c2

V1 V2

A

B

Oil Passage Legend

V = to controlbank

C = to cylinder



�

B2

DIRECT OPENING HYDROPILOTED LOCK VALVE FUNCTIONAL DIAGRAM

Piloting ratio:2

1AAR =

Piloting pressure multiplier

A1 surface on which the pressure of the setting spring acts and pressure Pcil exerted by oil directly kept into the cylinder by ef-fect of the load applied

Fm

Ppil

Pcil

Pcil

Ppil

Fm

Pcil

A2 piloting surface on which piloting pressure Ppil acts.

Chart of piloting ratio

Holding valves


�

B2 Holding valves

1.2 “Overcenter” hydropiloted lock valvesThis type of valve lets oil leak out after a pressure peak caused by load swinging or by an overload but also due to an inner piloting pressure signal, caused by the manoeuvre carried out by the operator.

There are two types of valves:

A) Simple effect: it controls just a hydraulic line, i.e. from the side subject to the load position (ex: main boom cylinder), and the oil overflow when an overload takes place.

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 cylin-der by the max. load oscillations will not affect the cylinder, saving the crane structure.

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

Simple Effect

Oil Passage Legend V = to controlbank

C = to cylinder

V1 V2

c2 c1

V2 V1



�

B2

1.3 Influence of piloting ratio on crane operationThe selection of lock valve piloting ratio is essential for the proper operation of the crane.

With reference to the lock valve functional diagram indicated by:

cilP The pressure inside the cylinder due to the applied load

R Pilot Ratio

pilP Piloting pressure

mF The force exerted by set spring (this is a preset setting and therefore not adjustable)

1A the section on which Pcil pressure acts

You have that: 1APF tarm ⋅=

Equation of balance of forces is: 21 APAPF pilcilm ⋅=⋅+

that is: 211 APAPAP pilciltar ⋅=⋅+⋅

By developing the formula you have: ( )1

2

AAPPP ciltarpil ⋅+=

by recalling that the piloting ratio R is:

it is concluded that to obtain valve opening, a Ppil pressure must be conveyed to the valve:

R

PPP ciltarpil

+≥

In case of hidro-piloted valves with direct opening, the setting pressure is fixed and insignificant, therefore the previous one is converted into:

The valve will open when, in the oil delivery line, the piloting pressure is exceeded i.e. when the pressure R

Pcil is exceeded.

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.

2

1

AAR =

RPP cil

pil RPPP ciltar

pil+

≥

Holding valves


�

B2 Holding valves

Pcil Pcil

Ptar

mF Ppil

Fm

Pcil

Ppil

P from controlbank

V1V2

C1C2

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 operator’s will to carry out a given manoeuvre.

A2 piloting surface on which piloting pressure Ppil acts.

A1 surface on which the pressure of the setting spring acts and pres-sure Pcil exerted by oil directly kept into the cylinder by effect of the load applied

Lock valve layout

Pcil = Pressure caused by the applied load



�

B2Trend 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.

P cil, min P cil

Ppil, min (Pressione della linea di scarico olio)

Ppil

Ppil, Tar EFFER

Ppil, Tar modificata

Tar EFFER

Tar modificata

Tar

Set EFFER = EFFER original setting pressureSet changed = Setting pressure improperly changed in order to increase crane performance (INCREASED)Pcil, min = Minimum pressure inside cylinder (oil drain line pressure)Pcil, max, project = Maximum pressure into the cylinder allowed by projectPpil, max = Piloting pressure required for the valve to open for a fixed setting pressure value of lock valvePpil, min = Minimum piloting pressure required for the valve to open for a fixed setting pressure value of lock valve and with crane unloaded in the minimum pressure configuration inside the cylinder

Conclusions:

To open the valve, a higher piloting pressure will be required:

1) When the setting pressure value of lock valve increases.2) When the pressure induced by load, into cylinder decreases

changed setting

EFFER setting

Changed setting

EFFER setting

(Oil drain line pressure)

Holding valves


10

B2 Holding valves

1.4 Selecting the piloting ratioThe piloting ratios designed by EFFER for this type of valves change according to:

- Level of sensitivity that you want to achieve for that movement, looking for a compromise between idle han-dling and handling with the load.- Need to obtain certain movements at deliberately high pressure values.

Considering the generic relationship that binds the piloting pressure Ppil, valve setting pressure Ptar, pressure inside the cylinder induced by the load Pcil and piloting ratio R

RPPP ciltar

pil−

≥

You deduce that:

• A high piloting ratio allows a quick valve response. That means a higher lock valve responsiveness.

• A low piloting pressure value requires a higher piloting pressure for the valve to open. This allows a very good control of load handling.



11

B2

1.5 Hydropiloted Holding valve, type “Overcenter”: for “open-center” 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..

B. “Close-center” circuits – a circuit where the control bank spool is of the type “closed center” , or due to the opening of an “Overcenter” valve, the oil coming from the cylinder to go to the tank must open another valve applied to the control bank. This implies that you can create the counterpressures between the cyl-inder, the lock valve and the control bank that disrupt the proper op-eration of the crane: the closed centre circuit valves are also referred to as “balanced” as they are able to offset the above counterpressures.

Typical application are the main boom and the outer boom. These valves, marked “CC” – Closed center, were currently used, but in the last years they have mostly been replaced by the “Open Center” type.

Holding valves


12

B2 Holding valves

On the valve body, close to the ports, the following letters are punched:

“V”: to controlbank

“C”: to Cylinder

2 - Setting the holding valvesAs mentioned in the previous pages, the holding valves of “Overcenter” Type need to be set at a value defined by EFFER. If not, the following might occur:

- too low setting: The crane does not support the diagram load at the distance shown on the load diagram and the boom is unintentionally lowered.

- too high setting: it is possible to bring the maximum loads indicated in the crane performance table at distances that are higher than the slewing axis, if the load limiting device is not fitted; therefore the crane may be overloaded: the pressure peaks inside the cylinder cannot flow, therefore structural problems in the crane are possible.It is therefore essential to check that valves are set following EFFER prescriptions and to re-check the setting every 3 or 4 years of work.

The valve setting-screw must always be sealed (lead seal applied by EFFER in the factory or by an Authorized EFFER Workshop) and no signs of tampering must be found on the seal. Should this occur, any warranty would be automatically denied by EFFER.

To set (or to check the setting of ) a holding valve of “Overcenter Type”, connect the valve to a suitable equipment and simulate the valve opening due to the too high pressure value inside the crane cylinder.

V V

cc



1�

B2

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 doesn’t 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, you’ll 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.

b) controlbank with an adjustable main relief valve

2.1 Necessary toolsTo set the valve, following tools must be available at the workshop:

a) pressure gauge, with a large scale (to avoid reading mistakes)

Holding valves


1�

B2 Holding valves

d) tools for lead sealing. The holding valve setting-screw must always be sealed.

EFFER part #8850710

ø 37 mm L= 72 mm

EFFER part # 8850711

ø 30 mm L= 50 mm

Pliers EFFER part # 2008006

Lead sealing parts

EFFER part # 2008005 (1kg )

(1 kg = 240 lead sealing parts)

ANY CRANE WARRANTY WOULD BE AUTOMATICALLY DENIED BY EFFER IN CASE OF VALVES NOT LEAD SEALED.



1�

B2

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

c V

c V

2.2 Practical example of setting

We need to set a valve at a pressure of 320 bar.

A) Fit the pressure gauge on the hydraulic line under pressure that connects the hydraulic power unit to the hydraulic control bank.

B) Then fit a hose only, between the controlbank to the valve we want to set (to the specific port we set).

C) Plug the other port from the control bank.

D) Remove the seal plug applied on the setting screw and remove the stop nut fitted to the valve set screw relating to the line to be set.

c V

c V

Holding valves


1�

B2 Holding valves

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.

Small oil stream!

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.

c V

c V

320 bar

305 bar

c V

c V

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.



1�

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.

Valve fitted on cylinder by a fitting

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.

Valve fitted on cylinder with a flange connection

Holding valves


1�

B2 Holding valves

EFFER PaRT # 8866738



Codes and drawings of the flanges are listed below, and can be ordered to EFFER in case of need.


3/8 GASBSPP

2840

60

4060

10

M10



1�

B2






Holding valves


20

B2 Holding valves

� - Sequence valvesThe 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.

V V

c

Two types of sequence valves are fitted to the EFFER cranes:

A) “COMPENSATED TYPE” VALVE B) NON-COMPENSATED TYPE” VALVE

c



21

B2

3.1 “Compensated type” valve (use at average-high pressure values)

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.

Valve settingEx.: 200 bar

Valve settingEx.: 200 bar 70 bar 100 bar 120 bar

ON LINE

FLANGED

ON LINE

Holding valves


22

B2 Holding valves

3.3 Examples of set up sequence valves

3.2 “Non-Compensated type” valve (use at average-low pressure values)

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 re-quires 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.

40 bar 20 bar 20 bar

ON LINE

Valve settingEx.: 300 bar



2�

B2

� - Sequence valve settingIn order to ensure the correct sequence of crane extension out, all sequence valves are to be set. The setting values arereported in the hydraulic diagrams of the cranes.

The sequence valve has two hydraulic connections: one connection is direct to the crane controlbank, the other one is directto the cylinder.

4.1 Necessary toolsTo set the sequence valve, following tools must be available at the workshop:

A) Pressure gauge , with a large scale (to avoid reading mistakes)

B) Controlbank

C) Power pack

Holding valves


2�

B2

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.

4.2 Practical example of settingWe need to set the sequence valve by sending oil to the point of connection of the controlbank line and by adju-sting thespring setting. This adjustment can be internal or external.

for some years the dowel that presses the spring relating to valve setting has been locked by a small dowel

Use a 1.5 / 2 Allen wrench (depending on the type of valve) to remove the lock dowel.

Setting change:

If you tighten (clockwise) the setting value increases

If you loosen (counterclockwise) the setting value decreases

Internalsetting

Internalsetting

Externalsetting

Externalsetting


B3

SUPPLEMENTARY STABILIZERS

07-2008

Supplementary stabilizers


�

B3 Supplementary stabilizers

1 - Hydraulic plumbing (supplementary stabilizers to crane hydraulic circuit)Theplumbingofsupplementarystabilizerstothecranehydrauliccircuitvariesdependingfromthecranemo-del.

A) On small cranes,which do not feature stabilizers with hydraulic outlet, there is a dedicated lever on thecontrolbankandtheholdingvalvesonthestabilizerscylindersarefittedwithafaucet.Thruthisfaucetyouselectwhichcylinderyouwanttomanoeuvrethruthecontrolbanklever.


Besidesthecontrolbank,somelinefittingsallowtheconnectiontotheadditionalsupplementarystabilizers.Thesupple-mentarystabilizersmustbeequippedwithaholdingvalvewithfaucettoselectthestabilizertooperate.Whencarryingoutthisconnection,itisreallyimportantthatallbarrel-sideandrod-sidecylindersarekeptseparateanddirectedtothetwocontrolbankconnections.

Basic crane

Supplementary stabilizers Supplementary stabilizers


3

B3B) On mid and large size cranes,thereisadedicatedleveronthecontrolbankforthestabilizersmanoeuvre,andtwodivertervalves(oneoneachsideofthecrane,locatedclosetothebottomsidecontrolbank).Thruthesedivertervalves,youmayselectthestabilizer(front,rear)andthemanoeuvre(outlet,down)youwanttooperatebytheleveronthecontrolbank.Afterselectingthemanoeuvre,movethelevertooperatethestabilizer.

Thedivertervalves incorporatealsotheconnectionsfortheoil“outlet”ofadditionalsupplementarystabilizercylinders.Holdingvalvesappliedtothestabilizerverticalcylindersarenotequippedwithoilfaucet.

STOP

1

2

STOPSTOP

STOP

STOPSTOP

STOP STOP

3

4

1

2

3

4

Pos. Outlet

1 A 2 B 3 C 4 D

Pos. Outlet

1 A 2 B 3 C 4 D


Basic crane



�


C)Onthecraneswherethere is not adedicatedleveronthecontrolbank,thedivertervalveincorporatesalsothecontrolforthestabilizersmanoeuvre.Thereisonecontrolbank/divertervalveforeachsideofthecraneoroneservingbothsidesthruarod.

Firstyouselectbytheleverwhichmanoeuvreyouwanttoperform,then,bypushingorpullingthesameleveryouselectthedirectionofmanoeuvre(raiseorlower).

Thedivertervalves incorporatealsotheconnectionsfortheoil“outlet”ofadditionalsupplementarystabilizercylinders.

1 2

34

Pos. Oulet

1 A 2 B 3 C 4 D

Basic crane


4-way diverter



�

B3

6

7

8

5

1 2

3

4

Pos. Outlet

1 A 2 B 3 C 4 D 5 E 6 F 7 G 8 H

No hydraulic outletBasic crane


Basic crane


With hydraulic outlet

8-way diverter



�


Supplementary stabilizer hydraulic lateral outlet

Repeatedandprolongedimproperoperationofstabiliserexitwiththemechanicalsafetyretainerinserted(thisretainerpreventsfromanyunintentionalexitofthestabilizer),coulddamagethestabiliser,thusjeopardizingitsproperoperation.Inordertoavoidthisproblem,eachadditionalstabilizerwithhydraulicexitmusthaveapressurereducingvalve,code8866769k.

Itisamaximumpressurevalvethatlimitspressureat150barinsidethestabiliserhydrauliccircuit.Inthiswayitispossibletoensuretheperfectoperationoftheclosingretaineroftheadditionalstabilisers.

V1

T

T

V2

8866769 (QT.1)

Pleasefindbelowtheconnectionhydraulicdiagramoftheadditionalstabilisersafetyvalve.

Tothehydrauliccircuitofthecrane

V2

V2

V1

V1 T

150150



�

B3IMPORTANT:

Thehydraulicconnectionof thesupplementary stabilizers must ALWAYSbe madewithoutanyVALVEORFAUCETordiverterleftontheoillinetothecylindersrod-side.

Should this occur, the cylinder would swell as soon as it ismaneuvered.

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)

No obstacles or obstructions on this line !!!

Area “A-B”(Rod side)

Area “A”(Piston side)

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.



�

B3



B4

FILTERS

07-2008

Filters


�

B4 Filters

1-Delivery filterThecranesnotprovidedwithproportionalcontrolbankareequippedwithanoildeliveryfilterasastandard,lo-catedonthelineconveyingthehydraulicoilpassingfromthepumptothecontrolbank.

Correctfilterservicingoperationsgrantthereliabilityofthehydraulicsystemcomponents.

Filterby-passoperationisshownonthecloggedfilterindicator:theby-passdevicemakestheoilflowoutfromthefilterinlettotheoutletwhenthecartridgeiscloggedbyimpurities.

However,theby-passactivationisallowedonlyforalimitedperiodoftimetofinishthework,astheoperationoftheby-passmakesoilpassunfilteredandthereistheriskofreleasingcartridgeimpuritiesduetooildeliverypressureatthefilterinlet,andofdamagingthehydraulicsystemparts.

PleaserememberthatthestandardcraneequippedwiththeDMUdevicealsoincludestheLEPBfunction(seechapteroftheoperatormanualDMU).

Thisfunctionacousticallyandalsovisuallywarnsiftheoptionalpanelisfitted,whenthefilterisclogged.

Filtercartridgesaremadeof“inertinorganicfiber”.Theyareusuallycalled“papercartridges”soastodistinguishthemfromthecartridgesmadeofmetallicnet,havingalowerfinefilteringrate.

Donotcleanthecartridge,neitherwithliquidsnorwithair jet.Whentheindicatoroffiltercloggedlightsup,replacecartridges.

1.1 “Pall” Delivery filter feature

-Maximumoperatingpressure:400bar

-Maximumflow:100L/min.

-Temperaturerange:-43°C+120°C.

-By-passvalvesetting:3,4bar

-15micronfilteringcapacity

Ref. 1

Visualclogwarning

Ref. 2

Electricclogwarning

Ref. 3

Electricclogwarning(substitutionofwarningRef.2)

**

**

**

*

Filters Filters


�

B4

1.2 “Sofima” delivery filter feature




-By-passvalvesetting:5bar

-12micronmicronfilteringcapacity

Effer PARTS #

*Gasketset8919361

Filterequippedwithclogvisualwarning:8919356

filterequippedwithclogelectricwarning:8919357A

filtercartridge:8919358

Ref. 1 Visualclogwarning:8919360

Ref. 2 Electricclogwarning:8919372

Coupling:ø3/4”BSP

Effer PARTS #

* OilO-Ring:8009000 ** OilO-RingKit

Filterequippedwithclogvisualwarning:8919332



Ref. 1 Visualclogwarning:8919348

Ref. 2 Nomoreavailable,replacedbyRef. 3

Ref. 3 Electricclogwarning:8919347A

Note: indicator torque setting = 75 Nm (apply LOCTITE 243)

Note: indicator torque setting = 90 Nm

Ref. 1

Visualclogwarning

Ref. 2

Electricclogwarning

*

Filters


4

B4 Filters

1.3 “Sofima” delivery filter feature






Effer PARTS

*Gasketset8919364KG




Coupling:ø1”1/4BSP


Ref. 1

Electricclogwarning

*

Filters Filters


�

B4

1.4 “HYDAC” delivery filter feature






Effer PARTS

*Gasketset8919382

Filterequippedwithclogelectricwarning:8919378

Filtercartridge:8919379



Ref. 1

Electricclogwarning

*

Coupling:ø1”BSP

NOTE:Forsomemonthsin2008aclogelectricwarningwasfittedoncranes,withelectriccouplingasshowninthefigure,EFFERpartoftheelectricwarning8919384

Filters


�

B4 Filters

� - Air filter applied on the oil tankThelevelofthehydraulicoilinthetankchangesdependingonthecranecylinderposition:oilmax.levelisobtainedwhenallcranecylindersareretracted,whereasoilmin.levelisobtainedwhenallcranecylindersareout.

