You are on page 1of 242

THE POWER OF PERFORMANCE

SERVICE MANUAL 5

A B C
PARTE IDRAULICA HYDRAULIC SECTION PARTIE HYDRAULIQUE HYDRAULIK
BMI00027GB_0-29092008

Home

THE POWER OF PERFORMANCE

THE POWER OF PERFORMANCE

A B C

INSTALLAZIONE GRU E INTERVENTI TECNICI CRANE INSTALLATION AND TECHNICAL OPERATIONS INSTALLATION GRUE ET OPERATIONES TECHNIQUES INSTALLATION DES KRANES UND TECHNISCHE OPERATIONEN

PARTE IDRAULICA HYDRAULIC SECTION PARTIE HYDRAULIQUE HYDRAULIK

B1 CONTROLBANKS B2 HOLDING VALVES B3 SUPPLEMENTARY STABILIZERS B4 FILTERS B5 HOSES AND PIPES B6 WRENCH SETTING B7 HYDRAULIC / ELECTRO-HYDRAULIC LIMITING DEVICE B8 CONTROLBANKS B8.1 PROPORTIONAL CONTROLBANK HAWE B8.2 PROPORTIONAL CONTROLBANK SAUER-DANFOSS PVG 32 B8.3 PROPORTIONAL CONTROLBANK NORDHYDRAULIC RS 210 B9 F.P.I. DEVICE

PARTE ELETTRICA ELECTRICAL SECTION PARTIE ELECTRIQUE ELEKTRIK

THE POWER OF PERFORMANCE

THE POWER OF PERFORMANCE

INDEX

B1 CONTROLBANKS 1 Controlbanks on EFFER cranes............................................................................................................................ 2 2 Controlbank setting................................................................................................................................................ 7 B2 HOLDING VALVES 1 Lock valves................................................................................................................................................................. 2 2 Setting the holding valves..................................................................................................................................12 3 Sequence valves.....................................................................................................................................................20 4 Sequence valve setting .....................................................................................................................................23 B3 SUPPLEMENTARY STABILIZERS 1 Hydraulic plumbing (supplementary stabilizers to crane hydraulic circuit)...................................... 2 B4 FILTERS 1 Delivery filter............................................................................................................................................................. 2 2 Air filter applied on the oil tank.......................................................................................................................... 6 B5 HOSES AND PIPES 1 Hoses and pipes for hydraulic system.............................................................................................................. 2 2 Pipe fittings type UNF - JIC 37 (SAE J514)...................................................................................................... 4 3 UNF flat type pipe fittings, with O-Ring - (SAE J1453) . ...........................................................................17 B6 WRENCH SETTING 1 Torque wrench setting of hydraulic fittings................................................................................................... 2 B7 HYDRAULIC / ELECTRO-HYDRAULIC LIMITING DEVICE 1 Operating principle................................................................................................................................................. 3 2 Valves and components....................................................................................................................................... 9 3 Practical setting of the overload limiting device........................................................................................15 4 Operating sequences to set the load limiting device...............................................................................23 B8 CONTROLBANKS B8.0 HC-D3M Controlbank: technical improvements.................................................................................... 2

THE POWER OF PERFORMANCE

INDEX

B8.1 PROPORTIONAL CONTROLBANK HAWE Operation....................................................................................................................................................................... 7 1 Inlet element...........................................................................................................................................................10 2 Closing element.....................................................................................................................................................17 3 Lever element. .........................................................................................................................................................18 4 Troubleshooting.....................................................................................................................................................33 5 Variations for PSL 52-3..........................................................................................................................................35 6 Coupling with DMU..............................................................................................................................................41 7 HAWE Proportional controlbank: variable displacement pump .........................................................44 B8.2 PROPORTIONAL CONTROLBANK SAUER-DANFOSS PVG 32 Operation.....................................................................................................................................................................53 1 Inlet element...........................................................................................................................................................55 2 Control bank element..........................................................................................................................................61 3 Closing element.....................................................................................................................................................73 4 Assembly tie rod kit...............................................................................................................................................74 5 Variable displacement pump installation.....................................................................................................75 6 Emergency hand pump installation...............................................................................................................79 7 Troubleshooting.....................................................................................................................................................81 B8.3 PROPORTIONAL CONTROLBANK NORDHYDRAULIC RS 210 1 Introduction.............................................................................................................................................................85 2 Main head.................................................................................................................................................................87 3 Lever element. .........................................................................................................................................................91 4 Closing element.....................................................................................................................................................95 5 Valve block connection tie rods........................................................................................................................96 6 Microswitches for DMU. .......................................................................................................................................96 7 Mechanic microswitch adjustment and replacement..............................................................................98 B9 F.P.I. DEVICE 1 Description................................................................................................................................................................. 3 2 Functioning principle............................................................................................................................................. 4 3 Valves............................................................................................................................................................................ 6 4 Settings........................................................................................................................................................................ 7 5 Tunings........................................................................................................................................................................ 8 6 Operating instructions.........................................................................................................................................10 7 Electric connections..............................................................................................................................................11 8 Maintenance............................................................................................................................................................12

THE POWER OF PERFORMANCE

CONTROLBANKS B1

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Controlbanks

B1

1- Controlbanks on EFFER cranes


1.1 Types of controlbanks
Different types of controlbanks are used on EFFer cranes: Direct Actioning Controlbank Semiproportional Actioning Controlbank Proportional Actioning Controlbank DIRECt ACtIONING CONtROLBANK Two types of such valves are used by EFFer: Direct actioning controlbank of monobloc type These controlbanks allow only one pressure setting, on the main relief -valve, with all cylinders operating at the some max. pressure setting. Inner spools may be Open-center, Close-center, or mixed, depending from the type of movement they are designed to control and from the type of stop valve fitted on the crane cylinders. To fit additional controls to these types of valves, it is necessary to fit a second control bank next to the main control bank, and to carry out a carry-over type hydraulic connection. Direct actioning controlbank of sandwich type These controlbanks, in addition to the main pressure value, allow a pressure setting on each oil line to the cylinder, thanks to the check-relief valves fitted on each element of the controlbank. IInner spools may be open-centre, closed-centre, or mixed type, according to the crane movements to be checked, and the type of lock valves fitted to crane cylinders. To fit the additional controls, you can insert further individual elements using the new, longer tie-rods to reassemble the control bank. sEmIPROpORtIONAL ACtIONING CONtROLBANK Controlbanks called semiproportional are installed on some models of crane. In spite of the fact that they do not belong to the compensated proportional controlbank range, they are designed to allow crane movement drive not only without load applied to the hook, but also with a medium-high load respect to the maximum lifting capacity of the crane, simultaneously. COmpENsAtEd PROpORtIONAL ACtIONING CONtROLBANK Proportional operation control banks are also fitted by EFFER, i.e. control banks allowing the simultaneous operation of different crane movements even at low speed, and with the maximum load applied to the hook. These types of controlbanks are more complex than then previous ones and all technical information on this type of controlbank are reported in the following chapters.

THE POWER OF PERFORMANCE

Controlbanks
Controlbank Brand & Type Picture Fitted on Effer Models

B1

Galtech PL 25

18 28 35 30 E.P.

Dinoil DN

18 20 E. P. 38 42

Valvoil

20 E.P. 28 30 E.P. 35 40 42

Hydrocontrol HCD 10

55 62 65 75 80 100

THE POWER OF PERFORMANCE

Controlbanks
Controlbank Brand & Type Picture

B1
Fitted on Effer Models

Hydrocontrol HCD 3-M

95 120 140

Hydrocontrol HCD 4

110 110E 150 170 210 250

Hydrocontrol HCD 6

335

Nordhydraulic Semiproportional

110 110 E 130 145

THE POWER OF PERFORMANCE

Controlbanks
Controlbank Brand & Type Picture Fitted on Effer Models

165 275 305 310 325 340 370 440 470

B1

Danfoss Proportional

65 (OPTIONAL) 75 (OPTIONAL) 80 (OPTIONAL) 95 (OPTIONAL) 100 (OPTIONAL) 120 (OPTIONAL) 140 (OPTIONAL) 210 (OPTIONAL) 250 (OPTIONAL) 360 430 500 535 585 680 750 860 980 100N 1150 1250 1355 1750 400 460 520 550 600 720 850 920 80N 1050 1155 1350 1550

Hawe Proportional

THE POWER OF PERFORMANCE

Controlbanks

B1

1.2 Torque wrench setting of controlbank tie rods


Controlbanks of Sandwich type are equipped with gaskets to ensure correct part sealing. Therefore, it is really important to provide tie rods with correct torque wrench setting as a wrong setting may cause oil leaks or prevent control lever smoothness. Controlbank tie rods are built with special high resistance steel: the use of tie rods with features different from the genuine ones, may jeopardise the correct operation of the controlbank. The correct torque wrench setting of tie rods is reported below, together with the controls fitted on EFFER cranes in the past. DIRECt ACtIONING ANd sEmIPROpORtIONAL CONtROLBANKs:

Controlbank type
HYDROCONTROL HC-D3 HYDROCONTROL HC-D3M HYDROCONTROL HC-D4 HYDROCONTROL HC-D6 HYDROCONTROL HC-D12 MONSUN TYSON HV 07 SALAMI VD 081 ERPOZ DN 45 DINOIL DNC-50 DINOIL DNC-50 HYDROIRMA HDS 130

Tie rod diameter


tie rod M 8 tie rod M 8 tie rod M 10 tie rod M 10 tie rod M 12 tie rod M 8 tie rod M 8 tie rod M 12 tie rod M 8 tie rod M 10 tie rod M 8

Torque wrench setting


34 Nm 34 Nm 34 Nm 50 Nm 69 Nm 18 Nm 32 Nm 49 Nm 16 Nm 20 Nm 30 Nm

PROpORtIONAL ACtIONING CONtROLBANK

Controlbank type
HAWE - PSL 2 HAWE - PSL 3 HAWE - PSL 5
DANFOSS PVG 32

Tie rod diameter


nr. 2 tie rods M 8 nr. 1 tie rod M6 nr. 1 tie rod M 8 nr. 2 tie rod M10 nr. 3 tie rod M12 tie rod M 8

Torque wrench setting


23 Nm 9,5 Nm 22 Nm 46 Nm 60 Nm 23 Nm

THE POWER OF PERFORMANCE

Controlbanks

B1

2 - Controlbank setting
The correct controlbank setting grants the perfect operation of the crane. Therefore, it is really important to check the setting of the controlbank valves. NOTE: in order to perform crane overload tests, it is necessary to change and increase the controlbank setting values. When crane overload test are completed, it is necessary to set the controlbank according to the pressure values listed in the specific hydraulic diagram of the crane configuration When you carry out the check on crane pressures you also cancel a few small differences in setting arising from the real oil delivery, which the hydraulic pump, fitted to the truck, supplies. Later, we recommend to perform this check at least once a year. When checking the setting values, the truck engine shall run at the same rpm of the crane in working condition, with the hydraulic oil temperature in the crane oil tank at min. 20 C : any setting performed with oil at a lower temperature will jeopardise the correct standard operation of the crane.

Pliers EFFER part # 2008006 Lead seals EFFER part # 2008005 (1kg) (1 Kg = 240 lead seals)

After this operation, all the inspected valves shall be lead-sealed and no signs of tampering must be found on the seal. Should this occur, any warranty would be automatically denied by Effer. Correct crane setting values are shown on the technical data sheet referred to the hydraulic diagram of the crane configuration.

THE POWER OF PERFORMANCE

Controlbanks

B1

A correct hydraulic setting requires a reliable pressure gauge, and it is well known that pressure gauge suffer from early wear. If a certified pressure gauge is not available, Effer recommends to buy a sample pressure gauge to be used three or four times a year, so as to prove the exacteness of the pressure gauges used in the workshop. A digital and a traditional pressure gauge are shown herebelow.

To check controlbank setting, apply the pressure gauge to the controlbank, near the point of connection of the hydraulic pump line. (See the symbol X in the diagram in the previous page). A minipress quick coupling, with M16x2 thread, is fitted on all crane in production, in this point.

Code 8907726A

THE POWER OF PERFORMANCE

Controlbanks

B1

2.1 Monoblok type controlbank: pressure adjustment


The hydraulic diagram of a Monoblok type controlbank is shown below:

VG= 265 bar

As already mentioned, all the cylinders of a crane equipped with monoblock type controlbank, work at the same pressure value. Therefore, only one pressure setting has to be performed on the valve called main valve VG-. Apply a pressure gauge to the valve. No load shall be applied to the crane. Then raise or retract a cylinder to the full stroke. The pressure value on the gauge will show the setting value of the main valve. If the pressure value on the pressure gauge is not in accordance with the crane hydraulic diagram, adjust the valve setting screw: with the controlbank lever activated, turn the setting screw clockwise (screw) to increase pressure, and viceversa turn the setting screw anticlockwise (unscrew) to decrease pressure. When the correct pressure value is obtained, release the controlbank lever to lock the setting screw. After locking the valve setting screw, carry out an additional test as screwing may affect setting: a shift of + 5 bar compared to the pressure value shown in the hydraulic diagram is allowed.

VG

ThE OpERAtOR IN ChARGE OF thE AdJUstmENt h A s th E R E sp O N s I B I L I t Y O F th E R E AppLICAtION OF LEAd sEALs

THE POWER OF PERFORMANCE

Controlbanks

B1

2.2 Multiple element controlbank: pressure adjustment


Multiple element controlbanks allow checking the pressure value on each hydraulic line connecting the different crane cylinders. Two pressure adjusting valves, or just one, or no valve at all may be fitted on a controlbank element. If no pressure adjusting valve is fitted, the max. pressure value in the hydraulic circuit will be the same of the set main relief valve VG located at the controlbank inlet. Valves applied to the controlbank elements are called check-relief valves and are classified into: Vp/s Vp/r check-relief valve, controlling the max. pressure value allowed during a cylinder opening manouvre check-relief valve, controlling the max. pressure value allowed during a cylinder closing manouvre

VP/S - VP/R

VP/S - VP/R

VG

10

THE POWER OF PERFORMANCE

Controlbanks

B1

A) EXAmpLE OF CONtROLBANK sEttING wIth ChECK-RELIEF vALvE sEt At A hIGhER pREssURE thAN thE mAIN RELIEF vALvE

VG= 300 bar 1st boom cylinder 1)Vp/s = 320 bar 2) Vp/r = 140 bar

1)

320

2) 140
VG 300

Considering the setting data listed in the hydraulic diagram, youll notice that some check-relief valves are set at a higher value than the main relief valve, while other check-relief valves are set at a lower value. As the main relief valve controls the max. pressure allowed inside the controlbank, the aim of setting some checkrelief valves at a higher value than the main relief valve depends on the fact that it is necessary a small stream of oil flowing out of the cylinder when the crane is subjected to sudden movements with the max. load applied. The setting values listed in the hydraulic diagram of the controlbank mentioned above, show a check-relief valve set at a higher value than the main relief valve. In case of just one element or more elements set at a higher value than the main relief valve, take as a reference the element set at the highest pressure. PREssURE tEstING CAN BE dIvIdEd INtO twO stEps: Test of check-relief valve pressure Test of the main relief valve pressure

Apply the pressure gauge (no load shall be applied to the crane) and make a full end-stroke of the 1st boom cylinder: the pressure value on the pressure gauge corresponds to the set value of the main relief valve, that is 300 bar.

THE POWER OF PERFORMANCE

11

Controlbanks
In order to test the check-relief valves, increase the set pressure of the main relief valve VG. To obtain a higher pressure, keep the controlbank lever activated and turn the main relief valve adjusting screw clockwise (screw). Youll notice that the pressure gauge jumps up to 320 bar. As soon as pressure increase stops, release the controlbank lever, then screw the main relief valve adjusting screw half a turn: lock the screw in this position. Now test the set pressure of the check-relief valves VP/S and VP/R located on the controlbank, by shifting each controlbank lever and turning the valve adjusting screws. After checking the set pressure of the valves VP/S and VP/R according to the hydraulic diagram, set the main relief valve VG to 300bar. Make a full end-stroke of the 1st boom cylinder: the pressure value on the pressure gauge corresponds to the set value of the check relief valve (320 bar). Keep the controlbank lever activated and turn the main relief valve adjusting screw anticlockwise unscrew it- up to obtain a setting value slightly lower than the main valve value shown in the diagram, then turn the adjusting screw clockwise (screw up) until the desired value is achieved (300 bar).

B1

VG

VP/S

An additional check mush be also carried out after locking the valve adjusting screw, as the adjusting screw tightening may lead to slight changes in the preset setting value: however, a +/- 5 bar tolerance is allowed with respect to the pressure values shown in the hydraulic diagram.

VG

12

THE POWER OF PERFORMANCE

Controlbanks

B1

B) EXAmpLE OF CONtROLBANK sEttING wIth ChECK-RELIEF vALvE sEt At A LOwER pREssURE thAN thE mAIN RELIEF vALvE

VG = 340 BAR Vp/s = 315 BAR 315

340

In this case, al least one element is not equipped with main relief valve (see extension retraction). Follow the correct procedure hereunder: - perform a manouvre of extension retraction so as to check the pressure value of the main relief valve. If necessary, adjust the adjusting screw. - Check the pressure value of the main relief valves by shifting the controlbank levers, then turn the valve adjusting screws. ThE OpER AtOR IN ChARGE OF thE AdJUstmENt hAs thE REspONsIBILItY OF thE RE-AppLICAtION OF LEAd sEALs.

THE POWER OF PERFORMANCE

13

Controlbanks

B1

14

THE POWER OF PERFORMANCE

HOLDING VALVES B2

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Holding valves

B2

1 - Lock valves
The hydraulic system of EFFER cranes is designed in compliance with UNI EN12999: 2002/A2-2006 standards. The several safety devices required by the standards also include lock valves, often referred to as movement control valves or hydro-piloted lock valves on crane handling cylinders. When these valves are fitted, they allow: A) Handling the cylinder, or the crane, only with the hydraulic pump turned on. With the hydraulic pump off, or with the truck engine off, it is not possible to move the booms of the crane.

ST OP

OFF

B) Ensuring that the crane is fully stopped during the intervals between the various work stages in case of any oil leakage inside the control bank (if very worn out): hydraulic oil leaks from cylinders only when the lock valve opens, with the hydraulic pump on, and only as a result of a manoeuvre carried out by the operator.

ST OP

C) Preventing the load from going down unintentionally in case a hose breaks. The lock valve detects the difference in pressure inside the hydraulic circuit caused by this breakage, and immediately closes, thus preventing the oil from leaking out of the cylinder.

P STO

THE POWER OF PERFORMANCE

Holding valves

B2

D) Avoiding possible breaks in case of overloads. When the oil inside the cylinder exceeds the maximum pressure value, allowed by the project, the lock valve opens letting oil leak out of the tank, through the control bank. If the load limiting device is not fitted, the effect is a slow descent of the applied load. When the load limiting device is fitted, the lock valves are set to allow a maximum pressure value into the cylinder, which is higher than the load limiting device setting value, actually having an auxiliary safety function only.

ON

E) Limiting inner pressure peaks to cylinders moving booms for effect of dynamic pressure. If the pressure peak exceeds the valve setting value, this will cause its momentary opening. The pressure in surplus will be unloaded onto the oil return line. The chart shows the trend of instant pressure during the different work stages carried out with the maximum loads applied to hook; the lock valve setting value -ptar- corresponds to the max. pressure value allowed inside the cylinder.

p (bar)

ptar (bar)

Max. pressure value allowed inside the cylinder

t (sec)

THE POWER OF PERFORMANCE

Holding valves
There are different types of hydropiloted lock valves, EFFER uses: 1. Lock valve with direct hydropiloted opening. 2. Overcenter hydropiloted lock valve.

B2

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.

A
Oil Passage Legend V = to controlbank C = to cylinder Simple effect

C1

C2

V1

V2

C1

C2

Oil Passage Legend V = to controlbank C = to cylinder Double effect

V1

V2

This type of valves do not need to be set, like all hydropiloted valves, they are characterized by the so called piloting ratio R, this ratio of two particular oil sections inside the valve, and more precisely, it is the ratio between the area of the section on which the setting spring pressure acts in the closing direction added to pressure exerted by oil directly kept inside the cylinder and the section on which the piloting pressure acts. NOTE: Since the oil leakage from cylinder is not required following an overload, the closing or opening of cylinder (then the valve), are strictly linked to the operators will to carry out a manoeuvre.

THE POWER OF PERFORMANCE

Holding valves
DIRECT OPENING HYDROPILOTED LOCK VALVE FUNCTIONAL DIAGRAM

B2

Pcil
Fm

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

Ppil

Fm

Pcil
Ppil

A2 piloting surface on which piloting pressure Ppil acts.

Piloting pressure multiplier Chart of piloting ratio

Piloting ratio:

R=

A1 A2

THE POWER OF PERFORMANCE

Holding valves

B2

1.2 Overcenter hydropiloted lock valves


This 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.

C2

C1

Simple Effect

V2

V1

B) Double effect: the valves control both the cylinder hydraulic lines (ex: fly-jib or extension cylinder), when an oil overflow is necessary because of a crane overload.

Double Effect

V1

V2

Oil Passage Legend

V = to controlbank C = to cylinder

NOTE: These valves need a specific setting pressure value. When it is reached the valve opens, that is oil leaks out of the cylinder. The setting value defined by EFFER when designing the crane is such that pressure peaks generated in the cylinder by the max. load oscillations will not affect the cylinder, saving the crane structure.

THE POWER OF PERFORMANCE

Holding valves

B2

1.3 Influence of piloting ratio on crane operation


The 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:

Pcil R Ppil Fm A1

The pressure inside the cylinder due to the applied load Pilot Ratio Piloting pressure The force exerted by set spring (this is a preset setting and therefore not adjustable) the section on which Pcil pressure acts

You have that: Equation of balance of forces is: that is:

Fm = Ptar A1 Fm + Pcil A1 = Ppil A2

Ptar A1 + Pcil A1 = Ppil A2 Ppil = (Ptar + Pcil ) R= A2 A2 A1


By developing the formula you have:

A1 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:

Ppil

Ptar + Pcil R

In case of hidro-piloted valves with direct opening, the setting pressure is fixed and insignificant, therefore the previous one is converted into: P + Pcil P tar cil Ppil pil

R R

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

Pcil R

Conclusion: The necessary pressure value to have the opening of a hydro-piloted lock valve is influenced by the load on the crane hook. If lock valves with piloting ratios, other than expected, leads to have operating failures when handling the crane.

THE POWER OF PERFORMANCE

Holding valves

B2

Since an oil leakage from cylinder is also requested these valves, the cylinder, then the valve closing or opening, are closely linked both to the achievement of the maximum pressure allowed by the project, inside the oil line that you want to check, and to the operators will to carry out a given manoeuvre.