Inordertochangethelevel,airmustenterthetank.Airwillbepolluteddependingontheworkarea(i.e.whenthecraneoperatesinabuildingyard,thedustparticlescouldflowintothetankandmixwiththehydraulicoil).Particlesofeverykindcouldenterthetank,howeveranairfilterpreventsit,savingtheintegrityofthecomponentsofthehydraulicsystem.Astheimportanceofthisfilterisoftendiscarded,serviceitinanycase.Carryoutregularmaintenanceoperations,cleanitwithacompressedairjet,andreplaceitonceevery3-4yearsdependingontheworkareaofthecrane.

DifferenttypesofoiltankfiltersarefittedonEFFERcranes.Theairfilterlistisreportedbelow,includingfiltersfittedoncranesnotinproductionanymore,togetherwiththeindicationsfortheidentificationoftheexactpartnumberfortheorder.

1-EFFERPART #:8919345




ø40mm

ø50mm

Filters Filters


�

B4





80

38

100

80

50

80

28

65

45

Filters


�

B4

2.1 Oil tank hole for pump suction connection

MODELLO GRU DIMEN-SIONE FORO

Athreadedholefortheflowingoftheoiltothehydraulicpumpislocatedinthelowersideofthecraneoiltanks.Applyafaucetofcorrectsizebetweentheoiltankandtherubberhose,soastostoptheoilflowincaseofmain-tenanceoperationstothehydraulicpumportotheconnectinghoses.

Thisfaucetisalreadyfittedonsomemodelofoiltank.

Thediametersofthethreadedholes-differeningaccordingtothecranemodels-arelistedbelow.

CRANE MODEL HOLE DIMENSION

20-30-35-40-4218-28-38 ¾”GASBSPP

55-65-75-80-95-10062-110E

110-120-140150-170-210250-400-460

1”¼GASBSPP

47130-145155-165

335-360-430520-600-680

720-400-460-44N

1”½GASBSPP

275-305310-325-340-370

440-470500-550750-850

860-920-9801050-1150-12501155-1355-1550

1350-175080N-100N

2”GASBSPP



B5

HOSES AND PIPES

07-2008

Hoses and pipes


�

B5 Hoses and pipes

1- Hoses and pipes for hydraulic systemu Acarefulmaintenanceofhosesandpipesgrantreliabilityandsafetyduringcraneoperation.Flexhosesshallbeprovidedwithanintactexternalrubbercoatingforthetheprotectionofthemetallicnet.Otherwise,themetallicnetmaycorrodeforwear-and-tear,andthefactorofsafetyofthehosesmayreduceuptothehoseburst.

Themetallicnetshallbeintact.Ifsomemetallicwiresaredamagedbecauseofcrashes,replacethehoseimme-diately.

u Thehydraulicfittingsareappliedatthetipsoftheflexhosesbypressing.Incaseofoilleaks(evenofasmallquantity),replacethehoseimmediatelyasthehosepressingcannotgrantthereliabilityofthecraneanditssafeoperationanymore.

u Pipeconditionisimportantlikewise:crushedportionsofpipesmaycausehydraulicoiloverheating,andreducethecranespeed.

u Safetyrulesforcranedesignrequireflexhosesandpipeswithaminimumsafetyratebetweentheoperatingmax.pressureandtheburstingpressureofthepart.Thefollowingtechnicalindicationsletmakeprovisionalrepairsonthecrane,beforefittingthegenuinesparepartsuppliedbyeFFeR.

1.1 High pressure hoses for hydraulic system

PleasefindtheinnerdiameterofhosesfittedtoeFFeRcraneswithrespectoftheirnominaldiameter:

Inner diameter6 mm

Hose nominal diameter1/4”

8 5/16”

10 3/8”

12 1/2”

16 5/8”

19 3/4“

25 1”

Hoses and pipes Hoses and pipes


�

B5

1.2 Pipes for hydraulic system

Pleasefindhereunderthenominaldimensions(outerdiameter)andthetypeofmaterialsrelativetothemetallicpipesfortheconnectionofthehydraulicsystem.

uThehosesshallbeappropriatetobearamaximumworkingpressureequalto350bar.Itfollowsthat,sincetheyshouldhaveaburstsafetyfactorwhichshouldbeatleast4timeshigherthantheworkingpressure,theymusthaveaburstminimumpressureequalto1400bar.

Thehosesmustbeappropriatetoworkataworkingtemperaturerangingfrom-20°Cto+100°C.Thefollowingarethereferenceregulationsthehosesshouldbecompliantwith:

• UNI CEI EN ISO / IEC 17050 • UNI EN 853, 855, 856, 857 • ISO 4406

NOTE: A crane is also equipped with some hoses on hydraulic system relating to oil drain, i.e. to connect 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 diametermm

Thickness mm

8 1

12 1,5

16 2

20 2,5

25 3

32 3

Material: ST35.4

Fe35.2 UNI2897

NOTE: Drawn pipe, without welds

Operating pressure: 350 bar

Safety burst factor: 1:2,5

Hoses and pipes


�

B5 Hoses and pipes

� - Pipe fittings type UNF - jic �7° (SAE J51�)u Flareishighthicknesssimple-walledtype.Thequalityofcouplingmadedependsonthecorrectexecutionofthiswork.Allcracks,exfoliationorsimplemarksontheinnerconejeopardisethecouplingtightness.Tightenthecouplingusingadynamometricwrench:anexcessivetighteningcancausethematerialtobesquashedintheconicalpartwithitspossibledetachmentonthecylindricalsideofthepipeline.

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.

Ifitisimpossibletouseadynamometricwrench,doasfollows:

1)useanormalwrench,withoutfittingextensions,

2)tightenthefittingwiththestrengthofyourarms,withoutexaggerating,

3)loosenby1/2turn

4)tightenthefittingagain,andtrytobringthestoppingpointtoapositionthathastobe1/4turnmoreadvan-cedthanthefirsttighteningmade.

1 2 3 4

BUSHING NUT

PIPe

37¡°



5

B5

COUPlINg THE PIPES/HOSES

Ø Pipe mm Hose Coupling thread

8 1/4” 1/2”20filUNF-JIC37°

12 3/8” 3/4”16filUNF-JIC37°

16 1/2” 7/8”14filUNF-JIC37°

20 3/4” 1”1/16”12filUNF-JIC37°

25 1” 1”5/16”12filUNF-JIC37°

32 1”1/4” 1”5/8”12filUNF-JIC37°

Hoses and pipes


�

B5 Hoses and pipes

NUT - JIC 37°

A

2.1 EFFER codes of pipe fittings, UNF - JIC 37° - SAE J514 typeOIl INlETS TO BE WElDED - JIC 37° °

F

F1

H

F Effer code H Ø F1

1/2”20filUNF-JIC37° 9300601 22,5 8,5

3/4”16filUNF-JIC37° 9300602 18 12

7/8”14filUNF-JIC37° 9300603 20 16

1”1/16”12filUNF-JIC37° 9300604 23 20

1”5/16”12filUNF-JIC37° 9300500 41 29,5

Pipe outer Ø mm Effer code A UNF

8 9320800 1/2”20filUNF-JIC37°

12 9320900 3/4”16filUNF-JIC37°

16 93201000 7/8”14filUNF-JIC37°

20 93201100 1”1/16”12filUNF-JIC37°

25 93201200 1”5/16”12filUNF-JIC37°

32 93201300 1”5/8”12filUNF-JIC37°



B5

7

F

Pipe outer Ø mm Effer code Ø F mm

8 9321600 8

12 9321700 12

16 9321800 16

20 9321900 20

25 9322000 25

32 9322100 32

BUSHINg

REDUCTION - JIC 37°

CA

Ø 1 Pipe Ø 2 Pipe Effer code A UNF C UNF

12 8 9333400 3/4”16filUNF-JIC37° 1/2”20filUNF-JIC37°

1612

9333500 7/8”14filUNF-JIC37° 3/4”16filUNF-JIC37°

209333600 1”1/16”12filUNF-JIC37° 3/4”16filUNF-JIC37°

16 9333700 1”1/16”12filUNF-JIC37° 7/8”14filUNF-JIC37°

2520

9333800 1”5/16”12filUNF-JIC37° 1”1/16”12filUNF-JIC37°

329333900 1”5/8”12filUNF-JIC37° 1”1/16”12filUNF-JIC37°

25 9334000 1”5/8”12filUNF-JIC37° 1”5/16”12filUNF-JIC37°

16 8 9334100 7/8”14filUNF-JIC37° 1/2”20filUNF-JIC37°

32 20 9334002 1”5/8 1”1/16

38 32 9334001 1”7/8 1”5/8

Hoses and pipes


�

B5 Hoses and pipes

FEMAlE PlUg - JIC 37°

APipe outer Ø mm Effer code A UNF

8 9335100 1/2”20filUNF-JIC37°

12 9335200 3/4”16filUNF-JIC37°

16 9335300 7/8”14filUNF-JIC37°

20 9335400 1”1/16”12filUNF-JIC37°

25 9335500 1”5/16”12filUNF-JIC37°

32 9335600 1”5/8”12filUNF-JIC37°

MAlE PlUg - JIC 37°

A


8 9334300 1/2”20filUNF-JIC37°

12 9334400 3/4”16filUNF-JIC37°

16 9334500 7/8”14filUNF-JIC37°

20 9334600 1”1/16”12filUNF-JIC37°

25 9334700 1”5/16”12filUNF-JIC37°

32 9334800 1”5/8”12filUNF-JIC37°



�

B5

PANEl CONNECTOR - JIC 37°

AAJOINT - JIC 37°

AA


8 9324000 1/2”20filUNF-JIC37°

12 9324100 3/4”16filUNF-JIC37°

16 9324200 7/8”14filUNF-JIC37°

20 9324300 1”1/16”12filUNF-JIC37°

25 9324400 1”5/16”12filUNF-JIC37°

32 9324500 1”5/8”12filUNF-JIC37°


8 9322400 1/2”20filUNF-JIC37°

12 9322500 3/4”16filUNF-JIC37°

16 9322600 7/8”14filUNF-JIC37°

20 9322700 1”1/16”12filUNF-JIC37°

25 9322800 1”5/16”12filUNF-JIC37°

32 9322900 1”5/8”12filUNF-JIC37°

Hoses and pipes


10

B5 Hoses and pipes

90°-BEND - JIC 37°A

A

UNION TEE - 3 MAlE CONNECTORS - JIC 37°

A

K


8 9331000 1/2”20filUNF-JIC37°

12 9331100 3/4”16filUNF-JIC37°

16 9331200 7/8”14filUNF-JIC37°

20 9331300 1”1/16”12filUNF-JIC37°

25 9331400 1”5/16”12filUNF-JIC37°

32 9331500 1”5/8”12filUNF-JIC37°


8 9323200 1/2”20filUNF-JIC37°

12 9323300 3/4”16filUNF-JIC37°

16 9323400 7/8”14filUNF-JIC37°

20 9323500 1”1/16”12filUNF-JIC37°

25 9323600 1”5/16”12filUNF-JIC37°

32 9323700 1”5/8”12filUNF-JIC37°



11

B5

UNION TEE - 2 MAlE CONNECTORS, 1 FEMAlE CONNECTOR - JIC 37°

CROSS - JIC 37°


8 9335900 1/2”20filUNF-JIC37°

12 9336000 3/4”16filUNF-JIC37°

16 9336100 7/8”14filUNF-JIC37°

20 9336200 1”1/16”12filUNF-JIC37°

25 9336300 1”5/16”12filUNF-JIC37°

32 9336400 1”5/8”12filUNF-JIC37°


8 9332600 1/2”20filUNF-JIC37°

12 9332700 3/4”16filUNF-JIC37°

16 9332800 7/8”14filUNF-JIC37°

20 9332900 1”1/16”12filUNF-JIC37°

25 9333000 1”5/16”12filUNF-JIC37°

32 9333100 1”5/8”12filUNF-JIC37°

Hoses and pipes


1�

B5 Hoses and pipes

UNION TEE - 2 MAlE CONNECTORS, 1 FEMAlE CONNECTOR - JIC 37°

NIPPlE F+M - JIC 37° UNF / gAS BSPP


8 9331800 1/2”20filUNF-JIC37°

12 9331900 3/4”16filUNF-JIC37°

16 9332000 7/8”14filUNF-JIC37°

20 9332100 1”1/16”12filUNF-JIC37°

25 9332200 1”5/16”12filUNF-JIC37°

32 9332300 1”5/8”12filUNF-JIC37°

Pipe outer Ø mm Effer code A UNF B GAS BSPP

12 9320000 3/4”16filUNF-JIC37° 3/8”

16 9320100 7/8”14filUNF-JIC37° 1/2”

20 9320200 1”1/16”12filUNF-JIC37° 3/4”

25 9320300 1”5/16”12filUNF-JIC37° 1”

8 9320400 1/2”20filUNF-JIC37° 1/4”

12 9320500 3/4”16filUNF-JIC37° 1/2”

16 9320101 7/8”14filUNF-JIC37° 3/8”



1�

B5

BANIPPlE M+M - JIC 37° UNF / gAS BSPP


8

9325600

1/2”20filUNF-JIC37°

1/4”

9325700 3/8”

9339601 1/2”

9325610 1/8”

12

9325800


1/4”

9325900 3/8”

9326000 1/2”

16

9326200


3/8”

9326300 1/2”

9326400 3/4”

20

9326600

1”1/16”12filUNF-JIC37°

1/2”

9326700 3/4”

9326800 1”

259326900

1”5/16”12filUNF-JIC37°3/4”

9327000 1”

32

9327100

1”5/8”12filUNF-JIC37°

1”

9327200 1”1/4”

9327300 1”1/2”

Hoses and pipes


1�

B5 Hoses and pipes

90°-BEND - M+M - JIC 37° UNF / gAS BSPP

A

B

H

Pipe outer Ø mm Effer code A UNF B GAS BSPP H

8 9327600 1/2”20filUNF-JIC37° 1/4” 33

12

9327700 3/4”16filUNF-JIC37° 1/4” 34

9327800 3/4”16filUNF-JIC37° 3/8” 36.5

9327900 3/4”16filUNF-JIC37° 1/2” 42.5

9328811 3/4”16filUNF-JIC37° 3/8” 34

16 9328000 7/8”14filUNF-JIC37° 1/2” 42.5

209328100 1”1/16”12filUNF-JIC37° 1/2” 48.5

9328200 1”1/16”12filUNF-JIC37° 3/4” 48.5

259328300 1”5/16”12filUNF-JIC37° 3/4” 51.5

9328400 1”5/16”12filUNF-JIC37° 1” 51.5

16

9328700 7/8”14filUNF-JIC37° 3/4” 48.5

9328800 7/8”14filUNF-JIC37° 1/2” 79

9328812 7/8”14filUNF-JIC37° 1/2” 36

9328813 7/8”14filUNF-JIC37° 3/8” 39.5



15

B5

A

B

45°-BEND M+M - JIC 37° UNF / gAS BSPP


16 9329000 7/8”14filUNF-JIC37° 1/2”

20 9329100 1”1/16”12filUNF-JIC37° 3/4”

12 9329400 3/4”16filUNF-JIC37° 1/2”

16 9329510 7/8”14filUNF-JIC37° 3/8”

16 9329511 7/8”14filUNF-JIC37° 3/4”

UNION TEE - 2 MAlE CONNECTORS - JIC 37° IN lINE - 1 gAS BSPP 90°-MAlE CONNECTOR

AA

B


12 9330300 3/4”16filUNF-JIC37° 3/8”

16 9330400 7/8”14filUNF-JIC37° 1/2”

20 9330500 1”1/16”12filUNF-JIC37° 3/4”

25 9330600 1”5/16”12filUNF-JIC37° 1”

Hoses and pipes


1�

B5 Hoses and pipes

UNION TEE - 2 MAlE CONNECTORS JIC 37° / gAS BSPP IN lINE - 1 JIC 90°-MAlE CONNECTOR


12 9329600 3/4”16filUNF-JIC37° 3/8”

16 9329700 7/8”14filUNF-JIC37° 1/2”

20 9329800 1”1/16”12filUNF-JIC37° 3/4”

25 9329900 1”5/16”12filUNF-JIC37° 1”

12 9330200 3/4”16filUNF-JIC37° 1/4”

8 9329601 1/2”16filUNF-JIC37° 1/4”

REDUCTION F+M gAS / gAS-BSPP-

BD

Effer code B GAS D GAS

9337000 3/4” 3/8”

9337200 1” 1/2”

9337300 1” 3/4”

9337400 1”1/4 3/4”

9337600 1”1/2 1”



17

B5

COUPlINg THE PIPES/HOSES

� - UNF flat type pipe fittings, with O-Ring - (SAE J1�5�) Thepipeendismanufacturedinordertogetaflatsurface.ThefittingthatiscoupledwiththepipeisequippedwithanO-Ringonthefrontsurface;thereforethehydraulictightnessisguaranteedbyajoint.

Thesearetheadvantagesofthiskindoffittingswithjoint:

-noblows-by.

-noneedforaspecificequipmentforacorrecttightening

-resistancetoexcessivetightening

-possibilitytocarryoutseveralremovals

Assaidabove,tighteningcanbecarriedoutwithouttheuseofparticularequipment;whentheO-Ringjointisdeformedthepipeandthefittingcollideonthefrontthusnotallowingthenuttobescrewedup.

Incaseofoilleaks,replacetheO-Ringjoint(seetablebelow).