P from controlbank

Pcil Ptar Fm
Pcil = Pressure caused by the applied load

Pcil

Ppil

C2

C1
A2 piloting surface on which piloting pressure Ppil acts.

Pcil

Fm

Ppil

V2
A1 surface on which the pressure of the setting spring acts and pressure Pcil exerted by oil directly kept into the cylinder by effect of the load applied

V1

Lock valve layout

THE POWER OF PERFORMANCE

Holding valves
Trend of piloting pressure

B2

The chart shows the piloting pressure required for the valve to open when the setting pressure and the cylinder inner pressure induced by effect of the load applied to brane hook are changed.

Ppil
changed setting modificata Ppil, Tar

Tar
EFFER setting EFFER Ppil, Tar

Tar modificata Changed setting

Tar EFFER EFFER setting

Ppil, min

(Pressione della linea (Oil drain line pressure) di scarico olio)

P cil, min

P cil

Set EFFER = Set changed = Pcil, min = Pcil, max, project = Ppil, max = Ppil, min = Conclusions:

EFFER original setting pressure Setting pressure improperly changed in order to increase crane performance (INCREASED) Minimum pressure inside cylinder (oil drain line pressure) Maximum pressure into the cylinder allowed by project Piloting pressure required for the valve to open for a fixed setting pressure value of lock valve 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

To open the valve, a higher piloting pressure will be required: 1) 2) When the setting pressure value of lock valve increases. When the pressure induced by load, into cylinder decreases

THE POWER OF PERFORMANCE

Holding valves

B2

1.4 Selecting the piloting ratio


The 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 handling 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

Ppil

Ptar Pcil R

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.

10

THE POWER OF PERFORMANCE

Holding valves

B2

1.5 Hydropiloted Holding valve, type Overcenter: for opencenter circuits and for close-center circuits
Within the Overcenter type of holding valves, two types of valves can be found on an Effer crane, depending on the type of hydraulic circuit provided: A. Open-center circuits (controlbank spool designed for open center). The controlbank lever of this spool is not activated and the two lines from the cylinder are directly connected to the oil delivery line, i.e. to the oil tank. This means, in practice, that when an overcenter valve opens up due to an overload manoeuvre, the oil flow to the tank is allowed. This type of circuit is especially designed for extension control .

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 cylinder, the lock valve and the control bank that disrupt the proper operation 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.

THE POWER OF PERFORMANCE

11

Holding valves

B2

2 - Setting the holding valves


As 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.

C V

C V

On the valve body, close to the ports, the following letters are punched: V: C: to controlbank to Cylinder

12

THE POWER OF PERFORMANCE

Holding valves

B2

2.1 Necessary tools


To set the valve, following tools must be available at the workshop: a) pressure gauge, with a large scale (to avoid reading mistakes)

b)

controlbank with an adjustable main relief valve

c) electro-hydraulic powerpack, with a recommended oil flow 6-8 l./min.

To set the valve, oil shall be sent to the port C of the valve, checking that oil starts flowing out from port V when the required pressure value is read on the pressure gauge. When setting one oil line of the valve, the second oil line doesnt need to be plugged. If for example the required value is 320 bar, the setting screw on the valve shall be turned until, when reading the value 320 on the pressure gauge, the thinnest possible stream (though continuous, not by drops) starts getting out. To check that setting was correct, youll then check that, at a pressure value lower by 10 bar (in the example: 310 bar), the stream stops completely, and which increasing by 10 bar compared to the setting one (in the example: 330 bar) the valve opens completely.

THE POWER OF PERFORMANCE

13

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

B2

Pliers EFFER part # 2008006

Lead sealing parts EFFER part # 2008005 (1kg ) (1 kg = 240 lead sealing parts)

EFFER part #8850710 37 mm l= 72 mm

EFFER part # 8850711 30 mm l= 50 mm

Any CRANE warranty would be automatically denied by Effer in case of valves not lead sealed.

14

THE POWER OF PERFORMANCE

Holding valves

B2

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 C

V V

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 C

V V

THE POWER OF PERFORMANCE

15

Holding valves
F) If there is no oil leakage:

B2

1) unscrew the lock valve adjusting screw slightly to decrease its setting value, by shifting the control bank lever to the opposite direction for oil to be conveyed to the clogged branch of control bank. The manoeuvre has the only purpose to release the residual pressure inside the valve, which could alter its setting. Valve setting is considered to be correct when you see the leakage of a small continuous drizzle of oil fromV, when the setting pressure value is achieved.

320 bar

C C

V V
Small oil stream

2) Using the control bank main valve, check that there is no oil leakage at a value of 310 bar. 3) Using the control bank main valve, check that the lock valve opens completely at a value of 330 bar.

305 bar

No oil out!

!!!

4) Fix the set screw on the valve, and check again that the settings match, both at the value of 320 bar, at the lower value of 310 bar, and at the higher value of 330 bar. 5) Apply the seal to the part concerning the setting adjustment. Note: a plexiglas guard should be used to protect the operator from the oil streams out of the valve.

16

THE POWER OF PERFORMANCE

Holding valves

B2

EFFER holding valves differ in the hydraulic connection, depending on the type and size. Since the 90s, effer ha has been using holding valves named flange-coupled, i.e. holding valves connected to the cylinders by seal and fastening screws instead of a pipe.

Valve fitted on cylinder by a fitting

Valve fitted on cylinder with a flange connection

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.

THE POWER OF PERFORMANCE

17

Holding valves

B2

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

EFFER pArt #

8866738

EFFER pArt #

8866739

60

10

40

8866740

M10

EFFER pArt #

40 60

28

3/8 GAS BSPP

EFFER pArt #

8866741

18

THE POWER OF PERFORMANCE

Holding valves

B2

EFFER pArt #

8866742

EFFER pArt #

8866743

EFFER pArt #

8866744

EFFER pArt #

8866745

EFFER pArt #

8866746

THE POWER OF PERFORMANCE

19

Holding valves

B2

3 - Sequence valves
The sequence valves allow hydraulic oil to continue its way inside the pipes only when the pressure value exceeds the setting value set on the valve. Their typical application is on the extension cylinders, on which the sequence valves allow the cylinders and the extensionsto exit in sequence.

Two types of sequence valves are fitted to the EFFER cranes: A) Compensated type valve B) Non-Compensated type valve

20

THE POWER OF PERFORMANCE

Valve setting Ex.: 200 bar

Holding valves

B2

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

Valve setting Ex.: 200 bar

70 bar

100 bar

120 bar

This type of valve is used when, in the project phase, it is necessary to limit the thrust pressure inside the first extension cylinder. When running an extension exit manoeuvre, if the pressure opens a sequence valve, this valve requires a very limited pressure to remain opened. Absorption of these valves is only 10 bar, corresponding to the pressure loss which occurs because oil goes through the valve; therefore all the extension cylinders work at about the same maximum thrust pressure.

ON LINE FLANGED

ON LINE

THE POWER OF PERFORMANCE

21

Holding valves

B2

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

Valve setting Ex.: 300 bar

40 bar

20 bar

20 bar

This type of valve is used when the pressure inside the first few extension cylinders must be high for reason of design. When running an extension exit manoeuvre, if the pressure makes a sequence valve open, this valve requires a pressure value equal to the setting value, to remain opened; therefore the first cylinders work at a thrust pressure which is higher than the following cylinders.

3.3 Examples of set up sequence valves


ON LINE

22

THE POWER OF PERFORMANCE

Holding valves

B2

4 - Sequence valve setting


In 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 tools


To 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

THE POWER OF PERFORMANCE

23

Holding valves

B2

4.2 Practical example of setting


We need to set the sequence valve by sending oil to the point of connection of the controlbank line and by adjusting thespring setting. This adjustment can be internal or external.

Internal setting

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

Internal setting

External setting

External setting

We need to set a valve at a pressure of 40 bar. We adjust the valve setting-screw until 40 bar is achieved and a small streamof oil (not only drops) comes out. Increase pressure to the controlbank of approx. 10 bar and check that a stream of oilcorresponding to the whole power pack oil capacity flows out of the sequence valve. Note: a plexiglas guard should be used to protect the operator from the oil streams out of the valve.

24

THE POWER OF PERFORMANCE

SUPPLEMENTARY STABILIZERS B3

Service Manual

Rev.

07-2008

GB

Supplementary stabilizers

B3

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


The plumbing of supplementary stabilizers to the crane hydraulic circuit varies depending from the crane model. A) On small cranes, which do not feature stabilizers with hydraulic outlet, there is a dedicated lever on the controlbank andthe holding valves on the stabilizers cylinders are fitted with a faucet. Thru this faucet you select which cylinder youwant to manoeuvre thru the controlbank lever.

Basic crane

Supplementary stabilizers

Besides the controlbank, some line fittings allow the connection to the additional supplementary stabilizers. The supple-mentary stabilizers must be equipped with a holding valve with faucet to select the stabilizer to operate. When carryingout this connection, it is really important that all barrel-side and rod-side cylinders are kept separate and directed to the two controlbank connections.

THE POWER OF PERFORMANCE

Supplementary stabilizers

B3

B) On mid and large size cranes, there is a dedicated lever on the controlbank for the stabilizers manoeuvre, and two divertervalves (one on each side of the crane, located close to the bottomside controlbank). Thru these diverter valves, you mayselect the stabilizer (front, rear) and the manoeuvre (outlet, down) you want to operate by the lever on the controlbank. After selecting the manoeuvre, move the lever to operate the stabilizer.

Pos. Outlet 1 2 3 4
STOP 4 1

A B C D
Supplementary stabilizers

STOP

STOP

3 STOP

Basic crane

1 STOP STOP

Pos. Outlet 1 2 3 4 A B C D

STOP 3

STOP

The diverter valves incorporate also the connections for the oil outlet of additional supplementary stabilizer cylinders. Holding valves applied to the stabilizer vertical cylinders are not equipped with oil faucet.

THE POWER OF PERFORMANCE

Supplementary stabilizers

B3

C) On the cranes where there is not a dedicated lever on the controlbank, the diverter valve incorporates also the control for the stabilizers manoeuvre. There is one controlbank/diverter valve for each side of the crane or one serving both sides thru a rod. First you select by the lever which manoeuvre you want to perform, then, by pushing or pulling the same lever you select the direction of manoeuvre (raise or lower). The diverter valves incorporate also the connections for the oil outlet of additional supplementary stabilizer cylinders.

Pos. Oulet 1 2 3 4
4 3

4-way diverter

A B C D

Supplementary stabilizers

Basic crane

THE POWER OF PERFORMANCE

Supplementary stabilizers

B3

Pos. Outlet
3

8-way diverter
6 5

1 2 3 4 5 6 7 8

A B C D E F G H

Supplementary stabilizers

Supplementary stabilizers

Basic crane No hydraulic outlet

Basic crane With hydraulic outlet

THE POWER OF PERFORMANCE

Supplementary stabilizers

B3

Supplementary stabilizer hydraulic lateral outlet


Repeated and prolonged improper operation of stabiliser exit with the mechanical safety retainer inserted (this retainer prevents from any unintentional exit of the stabilizer), could damage the stabiliser, thus jeopardizing its proper operation. In order to avoid this problem, each additional stabilizer with hydraulic exit must have a pressure reducing valve, code 8866769k. It is a maximum pressure valve that limits pressure at 150 bar inside the stabiliser hydraulic circuit . In this way it is possible to ensure the perfect operation of the closing retainer of the additional stabilisers.

8866769 (QT.1)
T

V1

V2

T
Please find below the connection hydraulic diagram of the additional stabiliser safety valve.