90°BUSHING NUT

PIPe

Ø Pipe Thickness Ø Hose Coupling thread

8 1 5/16” 11/16”-16UNF-frontO-Ring

10 2 5/16” 11/16”-16UNF-frontO-Ring

12 1.5 1/2” 13/16”-16UNF-frontO-Ring

14 2 1/2” 1”-14UNF-frontO-Ring



20 2.5 3/4” 1”3/16-12UNF-frontO-Ring

22 2.5 1” 1”7/16”-12UNF-frontO-Ring

25 3 1” 1”7/16”-12UNF-frontO-Ring

32 3 1”1/4 1”11/16”-12UNF-frontO-Ring

Hoses and pipes


1�

B5 Hoses and pipes

O-RINg JOINT

F

BD

Pipe outer Ø mm Effer code F thread

UNF O-RingD

mmB

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 1”11/16-12 29.87 1.78

35-38 9342606 2”-12 37.82 1.78



1�

B5

3.1 EFFER codes of pipe fittings, type UNF front O-Ring -SAE J1453OIl INlETS TO BE WElDED

RACCORDI SPECIAlI

F1H

F

Pipe outer Ø mm Effer code F UNF O-Ring H Ø 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 1”11/16-12 42 25

Pipe outer Ø mm Effer code F UNF O-Ring H Ø F1

12 9340507 13/16-16 26 9,6

14÷16 9340522 1”-14 33,5 22,5

18-20 9340505 1”3/16-16 37,5 25

22-25 9430506 1”11/16-12 42 30

Hoses and pipes


�0

B5 Hoses and pipes

UNF O-RINg NUT

F

UNF O-RINg BUSHINg

F

L

Pipe outer Ø 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

Pipe outer Ø mm Effer code F mm

10 9341150 10

12 9341151 12

14 9341152 14

16 9341153 16

20 9341154 20

22 9341156 22

25 9341155 25



�1

B5

UNF O-RINg FEMAlE PlUg

F

UNF O-RINg MAlE PlUg

B

F

L


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 Ø 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

Hoses and pipes


��

B5 Hoses and pipes

JOINT M + M, UNF O-RINgF F1

Pipe outer Ø mm Effer code F GAS CIL BSPP 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” 1”-14

18-20 9341812 1/2 1”3/16-12

18-20 9341813 3/4 1”3/16-12

18-20 9341814 1” 1”3/16-12

18-20 9341815 1”1/4 1”3/16-12

22-25 9341816 3/4 1”7/16-12

22-25 9341817 1” 1”7/16-12



��

B5

JOINT M + M, UNF O-RINgF F1


22-25 9341818 1”1/4 1”7/16-12

22-25 9341819 1”1/2 1”7/16-12

JOINT M + M, UNF O-RINg

F 1 2 F1

Pipe outer Ø 1 mm

Pipe outer Ø 2 mm Effer code F UNF -

O-RingF 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 16 9341904 1”-14 13/16-16

18-20 18-20 9340127 1”3/16-12 1”3/16-12

20 20 9340139 1”3/16-12 1”-14

22-25 22-25 9340128 1”7/16-12 1”7/16-12

25 25 9340129 1”7/16-12 1”3/16-12

Hoses and pipes


��

B5 Hoses and pipes

JOINT M + M, UNF O-RINg / UNF JIC 37°F F1

Pipe outer Ø 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

PANEl CONNECTOR, UNF O-RINg

F F


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



�5

B5

NIPPlES M + F, UNF O-RINgF F1


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” 1”3/16-12

22-25 9341710 3/4 1”7/16-12

22-25 9341711 1” 1”7/16-12

22-25 9341712 1”1/4 1”7/16-12

Hoses and pipes


��

B5 Hoses and pipes

F1FREDUCTION M + F UNF O-RINg

Pipe outer Ø mm 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 1”3/16-12 13/16-16

20-16 9342105 1”3/16-12 1”-14

25-16 9342106 1”7/16-12 1”-14

25-20 9342107 1”7/16-12 1”3/16-12

32-20 9342108 1”11/16-12 1”3/16-12

32-25 9342109 1”11/16-12 1”7/16-12

38-25 9340130 2”-12 1”7/16-12

38-32 9340105 2”-12 1”11/16-12



�7

B5

90°-BEND M + 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

UNION TEE, 2 MAlE CONNECTORS, 1 FEMAlE CONNECTOR UNF O-RINg

F1

L1L

F F1


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

Hoses and pipes


��

B5 Hoses and pipes

UNION TEE, 2 MAlE CONNECTORS, 1 FEMAlE CONNECTOR UNF O-RINg

F

L1

L

F1


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

REDUCTION M + F UNF O-RINg

F1

Effer code F GAS BSPP

9342702 1/4

9342703 1/4

9342704 1/4

9342705 1/4

9342706 1/4

Effer code F 1 GAS BSPP

9341102 11/16-16

9341103 13/16-16

9341104 1”-14

9341105 1”3/16-12

9341106 1”7/16-12

FL

Hoses and pipes


�0

B5 Hoses and pipes

3.2 UNF front flat seal terminals, with O-Ring (SAE J1453 to be welded) ItmayberequiredtocarryoutrepairswithouttheavailabilityofapipethatisaneFFeRoriginalsparepart.

NOTE: It is obvious all the above will be required to carry out the first repair.

It is understood that then it will be necessary to fit the original spare part as soon as possible.

BUSHINGTOBeWeLDeDNUT

PIPe

eFFeRcansupplybushingstobeweldedtothepipeend.

Thesebushingsmustbecoupledwithspecificnuts.

Pipe outer Ø (A) mm Bushing code Nut code F

10 9341080 9341000 11/16-16UNFfrontO-Ring

12 9341081 9341001 13/16-16UNFfrontO-Ring

14 9341082 9340116 1”-14UNFfrontO-Ring

16 9341083 9340116 1”-14UNFfrontO-Ring

20 9341084 9340117 1”3/16-12UNFfrontO-Ring

22 9341085 9340118 1”7/16-12UNFfrontO-Ring

25 9341086 9340118 1”11/16-12UNFfrontO-Ring

FA



�1

B5

3.2.1 Instructions to carry out welding on the ogive

Theogivesshouldbefittedtotheendofthepipesbybrazing.

Preparing the surfaces

u Allsurfacestobejoinedandthezonesclosetothemmustbepreviouslycleanedinordertoremovealltracesofdirt,grease,paint,superficialoxides,zinccoating,etc.Todosoitisnecessarytodegreaseandgrind,withtheutmostcare,andbymeansofanabrasivecloth,thepipeoutersurfacesandthesurfacesinsidetheogiveinthecouplingareasindicatedinthefigure1.Grindingisessentialtoroundthecornersandtomakethesurfacesroughinordertoimprovetheweld.

Fig. 1

roundthecorners

Surfacestobedegreasedandground

Thisoperationmustbedoneshortlybeforeweldinginordertopreventanynewformationofsuperficialoxides.

Welding

u Tobrazetheogivesonthehydraulichosesitisnecessarytoprovide:

a) - Alloy EN 1044 type Ag 102

b) - deoxidizer paste EN 1045 type H10 (example: alloy BRAZE TEC 5600 with deoxidizer BRAZE TEC)

Spreadthepastebymeansofabrushontheareastobewelded.

u Positiontheogiveandthepipewiththeaxisoftheverticaljointverticallyonasupportsurfacemadeupofrefractorymaterialtoavoidanylossofheat.Preheatinwidthandindepthwithaneutralorslightlycarburazingflamewithoutdirectingtheflametothejointopening.Forthe20-and25-mmdiameterpipepreheatthepipetoagreaterextent.Assoonasthedeoxidizerliquefies(materialcolourwillbedarkred)andflowsfreely,meltthetipofthestick,removeadropoffillermetalandpositionitonthejoint(figure2).

Filler metal deposit area Fig. 2

Hoses and pipes


��

B5Blowpipeinclination30-45°andblowpipeendat1-2cm.fromthesurface.Duringmeltingofthefillermetal,makethestickturnslowlybetweenyourfingersandavoidoverheatingthepiece.

Makethemetalflowalongthejointwithacontinuousmovementoftheflame.Depositotherfillermaterialuntilitcomesoutofthelowersideoftheogive.

AFTER COMPlETINg THE WElD, DURINg THE vISUAl CHECk FROM THE INNER SIDE A REgUlAR SEAM ON THE WHOlE CIRCUMFERENCE MUST BE DETECTED.

Makethemetalflowalongthejointwithacontinuousmove-mentoftheflame.

Depositotherfillermaterialuntilacollarisformedallalongtheoutercircumferenceofthepipe(seefigure).

Cleaning the welded joint

u Afterfinishingwelding,withthepiecestillhot(300°Cmaximum),dipthebrazedareaofthepipeinwarmwaterinordertoeliminatetheresiduesofdeoxidier.Ifnecessary,cleanthesurfacesusingabrushmadeupofhardsilks.

Safety at workplace

u Weldingshouldbecarriedoutinawell-ventilatedplacetoavoidinhalingthegases/vapoursexhaustedwhileweldingandgettingincontact(withyourskinoryoureyes)withthedeoxidizerpaste.Complywiththerecom-mendationsofthesupplierofthebrazingmaterials.

Service Manual GB


B6

WRENCH SETTINGS

07-2008 Rev. 3

Wrench settings


�

B6 Wrench settings

1 - Torque wrench setting of hydraulic fittingsHydraulic fittings fitted on EFFER cranes to be tightened with dynamometric wrench, have two types of threads:

1- Cylinder gaS - BSPP - 2- unf - JiC 37°- Sae J514

The cylinder gas - BS PP thread - is typical of hydraulic fittings located in the points of connections, such as valves, controlbanks, rotary controlbanks, filters, etc. Sealing is provided by a gasket located on the faying sur-face of the fitting.Unf - JIC 37° thread provides a mechanical sealing between the two faying surfaces tilted to 37° of the connec-ting components. It is generally located in the point of connection between fittings and pipes or hoses.Hydraulic fittings require a correct torque to grant sealing.

nOTe: if a fitting leaks oil, it is useless or even dangerous to tighten it “strongly” by means of extensions applied at the tip of the tools, as you may damage or brake the fitting.

If a fitting with correct torque setting leaks oil, look for the cause. A damaged seal on a gas type fitting or on a JIC 37° type fitting or a fault on the surfaces may cause oil leak.Warning: fittings on heat exchanger oil tank and on discharge filter shall not be tightened with dynamometric wrench, as the circuits are at low pressure and a light tightening is enough. We enclose the following three tables, with the correct torque wrench setting of fittings:

1.1 Torque wrench setting of pipe fittings - Coupling thread type unf JiC 37° - (Sae J514)

Ø Pipe diameter Nm

8 26

12 58

16 95

20 130

25 200

32 260

38 330

Wrench settings Wrench settings


�

B6

1.2 Torque wrench setting of hose fittings - Coupling thread type unf JiC 37° - (Sae J514)

Ø Hose diameter Nm

¼” 31

3/8” 61

½” 95

¾” 130

1” 190

1.3 Torque wrench setting of “gaS CylindriC BS PP” thread fittings

Thread Nm

¼” 31

3/8” 61

½” 95

¾” 160

1” 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.


B7

Hydraulic / electro-hydraulic limiting device


07-2008



�

B7 Hydraulic / electro-hydraulic limiting device

Hydraulic / electro-hydraulic limiting device Hydraulic / electro-hydraulic limiting device


�

B7

1 - Operating principleINTRODUCTION

u TheoverloadlimitingdevicefittedtotheEFFERcraneshasbeendesignedaccordingtotheEN12999–A2rules.TheaimofEFFERistosupplyasafetydevicewhich,insteadofpenalizingtheuserofthecrane,makestheoperator’sworksaferaccordingtothefeatures indicated inthe loaddiagrams,avoidingtheriskofdamagingpeopleandthings.Acranewiththeoverloadlimitingdevicecorrectlysetgrantstheuserasafeandreliableuseinthetime.

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:- Craneswithliftingcapacityequaltoorgreaterthan1000KG,indicatedintheloaddiagram.- Craneswhosemaximumnetliftingmomentishigherthanorequalto40.000Nm(4Txm).

Theloadlimitingdevicefittedtothecranemusthavethreedifferentfunctions:1) avoidingoverloadsintheframe2) avoidingtheriskofoverturningthevehicle3) avoidingdangerousmovementsoftheload

uThesamesetofstandards,underpoint5.6.4,providesfortheworkerisacousticallywarnedwhenthecranereaches 90% of its maximum lifting capacity, and when 100% of its maximum lifting capacity is achieved, adifferentwarningsignalnoiseisemitted.u Underpoint5.6.7ofthesamesetofstandardsitisreportedthatonthecraneswitharadiocontroltohandlethebooms,orahorizontaloutreachofmore than12metres,anacousticalarmdevicemustbeprovided, forexample,aKLAXON,operablebytheworkerfromanycontrolstationused.

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 Itmayoccurthatthecranetip,whenthemaximumloadthatcanbeliftedisappliedtothehook,yields,ordoesnotremainperfectlystopped.Furthermore,thestandardsmentionedabove,stateunderpoint5.5.7,asfollows:-Thecranetipcanhaveasmallunintentionalspeedofdescent,whenthemaximumnominal loadisapplied.However,itmustnotbehigherthan0,5%ofcraneoutreachperminute

u THE EUROPEAN STANDARD EN 12999 – A2, underpoint5.6.2,indicatesthemaximumtolerancewhichtheloadlimitingdevicecanhave:thisvariesaccordingtothelengthofthecraneandtheloadappliedtothehook.TheloadlimitingdevicesfittedtoEFFERcranesareveryaccuratedevices:itisnotnecessarytorefertotoleranceallowedbythestandardstoconsiderthedeviceoperationappropriate.

All EffER cranes are able to handle the loads indicated in the table.



�


Inhibited movements

u Theprinciplegoverningthehydraulic/electro-hydrauliclimitingdevicefittedtotheEFFERcranesistoauto-maticallyinhibitcertaincranemovementswheninsidealiftingcylinderthemaximumpressurevalueallowedbytheprojectisreached.Thispressurevalueisdependentontheloadapplied.Therefore,somemovementsareinhibitedwhenthecraneachievesitsmaximumperformance.

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.

1.1 Movements inhibited by the limiting deviceTheinhibitedmovementsarethosemovementswhichoverweightthecraneloadmoment:

u a - Crane with slewing mechanical limitation (operatingby180°onthetruckbody:“workingareaA”):

Thefollowingmanoeuvresarelocked:

-allboomdescents,

-theouterboomandthefly-jibrise,

-allthehydraulicextensionexits,

-thewinchrise.



�

B7

u b - Crane with slewing mechanical limitation and proportional controlbank:(operatingby180°onthetruckbody:“workingareaA”):

Thefollowingmanoeuvresarelocked:-1stboomdescent-extensionsout-winchrise-outerboomandsupplementaryjib:anelectricrocker arm (REF. X) detects the boom positionwithrespecttothehorizontalline:whenboomsareabovethehorizontalline,theboomdescentisinhibitedwhilewhenboomsarebelowthehori-zontalline,theboomdescentisallowed.

Inhibited movements

Ref. X

EffER part # 9394696 EffER part # 9394767



�


c1-Overload limiting device operation in the working area A

Whenthedeviceisoperatedinthe180°max.operatingareabehindthetruckcab,thefollowingmanoeuvresarelocked:

-1stboomdescent

-extensionsout

-winchrise

-outerboomandsupplementaryjib:anelectricrockerarm(ref. X)detectstheboompositionwithrespecttothehorizontalline:whenboomsareabovethehorizontalline,theboomdescentisinhibitedwhilewhenboomsarebelowthehorizontalline,theboomdescentisallowed.

Inhibited movements


Ref. X

c- Crane with slewing electrical limitation: thetruckbody”workingareaA”issurroundedbyelectricalsen-sors.

Thiscraneversionallowsobtainingthemaximumoperationonthetruckbody”workingareaA”,andreducedoperationover180°inthefrontofthetruckcab”workingareaB”.Theoperationdependsonthestabilityofthetruck/cranecombination.

Slewing control systems:

Proximity fitted on crane withslewing by rack and pinion

Switch fitted on cranewith slewing ring

Proximity fitted on cranewith slewing ring



7

B7

c2-Overload limiting device operation in the working area B

Whenthedeviceisoperatedinthe180°areainfrontofthetruckcab,inadditiontowhatwasexplainedinsectionc1,theboomrisesarelockedtoo,whatevertheirposition.

12

3

4

direction1=itiscompulsorytocontinuethemanoeuvre

direction2=itiscompulsorytoperformtheinversemanoeuvre

Iftheoverloadlimitingdeviceisoperatedinthisworkingarea,asaresultofaslewingmanoeuvreyoumay:

- Crane with rack slewing:

performtheslewingmanoeuvreinbothdirections.(Theoverload

limitingdevicedoesnotinterfereoncraneslewingmovement)

- Crane with slew ring:

performtheslewingmanoeuvreinthedirectionthatmakesthe

craneboomreachthehighestliftingcapacityareaAthroughthe

shortestway.

direction3=itiscompulsorytoperformtheinversemanoeuvre

direction4=itiscompulsorytocontinuethemanoeuvre

StandardworkingAreainwhichtheoverloadlimitingdeviceoperated



�


c3- Overload limiting device operation during crane slewing passing from the working area A to the working area B

Iftheoverloadlimitingdeviceisoperatedasaresultofaslewingmanoeuvretoenterthe180°areainfrontofthecab,theinversemanoeuvreisallowedautomatically.

-Cranewithpinion/rack -Cranewithslewingring



�

B7

2.1 Hydraulic connections to the “load limiter valve” EFFERusesseveraltypesofvalvestooperatetheloadlimitingdevice.Thesemaybehydraulic,orelectrohydrau-lic,accordingtothetypeofcranesandoptionalpiecesfitted.Thefollowingaretheconnectionstothesevalves,alongwiththeirfunction:

� - Valves and components

Ref. Connections

T Connectiontotheoiltank,withoutpassingthroughthedrainfilter.Thevalvedrainageoilcomesoutofthishole.

P Itisconnectedtothepipeconnectingthehydraulicpumptothecranecontrolbank.

P1Thehydraulicpipeisconnectedhere.Thispipeconveysthepressurevaluetothevalveinsidethecyl-inder/sonwhichthedevicedetectsthepressurevalue:whentheallowedmaximumvalueisachieved,thenthedeviceisoperated.

RS

Thehydraulicpipeisappliedhere.Itconnectstotheextensionelementinletconveyingoiltotheexten-sioncylinderduringthereturnmanoeuvre.Thissignalinhibits,forawhile,theloadlimitingdevice,that,however,comesintooperationagainiftheconditionscausingitsoperationpersist.Youmaybenefitfromthismanoeuvrewhenyouhavetoreleasethecranefromthedeviceoperationasaresultofalimitstopmanoeuvrecarriedoutwiththefirstboomcylinderorwhenthedevicecomesintooperationfurthertoaswingingoftheload.

S Oilcomesoutofthisholewhentheloadlimitingdevicecomesintooperationtofeedthecylinderspreventingtheoperationofsomeofthecontrolbankfunctions.

IApipeconnectionpointconnectedwiththefirstboomelementinletconveyingoiltothefirstboomcylinderduringthisboomdescentmanoeuvre.Thishydraulicconnectionoptimisestheloadlimitingdeviceoperationfurthertotheboomdescentmanoeuvre,bycorrectingtheeffectofthefrictionexist-ingonthecranepins(Notfittedonsomesmallmiddlerangecranes).

If Ahydraulicpipeconnectionpointconnectedwiththefirstboomelementinletconveyingoiltothefirstboomcylinderduringthisboomrisemanoeuvre.

M Pressuregaugeattachmentpoint.

v Register for the valve setting value change. for the correct operation sequence, please see the following sections.

ETap,leadcoatedbyEFFER.Thistapoverridestheloadlimitingdevice.Whenoverloadtestsaretobeperformed,theoperationoftheloadlimitingdevicehastobeblockedmomentary.Thisoverridehastobeperformedwhenthedeviceisnotturnedonduetothecranemax.performance.NOTE: Saidtapmustbealwayssealed.Iffoundunsealed,thecranewarrantydecays.

DElectricalmicroswitch-EffER part #9394704.Whentheloadlimitingdevicecomesintooperation,asmallpistoninsidethevalve,operatesthemicroswitch,conveyingthesignaltothecraneelectricalcomponent.

L Apipeconnectionpointconnectedwiththecontrolbankelementinlet:thefirstboomdescend-jibrise(iffitted)-(inlet marked with M ed N)

H Pipe connection point to send a pressure signal to the load limiter valve to delay the operationipeconnectionpointtosendapressuresignaltotheload limiter valve to delay the operationloadlimitervalvetodelaytheoperation(inlet marked with P)

g Connectionpointfor a pressure switch, if mounted.forapressureswitch,ifmounted.

Z Connectionpoint for cylinder pressure signals activating the load limiting device.forcylinderpressuresignalsactivatingtheloadlimitingdevice.



10


EffER part #8865715

EffER part #8865717

i

e

p1

v

rssm

t

t

e

p1

m

s

rs

vi

2.2 ComponentsOverloadlimitingvalve

Overloadlimitingvalve



11

B7

EffER part #8865716

rs s dm

v i

p1

te

EffER part #8865784

iF

mrs

t

p

p1





1�


EffER part #8865776

EffER part #8866777

L

v

Z

L

H

p1

Z Z

L.S.signalfeeder

Max.pressurevalve



1�

B7

EffER part #8850217

EffER part #8864920

EffER part #8865713Flip-Flopvalve

Shockabsorbingpistonaccumulator

Max.pressurevalve

EffER part # 8866707 Pressureswicth


EffER part #8864939

+



1�


EffER part #8866708 Solenoidvalvewithmax.pressurevalve

EffER part #8865794 Max.pressurevalveEffER part #8877006

EffER part #9394654 EffER part #9394762Electricmicroswitch

Gauge

Proximity

S2+

-

bn bk

bu

S2



1�

B7

� - Practical setting of the overload limiting deviceTheloadlimitingdeviceistestedbyEFFERonthetestbenchwithoutloads.

Therefore,oncetheinstallationiscompletedandoncethesettingvaluesofthehydrauliccontrolbankarecheckedincompliancewiththeEFFERgivenvaluesreportedinthecranehydraulicdiagramtheinstallatorshalltestthecorrectfunctioningoftheloadlimitingdevice,inpractice,byhandlingloads.(Settingsmaychangeduetodiffer-entcrane/hydraulicpumpcombination).

Theidealusefulloadcanbedeterminedbyconsideringthecranemax.liftingcapacityattheendofthesecond-lasthydraulicextension(second-lasthydraulicextensionofthebasiccraneinhorizontalconfigurationwhentestingtheoverloadlimitingdeviceofthebasiccrane,second-lastsupplementaryextensioninarticulatedconfigurationwhentestingtheoverload limitingdeviceof thesupplementary jib,alwaysrespectingthecurvesof the loaddiagramofthecrane).

Thetest/settingoftheoverloadlimitingdeviceinthefrontworkingareacanbeperformedwiththebasiccraneonly.

It is advisable to apply loads heavier (+/-10%,15%) than the loads indicated in the diagrams, to prevent the last extension hydraulic stroke from causing oscillation of the applied load and the unnecessary operation of the device.

Basiccrane(workingareaA) Basiccrane(workingareaB)Basiccrane+supplementaryjib

(workingareaA)

AvAILABLE CONfIgURATIONS TO TEST THE OvERLOAD LIMITINg DEvICE OPERATION PRACTI-CALLy



1�


3.1 Calculation of the point of intervention of the overload limiting device

Usingasimplemathematicalproportionitispossibletodeterminethecorrectpointofinterventionoftheoverloadlimitingdevice,asthefollowingexample:

m7,8kg4800

m10kg3400

-Takealoadof3800 kg asreference,namedPx

-Takingasreferencecraneloaddiagram,identifythehydraulicextensioncapableofliftingsuchload,inthatcasethe3rdextension.

-Calculateasfollows:

(d1x P1) + (d2 x P2) : 2 =(7,8m x 4800kg) + (10m x 3400kg) : 2 = 9,4 m Px 3800 kg

-Theresultisthatourcranecanliftaloadof3800 kgatamax.outreachof9.4 mfromtheslewingaxis.

NOTE: In order to set correctly the point of intervention of the overload limiting device, see the instructions of the following chapter.

3.2 Crane boom position during the practical testsDuringoverloadingtests,maximumattentionhastobepaidtothepositionofthecranebooms:awrongboom

positioningmayjeopardisetheresultofthetest.

Therefore,followtheinstructionsbelowwithgreatcare.

3.2.1 TESTINg THE BASIC CRANE (wORKINg AREA A)

Positionthe1stboomofthecranesoastohavethemax.fulcrumbetweenthe1stboomcylinderandthecol-umn/mainboomhingepoint.

Thedistancefshallbethemaximumone.

• Crane without connecting rod between column and 1st boom

Themax.valuefi.edistanceperpendiculartothecylinderaxis-isachievedwhentheliftingcylinderaxisisatthefarthestpointfromtheboomcolumnpin.

• Crane with connecting rod between column and 1st boom

Themax.distancef“isachievedwhentheaxisofthelongestconnectingrod“i.e.linepassingtroughtwopinsfasteningthesameconnectingrod”,issomedegreesabovethehorizontalline(asshowninfigure).

d1P1

d2P2



17

B7

NOTE: The load diagrams show the angle that the 1st boom must reach, to get the maximum distance f.

1

2

f

f

Restthecrane2ndboominhorizontalposition.Performamanoeuvreofextensionsoutatthemax.speed,avoidoscillatingtheload.Itisadvisabletoapplyropesorchainsasshortaspossibletolifttheload.

Duringthetestsof thepointof interventionof theoverload limiting device do not change the craneboomposition:thesolemanoeuvreallowedisexten-sionsout/extensionsretracted(manoeuvre1).

When the test of the point of intervention is com-pleted, rise the 1st boom cylinder to lift the load(manoeuvre2).

A crane with the overload limiting device correctly set is able to lift the indicated load, according to the data reported in the load diagram.

+2°÷4°



1�


3.3 Testing the basic crane (working area B)TheoverloadlimitingdeviceissetbyEFFERconsideringthecraneinstalledonatruckwithminimumtare,respec-tingtheweightsontheaxles.Inconsequenceofit,itmaybenecessarytoadjustthecraneworkingdiagramandtosetthepointofinterventionoftheoverloadlimitingdeviceasaprecaution.

Inordertoobtaintheperformancesresultingfromthestabilitycalculations,accordingtothespecificconfigurationdata,itisnecessarytochangetheEFFERsettingvalue.

Thestabiltycalculationsprovideanewloaddiagram(tobeappliedtothecranecontrolpost).Now,followingtheinstructionsoftheprevioussection,youcandeterminethepointofinterventionoftheoverloadlimitingdeviceaccordingtotheloadsavailable.

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.

?



1�

B7

3.4 fly-jib position during the practical tests

MAX.

- (2°÷ 3°)

Off

Duringtheteststochecktheloadlimitingdevicepointof operation, it is very important to properly place thecranebooms:anyerrorinpositioningmayjeopardisethetestresult.

Followtheinstructionsbelowthoroughly.

NOTE: This test does not affect the basic crane test, since the overload limiting device receives the pres-sure signal directly from the jib cylinder.

Inordertoavoidthepossibleinterventionoftheoverloadlimitingdevicecausedbythebasiccrane,makethecraneboomsrestjustbelowthemax.verticalpositionandretractthecraneextensionscompletely.

Setthefly-jibinhorizontalposition.

To limit structural skids resulting from truck decliningposition,werecommendpositioningthecraneboomsintheareaoverthebucket–lengthwise-



�0


Thefollowingexamplesshowthatthesecond-lastextensioncanliftaloadof1170kg(fig.1)and920kg(fig.2).

3.5 Point of intervention of the overload limiting device

0 2 4 6 8 10 12 m

0

2

4

6

8

10

12

14

16

18

20

22

24

14 16 18 20 22

6S+JIB 4S

20.14 510

22.04 435

27.74 295

29.78 230

31.81 170

m kg

m kg

85°�

23.94 385

25.84 325

2080kg 1430 670

920 530

9.70 2080

13.50920

17.30530

m kg

11.601430

15.40670

fig.1

fig.2

0 2 4 6 8 10 12 14 m

0

4

6

8

10

12

14

16

18

m83°

16 18 20 22

20

22

24

26

2

12° 1000 Kg

16.01 m

845 Kg

17.98 m

740 Kg

19.98 m

665 Kg

21.98 m

560 Kg

24.09 m

480 Kg

26.20 m

28

30

24 26 28

32

2800 Kg

670 Kg1760 Kg 1170 Kg 880 Kg

530 Kg

Now,bytakingasareferencetheloaddiagram,fixthemax.loadthatcanbeliftedbythesupplementaryfly-jib.

Differentloaddiagramtypesare available: with curves(Fig.1),withloadvaluesanddistancefromtheaxisofro-tation(Fig.2).



�1

B7Youshouldlaydownaloaddiagramconcerningthejib,whichisindependentofthecrane:asiftheadditionaljibwas.....keptinhand.....

Afterfindingthevaluesrelatingtothemaximumloadsthatcanbemovedbythejib,youhaveto identifydistances:thesedataareessentialtoapplythemathematicalformulathatdeterminestheloadlimitingdeviceproperpointofoperation.

How to determine the values from m1 to m5 ?

The crane diagram in horizontal configuration will help you.

The value m1 is equal to distance AB

The value m2 is equal to distance AC

And so on until the value m5 that is equal to the distance AD. Fromthissimplecalculation,youcandeter-minetheadditionaljibfeatures:distancesandmaximumliftingcapacity.

m

1 2 3 4 5

A B C D E F

mkg

kg?

?



��


3.6 Conclusion

uIntheconfigurationofhorizontalcraneandjib,withbasiccraneextensionscompletelyout,themax.liftingcapacityofthesupplementaryjibiscontrolledbytheoverloadlimitingdeviceconnectedtothebasiccrane.

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).

uIntheconfigurationofbasiccraneextensionscompletelyretracted,themax.liftingcapacityofthesupplemen-taryjibiscontrolledbytheoverloadlimitingdeviceconnectedtothesupplementaryjibcylinder.

Followingtheinstructionsofsection3.1,checkthepointofinterventionoftheoverloadlimitingdevicewithrespecttothesupplementaryjib.

NOTE: In order to modify the point of intervention of the overloadlimiting device, see the instructions of the following chapter.



��

B7

� - Operating sequences to set the load limiting deviceAsexplainedinthepreviouschapters,youcanimaginethattherearemanyloadlimitingdevicesonacrane,de-

pendinguponthenumberofaccessoriesorperformance:

-thepresenceofanadditionaljib

-acranewithF.P.I.system

-acraneworkinginthefrontworkingarea–Barea-

-acranewherealsothesecondboomcylinderinnerpressureisdetectedbythedevice

Allthisimpliesthataspecificoperatingsequenceduringtheloadlimitingdevicesettingmustberespected,asallthevariableslistedaboveare“interconnected”onetotheother:Ifonesettingvalueischanged,allthefollowingsettingvaluesarechangedaswell.

Pleasefindbelowtheoperatingsequencetobefollowedtosettheloadlimitingdevice,incasethecranereferredtoisabasiccrane.

- 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.

Fortheoperatingsequencetobefollowedtosettheloadlimitingdevice,incasethecranereferredtoisabasiccranewithadditionalhydraulicjib,pleaserefertopage29.

from § 4.11 to § 4.21 -



��


4.1 Basic crane with manual controlbank, not proportional, operating in the rear work area onlyTheoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstboomcylinder.Whentheoverloadlimitingdeviceoperates,thepumpoilisconveyeddirectlytothetank,andthecranestops.

Setting points

Valveref.1controlsoverloadlimitingdeviceoperation.

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 dur-ing 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.

4.2 Basic crane with manual controlbank, not proportional, operating in the rear work area only

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstboomcylinder.

Setting points

Valveref.1controlsoverloadlimitingdeviceoperation.

1 2

1



��

B7

4.3 Basic crane with proportional controlbank, and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, accord-ing to the special setting

Theoverloadlimitingdeviceoperateswhenthemax.pres-surevalueisreachedinsidethefirstboomcylinder.

Setting points

1sttest:operationoftheoverloadlimitingdeviceinthefrontworkarea.Valveconcernedref.1.

2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea.Valveconcernedref.2.

4.4 Basic crane with manual controlbank, not proportional, operating in the rear work area only

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstref.1orthe2ndboomcylinderref.2.Themax.pressurevalueisthesameforboththecylinders.

Setting points

13

2

Thevalveref.3controlstheoperationoftheoverloadlimitingdevice.

12



��


1 4

5

3

2

1

2

3

4.5 Basic crane with proportional controlbank, and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, accord-ing to the special setting

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstref.1orthe2ndboomcylinderref.2.Ahigherpressurevalueinsidethe2ndboomcylinderisallowed,respecttothe1stboomcylinder:valveref.3operatestocompensatepressurevalues.

Setting points



3rdtest:valvesettingref.3.Thisisafixedsetting.Tocheckthesettingvalue,removethevalveandtestit at the test bench.This test may be necessarywhentheoverloadlimitingdevicereleasesduringa manoeuvre of max. opening of the 2nd boomwithout load applied.

4.6 Basic crane with proportional controlbank, operating in the rear work area only

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstref.1orthe2ndboomcylinderref.2.Themax.pressurevalueisthesameforboththecylinders.

Setting points

1sttest:operationoftheoverloadlimitingdeviceintherearworkarea.Valveconcernedref.3.



�7

B7

2

1

4.7 Basic crane with manual controlbank, not proportional, with device f. P. I, and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, according to the special setting


Setting points


2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea.Valveconcernedref.2withFPIdeviceOFF.

3rdtest:operationoftheoverloadlimitingdevicewithFPIdeviceON.Valveconcernedref.3.

4.8 Basic crane with proportional controlbank, and electrical limitation of the work area behind cabin: crane operating capacity in the cabin area is set by a pressure switch

Thecranecanoperateinthecabinworkarea,accordingtothespecialsetting.Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreached

Setting points



132



��


4.9 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

Thecranecanoperateinthecabinworkarea,accordingtothespecialsetting.

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

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstref.1orthe2ndboomcylinderref.2.Ahigherpressurevalueinsidethe2ndboomcylinder is allowed, respect to the 1st boomcylinder: valve ref. 3 operates to compensatepressurevalues.

Setting points

1sttest:operationoftheoverloadlimitingde-viceinthefrontworkarea.Valveconcernedref.4.

2ndtest:operationoftheoverloadlimitingde-viceintherearworkarea.Valveconcernedref.5withFPIdeviceOFF.

3rd test: operation of the overload limitingdevicewithFPIdeviceON.Valveconcernedref.6.


Setting points


2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea.Valveconcernedref.2withFPIdeviceOFF.

3rdtest:operationoftheoverloadlimitingdevicewithFPIdeviceON.Valveconcernedref.3.

41

2

5

3

6

23

1



��

B7

Pleasefindbelowtheoperatingsequencetobefollowedtosettheloadlimitingdevice,incasethecranereferredtoisabasiccranewithadditionalhydraulicjib.

4.11a Basic crane with supplementary hydraulic jib, manual con-trolbank, not proportional, operating in the rear work area onlyTheoperationoftheoverloadlimitingdeviceofthebasiccranetakesplace whenthemax.pressurevalue isreachedinsidethefirstref.1orthe2ndboomcylin-derref.2.Theoverloadlimitingdeviceoperatesalsowhenthemax.pressurevalueisreachedinsidethejibcylinderref.3.