V1

V2 150 150

V1

V2

To the hydraulic circuit of the crane

THE POWER OF PERFORMANCE

Supplementary stabilizers
IMPORTANT:

B3

The hydraulic connection of the supplementary stabilizers must ALWAYS be made without any VALVE OR FAUCET ordiverter left on the oil line to the cylinders rod-side. Should this occur, the cylinder would swell as soon as it ismaneuvered.

Area A (Piston side)

Area A-B (Rod side)

No obstacles or obstructions on this line !!!

Sending oil to the line indicated by blue arrow, in the upper cylinder chamber you generate a force equal to thepressure of the oil sent multiplied by the barrel area: F = PxA If anything (valve, faucet etc.) obstructs the oil line coloured in red, preventing the oil from flowing out to thecontrolbank or to the oil tank, the same force presses then into the lower chamber of the cylinder and since therethe area is much smaller than in the upper chamber, the resulting pressure will be, according to the sameformula :

P= F / (A-B)
Since the area difference between chamber A and B is very small, the new value of pressure is then very highand exceeds the structural design of the cylinder, with a swelling as a result.

THE POWER OF PERFORMANCE

Supplementary stabilizers

B3

THE POWER OF PERFORMANCE

FILTERS B4

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Filters

B4

1-Delivery filter
The cranes not provided with proportional controlbank are equipped with an oil delivery filter as a standard, located on the lineconveying the hydraulic oil passing from the pump to the controlbank. Correct filter servicing operations grant the reliability of the hydraulic systemcomponents. Filter by-pass operation is shown on the clogged filter indicator: the by-pass device makes the oil flow outfrom the filter inlet to the outlet when the cartridge is clogged by impurities. However, the by-pass activation is allowed only for a limited period of time to finish the work, as the operation of the by-passmakes oil pass unfiltered and there is the risk of releasing cartridge impurities due to oil delivery pressure at the filterinlet, and of damaging the hydraulic system parts. Please remember that the standard crane equipped with the DMU device also includes the LEPB function (see chapter of the operator manual DMU). This function acoustically and also visually warns if the optional panel is fitted,when the filter is clogged. Filter cartridges are made of inert inorganic fiber. They are usually called paper cartridges so as to distinguish them fromthe cartridges made of metallic net, having a lower fine filtering rate. Do not clean the cartridge, neither with liquids nor with air jet. When the indicator of filter clogged lights up, replacecartridges.

1.1 Pall Delivery filter feature


- Maximum operating pressure: 400 bar - Maximum flow: 100 L/min. - Temperature range: -43C +120C. - By-pass valve setting: 3,4 bar - 15 micron filtering capacity

Ref. 1
Visual clog warning

** ** **

Ref. 2
Electric clog warning

Ref. 3
Electric clog warning (substitution of warning Ref. 2)

THE POWER OF PERFORMANCE

Filters
Effer PARTS #

B4

Oil O-Ring: 8009000

Oil O-Ring Kit ** Filter equipped with clog visual warning: 8919332 filter equipped with clog electric warning:8919346A filter cartridge: 8919333

Ref. 1 Visual clog warning: 8919348 Ref. 2 No more available, replaced by Ref. 3 Ref. 3 Electric clog warning:8919347A Note: indicator torque setting = 75 Nm (apply LOCTITE 243)

1.2 Sofima delivery filter feature


- Maximum operating pressure: 420 bar - Maximum flow:130 L/min. - Temperature range: -25C +110C. - By-pass valve setting: 5 bar - 12 micron micron filtering capacity Coupling: 3/4 BSP

Ref. 1
Visual clog warning

Ref. 2
Electric clog warning

Effer PARTS # set 8919361 * Gasket Filter equipped with clog visual warning: 8919356 filter equipped with clog electric warning: 8919357A filter cartridge: 8919358 Ref. 1 Ref. 2 Visual clog warning: 8919360 Electric clog warning:8919372

Note: indicator torque setting = 90 Nm

THE POWER OF PERFORMANCE

Filters

B4

1.3 Sofima delivery filter feature

- Maximum operating pressure: 420 bar - Maximum flow: 200 L/min. - Temperature range:-25C +110C. - By-pass valve setting: 5 bar - 12 micron filtering capacity Coupling: 1 1/4 BSP

Ref. 1
Electric clog warning

Effer PARTS Gasket set 8919364KG

filter equipped with clog electric warning: 8919364 A filter cartridge: 8919365 Ref. 1 Electric clog warning: 8919372

Note: indicator torque setting = 90 Nm

THE POWER OF PERFORMANCE

Filters

B4

1.4 HYDAC delivery filter feature

- Maximum operating pressure: 400 bar - Maximum flow: 140 L/min. - Temperature range: -25C +110C. - By-pass valve setting: 7 bar - 10 micron filtering capacity Coupling: 1 BSP

Ref. 1
Electric clog warning

Effer PARTS Gasket set 8919382

Filter equipped with clog electric warning: 8919378 Filter cartridge: 8919379 Ref. 1 Electric clog warning: 8919380 Note: indicator torque setting = 100 Nm

NOTE: For some months in 2008 a clog electric warning was fitted on cranes, with electric coupling as shown in the figure, EFFER part of the electric warning 8919384

THE POWER OF PERFORMANCE

Filters

B4

2 - Air filter applied on the oil tank


The level of the hydraulic oil in the tank changes depending on the crane cylinder position: oil max. level is obtained when allcrane cylinders are retracted, whereas oil min. level is obtained when all crane cylinders are out. In order to change the level, air must enter the tank. Air will be polluted depending on the work area (i.e. when the craneoperates in a building yard, the dust particles could flow into the tank and mix with the hydraulic oil). Particles of everykind could enter the tank, however an air filter prevents it, saving the integrity of the components of the hydraulic system. As the importance of this filter is often discarded, service it in any case. Carry out regular maintenance operations, cleanit with a compressed air jet, and replace it once every 3-4 years depending on the work area of the crane. Different types of oil tank filters are fitted on EFFER cranes. The air filter list is reported below, including filters fitted on cranes not in production any more, together with the indications for the identification of the exact part number for theorder.

1- EFFER PART #: 8919345

2- EFFER PART #: 8918403

40 mm 3- EFFER PART #: 8916450

50 mm 4- EFFER PART #: 8916500

THE POWER OF PERFORMANCE

Filters

B4

80

5- EFFER PART #: 8916605


80 50 80

6- EFFER PART #: 8916650


100 38 45

7- EFFER PART #: 8916505


65 28

8- EFFER PART #: 8916100

THE POWER OF PERFORMANCE

Filters

B4

2.1 Oil tank hole for pump suction connection


A threaded hole for the flowing of the oil to the hydraulic pump is located in the lower side of the crane oil tanks. Apply a faucet of correct size between the oil tank and the rubber hose, so as to stop the oil flow in case of maintenance operations to the hydraulic pump or to the connecting hoses. This faucet is already fitted on some model of oil tank. The diameters of the threaded holes - differening according to the crane models- are listed below.

CRANE MODEL
20 -30 - 35- 40 - 42 18 - 28 - 38 55 - 65 - 75 - 80 - 95 - 100 62 - 110E 110 - 120 - 140 150 - 170 - 210 250 - 400 - 460 47 130 - 145 155-165 335 - 360 - 430 520 - 600 - 680 720 - 400 - 460 - 44N 275 - 305 310 - 325 - 340 - 370 440 - 470 500 - 550 750 - 850 860 - 920 - 980 1050 - 1150 - 1250 1155 - 1355 - 1550 1350 - 1750 80N - 100N

HOLE DIMENSION MODELLO GRU GAS BSPP DIMENSIONE FORO


1 GAS BSPP

1 GAS BSPP

2 GAS BSPP

THE POWER OF PERFORMANCE

HOSES AND PIPES B5

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Hoses and pipes

B5

1- Hoses and pipes for hydraulic system


u A careful maintenance of hoses and pipes grant reliability and safety during crane operation. Flex hoses shall be
provided with an intact external rubber coating for the the protection of the metallic net. Otherwise, the metallic net may corrode for wear-and-tear, and the factor of safety of the hoses may reduce up to the hose burst. The metallic net shall be intact. If some metallic wires are damaged because of crashes, replace the hose immediately.

u The hydraulic fittings are applied at the tips of the flex hoses by pressing. In case of oil leaks (even of a small
quantity), replace the hose immediately as the hose pressing can not grant the reliability of the crane and its safe operation anymore. the crane speed.

u Pipe condition is important likewise: crushed portions of pipes may cause hydraulic oil overheating, and reduce u Safety rules for crane design require flex hoses and pipes with a minimum safety rate between the operating

max. pressure and the bursting pressure of the part. The following technical indications let make provisional repairs on the crane, before fitting the genuine spare part supplied by EffEr.

1.1 High pressure hoses for hydraulic system

Please find the inner diameter of hoses fitted to EFFER cranes with respect of their nominal diameter:

Inner diameter 6 mm
8 10 12 16 19 25

Hose nominal diameter 1/4


5/16 3/8 1/2 5/8 3/4 1

THE POWER OF PERFORMANCE

Hoses and pipes

B5

u The hoses shall be appropriate to bear a maximum working pressure equal to 350 bar. It follows that, since they should have a burst safety factor which should be at least 4 times higher than the working pressure, they must have a burst minimum pressure equal to 1400 bar. The hoses must be appropriate to work at a working temperature ranging from -20 C to + 100 C. The following are the reference regulations the hoses should be compliant with:

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.

1.2 Pipes for hydraulic system


Please find hereunder the nominal dimensions (outer diameter) and the type of materials relative to the metallic pipes for the connection of the hydraulic system.

Outer diameter mm
8 12 16 20 25 32

Thickness mm
1 1,5 2 2,5 3 3

Material:

ST 35.4 Fe 35.2 UNI 2897

NotE: Drawn pipe, without welds


Operating pressure: 350 bar Safety burst factor: 1:2,5

THE POWER OF PERFORMANCE

Hoses and pipes

B5

2 - Pipe fittings type UNF - jic 37 (SAE J514)


u Flare is high thickness simple-walled type. The quality of coupling made depends on the correct execution of
this work. All cracks, exfoliation or simple marks on the inner cone jeopardise the coupling tightness. Tighten the coupling using a dynamometric wrench: an excessive tightening can cause the material to be squashed in the conical part with its possible detachment on the cylindrical side of the pipeline.

37

BUSHING

NUT

PIPE

NOTE: The perfect wet seal is guaranteed by a perfect tightening of the fitting. In chapter A6 you can find a table which shows the setting value of the torque wrench. If it is impossible to use a dynamometric wrench, do as follows: 1) use a normal wrench, without fitting extensions, 2) tighten the fitting with the strength of your arms, without exaggerating, 3) loosen by 1/2 turn 4) tighten the fitting again, and try to bring the stopping point to a position that has to be 1/4 turn more advanced than the first tightening made.

THE POWER OF PERFORMANCE

Hoses and pipes


CoupLinG the pipes/hoses

B5

Pipe mm
8 12 16 20 25 32

Hose
1/4 3/8 1/2 3/4 1 1 1/4

Coupling thread
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

THE POWER OF PERFORMANCE

Hoses and pipes

B5

2.1 EFFER codes of pipe fittings, UNF - JIC 37 - SAE J514 type
OIL INLETS TO BE WELDED - JIC 37

F1

F
1/2 20 fil UNF - JIC 37 3/4 16 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12 fil UNF - JIC 37

Effer code
9300601 9300602 9300603 9300604 9300500

H
22,5 18 20 23 41

F1
8,5 12 16 20 29,5

NUT - JIC 37

A
Pipe outer mm
8 12 16 20 25 32

Effer code
9320800 9320900 93201000 93201100 93201200 93201300

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

THE POWER OF PERFORMANCE

Hoses and pipes


BushinG

B5

Pipe outer mm
8 12 16 20 25 32

Effer code
9321600 9321700 9321800 9321900 9322000 9322100

F mm
8 12 16 20 25 32

Reduction - JIC 37

1 Pipe
12 16 20 25 32 16 32 38

2 Pipe
8 12 16 20 25 8 20 32

Effer code
9333400 9333500 9333600 9333700 9333800 9333900 9334000 9334100 9334002 9334001

C
A UNF
3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 5/8 1 7/8

C UNF
1/2 20 fil UNF - JIC 37 3/4 16 fil UNF - JIC 37 3/4 16 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12 fil UNF - JIC 37 1/2 20 fil UNF - JIC 37 1 1/16 1 5/8

1 5/16 12 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37


THE POWER OF PERFORMANCE

Hoses and pipes


FemaLe pLuG - JIC 37

B5

Pipe outer mm
8 12 16 20 25 32

A
Effer code
9335100 9335200 9335300 9335400 9335500 9335600

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

MaLe pLuG - JIC 37

Pipe outer mm
8 12 16 20 25 32

Effer code
9334300 9334400 9334500 9334600 9334700 9334800

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

THE POWER OF PERFORMANCE

Hoses and pipes


Joint - JIC 37

B5

Pipe outer mm
8 12 16 20 25 32

Effer code
9322400 9322500 9322600 9322700 9322800 9322900

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

PaneL connector - JIC 37

Pipe outer mm
8 12 16 20 25 32

Effer code
9324000 9324100 9324200 9324300 9324400 9324500

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

THE POWER OF PERFORMANCE

Hoses and pipes


90-bend - JIC 37

B5

Pipe outer mm
8 12 16 20 25 32

Effer code
9331000 9331100 9331200 9331300 9331400 9331500

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

Union tee - 3 maLe connectors - JIC 37

Pipe outer mm
8 12 16 20 25 32

Effer code
9323200 9323300 9323400 9323500 9323600 9323700

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

10

THE POWER OF PERFORMANCE

Hoses and pipes


Cross - JIC 37

B5

Pipe outer mm
8 12 16 20 25 32

Effer code
9335900 9336000 9336100 9336200 9336300 9336400

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

Union tee - 2 maLe connectors, 1 femaLe connector - JIC 37

Pipe outer mm
8 12 16 20 25 32

Effer code
9332600 9332700 9332800 9332900 9333000 9333100

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

THE POWER OF PERFORMANCE

11

Hoses and pipes


Union tee - 2 maLe connectors, 1 femaLe connector - JIC 37

B5

Pipe outer mm
8 12 16 20 25 32

Effer code
9331800 9331900 9332000 9332100 9332200 9332300

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/8 12 fil UNF - JIC 37

NippLe F+M - JIC 37 UNF / GAS BSPP

Pipe outer mm
12 16 20 25 8 12 16

Effer code
9320000 9320100 9320200 9320300 9320400 9320500 9320101

A UNF
3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37

B GAS BSPP
3/8 1/2 3/4 1 1/4 1/2 3/8

12

THE POWER OF PERFORMANCE

Hoses and pipes


NippLe M+M - JIC 37 UNF / GAS BSPP

B5

Pipe outer mm

Effer code
9325600 9325700

B
A UNF

B GAS BSPP
1/4 3/8

9339601 9325610 9325800 9325900 9326000 9326200 9326300 9326400 9326600 9326700 9326800

1/2 20 fil UNF - JIC 37

1/2 1/8 1/4 3/8 1/2 3/8 1/2 3/4 1/2 3/4 1

12

3/4 16fil UNF - JIC 37

16

7/8 14 fil UNF - JIC 37

20

1 1/16 12 fil UNF - JIC 37

25

9326900 9327000 9327100 9327200 9327300

1 5/16 12fil UNF - JIC 37

3/4 1 1 1 1/4 1 1/2

32

1 5/8 12 fil UNF - JIC 37

THE POWER OF PERFORMANCE

13

Hoses and pipes


90-bend - M+M - JIC 37 UNF / GAS BSPP

B5

B
Pipe outer mm
8

Effer code
9327600 9327700 9327800

A UNF
1/2 20 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 3/4 16fil UNF - JIC 37 3/4 16fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37

B GAS BSPP
1/4 1/4 3/8 1/2 3/8 1/2 1/2 3/4 3/4 1 3/4 1/2 1/2 3/8

H
33 34 36.5 42.5 34 42.5 48.5 48.5 51.5 51.5 48.5 79 36 39.5

12

9327900 9328811 9328000 9328100 9328200 9328300 9328400 9328700 9328800 9328812 9328813

16 20 25

16

14

THE POWER OF PERFORMANCE

Hoses and pipes


45-Bend M+M - JIC 37 UNF / GAS BSPP

B5

Pipe outer mm
16 20 12 16 16

Effer code
9329000 9329100 9329400 9329510 9329511

Union tee - 2 maLe connectors - JIC 37 in Line - 1 GAS BSPP 90-maLe connector
A A

Pipe outer mm
12 16 20 25

A UNF
7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 7/8 14 fil UNF - JIC 37

B GAS BSPP
1/2 3/4 1/2 3/8 3/4

Effer code
9330300 9330400 9330500 9330600

A UNF
3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37

B GAS BSPP
3/8 1/2 3/4 1

THE POWER OF PERFORMANCE

15

Hoses and pipes

B5

Union tee - 2 maLe connectors JIC 37 / GAS BSPP in Line - 1 JIC 90-maLe connector

Pipe outer mm
12 16 20 25 12 8

Effer code
9329600 9329700 9329800 9329900 9330200 9329601

A UNF
3/4 16fil UNF - JIC 37 7/8 14 fil UNF - JIC 37 1 1/16 12 fil UNF - JIC 37 1 5/16 12fil UNF - JIC 37 3/4 16fil UNF - JIC 37 1/2 16fil UNF - JIC 37

B GAS BSPP
3/8 1/2 3/4 1 1/4 1/4

Reduction F+M GAS / GAS-BSPP-

Effer code
9337000 9337200 9337300 9337400 9337600

B
B GAS
3/4 1 1 1 1/4 1 1/2

D GAS
3/8 1/2 3/4 3/4 1

16

THE POWER OF PERFORMANCE

Hoses and pipes

B5

3 - UNF flat type pipe fittings, with O-Ring (SAE J1453)


The pipe end is manufactured in order to get a flat surface. The fitting that is coupled with the pipe is equipped with an O-Ring on the front surface; therefore the hydraulic tightness is guaranteed by a joint. These are the advantages of this kind of fittings with joint: - no blows-by. - no need for a specific equipment for a correct tightening - resistance to excessive tightening - possibility to carry out several removals

90

BUSHING

NUT

PIPE

As said above, tightening can be carried out without the use of particular equipment; when the O-Ring joint is deformed the pipe and the fitting collide on the front thus not allowing the nut to be screwed up. In case of oil leaks, replace the O-Ring joint (see table below).

CoupLinG the pipes/hoses


Pipe
8 10 12 14 16 16 20 22 25 32

Thickness
1 2 1.5 2 2 2 2.5 2.5 3 3

Hose
5/16 5/16 1/2 1/2 1/2 5/8 3/4 1 1 1 1/4

Coupling thread
11/16 -16 UNF - front O-Ring 11/16 -16 UNF - front O-Ring 13/16 -16 UNF - front O-Ring 1-14 UNF - front O-Ring 1-14 UNF - front O-Ring 1-14 UNF - front O-Ring 1 3/16 - 12 UNF - front O-Ring 1 7/16 -12 UNF - front O-Ring 1 7/16 -12 UNF - front O-Ring 1 11/16 -12UNF - front O-Ring

THE POWER OF PERFORMANCE

17

Hoses and pipes


O-RinG JOINT

B5

Pipe outer mm
8 - 10 12 14 16 18 - 20 22 - 25 28 32 35 - 38

Effer code
9342600 9342601 9342602 9432603 9342604 9342605 9342606

F thread UNF O-Ring


11/16-16 13/16-16 1-14 1 3/16-16 1 7/16-12 111/16-12 2-12

D mm
9.25 12.42 15.60 18.77 23.52 29.87 37.82

B mm
1.78 1.78 1.78 1.78 1.78 1.78 1.78

18

THE POWER OF PERFORMANCE

Hoses and pipes

B5

3.1 EFFER codes of pipe fittings, type UNF front O-Ring -SAE J1453
OiL inLets to be weLded

F1

Pipe outer mm
12 14 16 18 - 20 22 - 25

Effer code
9340146 9340147 9340148 9430112

F UNF O-Ring
13/16-16 1-14 1 3/16-16 111/16-12

H
25 33,5 37,5 42

F1
12 16 20 25

Pipe outer mm
12 14 16 18 - 20 22 - 25

Effer code
9340507

F UNF O-Ring

H
26 33,5 37,5 42

F1
9,6 22,5 25 30

13/16-16 Raccordi speciaLi 1-14 1 3/16-16 111/16-12

9340522 9340505 9430506

THE POWER OF PERFORMANCE

19

Hoses and pipes


UNF O-RinG NUT

B5

Pipe outer mm
10 12 14 - 16 20 25 - 22,5 28 - 32 35 - 38

F
Effer code
9341100 9341101 9341102 9341103 9341104 9341105 9341106

F UNF - O-Ring
11/16-16 13-16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2 -12

UNF O-RinG BushinG


L

Pipe outer mm
10 12 14 16 20 22 25

Effer code
9341150 9341151 9341152 9341153 9341154 9341156 9341155

F mm
10 12 14 16 20 22 25

20

THE POWER OF PERFORMANCE

Hoses and pipes


UNF O-RinG FemaLe pLuG

B5

F
Pipe outer mm
8- 10 12 14 16 18 - 20 22 - 25 28 - 32 35 - 38

Effer code
9342500 9342501 9340136 9340137 9340138 9342502 9342503

F UNF - O-Ring
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2 -12

UNF O-RinG MaLe pLuG


L B

Pipe outer mm
8- 10 12 14 16 18 - 20 22 - 25 28 - 32 35 - 38

Effer code
9342400 9342401 9340120 9340121 9340122 9342402 9342403

F UNF O-Ring
11/16-16 13-16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2 -12

L mm
19,5 22 26 27,5 28 28 28

B mm
19 22 27 32 38 46 55

THE POWER OF PERFORMANCE

21

Hoses and pipes


Joint M + M, UNF O-RinG

B5

Pipe outer mm
8 - 10 8 - 10 8 - 10 8 - 10 12 12 12 12 14 - 16 14 - 16 14 - 16 14 - 16 18 - 20 18 - 20 18 - 20 18 - 20 22 - 25 22 - 25

Effer code
9341800 9341801 9341802 9341803 9341804 9341805 9341806 9341807 9341808 9341809 9341810 9341811 9341812 9341813 9341814 9341815 9341816 9341817

F1

F GAS CIL BSPP


1/4 3/8 1/2 3/4 1/4 3/8 1/2 3/4 3/8 1/2 3/4 1 1/2 3/4 1 11/4 3/4 1

F1 UNF O-Ring
11/16-16 11/16-16 11/16-16 11/16-16 13-16-16 13-16-16 13-16-16 13-16-16 1-14 1-14 1-14 1-14 1 3/16-12 1 3/16-12 1 3/16-12 1 3/16-12 1 7/16-12 1 7/16-12