Setting points

1sttest:operationoftheoverloadlimitingdeviceofthesupplementaryjib:Valveconcernedref.4.

2ndtest:operationoftheoverloadlimitingdeviceofthebasiccrane(supplementaryjibnotfitted):Valveconcernedref.5.

1

4.11b Basic crane with supplementary hydraulic jib, manual con-trolbank, not proportional, operating in the rear work area onlyTheoperationoftheoverloadlimitingdeviceofthebasiccranetakesplace whenthemax.pressurevalue is

reachedinsidethefirstref.1orthe2ndboomcylin-derref.2.Theoverloadlimitingdeviceoperatesalsowhenthemax.pressurevalueisreachedinsidethejibcylinderref.3.

Setting points


2ndtest:operationoftheoverloadlimitingdeviceofthebasiccrane(supplementaryjibnotfitted):Valveconcernedref.5.

5

1

3 JIB

4

2

5

3 JIB

4

2



�0


4.12 Basic crane with supplementary hydraulic jib, manual con-trolbank, not proportional, and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, according to the special set-ting

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstref.1orthe2ndboomcylinderref.2.Ahigherpressurevalueinsidethe2ndboomcylinderisallowed,respecttothe1stboomcylinder:valveref.4operatestocompensatepressurevalues.Theoverloadlimitingdeviceoperatesalsowhenthemax.pressurevalueisreachedinsidethejibcylinderref.3.

Setting points

1st test: operation of the overload limiting deviceinthefrontworkarea(nosupplementaryjibap-plied).Valveconcernedref.5.

2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea(nosupplementaryjibapplied).Valveconcernedref.6.

3rdtest:valvesettingref.4.Thisisafixedsetting.Tocheckthesettingvalue,removethevalveandtestitat the testbench.This testmaybenecessarywhentheoverloadlimitingdevicereleasesduringamanoeuvreofmax.openingofthe2ndboomwithout load applied.

4thtest:operationoftheoverloadlimitingdeviceofthesupplementaryjib.Valveconcernedref.7.

4.13 Basic crane with supplementary hydraulic jib, proportional controlbank, operating in the rear work area only

The overload limiting device operates when the max.pressurevalueisreachedinsidethefirstboomcylinderref.1andinsidethejibcylinder.ref.2.

Setting points


2nd test: operation of the overload limiting device ofthebasiccrane(nosupplementaryjibapplied):Valveconcernedref.4.

4

1

6

2

7

5

3 JIB

4

1

3

2 JIB



�1

B7

4.14 Basic crane with supplementary hydraulic jib, proportional controlbank, and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, according to the special setting

Theoverloadlimitingdeviceoperateswhenthemax. pressure value is reached inside the firstboom cylinder ref. 1 or inside the jib cylinderref.2.

Setting points

1sttest:operationoftheoverloadlimitingdeviceinthefrontworkarea(nosupplementaryjibapplied).Valveconcernedref.3.

2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea(supplementary jibnotfitted).Valveconcernedref.4.

3rdtest:operationoftheoverloadlimitingdeviceofthesupplementaryjib:Valveconcernedref.5.

4.15 Basic crane with supplementary hydraulic jib, proportional controlbank, operating in the rear work area only

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirst boom cylinder ref. 1 or inside the jibcylinder.ref.2.

Setting points

1st test: operation of the overload limitingdevice of the supplementary jib:Valveconcernedref.3.

2ndtest:operationoftheoverloadlimitingdeviceofthebasiccrane(nosupplemen-taryjibapplied):Valveconcernedref.4.

1

3

4

5

2 JIB

13

4

2 JIB



��


1

3

4

5

2 JIB

4.16 Basic crane with supplementary hydraulic jib, manual con-trolbank, not proportional, operating in the rear work area only

Theoverloadlimitingdeviceoperateswhenthemax.pres-surevalueisreachedinsidethefirstboomcylinderref.1orinsidethejibcylinderref.2.

Setting points


2ndtest:operationoftheoverloadlimitingdeviceofthebasiccrane(nosupplementaryjibapplied):Valvecon-cernedref.4.

4.17 Basic crane with supplementary hydraulic jib, proportional controlbank, and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, according to the special setting

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstboomcylinderref.

1orinsidethejibcylinderref.2.

Setting points

1sttest:operationoftheoverloadlimitingdeviceinthefrontworkarea(nosupplementaryjibapplied).Valveconcernedref.3.

2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea(supplementaryjibnotfitted).Valveconcernedref.4.

3rdtest:operationoftheoverloadlimitingdeviceof the supplementary jib:Valve concernedref.5.

4

1

2 JIB

3



��

B7

1

2 JIB

1

3

4

6

5

3

2 JIB

4

5

4.18 Basic crane with supplementary hydraulic jib, proportional controlbank, with f.P.I device and electrical limitation of the work area behind cabin: the crane can operate in the cabin work area, according to the special set-ting

The overload limiting device operates when themax.pressurevalueisreachedinsidethefirstboomcylinderref.1orinsidethejibcylinderref.2.

Setting points

1st test:operationof theoverload limitingdeviceinthefrontworkarea(nosupplementaryjibap-plied).Valveconcernedref.3.

2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea(supplementaryjibnotfitted).Valveconcernedref.4withFPIdeviceOFF.

3rdtest:operationoftheoverloadlimitingdeviceintherearworkarea(supplementaryjibnotfitted).Valveconcernedref.5withFPIdeviceON.

4thtest:operationoftheoverloadlimitingdeviceofthesupplementaryjib:Valveconcernedref.6.

4.19 Basic crane with supplementary hydraulic jib, proportional controlbank, and electrical limitation of the work area behind cabin: crane operating capacity in the cabin area is set by a pressure switch

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstboomcylinderref.1orinsidethejibcylinderref.2.

Setting points


2ndtest:operationoftheoverloadlimitingdeviceintherearworkarea (nosupplementary jibapplied).Valveconcernedref.4.

3rdtest:operationoftheoverloadlimitingdeviceinthefrontworkarea(nosupplementaryjibapplied).Valveconcernedref.5.



��

B7

61

2 JIB

3

4

5

81

2

57

43 JIB

6

4.20 Basic crane with supplementary hydraulic jib, proportional controlbank, with f.P.I device acting on the basic crane and on the supplementary jib, and electrical limitation of the work area behind cabin: crane operating capacity in the cabin area is set by a pressure switch

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstboomcylinderref.1orinsidethejibcylinderref.2.

4.21 Basic crane with supplementary hydraulic jib, proportional controlbank, with f.P.I device acting on the basic crane and on the supplemen-tary jib, and electrical limitation of the work area behind cabin: crane operating capacity in the cabin area is set by a pressure switch

Theoverloadlimitingdeviceoperateswhenthemax.pressurevalueisreachedinsidethefirstboomcylinderref.1,the2ndboomcylinderref.2,andthejibcylinderref.3.Ahigherpressurevalueinsidethe2ndboomcylinderisallowed,respecttothe1stboomcylinder:valveref.4operatestocompensatepressurevalues.

Setting points

1sttest:operationoftheoverloadlimitingdeviceof the supplementary jib:Valve concernedref.5.

2ndtest:operationoftheoverloadlimitingde-viceintherearworkarea(nosupplementaryjib applied).Valve concerned ref. 6 with FPIdeviceOFF.

3rdtest:operationoftheoverloadlimitingdevicewithFPIconnected(nosupplementaryjibap-plied).Valveconcernedref.7.

4thtest:operationoftheoverloadlimitingdeviceinthefrontworkarea(nosupplementaryjibapplied).Valveconcernedref.8.

Setting points


2ndtest:operationoftheoverloadlimitingde-viceintherearworkarea(nosupplementaryjibapplied).Valveconcernedref.4 withFPIdeviceOFF.

3rdtest:operationoftheoverloadlimitingdevicewithFPION(nosupplementaryjibapplied).Valveconcernedref.5.

4thtest:operationoftheoverloadlimitingdeviceinthefrontworkarea(nosupplementaryjibapplied).Valveconcernedref.6.

B8

CONTROLBANKS


Service Manual 07-2008 GB Rev. 3

Controlbanks


�

B8 Controlbanks

OIL SEEPAGE BETWEEN ELEMENTS

Oil seepage between elements is caused by the large inner surface relative to the oil delivery channel. This sur-face has created a force which could cause the tie rods joining the controlbank elements to be stretched out with subsequent extrusion of the o-ring.

B.8.0 - HC-D3M Controlbank: technical improvementsA modified HC-D3M controlbank will start to be applied since May 2000. This is to avoid poor reliability caused by oil seepage between elements along with oil leakages from lower plugs. The application of these modified controlbanks can be identified by the presence of plastic plugs which are applied on the nuts locking the three controlbank closing tie rods.

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:



3

B8If 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.

previousversion

newversion

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

type PSL 41-3 type PSL 52-3

Features: Max. working pressure 420 bar

Max. oil inlet capacity 100 lt/min.

Standard supply voltage 24 volt

Supply voltage on request 12 volt

Features: Max. working pressure 420 bar

Max. oil inlet capacity 200 lt/min

Standard supply voltage 24 volt

Supply voltage on request 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 con-trolbank.

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 ele-ment. 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 environ-ment. Make sure impurities do not enter the controlbank. Even touching the components with very dirty hands may jeopardise the correct operation of the controlbank.

Controlbanks


8

B8.1 Controlbanks

757-2

758-2

760-2

762-2

761-2

Identification of the parts PSL 41-3

5- Plug instead of check-relief valve

6- Check relief valve

1- Inlet element 2- Closing element

3- Lever element 4- Main pressure valve



�

B8.1

763-2763-3

761-3

760-3

765-2765-3

7- Radio control solenoid 8- Relief solenoid - load moment limit - (L.S.)

9- Inlet solenoid valve 10- Control lever

11- Control lever support

12- Rod return device 13- Controlbank tie rods

Controlbanks


10

B8.1 Controlbanks

1 - Inlet element

The following main components are applied to the inlet element:

1.1 - Max. pressure control valve also called “main valve”.

1.2 - Inlet compensator

1.3 - Exhaust solenoid valve

1.4 - Pressure gauged screw to eliminate pressure peaks

1.5 - Coupling for pressure gauge

1.6 - Pressure reducing valve

1.1 Main valve - EFFER code # 8990920- The valve is screwed to the body and is fastened with Loctite: if you need to remove it for service, act on the hexagon heavily. The hexagon size is 32 mm.

- External oil-hydraulic sealing is assured by a gasket (1) type O-ring 23,52 x 1,78 EFFER code # 8002100

- 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 remark-able 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.



11

B8.1

CAUTION: Always clean the components carefully before mounting the parts.

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).

parts inside the body of the inlet element

1 2

3

Fig. 1

Fig. 2

X

A B Y

Controlbanks


12

B8.1 Controlbanks

1.2 Inlet compensator

- Unscrew the four cap screws (1) -with a 5-mm Allen wrench - then remove the plug (2) securing the cylinder (3) called “inlet compensator”.

NOTE: The pressure exerted by the inner spring (4) 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 shall run freely in its seat, and the ports for oil flow shall be free from impurities.

- External oil-hydraulic sealing is assured by a gasket (5) type O-ring 17,12 x 2,62 Code # EFFER 8006000.

- 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.


* Version for changing control bank feed with fixed displacement pump to variable displacement pump (or viceversa), by turning screw (see section 7).

1 2

5

1 2

5

1

2

5

1 2

5

44

l = 5,8 cm(cod.8991268)

(cod.1932893)

3(cod.1932893H)

3

l = 6,8 cm(cod.8991972)

4

l = 5,8 cm(cod.8991268)

(cod.1932893)

3 4

(cod.1932893H)

3

l = 6,8 cm(cod.8991972)

17,3 mm

12,2 mm * *

f e e d w i t h f i x e d displacement pump

feed with variable displacement pump



13

B8.1

1.3 Relief solenoid valve

EFFER code # 8990765 for the 24-volt version - EFFER code # 8990919 for the 12-volt version

As explained in the foreword, if no lever is activated from the controlbank, the oil delivered by the pump returns to the tank, without passing through the controlbank.In order to make the oil reach the different lever elements, not only must a control lever be activated, but also the inlet solenoid valve must be enabled. That fact implies that the solenoid valve must be connected electrically by radio. The electric connection is performed so as to ensure continuous power supply when using the controlbank manu-ally, while, when using a radio remote control, the power supply occurs only when a lever on the transmitter is turned on. Even the activation of the electric stop-buttons of the crane may prevent the power supply to the solenoid valve.The solenoid valve is secured by four cap screws (1), which are to be tightened by a 3-mm Allen wrench. It is advisable to fasten those screws with a torque wrench: tightening torque 4 Nm. External oil-hydraulic sealing is assured by three O-rings (2) type 6x1,5 EFFER code # 8182272.A cylindrical point is located in the centre of the electric solenoid : by pushing it with a shaped tool, or simpler with a nail, the oil is diverted to the lever elements. This operation may be useful when you need to activate the crane in case of a failure of the solenoid valve or of the electric circuit of the crane.

CAUTION: Always clean the components carefully before mounting the parts.In case of mal-functioning or damage to the solenoid valve coil, the crane can be operated by cutting out the coil. Remove the coil and plug the two holes located on the solenoid valve with the screws (TE M4 x 6) and the corresponding seals, as shown in the picture. Perform all the operations with great care, as the function corresponding to the eliminated coil is now without the safety devices.

Coil input:

24 Volt = 1,1 A

12 Volt = 2,2 A

1

2

Controlbanks


14

B8.1 Controlbanks

535

1.4 Gauged screw to eliminate pressure peaks

u A hexagonal-head screw, removable with a 13-mm wrench, is located on the element side, on which the hydraulic ports for the oil inlet (from the pump) and the oil outlet (to the tank) are placed too.

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.


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 won’t last anyway more than few seconds at the very beginning of the lever operation, and which grants a much more constant boom operation).

Screw A: EFFER code # 8991081 (ø 9,6) high damping calibrated screw

Screw B: EFFER code # 8991261 direct calibrated screw EFFER code # 8991154 since 2001 (ø 9,3) Low damping calibrated screw

NOTE. Controlbanks Model 3 and Model 5 are equipped with the same calibrated screws.

773

A

B



15

B8.1

A

1.5 Coupling for pressure gauge

u Some caps are placed on the element side opposite to the relief solenoid valve. Next to one cap, the letter M is punched (pressure gauge coupling).

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 valve’s, you know already that you’ll first have to make a full end-stroke of the cylinder you are going to set, before proceeding with the setting. In doing this, you’ll 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 pressure did never occur in the circuit related to the check-relief valve being set.

M

772

Controlbanks


1�

B8.1 Controlbanks

1.6 Pressure-reducing valveOn the inlet element, under the plug markek with the letter A, a pressure-reducing valve is provided when the 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.

The pressure-reducing valve is meant to keep constantly a pressure of 20 bar in the circuit activating the lever under the radio-remote signals. (pressure not detected by the pres-sure gauge).

X) Pressure-reducing valve complete with gaskets: for standard crane, EFFER code # 8991262.

Y) Pressure-reducing valve complete with gaskets: for crane supplied with DMU ,

EFFER code # 8991470.


775

776776

NOTE: on crane equipped with DMU, pressure inside the control lever circuit is 40 Bar (pres-sure not detected by the pressure gauge).

X = 7 mm

Y = 18,5 mm



1�

B8.1

2- Closing element

u The closing element of the controlbank is meant for closing the controlbank but also for collecting the drain oil inside the controlbank (which is then sent to the tank).It is very important that the oil reaches the tank as smooth and simple as possible.Moreover, it is vital that the backpressure does never exceed 15 bar on the line from the controlbank to the hose reaching the oil tank. Should such a value be higher, the control levers might get stuck or worst, an oil leak from the rod-return device might occur.

Closing element, EFFER code # 8990634.

758-2

Controlbanks


18

B8.1 Controlbanks

3 - Lever elementThe main parts of the lever element are listed hereunder, with notes for each of them:

3.1 - ELEMENT BODY..................................................................................... (1)3.2 - ROD RETURN DEVICE .......................................................................... (2)3.3 - CONTROL LEVER SUPPORT .............................................................. (3)3.4 - INNER CURSOR .................................................................................... (4)3.5 - FLIP-FLOP VALVE ................................................................................... (5)

5 4

3

2

1



1�

B8.1

3.6 - ELEMENT COMPENSATOR ................................................................. (6)3.7 - CHECK RELIEF VALVES/ CAP INSTEAD OF THE VALVE .............. (7)3.8 - RADIO REMOTE CONTROL SOLENOID ........................................ (8)3.9 - LOAD MOMENT LIMIT SOLENOID - (L.S.) ................................... (9)

Lever:

EFFER code # 8990896

A

A Gasket set, EFFER code # 8990893B Gasket set, EFFER code # 8991260

B B B B

6

8

7

9

O-rings are coded as follows: Controlbank, class 3Gasket set, inlet element EFFER code # 8990893Gasket set, elements EFFER code # 8991260Controlbank, class 5Gasket set, inlet element EFFER code # 8991333Gasket set, elements EFFER code # 8991334

Controlbanks


20

B8.1 Controlbanks

3.1 Element body

u The element body is made of steel, and is secured to the controlbank by three tie rods (two M10, and one M8). One or more elements can be fitted in the controlbank to activate different hydraulic functions: this type of con-trolbank 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. ele-ments bodies

Tie rod M 10 Tie rod M 8

4 8991068 8991072

5 8991069 8991073

6 8991070 8991074

7 8991071 8991075

8 8991097 8991098

9 8991220 8991219

10 8991222 8991221

Tightening torque necessary for the correct operation of the controlbank:

PSL4 PSL2 PSL5

Tie rod M 8 22 Nm Tie rod M 6 16 Nm Tie ord M12 60 Nm

Tie rod M 10 40 Nm

NOTE: The tightening torque shall be applied or checked only when the controlbank temperature is below 30°C after operation.