22

THE POWER OF PERFORMANCE

Hoses and pipes


Joint M + M, UNF O-RinG

B5

Pipe outer mm
22 - 25 22 - 25

Effer code
9341818 9341819

F1
F GAS CIL BSPP
11/4 11/2

F1 UNF O-Ring
1 7/16-12 1 7/16-12

Joint M + M, UNF O-RinG

Pipe outer 1 mm
8 - 10 10 12 12 14 -16 16 18 - 20 20 22 - 25 25

Pipe outer 2 mm
8 - 10 10 12 12 14 -16 16 18 - 20 20 22 - 25 25

F1

Effer code
9341900 9341901 9340145 9341902 9341903 9341904 9340127 9340139 9340128 9340129

F UNF O-Ring
11/16-16 11/16-16 13/16-16 13/16-16 1-14 1-14 1 3/16-12 1 3/16-12 1 7/16-12 1 7/16-12

F 1UNF O-Ring
11/16-16 9/16-18 13/16-16 11/16-16 1-14 13/16-16 1 3/16-12 1-14 1 7/16-12 1 3/16-12

THE POWER OF PERFORMANCE

23

Hoses and pipes

B5

Joint M + M, UNF O-RinG / UNF JIC 37

Pipe outer mm
8 - 10 12 14 - 16 18 - 20 22 - 25

Effer code
9341818 9341819 9341802 9341803 9341804

F1

F UNF - O-Ring
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12

F1 UNF JIC 37
9/16-18 1 7/16-12 7/8-14 1 1/16-12 1 5/16-12

PaneL connector, UNF O-RinG

Pipe outer mm
8- 10 12 14 16 18 - 20 22 - 25 28 - 32 25 - 38

F
Effer code
9342200 9342201 9342202 9342203 9342204 9342205 9342206

F UNF - O-Ring
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2 -12

24

THE POWER OF PERFORMANCE

Hoses and pipes


NippLes M + F, UNF O-RinG

B5

Pipe outer mm
8 - 10 8 - 10 8 - 10 12 12 14 - 16 14 - 16 14 - 16 18 - 20 18 - 20 22 - 25 22 - 25 22 - 25

Effer code
9341700 9341701 9341702 9341703 9341704 9341705 9341706 9341707 9341708 9341709 9341710 9341711 9341712

F1

F GAS CIL BSPP


1/4 3/8 1/2 3/8 1/2 3/8 1/2 3/4 3/4 1 3/4 1 1 1/4

F1 UNF O-Ring
11/16-16 11/16-16 11/16-16 13-16-16 13-16-16 1-14 1-14 1-14 1 3/16-12 1 3/16-12 1 7/16-12 1 7/16-12 1 7/16-12

THE POWER OF PERFORMANCE

25

Hoses and pipes


Reduction M + F UNF O-RinG

B5

Pipe outer mm
10-8 12-6 12-10 16-12 20-12 20-16 25-16 25-20 32-20 32-25 38-25 38-32

Effer code
9342100 9342101 9342102 9342103 9342104 9342105 9342106 9342107 9342108 9342109 9340130 9340105

F1

F O-Ring
11/16-16 13/16-16 13/16-16 1-14 13/16-12 13/16-12 17/16-12 17/16-12 111/16-12 111/16-12 2-12 2-12

F1 UNF O-Ring
9/16-18 9/16-18 11/16-16 13/16-18 13/16-16 1-14 1-14 13/16-12 13/16-12 17/16-12 17/16-12 111/16-12

26

THE POWER OF PERFORMANCE

Hoses and pipes


90-bEND M + F UNF O-RinG

B5

Pipe outer mm
10 12 14-16 18-20 22 - 25

Effer code
9341400 9341401 9341402 9341403 9341404

F UNF - O-Ring
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12

Union tee, 2 maLe connectors, 1 femaLe connector UNF O-RinG


L L1

F1

Pipe outer mm
8-10 12 14-16 18-20 22 - 25 28 - 32 35 - 38

F1

Effer code
9341500 9341501 9341502 9340140 9340102 9341503 9340103

F UNF - O-Ring
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2 -12

THE POWER OF PERFORMANCE

27

Hoses and pipes


Union tee, 2 maLe connectors, 1 femaLe connector UNF O-RinG

B5

L1

Pipe outer mm
8-10 12 14-16 18-20 22 - 25 28 - 32 35 - 38

Effer code
9341500 9341501 9341502 9340140 9340102 9340503 9340103

F1

F UNF - O-Ring
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2 -12

28

THE POWER OF PERFORMANCE

Hoses and pipes


Reduction M + F UNF O-RinG

B5

Effer code
9342702 9342703 9342704 9342705 9342706

F GAS BSPP
1/4 1/4 1/4 1/4 1/4

Effer code
9341102 9341103 9341104 9341105 9341106

F1 GAS BSPP
11/16-16 13/16-16 1-14 1 3/16-12 1 7/16-12

THE POWER OF PERFORMANCE

29

Hoses and pipes

B5

3.2 UNF front flat seal terminals, with O-Ring (SAE J1453 to be welded)
It may be required to carry out repairs without the availability of a pipe that is an EFFER original spare part.

BUSHING TO BE WELDED NUT

A
PIPE EFFER can supply bushings to be welded to the pipe end. These bushings must be coupled with specific nuts.

Pipe outer (A) mm


10 12 14 16 20 22 25

Bushing code
9341080 9341081 9341082 9341083 9341084 9341085 9341086

Nut code
9341000 9341001 9340116 9340116 9340117 9340118 9340118

11/16-16 UNF front O-Ring 13/16-16 UNF front O-Ring 1-14 UNF front O-Ring 1-14 UNF front O-Ring 1 3/16-12 UNF front O-Ring 1 7/16-12 UNF front O-Ring 1 11/16-12 UNF front O-Ring

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.

30

THE POWER OF PERFORMANCE

F
F

Hoses and pipes

B5

3.2.1 Instructions to carry out welding on the ogive


The ogives should be fitted to the end of the pipes by brazing. Preparing the surfaces

u All surfaces to be joined and the zones close to them must be previously cleaned in order to remove all traces

of dirt, grease, paint, superficial oxides, zinc coating, etc. To do so it is necessary to degrease and grind, with the utmost care, and by means of an abrasive cloth, the pipe outer surfaces and the surfaces inside the ogive in the coupling areas indicated in the figure 1. Grinding is essential to round the corners and to make the surfaces rough in order to improve the weld.

Surfaces to be degreased and ground

Fig. 1

round the corners This operation must be done shortly before welding in order to prevent any new formation of superficial oxides. Welding

u To braze the ogives on the hydraulic hoses it is necessary to provide:


a) - Alloy EN 1044 type AG 102 b) - deoxidizer paste EN 1045 type H10 (example: alloy BRAZE TEC 5600 with deoxidizer BRAZE TEC) Spread the paste by means of a brush on the areas to be welded.

u Position the ogive and the pipe with the axis of the vertical joint vertically on a support surface made up of
refractory material to avoid any loss of heat. Preheat in width and in depth with a neutral or slightly carburazing flame without directing the flame to the joint opening. For the 20- and 25-mm diameter pipe preheat the pipe to a greater extent. As soon as the deoxidizer liquefies (material colour will be dark red) and flows freely, melt the tip of the stick, remove a drop of filler metal and position it on the joint (figure 2).

Fig. 2 Filler metal deposit area

THE POWER OF PERFORMANCE

31

Hoses and pipes

B5

Blowpipe inclination 30-45 and blowpipe end at 1-2 cm. from the surface. During melting of the filler metal, make the stick turn slowly between your fingers and avoid overheating the piece. Make the metal flow along the joint with a continuous movement of the flame. Deposit other filler material until it comes out of the lower side of the ogive.

After compLetinG the weLd, durinG the VisuaL checK from the inner side a reGuLar seam on the whoLe circumference must be detected.
Make the metal flow along the joint with a continuous movement of the flame. Deposit other filler material until a collar is formed all along the outer circumference of the pipe (see figure).

Cleaning the welded joint

u After finishing welding, with the piece still hot (300C maximum), dip the brazed area of the pipe in warm
water in order to eliminate the residues of deoxidier. If necessary, clean the surfaces using a brush made up of hard silks. Safety at workplace

u Welding should be carried out in a well-ventilated place to avoid inhaling the gases/vapours exhausted while
welding and getting in contact (with your skin or your eyes) with the deoxidizer paste. Comply with the recommendations of the supplier of the brazing materials.

32

THE POWER OF PERFORMANCE

WRENCH SETTINGS B6

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Wrench settings

B6

1 - Torque wrench setting of hydraulic fittings


Hydraulic 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 surface of the fitting. Unf - JIC 37 thread provides a mechanical sealing between the two faying surfaces tilted to 37 of the connecting 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)

Pipe diameter
8 12 16 20 25 32 38

Nm
26 58 95 130 200 260 330

THE POWER OF PERFORMANCE

Wrench settings

B6

1.2 Torque wrench setting of hose fittings - Coupling thread type unf JIC 37 - (SAE J514)

Hose diameter
3/8 1

Nm
31 61 95 130 190

1.3 Torque wrench setting of GAS CYLINDRIC BS PP thread fittings

Thread
3/8 1

Nm
31 61 95 160 230

THE POWER OF PERFORMANCE

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.

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device B7

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

1 - Operating principle
INTRODUCTION
u The overload limiting device fitted to the EFFER cranes has been designed according to the EN 12999 A2
rules. The aim of EFFER is to supply a safety device which, instead of penalizing the user of the crane, makes the operators work safer according to the features indicated in the load diagrams, avoiding the risk of damaging people and things. A crane with the overload limiting device correctly set grants the user a safe and reliable use in the time. LTHE EUROPEAN STANDARD EN 12999 A2, UNDER POINT 5.6.1.1, proVides For the presence oF the load limitinG deVice on those cranes that haVe eVen onlY one oF the FolloWinG reQuirements: Cranes with lifting capacity equal to or greater than 1000 KG, indicated in the load diagram. Cranes whose maximum net lifting moment is higher than or equal to 40.000 Nm (4T x m). The load limiting device fitted to the crane must have three different functions: 1) avoiding overloads in the frame 2) avoiding the risk of overturning the vehicle 3) avoiding dangerous movements of the load

u The same set of standards, under point 5.6.4, provides for the worker is acoustically warned when the crane

reaches 90% of its maximum lifting capacity, and when 100% of its maximum lifting capacity is achieved, a different warning signal noise is emitted. u Under point 5.6.7 of the same set of standards it is reported that on the cranes with a radio control to handle the booms, or a horizontal outreach of more than 12 metres, an acoustic alarm device must be provided, for example, a KLAXON, operable by the worker from any control station used. N.B: Note that the KLAXON function on the cranes operated by the radio control and without the DMU load limiting device, is assigned to truck klaxon electrical connections; such connection is carried out by the crane installer.

u It may occur that the crane tip, when the maximum load that can be lifted is applied to the hook, yields, or

does not remain perfectly stopped. Furthermore, the standards mentioned above, state under point 5.5.7, as follows: - The crane tip can have a small unintentional speed of descent, when the maximum nominal load is applied. However, it must not be higher than 0, 5% of crane outreach per minute

u THE EUROPEAN STANDARD EN 12999 A2, under point 5.6.2, indicates the maximum tolerance which the
load limiting device can have: this varies according to the length of the crane and the load applied to the hook. The load limiting devices fitted to EFFER cranes are very accurate devices: it is not necessary to refer to tolerance allowed by the standards to consider the device operation appropriate. All EFFER cranes are able to handle the loads indicated in the table.