Hydraulic sealing of the different body elements is assured by gaskets type O-ring:

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



21

B8.1

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.

control bank

without DMU

control bank for DMU

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 valvesIn 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.

*

NB: All’interno di questo blocchetto c’è una sfera “FLIP-FLOP”. Se un’impurità impedisce lo scorri-mento della sfera, il primo braccio della gru non esegue la manovra di salita.

*

NOTE: A “FLIP-FLOP” ball is located inside the block. If impurities prevent ball sliding, the crane 1st boom can not rise.

Controlbanks


22

B8.1 Controlbanks

3.2 Rod return device u The rod return device is made with two springs (A) and two spacers (B). This device is aimed at bringing and 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.


2

3

A

B

A

1



23

B8.1

3.3 Lever support

u The lever support is secured to the element body by four Allen screws (1) - screw hexagon: 5 mm -.

u Hydraulic sealing between the lever support and the element body is assured by a gasket (2) O-ring 36,17 x 2,62 Code # EFFER 8007600.

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.



13 2 3

789

4

5

6

Controlbanks


24

B8.1 Controlbanks

3.4 Inner cursor

u Different types of inner cursors are available: open centre, closed centre, open or closed centre at the ports A or B.

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 recom-mend, 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).


0 80 140

O 80 140 oL 80 140

2 1

X

A BA B

O = Oper Centre L = Closed Centre B = 1/2 1/2 Closed centre

PORT A / B

Code PORT A / B

Code POTR A / B

Code

O-10/10 8991226 L-25 / 25 8990833 B-16 / 25 8991233

O-16 / 16 8991227 L-40 / 40 8991155 R-40/80-40 8991469

O-25 / 25 8990758 L-16 / 16 8991232 R-40/63-40 8991471

O-40 / 40 8991137 L-63 / 63 8991133

O-63 / 63 8990921O-80 / 80 8991099

O-16 / 25 8991228

O-25 / 40 8991111O-40 / 63 8991112

O-40 / 80 8991110O-25 / 16 8991229

O-40 / 25 8991150

O-63 / 40 8991230O-80 / 40 8991231



25

B8.1

3.5 Flip-flop valve

u The hydraulic signal generated by the compensators of each element shall all reach the compensator fitted on 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.

3.6 Element compensator

u Each lever element is fitted with a compensator, meant to “call” from the inlet compensator the quantity of oil required by the operator who is activating a lever of the controlbank.

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

780

Controlbanks


2�

B8.1 Controlbanks

3.7 Check-reliefvalves/Cap instead of the valve u As mentioned in section 3.1, some elements may be fitted with check-relief valves, depending from the design of the controlbank matching a given crane model. Usually, the check-relief valves are fitted when the pressure, at one or both element ports, needs to be set lower than the value set for the main relief valve - see section 1.1-. uThe 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 -(figure X)-. If no pressure adjustment is required at one of the port of the lever element (the value of pressure does not differ from the max. pressure value admitted), only the cylindrical-head nut is fitted-(figure Y)-.

- Figure X: Check-relief valve, code # 8990623

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.

- Figure Y: Cap instead of the pressure adjusting valve, code # 8990624

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.


790

792 791

Y

1

2

3

1a

3a

44

X



2�

B8.1

3.8 Radio remote control solenoid 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 move-ments 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.

* The following code # corresponds to a complete kit including : solenoid , gaskets, fastening screws, connector, and the 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.


NOTE: The inner valve (4) shall run smoothly, under the pressure of the spring. Manually check the correct operation of the inner valve.

EFFER code # 8991125 , crane without DMU

EFFER code # 8991473 , crane with DMU

793

797

1

2

35 4

3

2

1

Controlbanks


28

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

EFFER Code # 8991126, corresponding to the delivery of No. 2 caps.

- These caps, can be fitted and adjusted by a standard screwdriver. The hydraulic sealing of said caps is assured by gaskets type O-ring 12,42 x 1,78 EFFER Code # 8001400.

Caution: a plastic gasket (5) is housed at the bottom of the seat of the element body. Make sure to not remove that gasket accidentally, as its presence is essential for the correct operation of the controlbank in both the two versions (the arranged one, and with radio remote control).


894



2�

B8.1

3.9 Load moment limit solenoid (L.S.) u Some safety devices installed on the crane, such as for example the load limiting device, the winch end stroke, 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 Max. absorption: 1.4 A.

Coil 24 volt code # 8990589 Max. absorption: 0.7 A.

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.

2

1

798

800

BA

3

Controlbanks


30

B8.1 Controlbanks

The lever element has two ports: port A and port B.

The lever element can be locked in three ways:

1 = port A inhibited 2 = port B inhibited 3= port A and port B inhibited

The movement to be locked (and its direction) is determined by Effer when designing the matching of a control-bank to a given crane model.

The electric connections to the solenoid are the following:

Connection at point 1, permanently negative polarity.

1: Connection to point 2, positive voltage when the movement is not locked

2: Connection to point 3, positive voltage when the movement is not locked

3: Connection to points 2 and 3, positive voltage when the movements are not locked.

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.

B A

3

4

4

5

5

3

3

799

800

803

17,5÷17,6

Copper gaske t 12x16x1,5

3

2

1



31

B8.1u 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.

6

4

5

882

Copper gaske t 12x16x1,5

Controlbanks


32

B8.1 Controlbanks

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

805

802



33

B8.1

4 - Troubleshooting1 / Trouble 2 / Cause 3 / Remedy

1 A - No crane motion is possible, although the hydraulic pump oper-ates perfectly.

2.1- Inlet compensator stuck in closed position because of impurities.

3.1- See section 1.2 regarding the indications for the removal of the inlet compensator, and its working

2.2 - No electric supply to the inlet solenoid valve.

3.2- To check the operation of the solenoid valve, supply voltage to the valve by con-necting it to a wire applied directly to the truck batteries. In this way, you find out if the trouble comes from the electric con-nection of the crane or from the coil of the solenoid valve.

2.3 - Solenoid valve coil burnt 3.3 - If the coil of the solenoid valve is faulty, to fold the crane anyway, press the cylin-dric point in the centre of the solenoid, as described in section 1.3.

2.4 - The gauged screw to eliminate pressure peaks on the drain line is clogged.

3.4 - Remove the gauged screw and clean the ports with an air jet. For additional informa-tion, see section 1.4.

1 B -The crane does not per-form a specific move-ment, when activating the lever of control-bank. The L.S. solenoid is fitted on the lever element.

2.1- The pin fitted to the L.S. sole-noid is damaged.

3.1- Check pin size according to the instructions in section 3.9; if necessary, make a test by removing a pin from another solenoid.

2.2- The L.S. solenoid controlling a specific movement does not get any electric supply.

3.2- Connect a cable to the batteries of the truck, with negative polarity applied to point 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 a specific movement is dam-aged.

3.3 - If the solenoid is faulty, in order to perform the inhibited manoeuvre so as to fold the crane, press the cylindric point in the centre of the solenoid, as described in section 3.9.

1 C - All crane movements are slow

2.1- The inlet compensator doesn’t perform a complete stroke.

3.1- Damaged compensator or seat, not allow-ing the compensator to slide smoothly, see section 1.2.

2.2- Gauged screw to eliminate hammers in the drain line, par-tially clogged.

3.2- Remove the pressure gauged screw and clean the ports with an air jet. For additional information, see section1.4.

Controlbanks


34

B8.1 Controlbanks

1 / Trouble 2 / Cause 3 / Remedy

1 D - A crane movement can be performed at low speed only

2.1- Flip-flop valve related to that specific lever element does not slide smoothly in its seat.

3.1- Remove the flip-flop valve and clean the seat with an air jet. For additional informa-tion, see section 3.4.

1 E- A lever of the control-bank does not move when activated by the radio remote control

2.1- The fault may come from a trouble in the electronic system of the radio remote control, or the solenoid of the control-bank. .

3.1- Replace the electric connection of the solenoid related to the movement not performed, with a connection related to a working movement: if the trouble is still present, replace the remote control activa-tor - 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 operate by the radio re-mote control, but only in manual.

2.1- The pressure reducing valve is stuck

3.1- Remove the pressure reducing valve, clean with an air jet, then fit it.

For additional information, see section 1.6.

1 G - The max. pressure valve can not be de-tected anymore by the controlbank.

2.1- The main relief valve is dirty or faulty

3.1- Remove the main valve - see section 1.1- and check that the small semispheric-head piston is free from impurities or surface scores. Otherwise, fit a new valve.



35

B8.1

5 - Variations for PSL 52-3 (Crane with safety device type DMU, with inlet pressure reducing valve calibrated at 40 bar)

u Versions PSL 52-3 of Hawe control banks are changed from the PSL 41-3 version described in the previous paragraphs, mostly because they are equipped with an inlet element of greater size which is, therefore, able to manage a quantity of oil conveyed by the higher pump: 200 l/min.

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

u The following main components are fitted to the inlet element:

5.1 - Maximum pressure check valve commonly referred to as main valve

5.2 - Pressure reducing valve

5.3 - Oil drain solenoid valve

5.4 - Calibrated screw to remove pressure peaks

5.5 - Plud named by HAWE “DVV”

5.6 - LS connection for variable delivery pump

5.7 - Oil pressure gauge connection

5.8 - Plug


5.6

5.8

5.1

5.2

5.7

5.5

5.4

245

249

248

5.9

Controlbanks


3�

B8.1 Controlbanks

5.1 Maximum pressure check valve (generally referred to as main valve, EFFER Code # 8990623)

u On this type of control bank the main valve operates the inlet compensator: this is a piloted type operation.

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.


1

2

3

4

792



3�

B8.1

5.2 Pressure reducing valve

u On the inlet element, under the plug markek with the letter A, a pressure-reducing valve is provided when the 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.

775

A

X = 7 mm

Y = 18,5 mm

u The pressure-reducing valve is meant to keep constantly a pressure of 20 bar in the circuit activating the lever under the radio-remote signals (pressure not detected by the pressure gauge).

NOTE: on crane equipped with DMU, pressure inside the control lever circuit is 40 Bar (pressure not detected by the pressure gauge).

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.


Controlbanks


38

B8.1 Controlbanks

5.3Oil drain solenoid valve

u For all technical information concerning the oil drain solenoid valve please refer to

chapter 1.3 of the PSL 41-3 control bank.

5.4 Screw calibrated to remove pressure peaks

u For all technical information concerning the screw calibrated to remove

pressure peaks please refer to chapter 1.4 of the PSL 41-3 control bank.

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.

771



3�

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.

5.7 Oil pressure gauge connection

u The hole located under to this plug is related to the hydraulic connection of the oil pressure gauge. A filter (E) 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.

Controlbanks


40

B8.1 Controlbanks

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.

5.9 Inlet compensator

u Unscrew the cap screw (1) -with a 5-mm Allen wrench - then remove the cylinder (2) called “inlet compensator”.

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

2

3

4

5



41

B8.1

u The load control device DMU coupled with a control bank HAWE requires fitting a microswitch to every lever 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 won’t 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.

� - Coupling with DMU

The microswitch is positioned inside a cylinder, fitted to the control bank body through 4 socket head screws – 4-mm screw socket head -.

Microswitch supplied as a spare part. EFFER code # 8991377 (*).

The hydraulic tightness between the body of the element and the body containing the microswitch is guaranteed by a gasket, EFFER code 8002800 O-ring type 34.65 x 1.78.

236237

241

*

Controlbanks


42

B8.1 Controlbanks

Programming procedure “TEACH-IN” of microswitch zero position (programmer Effer code 8991377)

If it is necessary to replace the microswitch, it is required to programme the “ø” point or the lever neutral posi-tion

EFFER Code PROGRAMMER

NOTE: to connect the programmer to batteries:

Bring wire 1 to POSITIVE pole

Bring wire 2 to NEGATIVE pole

PROCEDURE:

1) Connect the power supply to the programmer, and the

other electrical cable to the microswitch to be programmed.

2) Press the “ON” button and KEEP IT PRESSED. The “OUT A” LED is turned on.

3) With the “ON” button pressed press the button “PROG”, release it and press it again n a few seconds (max 3), and then keep it pressed. The “OUT B” LED is turned on.

Result:

a) “OUT A” and“OUT B” LEDs are permanently lighted :

The zero position of the lever was accepted and therefore the centering of the lever was carried out. If the lever is shifted to both directions, check that the same shift causes the LED for the corresponding direction to turn off .

b) One of the two “OUT A” and “OUT B” leds flashes:

The zero position of the lever was not accepted and you have to proceed to the mechanical centering of the mag-net inside the metal cylinder, once disassembled.

If the “OUT A”led flashes the magnet is protruding too much and it is necessary to screw it up by 1-1.5 turns clockwise. Then, proceed to “teach-in” from the point 2) and if necessary, repeat the operation of mechanical centering of the magnet.

If the “OUT B” led flashes the magnet is turned inwards too much and it is necessary to unscrew it by 1-1.5 turns counterclockwise. Then, proceed to “teach-in” from point 2) and if necessary, repeat the operation of mechanical centering of the magnet.

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.



43

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 – 10-mm 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.

Controlbanks


44

B8.1 Controlbanks

� - HAWE Proportional controlbank: variable displacement pump u a) Control bank type PSL 41-3 (elements of size 3)The inlet compensator comes with a spring inside - see section 1.2 -. This spring is removed in the version of con-trolbank for variable displacement pump and replaced by a pin of the size shown in the drawing below.

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.

Cylinder EFFER Code # 1932893

steel

LS

36,7 ÷ 36,8 mm

r =1mm

ø 10,6 ÷ 10,7 mm54,7 ÷ 54,8 mm

acciaior =1mm

ø 10,6 ÷ 10,7 mm

u b) Control bank type PSL 41-3 (elements of size 3)The inlet compensator plug is equipped with a protruding screw (1) : a different location of this screw differenti-ates an operation with fixed pump from an operation with variable displacement pump.

feeding by fixed displacement pump

feeding by variable displace-ment pump

1

Cylinder EFFER Code # 1932893H



45

B8.1

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 # 8991234To 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 ø 0,6).

Required material: number 1 Code 8991430

A

B

LS

A

A1

CB

A1

N.B.: If, during the operating tests, you will note that, when a movement of the crane stops, the pressure value decreases very slowly, you must make the change below on the screw “ANTIDUMPING” B as shown in the figure.

Controlbanks


4�

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:

1) Unscrew the screw A and remove the inner dowel B.

2) Under the screw A place the dowel C EFFER code 8991430, with central hole ø 0.6.

3) Unscrew the screw D and place the dowel B previ-ously removed.

4) Tighten the screw D.

Required material: number 1 Code 8991430

A

C

D

B

B



4�

B8.1

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.

LSLS

7.1 Maximum working pressure settingWhen 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 pressure2) MAXIMUM WORKING pressure

1) STAND-BY pressureEven 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.

V. max.

V. max. PUMP

If the pressure gauge is fitted to the LS hydraulic line (joining the LS connec-tion 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.

Controlbanks


48

B8.1 Controlbanks

CRANES WITH ELECTRO-HYDRAULIC FPI DEVICE

V. max. pump

V. max. (A)

The cranes equipped with the F. P. I electro-hydraulic device, have two maximum pressure value settings , allowed inside the hydraulic circuit:

1- The main overpressure valve on control bank, which adjusts the pressure value when the F. P. I system is turned on (REF. A)

2- The main overpressure valve on F-P.I valve block, which adjusts the pressure value when the F. P. I system is turned of (REF. B) Following the instructions above, carry out the hydraulic setting relating to STAND-BY pressure and maximum working pressure bearing in mind that it is always the main valve at the control bank entry which you must in-crease by the setting value, transforming it into a safety valve; this is always the main overpressure valve fitted to the crane that must be set at the maximum pressure value allowed for that specific crane model.

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 de-tected.

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.



4�

B8.1

Oil diverter tap

Flow regulator valve


Flip-flop valve


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.

12

3

L.S.

added use

Controlbanks


50

B8.1

Features: Maximum working pressure 350 bar, continuous work

Inlet maximum oil flow rate: 150 l/min with variable displacement pump

140 l/min with fixed displacement pump

Standard supply voltage 24 volt (22 ÷ 30 volt)

Supply voltage on request 12 volt (11÷ 15 volt)

Proportional controlbank

DANFOSS - PVG 32 -B8.2

PVG 32


Controlbanks SAUER-DANFOSS


52

B8.2 Controlbanks SAUER-DANFOSS

Controlbanks SAUER-DANFOSS Controlbanks SAUER-DANFOSS


53

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 pos-sible 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.

NOTE: If you unscrew the dowel, all the oil goes into pressure and is not drained.



54


3

2

4

Identification OF SAUER-DANFOSS PVG 32 Model components

1- Inlet element

2- Control bank element

3- Closing element

4- Assembly tie rod kit

1

4

4



55

B8.2

1- Inlet elementComplete 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.


1.3 - 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

1.3

1.4

Kit complete with all seals on the inlet element - EFFER code 8990712

1.1

1.6

1.5

1.2

1.5

1.61.11.3

1.2

1.4



56


1.1 Main valve

Main valve - EFFER CODE 8990178

u If it has to be disassembled for maintenance or to carry out adjustments of the setting value, act on the hexa-gon. 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.

1.12

1

3



57

B8.2

1.2 Inlet compensatoru The inlet compensator is fitted under a plastic plug, located on the side opposite to the solenoid valve.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 loose-ning 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 signi-ficantly 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.


1

5

2

4

3

1.2



58


1.3 Unloading solenoid valve

Effer Code 8991454 for 24-volt version - Effer Code 8991560 for 12-volt version

As explained in the introductory page, if no control bank lever is operated the oil conveyed by the pump goes back to the tank without passing through the control bank.To make the oil continue into the control bank, it is necessary not only to operate a control bank lever but also to ensure the solenoid valve electric enable at inlet: the solenoid valve must therefore be electrically powered.The electric connection is performed so as power is supplied continuously during the manual use of the control bank, whereas if a radiocontrol is used power is supplied only when a push-button board joystick is operated.The operation of the emergency stop buttons on the crane will also cut off power supply to the solenoid valve.This is a cartridge type solenoid valve and is screwed up in its own seat. Hexagon is 24 mm. It is recommended to lock the valve with a dynamometric wrench: Torque wrench setting 45 Nm.- The hydraulic sealing towards the outside is ensured by a 9x2 O-ring Ref. 1 type 12.8 x 1.28 and by one Ref. 2 type 16.36 x 2.21.The coil is provided with a mechanical retaining emergency, which can be operated by pressing and turning the pusher. This operation can be useful if you want to operate the crane in case of failure either in the solenoid valve or in the crane electric part. Once the emergency manoeuvre is over, it is necessary to bring the solenoid valve to an unloading condition to avoid the operation of the crane safety systems to be stably turned off.WARNING: Always clean the components carefully before assembly.

Coil power input: 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

2

12

3

1.3



59

B8.2

1.4 Additional pressure gauge connection

u On the element side opposite to the unloading solenoid valve there is a plug next to which the letter M is punched: Pressure gauge connection. This is the correct point where a pressure gauge has to be fitted to monitor the pressure values inside the control bank if you do not want to use the connection provided on the crane hydraulic system.Please find below a few points, that we deem important to highlight, about the data that are read on the pressure gauge (both if fitted to the point provided by the EFFER system, and if fitted to this point):u As soon as the oil is conveyed to the control bank a pres-sure value of 12-16 bar appears on the pressure gauge. This is normal, and is the pressure value required for the operation inside the control bank. This value must not be added to the values reported on the crane setting tables.u If a movement of the crane is carried out, the value of the necessary pressure for that movement will be read on the pressure gauge until it reaches the setting value at maxi-mum. u If it is required to check the setting of a particular valve set at a much lower value than the main overpressure valve setting value, it is known that it is necessary to perform a movement having the cylinder, connected to the circuit to be checked, already in the limit stop position.The hydraulic sealing towards the outside is ensured by a special seal EFFER code 8991581 Ref. 1.

1.5 Hydraulic connection for L.S.

u A connection called L.S. is provided on the inlet element side. In case a variable delivery pump is fitted, the hydraulic pipe that conveys the “oil demand” signal to the pump com-pensator, must be connected to this connection.

u This connection can be closed by a plug that can be removed using a 6-mm Allen wrench, or may be engaged by a pipe/solenoid valve, according to specific crane version. In this case, if you want to match the crane and a variable delivery pump, you must add a hydraulic branch as close as possible to the hole LS on the control bank element.

1

1.4

1.5



60


1.6

1.6 Pressure reducing valve Effer Code 8990177

u On the inlet element, next to the port marked with “P”, a pressure reducing valve is fitted when the control bank has the coils for operation by a radiocontrol, or more simply the prearrangement for the coils.u The pressure reducing valve has the function to main-tain a pressure of 13.5 bar inside the circuit that operates the control levers under the impulse of a radiocontrol.This valve has a pre-arranged setting, and does not need any adjustments and/or maintenance.




61

B8.2

2 - Control bank element

Listed below are the main parts included in the lever element, with a comment for each of them:

2.1 - ELEMENT BODY

2.2 - MECHANICAL LEVER CONTROL

2.3 - INNER SPOOL

2.4 - FLIP-FLOP VALVE

2.5 - ELEMENT COMPENSATOR

2.6 - PRESSURE ADJUSTING VALVES

2.7 - CLOSING COVER

2.8 - RADIOCONTROL COIL

2.6

2.22.8 2.1

2.6

2.5

2.3

2.4

2.6

2.7



62


2.1 Element body

u The element body is built in cast iron, and it is locked in the control bank by three tie rods (M8). it is possible 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.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/antica-vitation 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.

ba

ab

2.1

A

B

123

4ba



63

B8.2

2.2 Mechanical lever controlNote: The return device of the stem is built in the spool and is represen-ted by a spring, whose function is to bring and maintain the element spool in its central position when the control lever is not operated, either manually or by the radiocontrol. u Using four cheese-headed screws Ref. 1, removable with a 5-mm set-screw wrench, you can disassemble the lever control. The torque wrench setting of the screws is 8Nm.u Hydraulic sealing between the element body and the cover is ensured by: - a shaped seal Ref. 2 and by two O-Rings ø 5 X 2 Ref. 3.N.B: With the Effer Code 8990714 a KIT including all seals fitted between the element and the cover is sup-plied.u The oil flow rate of the various lever elements, and even better the maximum oil flow rate that can go out of the two lever element ports, are project data. Two adjusting screws Ref. 4 are fitted to the lever element. These screws have the function to limit the mechanical stroke of the lever Ref. 5, in case it is required to further decrease the oil flow rate even on a lever element port only.u By screwing the adjusting screws (4) there will be a reduction of the oil flow rate to the relative lever element port until the lever becomes inoperative. The upper screw limits the flow on the port opposite to the lever side (port B). uTo act on the stop nuts a 10-mm wrench is needed; for the adjusting screws, a 3-mm. setscrew wrench is requi-red.Important: the adjusting screw threaded section never has to protrude more than 12.5 mm. from the stop nut. With this dimension, the oil that is conveyed to the cylinder is already the maximum allowed by the spool.Complete mechanical control: EFFER code 8990312.WARNING: Always clean the components carefully before assembly.

4

2

3

1

5

5 1

4

2

3

2.2



64


2.3 Inner spool

u There are different types of inner spools: open center, closed center, open or closed center on the ports A or B, pressure control spools.

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 com-municate 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 replace-ment 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.


12

1

2Z

Z

2.3



65

B8.2

Listed below are the Effer codes of the spools that are mainly fitted to the cranes:

EFFER Code Code Description

8991568 157B7002 40 - l/min. Spool in closed center




8991486 157B71355-l/min. Spool in open center con pressure control on ports A and B (PC -> AB)

8991572 157B706240-l/min. Spool in closed center with pressure control on port A (PC -> A) and flow rate control on port B

8991573 157B707240-l/min. Spool in closed center with pressure control on port B (PC -> B) and flow rate control on port A

8990469 157B7121 25 - l/min. Spool in open center



8991574 157B717240-l/min. Spool in open center with pressure control on port B (PC -> B) and flow rate control on port A

8991575 157B7421 25-l/min. Spool with B closed and A in T

8991576 157B7502 40-l/min. Spool with A closed and B in T

8991577 157B9505 40/100 - l/min. Differential spool in open center

8991578 157B9591Differential spool in closed center in A and open center in B P → A 40 l/min., A → T 40 l/min., P → B 25 l/min., B → T 25 l/min.Flow rate control on port A, pressure control on port B

8991579 157B9592Differential spool open center P → A 40 l/min., A → T 40 l/min., P → B 25 l/min., B → T 25 l/min.Flow rate control on ports A and B

8991580 157B9641Differential spool closed center in A and open center in BP → A 40 l/min., A → T 40 l/min., P → B 25 l/min., B → T 25 l/min.Flow rate control on port A, pressure control on port B



66


2.4 Flip-flop valve

u The hydraulic signals coming from the compensators of the various elements have to reach the compensator fitted to the inlet element. Since this element must send as much oil as demanded by the single compensators (of each element), all hydraulic signals are conveyed to a single inner passage. Every element is provided with two flip-flop valves that have the function to select the input of the different signals into the channel arriving to the inlet compensator. You can remove the flip-flop valve Ref. 1 from its seat using a M5 threaded screw. To remove the balls Ref. 2 use a magnet. Any impurity deposit on this valve would make the pressurisation of all the following elements difficult or impossible.

u The valve Ref. 3 cannot be removed; correct operation is achieved when the ball moves freely pushed by a light air blow.

2.5 Element compensator

u Each lever element is provided with a compensator, whose function is to demand the compensator located on the inlet element for the oil amount that the opera-tor wants to convey to a crane manoeuvre specifically selected by operating the lever control.

u 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 We do not supply it as a single spare part, therefore we recommend replacing the whole element in case it has deep marks as its seat will be certainly damaged.

u You can remove the compensator from its seat using a M6 threaded screw: it is advisable to remove the element of the control bank if you need to remove the control bank joining tie rod and the spacer bushing (see instructions in section 1.2). To remove the compensator lock plug - Ref. 1- use a M6 threaded screw and apply a lot of force.

u Hydraulic sealing is ensured by a seal -Ref. 2.

2.4

3

1

2

2 1

2.5

3

21



67

B8.2

2.6 Special pressure adjusting valves

u In the preceding paragraph we mentioned the pos-sibility of having the presence of two types of valves on the element body for maximum pressure control on the element ports: 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 car-ried out with any movement – passive pressure.- The presence of these valves is a project data item.

a) «Active pressure» control valveu The “active pressure” control valve is located under a plastic plug – Ref. 1 -: the maximum pressure on the specific hydraulic circuit corresponds to the setting value of the valve.This valve can be adjusted using a 6-mm setscrew wrench: By turning the register Ref. 2 clockwise the pressure value increases.-The hydraulic sealing towards the outside is ensured by a O-ring type seal. EFFER code 8991567 - Ref. 3 -

b) «Passive pressure» control valveu Further to crane performance increase carried out with any movement the pressure value inside the cylinders increases.When the project maximum value is achieved, this valve opens the passage by letting the oil flow out of the cylinder to the tank.This valve has also the “ANTICAVITATION” function.Another very important function of this valve is to damp the jerks due to a very fast use of the crane.The hydraulic sealing towards the outside is ensured by a O-ring type seal Effer Code 8991567- Ref.4 –

123

4

a

b



68


These valves have a non adjustable setting: the setting value is shown on the spring pressing piston.

Listed below are the fixed setting values used by Effer and the complete valve:

EFFER Codes Setting

8990151 125

8990152 140

8990329 150

8990330 160

8990150 210

8990328 250

8990149 280

8990147 300

8990148 320



69

B8.2

2.7 Closing cover

u A cover is fitted to the control lever opposite side, when the electric coil is not present - Ref. 1 – it is com-plete with seals for the hydraulic sealing towards the outside.

The cover complete with seals and fastening screws, has the EFFER code 8990447.

u Hydraulic sealing is ensured by the presence of two seals: - Ref. 2 and Ref. 3 -Commercial O-Ring seals Ref. 3: Special seals Ref. 2: The seal kit has the EFFER code 8990714.

1

2.7

3

2



70


2.8 Radiocontrol coil

u In case a control bank lever is operated by a radiocontrol, a proportional type electric coil is fitted to the side opposite to the manual control lever.Two types of coil are provided by EFFER:A) For cranes on which the DMU load control device is not present, recognisable also for the presence of a single electrical connection. 12-24 volt coil EFFER code 8991643B) For cranes on which the DMU load control device and the radiocontrol are present, recognizable also for the presence of two electrical connections:12-24 volt coil EFFER code 8991642C) For cranes on which the DMU load control device is present, without radiocontrol: 12-24 volt coil EFFER code 8991457Note: The lever direction detectors are present inside the B coils, these are essential for the operation of the DMU load control electronic device.u The lever can be moved in two directions with a single coil: forward and reverse- The coil is fitted using four cheese-headed screws - Ref. 1- removable using a 5-mm setscrew wrench.- Hydraulic sealing between the coil and the element body is ensured by special seals - Ref. 2- EFFER code 8990715 kit complete with oil seals. During the operation of the lever by radiocontrol, the lever vibrates. This is normal.

Warning: Every replacing operation of the electric coils has to be carried out under absolute clean conditions in order to avoid hazards for safety.Warning: Always clean the components carefully before assembly.

The coils B type have two electrical connectors:

1) black connector, for the connection to the DMU device

2) grey connector, for the connection to the radio control.

Note: If you disconnect the black cable relating to DMU from a coil, it is not possible to use the radio control on that specific function.

If you use the radio control, power must be supplied to the coil on pin 3 and 4 relating to DMU connection.

A

B

Radio control electric connection

DMU electric connection (Black connector)

Radio control electric connection (Grey con-nector)

DMU electric connection (no radiocontrol)

1

2

2

2

2.8

CV bat -V bat +

DMU



71

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.



72


2.9 HPCO (high pressure carry over) function u You may find a hydraulic control bank with an additional element, with which the function HPCO is carried out, on some crane models.

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 stabilisers3) 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.

uThe electrical control is sent to the coil that diverts oil to stabilizer system by operating a key selector placed in the lower part of the crane. Whereas when the crane is handled using a radio control, the electrical control to the coil, that diverts oil to the crane control bank interior, is sent from the radio control electric system, every time a radio transmitter joystick is operated.

uThis slider may be operated also manually, using the appropriate lever, if you have to run movements to fold the crane whenever a trouble arises. Therefore, this is to be considered as an emergency operation.

Stabilizers

CraneSee note 3 in the following page

HPCO SPOOLfixed delivery pump

HPCO SPOOLvariable delivery pump



73

B8.2

3 - Closing element, EFFER Code 8991458

u The closing element closes the P, T and LS ducts of the control bank.

The hydraulic sealing is ensured by O-ring type seals:n. 2 O-rings ø 5.0 x 2.0 n. 4 O-rings ø 5.0 x 2.0

With the EFFER code 8990717 you can buy the complete kit of seals ensuring the closing element hydraulic sea-ling.

Note 1:If the crane, where the HPCO function is provided, is also equipped with the DMU3000, it is not equip-ped 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 provi-ded 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 con-nection LS and the hydraulic pump connection LS.

In addition to what mentioned above, it is necessary to carrry out the operation of § 5.



74


4 - Assembly tie rod kit

u The element body is built in cast iron, and it is locked in the control bank by three tie rods (M8). It is possible 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

4 8991561

5 8990439

6 8990440

7 8990441

8 8990492

9 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



75

B8.2

u The EFFER cranes are built in the standard version to be supplied by fixed displacement hydraulic pump (constant oil flow rate).

u On request, EFFER can prear-range the crane control bank and the hydraulic system, as better explained below, to be supplied by a variable displacement hydraulic

5 - Variable displacement pump installation

ø 0,8 ÷ 1 mm �

pump (variable oil flow rate to control bank, depending on the demand from the manoeuvre that is being per-formed).

u On one side of the inlet body of the control bank the following stamping is shown: LS. This stamping is on a threaded hole - 1/4'’ gas thread - and the flexible hose conveying the oil demand signal to the pump, has to be connected to this point.We recommend using a flexible hose with 1/4’’ gas dia-meter.

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.

The oil passage inside the control bank inlet element has to be modified:for this modification a kit EFFER code 8991379 is required.

LS



76


u Below are the drawings concerning the inlet ele-ment change, from fixed flow pump into variable displacement pump.

Remove the plug complete with seal Ref. 1.

Unscrew and remove the plug Ref. 2 using a 2.5-mm Allen wrench and replace it with the gigler Rif. 3

Screw up the plug complete with seal Ref. 4.

The components Ref. 3 and Ref. 4 are included in the kit. EFFER code 8991379

Fixed displacement pump

Variable displacement pump

26 DKMH.PS.570.A5.02 520L0211

2

1

3

4

If crane controlbank is a HPCO type, it is necessary to change the spool, as written in §2.9



77

B8.2

VARIABLE DISPLACEMENT pump version

STANDARD Version with

fixed displacement pump

. LS signal connected to the crane control bank.

Flow regulator EFFER Code 8853750

Flip flop valve EFFER Code 8850217

T P

T PLS

AB

NOTE: References A and B are components to be added.

In case in addition to the crane control bank, another control bank has to be supplied by the variable dis-placement 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.



78


5.1 Variable displacement pump setting instructions

MLS

u 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 pressure2) MAXIMUM WORKING pressure

1) STAND-BY pressureEven 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 de-tected.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.



79

B8.2

6 - Emergency hand pump installation u An emergency hand pump may have to be installed on the crane: this is to operate the crane in case of failure in the pump installed on the truck.To supply a Danfoss control bank hydraulically with a hand pump – recommended displacement 50 cubic centi-metres per cycle – there are two possibilities:

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 ¼’’ 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.

1

2

4

3

5

M

3

1



80


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

7 7PT

LS

A B



81

B8.2

7 - Troubleshooting

1 / Problems 2 / Causes 3 / Solutions

1A. The crane does not execute any movement although it is certain that the hydraulic pump is per-fectly working.

2.1 Main valve locked by impurities. 3.1 See paragraph 1.1 for main valve disas-sembly and reset.

2.2 Inlet compensator locked in its closed position by impurities.

3.2 See paragraph 1.2 for its disassembly and operation. Moreover check that the special dowel is free from impurities.

2.3 Unloading solenoid valve not powered or burnt.

3.3 To check the solenoid valve operation, it can be powered using a cable con-nected 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 mechani-cal emergency applied on the coils as described in paragraph 1.3.

1B. The crane does not ex-ecute a specific movement although it is certain that the control bank levers and inner spool are not locked mechanically.

2.4 If fitted, special pressure adjusting valve clogged by impurities.

3.4 See paragraph 2.4 for its disassembly and operation.

2.5 The flip-flop valve does not pres-surise the signals because of the presence of impurities.

3.5 To clean the flip-flop valve refer to chap-ter 2.4, concerning disassembly..

1C. It is no longer possible to operate a movement using the radiocontrol.

2.6 Electrical problem in the module relative to a movement.

3.6 Module replacement. For replacement refer to chapter 2.8.

1D. It is no longer possible to operate movements using the radiocontrol but it is working manually.