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

u The principle governing the hydraulic /electro-hydraulic limiting device fitted to the EFFER cranes is to auto-

matically inhibit certain crane movements when inside a lifting cylinder the maximum pressure value allowed by the project is reached. This pressure value is dependent on the load applied. Therefore, some movements are inhibited when the crane achieves its maximum performance. NOTE: The following instructions deal with the winch and the supplementary jib: as they are optional parts, they may be not fitted to your crane.

1.1 Movements inhibited by the limiting device


The inhibited movements are those movements which overweight the crane load moment:

u a - Crane with slewing mechanical limitation (operating by 180 on the truck body: working area A):
The following manoeuvres are locked: - all boom descents, - the outer boom and the fly-jib rise, - all the hydraulic extension exits, - the winch rise.

Inhibited movements

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

u b - Crane with slewing mechanical limitation and proportional controlbank: (operating by 180 on the
truck body: working area A):

The following manoeuvres are locked: - 1st boom descent - extensions out - winch rise - outer boom and supplementary jib: an electric rocker arm (REF. X) detects the boom position with respect to the horizontal line: when booms are above the horizontal line, the boom descent is inhibited while when booms are below the horizontal line, the boom descent is allowed.

Ref. X
Inhibited movements

EFFER part # 9394696

EFFER part # 9394767

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

c- Crane with slewing electrical limitation: the truck body working area A is surrounded by electrical sensors. This crane version allows obtaining the maximum operation on the truck body working area A, and reduced operation over 180 in the front of the truck cab working area B. The operation depends on the stability of the truck/crane combination. Slewing control systems:

Proximity fitted on crane with slewing by rack and pinion

Switch fitted on crane with slewing ring

Proximity fitted on crane with slewing ring

c1-Overload limiting device operation in the working area A When the device is operated in the 180 max. operating area behind the truck cab, the following manoeuvres are locked: - 1st boom descent - extensions out - winch rise - outer boom and supplementary jib: an electric rocker arm (ref. X) detects the boom position with respect to the horizontal line: when booms are above the horizontal line, the boom descent is inhibited while when booms are below the horizontal line, the boom descent is allowed.

Ref. X

Inhibited movements

EFFER part # 9394696

EFFER part # 9394767

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device


c2-Overload limiting device operation in the working area B

B7

When the device is operated in the 180 area in front of the truck cab, in addition to what was explained in section c1, the boom rises are locked too, whatever their position.

If the overload limiting device is operated in this working area, as a result of a slewing manoeuvre you may:

- Crane with rack slewing: perform the slewing manoeuvre in both directions. (The overload limiting device does not interfere on crane slewing movement) - Crane with slew ring: perform the slewing manoeuvre in the direction that makes the crane boom reach the highest lifting capacity area A through the shortest way.

1 2

direction 1 = it is compulsory to continue the manoeuvre direction 2 = it is compulsory to perform the inverse manoeuvre

Standard working Area in which the overload limiting device operated

3 4

direction 3 = it is compulsory to perform the inverse manoeuvre direction 4 = it is compulsory to continue the manoeuvre

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

c3- Overload limiting device operation during crane slewing passing from the working area A to the working area B If the overload limiting device is operated as a result of a slewing manoeuvre to enter the 180 area in front of the cab, the inverse manoeuvre is allowed automatically.

- Crane with pinion/rack

- Crane with slewing ring

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

2 - Valves and components


2.1 Hydraulic connections to the load limiter valve
EFFER uses several types of valves to operate the load limiting device. These may be hydraulic, or electrohydraulic, according to the type of cranes and optional pieces fitted. The following are the connections to these valves, along with their function:

Ref. T P P1

Connections
Connection to the oil tank, without passing through the drain filter. The valve drainage oil comes out of this hole. It is connected to the pipe connecting the hydraulic pump to the crane controlbank. The hydraulic pipe is connected here. This pipe conveys the pressure value to the valve inside the cylinder/s on which the device detects the pressure value: when the allowed maximum value is achieved, then the device is operated. The hydraulic pipe is applied here. It connects to the extension element inlet conveying oil to the extension cylinderduring the return manoeuvre. This signal inhibits, for a while, the load limiting device, that, however, comes into operation again if the conditions causing its operation persist. You may benefit from this manoeuvre when you have to release the crane from the device operation as a result of a limit stop manoeuvre carried out with the first boom cylinder or when the device comes into operation further to a swinging of the load. Oil comes out of this hole when the load limiting device comes into operation to feed the cylinders preventing the operation of some of the controlbank functions. A pipe connection point connected with the first boom element inlet conveying oil to the first boom cylinder during this boom descent manoeuvre. This hydraulic connection optimises the load limiting device operation further to the boom descent manoeuvre, by correcting the effect of the friction existing on the crane pins (Not fitted on some smallmiddle range cranes). A hydraulic pipe connection point connected with the first boom element inlet conveying oil to the first boom cylinder during this boom rise manoeuvre. Pressure gauge attachment point. Register for the valve setting value change. For the correct operation sequence, please see the following sections. Tap, lead coated by EFFER. This tap overrides the load limiting device. When overload tests are to be performed, the operation of the load limiting device has to be blocked momentary. This override has to be performed when the device is not turned on due to the crane max. performance. NOTE: Said tap must be always sealed. If found unsealed, the crane warranty decays. Electrical microswitch- EFFER part # 9394704. When the load limiting device comes into operation, a small piston inside the valve, operates the microswitch, conveying the signal to the crane electrical component. A pipe connection point connected with the controlbank element inlet : the first boom descend - jib rise (if fitted) - (inlet marked with M ed N) P ipe connection point to send a pressure signal to the load limiter valve to delay the operation (inlet marked with P) Connection point for a pressure switch, if mounted. Connection point for cylinder pressure signals activating the load limiting device.

RS

S I IF M V E D L H G Z

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

2.2 Components
EFFER part # 8865717 Overload limiting valve

M P1

RS

EFFER part # 8865715

Overload limiting valve

M P1

RS E T S

10

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

EFFER part # 8865784

Overload limiting valve

RS M P1 IF

P T

EFFER part # 8865716

Overload limiting valve

RS

P1

THE POWER OF PERFORMANCE

11

Hydraulic / electro-hydraulic limiting device


EFFER part # 8866777 L.S. signal feeder

B7

EFFER part # 8865776

Max. pressure valve

z L

P1

H L

12

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device


EFFER part # 8850217 Flip-Flop valve EFFER part # 8865713 Max. pressure valve

B7

EFFER part # 8864920

Shock absorbing piston accumulator

EFFER part #8864939

+
EFFER part # 8866707

Pressure swicth

EFFER part # 9395058

EFFER part # 9395767

THE POWER OF PERFORMANCE

13

Hydraulic / electro-hydraulic limiting device


EFFER part # 8866708 Solenoid valve with max. pressure valve

B7

EFFER part # 8865794

Max. pressure valve

EFFER part # 8877006

Gauge

EFFER part # 9394654

Electric microswitch

EFFER part # 9394762

Proximity

S2

bn

bk

+ bu

S2

14

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

3 - Practical setting of the overload limiting device


The load limiting device is tested by EFFER on the test bench without loads. Therefore, once the installation is completed and once the setting values of the hydraulic controlbank are checked in compliance with the EFFER given values reported in the crane hydraulic diagram the installator shall test the correct functioning of the load limiting device, in practice, by handling loads. (Settings may change due to different crane/hydraulic pump combination). The ideal useful load can be determined by considering the crane max. lifting capacity at the end of the second-last hydraulic extension (second-last hydraulic extension of the basic crane in horizontal configuration when testing the overload limiting device of the basic crane, second-last supplementary extension in articulated configuration when testing the overload limiting device of the supplementary jib, always respecting the curves of the load diagram of the crane). The test/setting of the overload limiting device in the front working area can be performed with the basic crane only. 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.

Basic crane (working area A)

Basic crane + supplementary jib (working area A)

Basic crane (working area B)

AVAILABLE ConFiGuraTIONS TO TEST THE OVERLOAD LIMITING DEVICE OPERATION PRACTICALLY

THE POWER OF PERFORMANCE

15

Hydraulic / electro-hydraulic limiting device

B7

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


Using a simple mathematical proportion it is possible to determine the correct point of intervention of the overload limiting device, as the following example:

d1 m 7,8 P1 kg 4800 m 10 d2 kg 3400 P2

- Take a load of 3800 kg as reference, named Px - Taking as reference crane load diagram, identify the hydraulic extension capable of lifting such load, in that case the 3rd extension. - Calculate as follows:

(d1x P1) + (d2 x P2) : 2 = (7,8m x 4800kg) + (10m x 3400kg) : 2 = 9,4 m Px 3800 kg
- The result is that our crane can lift a load of 3800 kg at a max. outreach of 9.4 m from the slewing axis. NOTE: In order to set correctly the point of intervention of the overload limiting device, see the instructions of the following chapter.

3.2 Crane boom position during the practical tests


During overloading tests, maximum attention has to be paid to the position of the crane booms: a wrong boom positioning may jeopardise the result of the test. Therefore, follow the instructions below with great care. 3.2.1 TestinG the basic crane (WorkinG area A) Position the 1st boom of the crane so as to have the max. fulcrum between the 1st boom cylinder and the column/main boom hinge point. The distance f shall be the maximum one. Crane without connecting rod between column and 1st boom The max. value f i.e distance perpendicular to the cylinder axis- is achieved when the lifting cylinder axis is at the farthest point from the boom column pin. Crane with connecting rod between column and 1st boom The max. distance f is achieved when the axis of the longest connecting rod i.e. line passing trough two pins fastening the same connecting rod, is some degrees above the horizontal line (as shown in figure).

16

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

f f

+2 4

NOTE: The load diagrams show the angle that the 1st boom must reach, to get the maximum distance f. Rest the crane 2nd boom in horizontal position. Perform a manoeuvre of extensions out at the max. speed, avoid oscillating the load. It is advisable to apply ropes or chains as short as possible to lift the load.

During the tests of the point of intervention of the overload limiting device do not change the crane boom position: the sole manoeuvre allowed is extensions out/extensions retracted (manoeuvre 1). When the test of the point of intervention is completed, rise the 1st boom cylinder to lift the load (manoeuvre 2). 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.

THE POWER OF PERFORMANCE

17

Hydraulic / electro-hydraulic limiting device

B7

3.3 Testing the basic crane (working area B)


The overload limiting device is set by EFFER considering the crane installed on a truck with minimum tare, respecting the weights on the axles. In consequence of it, it may be necessary to adjust the crane working diagram and to set the point of intervention of the overload limiting device as a precaution. In order to obtain the performances resulting from the stability calculations, according to the specific configuration data, it is necessary to change the EFFER setting value.

?
The stabilty calculations provide a new load diagram (to be applied to the crane control post). Now, following the instructions of the previous section , you can determine the point of intervention of the overload limiting device according to the loads available. NOTE: In order to set correctly the point of intervention of the overload limiting device, see the instructions of the following chapter. NOTE: In this configuration, after the intervention of the overload limiting device (see chapter A7 - 1.1- C2), the load can not be lifted by the crane booms.