2.7 Pressure reducing valve clogged by impurities.

3.7 Clean the pressure reducing valve and replace. For disassembly refer to chapter 1.5.



82

B8.2

Specifications: Max. working pressure 350 bar / continuous working

Max. inlet oil delivery: 70 l/min with fixed displacement pump

Standard supply voltage 24 volt (22÷30 volt)

Supply voltage on request 12 volt (11÷15 volt)

Proportional valve block Nordhydraulic RS 210


B8.3

RS 210

Controlbanks Nordhydraulic


84

B8.3 Controlbanks Nordhydraulic

Controlbanks Nordhydraulic Controlbanks Nordhydraulic


85

B8.3

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.

Specifications:

Max. working pressure: 350 bar / continuous working

Max. inlet oil pressure: 70 l/min with fixed displacement pump

Standard supply voltage 24 volt (22 ÷ 30 volt)

Supply voltage on request 12 volt (11÷ 15 volt)

At the valve block inlet there is a compensator.

94

37

AG 1/2”

T1G 1/2”

AG 1/2”

T2G 1/2”

BG 1/2”

BG 1/2”

37

7035

42 11356

,590

45

5025

9(4X

)

22 36,54339,5 434343

27



86


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 com-pensator 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.

u Valve block gasket kit

a) Effer Code 8991512 is a gasket kit concerning one valve block lever element.

b) Effer Code 8991511 can be supplied with a gasket kit concerning the valve block inlet element.

B

A

A



87

B8.3

The main head is provided with the pressure gauge coupling, in the position shown by the arrow.

2 - Main headu The type of main head used by Effer requires the coupling for the oil sent by the pump (P1 = ½’’ GAS) and the coupling for the connection to the oil tank (T4 = ½’’ 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



88


2.1 Master valve

u The pressure is regulated by means of a 5 mm Allen wrench; in case you want to disassemble the inside cursor to clean carefully, unscrew the adjusting device completely.

NOTE: the cone end shall be integral, without surface marks.

Effer Code of complete master valve 8991590

The valve installed by Effer is suitable for a calibration between 240 and 350 bar.

2.1



89

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.

Effer Code of complete compensator 8991593.

2.2



90


2.3 Unloading solenoid valve

The unloading valve is available in the cranes with CE mark. In the cranes for other markets, a cap is available instead of a solenoid valve.

Effer Code of 12 Volt solenoid valve 8991591

Effer Code of 24 Volt solenoid valve 8991506

Effer Code of cap provided with gaskets 8991592

NOTE: The unloading solenoid valve is equipped with a manual emergency device.

Following an electric problem on the crane, it is possible to by-pass the solenoid valve by allowing the hydraulic oil to enter the valve block, by removing the present lead and pressing the knurled pin inwards.

2.3



91

B8.3

3 - Lever elementThe Effer cranes are provided with the lever elements shown below, i.e. with both closed and opened centre.

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.

The single spools positioned inside the different elements are “custom-made” for the specific functions. The ele-ments can be provided with one or two pressure reducing valves (also called anti-shock or special valves).

A

A

BB

3



92


3.1 Pressure reducing valve (anti-shock or special valve)

Element Cod. Effer

Rotation lever element (CE) Cod. Effer 8991513

Rotation lever element (not CE) Cod. Effer 8991514

1st boom lever element (CE) Cod. Effer 8991515

1st boom lever element (not CE) Cod. Effer 8991516

2nd boom lever element (CE) Cod. Effer 8991525

2nd boom lever element (not CE) Cod. Effer 8991526

Extension lever element (CE) Cod. Effer 8991517

Extension lever element (not CE) Cod. Effer 8991518

Addit. jib lever element (CE) Cod. Effer 8991519

Addit. jib lever element (not CE) Cod. Effer 8991520

Addit. extension lever element (CE) Cod. Effer 8991517

Addit. extension lever element (not CE) Cod. Effer 8991518

Winch lever element (CE) Cod. Effer 8991521

Winch lever element (not CE) Cod. Effer 8991522

Rotor/bucket lever element Cod. Effer 8991524

Rotation lever element (CE) Cod. Effer 8991513

Rotation lever element (not CE) Cod. Effer 8991514

The supplied elements are complete with oper-ating lever and sealing gaskets.

3.1

u Under a plastic cap there is a calibration pressure adjusting device of the pressure reducing valve.

The calibration value is adjusted by means of a cut screwdriver.

u The complete pressure reducing valve can be remo-ved by means of a 28 mm wrench.The lever elements without pressure reducing valve can be provided with a cap, a pre-setting element, or there can be nothing.



93

B8.3The cap can be removed by means of a 10 mm Allen wrench.

u In case you want to disassemble the inside compo-nents of the pressure reducing valve, loosen the adju-sting device completely, extract it by means of long nose pliers.

A valve with all single components is shown below.

The special valves are provided with calibration fields; the single code numbers are the following:

200 - 240 bar Effer code 8991532

240 - 300 bar Effer code 8991533

Cap complete with gasket instead of the pressure redu-cing valve. Effer code 8991595.



94


3.2 Lever support

u The lever support is installed in the lever element by means of two Allen wrenches that can be removed with a 4 mm Allen wrench.

The support can be supplied by Effer complete with gaskets: Code 8991594.

The control lever, complete with fastening pins, has Code 3L78013K.

3.3 Stem return device

u This valve block can be provided with two types of stem return devices:

1) For lever elements that are not connected to DMU load control device

Effer code of complete stem return device 8991509.

2) For lever elements that are connected to DMU load control device

Effer code of complete stem return device 8991510.

Both caps can be removed with a 4 mm hexagonal wrench.

3.2

1

2



95

B8.3

3.4 Non return valves

u Each lever element is provided with two non return valves: one for opening A and the other for opening B.

The above valves can be disassembled only after remo-ving 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.

Effer code of non return valve complete with gaskets 8991596.

4 - Closing element

The closing element, complete with gaskets, has Effer code 8991507.

3.43.4

A B

4



96


5 - Valve block connection tie rodsu The valve block element connection tie rods are made of special steel. The screw nuts that fasten the tie rods shall be tightened with 27 Nm torque wrench. The available quantities are: 3 screw nuts, 3 washers, 3 tie rods.

Tie rod kit Cod. Effer

Tie rod kit for 4 levers 8991500Tie rod kit for 5 levers 8991501Tie rod kit for 6 levers 8991502Tie rod kit for 7 levers 8991503Tie rod kit for 8 levers 8991504

NOTE: The kit includes the screw nut/washer.

6 - Microswitches for DMU

6

u The cranes with DMU load limiting device are pro-vided - on the lever elements that operate the crane movements - with microswitches that send an electric signal to the DMU, every time the lever is activated.These microswitches are applied to the part of the valve block opposed to the manual control levers.

u The sensor applied to the element cursor is provided with magnetic material: consequently, it shall not be touched with common steel equipment, thus avoiding to lose the magnetic properties.The microswitch is removed by unscrewing two Allen screws with 4 mm hexagonal wrench.



97

B8.3

To replace a microswitch or to remove the inside cursor of the lever element, it is necessary to have the special wrench shown in the photo, made of non-magnetic material.

Effer code of non-magnetic wrench 8991588.

The sensor shall be removed in the following operating sequence:

1) Insert the special wrench onto the sensor, by positioning the locking ring towards the wrench handle.

2) Push the locking ring forwards by centring it with respect to the cap that contains the stem return spring.

3) Unscrew the sensor by avoiding to put it on metallic surfaces

Effer code of the microswitch complete with screws and inside cursor: 8991508

NOTE: each microswitch is connected with its sensor.

In case different microswitches are disassembled, connect them to their sensors again.When mounting the microswitch, strew the front area with grease, where there is the gasket, in order to facilitate the insertion of the gasket into its housing.



98


7 - Mechanic microswitch adjustment and replacementu Two types of microswitches located on cranes where the DMU 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.

NB: Cranes manufactured in early 2005 are provided with me-chanic microswitches.Therefore, upon request of spare parts, we can only supply mechanic microswitches. The different sizes of the two types of microswitches do not make it possible to fit a mechanic microswitch next to elec-tronic microswitches: should an electronic microswitch need to be

7.1 Procedure for proper assemblyThe setting up of the device is carried out without removing the hydraulic control bank from the crane.

1) It is necessary to position the crane with the booms lifted, to free the area near the crane base and remove the guard marked with the letter (x).

a

e

c

b

d

x

replaced, it is necessary to fit all mechanic microswitches.The mechanic microswitch, unlike the electronic microswitch, requires being adjusted after being fitted to the hydraulic control bank.

u Mechanic microswitch componentsA) Microswitch support complete with two microswitches with their securing screws and washersB) Microswitch operating cam complete with two dowels (M6x6) for fastening and one dowel (M5x10) for adjustment.C) Plastic material bushing complete with gasketsD) Side closing plateE) Upper protection plug

u Equipment necessary for setupElectric cable necessary for adjustment, Effer code 9395670 Loctite type 222 Effer code 20040171 - Greaser- 2.5 - 4 – 5-mm Allen wrench. - about 10-cm Allen wrench extension

2) Disconnect the electric cables connected to the electronic micros-witch. It is advised to take note of the cable lay-out in order to recon-nect them in the same order on the mechanic microswitches.

Remove the electronic microswitches from the control bank.

We recommend you to carry out the setup and the complete adjust-ment of the microswitch starting from the element which is hardest to reach, i.e. the one which is closer to the stabiliser.



99

B8.3

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.

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 suit-able 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 micro-switch is secured to the block it will have an angulated position of approximately 30° on the left side with respect to the vertical axis

7.2 Procedure for proper adjustment

1) Connect the two terminals located at the end of the circuit electric cable with the two bulbs Effer code 9395670 to the truck batteries following the polarity according to the terminal colours. The cable is suitable for both 12-Volt powered trucks and 24-Volt powered trucks. Connect the other end of the cable to the microswitch connector that has to be adjusted.

2) First, position the cam (b) in the central area with respect to the two microswitches: neutral point. With the cam correctly po-sitioned in the neutral point, the two pilot lights are turned on. To adjust the cam position better with respect to the two micros-witches, you can use the dowel fitted to the cam rear end. Obvi-ously, 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 car-ried out this first centring, slightly tighten the two dowels which lock the cam to the centring pin.

M6 M5

c

b

a

a



100

B8.3

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

NB: A correct positioning is achieved when the two lights are turned off after the control bank slider has been moved by about 1-1.5 mm.

5) The two microswitches are locked by two screws (v) on the metal

To ease the work of the control bank inner springs, check that nothing can prevent double control rods from slid-ing, and lubricate the control lever connecting pins on both the control bank side and the double control side.

Insert the protection rectangular upper rubber grommet : to ease this insertion, which can be difficult because of the presence of the electric cables connected to the two microswitches, it may be necessary to remove a part of the plastic edge from the side that coincides with the electric cables using a cutter.

After completing the job, energize the crane: the DMU device has to carry out the normal starting procedure.

NOTE Final check: an essential condition for the correct operation of the mechanic microswitches is the following: when a control bank lever is released, the inner slider, that is the microswitch operating cam, has to return to the central position - neutral position -.

v

v

d

b

a

support (a). By loosening the two screws it is possible to change the height of the two microswitches, or it is pos-sible to change the stroke that the slider has to make before operating the two microswitches.

6) When the adjustment is over, tighten the two cam fastening dowels and the two microswitch fastening screws.

NB: Loctite previously applied allows the adjustment of the screws in about a hour: this time is sufficient to carry out the adjustment.

7) Lubricate the cam to ease the return of the slider to its neutral position - central position -, this return is carried out by the slider return springs.

8) Connect the mechanic microswitch connector to the relative cable of the DMU load limiting device.

9) Insert the side protection plate (d) on the side of the mechanic microswitch: the plate is stopped by the circular rubber grommet which must be inserted in the hole on the side of the microswitch. Once the plate is fitted, it is advisable to put a few drops of Loctite between the outer upper edge of the plate and the support of the micro-switches to prevent the vibrations from moving it from its position.


B9F.P.I. DEVICE

Service Manual 07-2008 GB Rev. 2

F.P.I. Device


�

B9 F.P.I. Device

F.P.I. Device 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 warn-ing 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)

u A higher pressure value inside the crane hydraulic circuit.

u 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.

Working with the crane:

During the work with the crane, you can work without turning on the device to take advantage of higher operating speeds: When the load limiting device comes into operation, you can turn on the F. P. I device in order to have a higher performance.

The operation of the load limiting device must be cancelled by a short manoeuvre of basic crane extension re-traction, before starting to work again: if the load limiting device comes into operation subsequently, this is an indication that the crane has reached its maximum allowed performance.

F.P.I. Device


�

B9 F.P.I. Device

� - Functioning principleu TheF.P.I.deviceworksbyreducingthedynamiceffectsoncranestructureduetoloadmovements.The valve Ref. 1 deductsaportionoftheoilsenttothecompensatorsofeachcontrolbankelement(forthoseelementscontrollingthecranebooms),thusreducingtheinternalstrokeofthespoolinsidetheelement,whichresultsintheendinalimitedoperatingspeedofthecrane. The solenoid valve applied on the unit is electrically powered when the F.P.I. device turns ON.

u A solenoid valve Ref. 2 -applied to the hydraulic circuit of the Overload Safety Device (OSD)- is energised whenever the F.P.I. device is switched ON. Therefore, the OSD will operate at a higher pressure value, allowing the crane to operate according to the performances stated in the load diagram. For additional information on the Overload Safety Device , see the section “Overload Safety Device”.

Ref. 1

Ref. 2



�

B9INCREASE IN THE MAXIMUM PRESSURE VALUE AVAILABLE FOR LIFTING

A function assigned to the valve that reduces the speed of the crane movements is also to increase the maximum pressure available for lifting when you operate the FPI.device.

Note that the adjuster marked in the design adjusts the pres-sure value relating to crane operation with the device off - the crane pressure value with FPI=OFF-

The pressure value with the device turned on, the crane pres-sure value with FPI=ON- is adjusted by the main valve fitted to the control bank.

F.P.I. Device


�

B9 F.P.I. Device

�- Valves3.1 F.P.I. valveTwo versions of F.P.I. valves are used:

1) EFFER part # 8866722 B for basic cranes

2) EFFER part # 8866723 B for cranes with fly-jib

Note: the a.m. parts # are related to a 24 VOLT power supply

SPEED ADJUSTINGSCREWSPEED

ADJUSTINGSCREW

PRESSUREADJUSTINGSCREW

SPEEDADJUSTINGSCREW

1 2



�

B9

3.2 Overload Safety Device pressure increase valve

A solenoid valve, EFFER part # 8866708, is fitted to increase the Overload Safety Device operating pressure when-ever the F.P.I. device is switched ON.

Note: the a.m. parts # are related to a 24 VOLT power supply

PRESSURE ADJUSTINGSCREW

� - Settingsu 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 Asexplainedabove,whentheF.P.I.isswitchedon,ahigherpressureisavailableinthecranecircuit.Theworkingpressureiscontrolled:bytheF.P.I.valve(whentheF.P.I.isoff ),whilethe(higher)pressurevalueiscontrolledbythemainreliefvalveofthecontrolbankwhentheF.P.I.ison.

Settingpoints

Setting point of the max. pressure value during operation when the F.P.I. is on.

Setting point of the max. pressure value during operation without F.P.I. on

Setting point of the hydraulic value acting the load limiter when the F.P.I. device is switched ON (for additional infor-mation see chapter “Load limiter”

F.P.I. Device


�

B9 F.P.I. Device

� - Tunings5.1 F.P.I. valve tuningsu 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.

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.

ADJUSTING SCREW

ADJUSTING SCREW

ADJUSTING SCREWADJUSTING SCREW

OUTER BOOM SPEED

FLY-JIB SPEED

MAIN BOOM SPEEDSTANDARD CRANE

GENERAL PRESSURE

ELECTRIC CONNECTOR E50



9

B9

5.2 Adjusting the activation point of the Overload Safety Device

u If necessary, follow the instructions written in the Overload Safety Device service manual to check the ac-tivation point of the Overload Safety Device. When performing this check, the crane, with the F.P.I. device switched ON, shall be free from accessory equipment (basic crane version). Moreover, check the effect of the Overload Safety Device activation on the hydraulic fly-jib knuckle (if fitted to the crane) in the work area, behind cabin.

u In case the activation point of the Overload Safety Device with F.P.I. switched ON needs to be changed, and also the settingof the pressure increase valve that controls the operation of the Overload Safety Device with F.P.I. switched ON needs to be adjusted, adjust the screw as shown in the drawing below.

PRESSURE ADJUSTING SCREW

ELECTRIC CONNECTOR

u Turn the screw clockwise to increase pressure and crane operating range. Otherwise, turn the screw coun-terclockwise 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.

E51

F.P.I. Device


10

B9 F.P.I. Device

� - Operating instructionsAs 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 radio-controller, 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 Over-load Safety Device will stop. In order to perform any manoeuvre, it is necessary:

a -to activate the F.P.I. device,

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.



11

B9

� - Electric connectionsThe following instructions refer to some relevant electric connec-tions.

u K 50: (EFFER spare part # 9394682 for 24 V. electric sup-ply).

Relay for the activation of the F.P.I. device energized by the radiosignal. The relay is electrically energized by the wire connectedto clamp 38.

u Clamp 38: the electric wire connecting the radio control receiver is attached to one side of the clamp 38.

u 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:

E50: F.P.I. solenoid valve

E51: solenoid valve for Overload Safety Device pressure increase.

K 50

E 50

E 51

F.P.I. Device


1�

B9

� - MaintenanceThe F.P.I. valve doesn’t 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.

HL50: (EFFER spare part # for 24 V. electric supply).

Warning light indicating F.P.I. device is switched ON

SA50: (EFFER spare part # 9394725).

Key switch for F.P.I. device activation.

Key switch for F.P.I. device activation.

lorry crane 2

Documents