18

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

3.4 Fly-jib position during the practical tests


During the tests to check the load limiting device point of operation, it is very important to properly place the crane booms: any error in positioning may jeopardise the test result. Follow the instructions below thoroughly. NOTE: This test does not affect the basic crane test, since the overload limiting device receives the pressure signal directly from the jib cylinder. MAX. - (2 3)

In order to avoid the possible intervention of the overload limiting device caused by the basic crane, make the crane booms rest just below the max. vertical position and retract the crane extensions completely. Set the fly-jib in horizontal position. To limit structural skids resulting from truck declining position, we recommend positioning the crane booms in the area over the bucket lengthwise -

OFF

THE POWER OF PERFORMANCE

19

Hydraulic / electro-hydraulic limiting device

B7
Fig.1

3.5 Point of intervention of the overload limiting device


Now, by taking as a reference the load diagram, fix the max. load that can be lifted by the supplementary fly-jib. Different load diagram types are available: with curves (Fig. 1), with load values and distance from the axis of rotation (Fig. 2).
32 m 83 30 28 26 24 22 20 18 16 14 12 10 1760 Kg 2800 Kg 1170 Kg 880 Kg 670 Kg 530 Kg 8 6 4 12 1000 Kg 16.01 m 740 Kg 19.98 m 560 Kg 24.09 m 2

10

12

14

665 Kg 845 Kg 17.98 m 21.98 m 16 18 20 22

480 Kg 26.20 m 0 24 26 28m

6S+JIB 4S
0 2 4 6 8 10 12 14 16 18 20 22 m

Fig.2
230 29.78 kg 170 m 31.81
24 22 20

85

2080 920 530 9.70 13.50 17.30 kg 670 1430 m 11.60 15.40

18 16 14 12 10

kg

1430 670 920 2080

530

6 4

The following examples show that the second-last extension can lift a load of 1170 kg (fig.1) and 920 kg (fig.2).

kg m

510 385 295 20.14 23.94 27.74 435 325 22.04 25.84

2 0

20

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

You should lay down a load diagram concerning the jib, which is independent of the crane: as if the additional jib was..... kept in hand.....

? ?

kg

After finding the values relating to the maximum loads that can be moved by the jib, you have to identify distances: these data are essential to apply the mathematical formula that determines the load limiting device proper point of operation.

m 1 2 3 4 5

How to determine the values from m1 to m5 ?

A
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. From this simple calculation, you can determine the additional jib features: distances and maximum lifting capacity.

kg m

THE POWER OF PERFORMANCE

21

Hydraulic / electro-hydraulic limiting device


Following the instructions of section 3.1, check the point of intervention of the overload limiting device with respect to the supplementary jib.

B7

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

3.6 Conclusion
u In the configuration of horizontal crane and jib, with basic crane extensions completely out, the max. lifting
capacity of the supplementary jib is controlled by the overload limiting device connected to the basic crane.

u In the configuration of basic crane extensions completely retracted, the max. lifting capacity of the supplementary jib is controlled by the overload limiting device connected to the supplementary jib cylinder.

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).

22

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

4 - Operating sequences to set the load limiting device


As explained in the previous chapters, you can imagine that there are many load limiting devices on a crane, depending upon the number of accessories or performance: - the presence of an additional jib - a crane with F.P.I. system - a crane working in the front working area B area - a crane where also the second boom cylinder inner pressure is detected by the device All this implies that a specific operating sequence during the load limiting device setting must be respected, as all the variables listed above are interconnected one to the other: If one setting value is changed, all the following setting values are changed as well.

Please find below the operating sequence to be followed to set the load limiting device, in case the crane referred to is a basic crane. - from 4.1 to 4.10 -

NOTE: A basic crane means that the crane is not provided with the equipment for the additional hydraulic jib.

For the operating sequence to be followed to set the load limiting device, in case the crane referred to is a basic crane with additional hydraulic jib, please refer to page 29. from 4.11 to 4.21 -

THE POWER OF PERFORMANCE

23

Hydraulic / electro-hydraulic limiting device

B7

in the rear work area only

4.1 Basic crane with manual controlbank, not proportional, operating


The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder. When the overload limiting device operates, the pump oil is conveyed directly to the tank, and the crane stops.

Setting points Valve ref. 1 controls overload limiting device operation. NOTE: valve fig.2 has a standard setting, according to its design, and can not be modified. This valve has the function to lock the overload limiting device during the 1st boom rise manoeuvre. If an increase of the standard value setting is performed, the max lifting values listed in the table can not be lifted.

4.2 Basic crane with manual controlbank, not proportional, operating


in the rear work area only
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder.

Setting points Valve ref. 1 controls overload limiting device operation.

24

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

of the work area behind cabin: the crane can operate in the cabin work area, according to the special setting
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder. Setting points 1st test: operation of the overload limiting device in the front work area. Valve concerned ref. 1. 2nd test: operation of the overload limiting device in the rear work area. Valve concerned ref. 2.

4.3 Basic crane with proportional controlbank, and electrical limitation

in the rear work area only

4.4 Basic crane with manual controlbank, not proportional, operating

The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. The max. pressure value is the same for both the cylinders. Setting points The valve ref. 3 controls the operation of the overload limiting device. 2 1

THE POWER OF PERFORMANCE

25

Hydraulic / electro-hydraulic limiting device

B7

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, according to the special setting

The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. A higher pressure value inside the 2nd boom cylinder is allowed, respect to the 1st boom cylinder: valve ref. 3 operates to compensate pressure values. 2 Setting points 1st test: operation of the overload limiting device in the front work area. Valve concerned ref. 4. 2nd test: operation of the overload limiting device in the rear work area. Valve concerned ref. 5. 3rd test: valve setting ref. 3. This is a fixed setting. To check the setting value, remove the valve and test it at the test bench. This test may be necessary when the overload limiting device releases during a manoeuvre of max. opening of the 2nd boom without load applied. 3

work area only

4.6 Basic crane with proportional controlbank, operating in the rear


The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. The max. pressure value is the same for both the cylinders.

2 Setting points 1st test: operation of the overload limiting device in the rear work area. Valve concerned ref. 3.

26

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

can operate in the cabin work area, according to the special setting

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

The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder. Setting points 1st test: operation of the overload limiting device in the front work area. Valve concerned ref. 1. 2nd test: operation of the overload limiting device in the rear work area. Valve concerned ref. 2 with FPI device OFF. 3rd test: operation of the overload limiting device with FPI device ON. Valve concerned ref. 3. 2 3 1

of the work area behind cabin: crane operating capacity in the cabin area is set by a pressure switch
The crane can operate in the cabin work area, according to the special setting . The overload limiting device operates when the max. pressure value is reached

4.8 Basic crane with proportional controlbank, and electrical limitation

1 Setting points 1st test: operation of the overload limiting device in the front work area. Valve concerned ref. 1. 2nd test: operation of the overload limiting device in the rear work area. Valve concerned ref. 2. 2

THE POWER OF PERFORMANCE

27

Hydraulic / electro-hydraulic limiting device

B7

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
The crane can operate in the cabin work area, according to the special setting . The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder.

Setting points 1st test: operation of the overload limiting device in the front work area. Valve concerned ref. 1. 2nd test: operation of the overload limiting device in the rear work area. Valve concerned ref. 2 with FPI device OFF. 3rd test: operation of the overload limiting device with FPI device ON. Valve concerned ref. 3. 1

4.10 Basic crane with proportional controlbank, with device F. P. I., and
electrical limitation of the work area behind cabin: crane operating capacity in the cabin area is set by a pressure switch. The crane can operate in the cabin work area, according to the special setting

The overload limiting device operates when the max. pressure value is reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. A higher pressure value inside the 2nd boom cylinder is allowed, respect to the 1st boom cylinder: valve ref. 3 operates to compensate pressure values. 2 Setting points 1st test: operation of the overload limiting device in the front work area. Valve concerned ref. 4. 2nd test: operation of the overload limiting device in the rear work area. Valve concerned ref. 5 with FPI device OFF. 3rd test: operation of the overload limiting device with FPI device ON. Valve concerned ref. 6. 3

28

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

Please find below the operating sequence to be followed to set the load limiting device, in case the crane referred to is a basic crane with additional hydraulic jib.

4.11a Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, operating in the rear work area only
The operation of the overload limiting device of the basic crane takes place when the max. pressure value is reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. The overload limiting device operates also when the max. pressure value is reached inside the jib 2 cylinder ref. 3. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 4. 2nd test: operation of the overload limiting device of the basic crane (supplementary jib not fitted): Valve concerned ref. 5. 1 5 4 3 JIB

4.11b Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, operating in the rear work area only
The operation of the overload limiting device of the basic crane takes place when the max. pressure value is reached inside the first ref. 1 or the 2nd boom cylinder ref. 2. The overload limiting device operates also when the max. pressure value is reached inside the jib cylinder ref. 3. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 4. 2nd test: operation of the overload limiting device of the basic crane (supplementary jib not fitted): Valve concerned ref. 5. 1 5 4 2

3 JIB

THE POWER OF PERFORMANCE

29

Hydraulic / electro-hydraulic limiting device

B7

4.12 Basic crane with supplementary hydraulic jib, manual controlbank, not proportional, and electrical limitation of the work area behind
cabin: the crane can operate in the cabin work area, according to the special setting

The overload limiting device operates when the max. pressure value is reached inside the first ref. 1or the 2nd boom cylinder ref. 2. A higher pressure value inside the 2nd boom cylinder is allowed, respect to the 1st boom cylinder: valve ref. 4 operates to compensate pressure values. The overload limiting device operates also when the max. pressure value is reached inside the jib cylinder ref. 3. Setting points 1st test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref. 5. 2nd test: operation of the overload limiting device in the rear work area (no supplementary jib applied). Valve concerned ref. 6. 3rd test: valve setting ref. 4. This is a fixed setting. To check the setting value, remove the valve and test it at the test bench. This test may be necessary when the overload limiting device releases during a manoeuvre of max. opening of the 2nd boom without load applied. 4th test: operation of the overload limiting device of the supplementary jib. Valve concerned ref. 7. 1 5 6 4 2 3 JIB 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. pressure value is reached inside the first boom cylinder ref. 1 and inside the jib cylinder. ref. 2. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 3. 2nd test: operation of the overload limiting device of the basic crane (no supplementary jib applied): Valve concerned ref. 4. 1 2 JIB

30

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

can operate in the cabin work area, according to the special setting

4.14 Basic crane with supplementary hydraulic jib, proportional controlbank, and electrical limitation of the work area behind cabin: the crane

The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder ref. 2. Setting points 1st test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref. 3. 2nd test: operation of the overload limiting device in the rear work area (supplementary jib not fitted). Valve concerned ref. 4. 3rd test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 5. 4

2 JIB

5 1

4.15 Basic crane with supplementary hydraulic jib, proportional controlbank, operating in the rear work area only
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder. ref. 2. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 3. 2nd test: operation of the overload limiting device of the basic crane (no supplementary jib applied): Valve concerned ref. 4. 1 3

2 JIB

THE POWER OF PERFORMANCE

31

Hydraulic / electro-hydraulic limiting device

B7

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

The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder ref. 2. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 3. 2nd test: operation of the overload limiting device of the basic crane (no supplementary jib applied): Valve concerned ref. 4. 4 3 1 2 JIB

can operate in the cabin work area, according to the special setting

4.17 Basic crane with supplementary hydraulic jib, proportional controlbank, and electrical limitation of the work area behind cabin: the crane
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder ref. 2.

Setting points 1st test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref. 3. 2nd test: operation of the overload limiting device in the rear work area (supplementary jib not fitted). Valve concerned ref. 4. 3rd test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 5. 4

2 JIB

5 1

32

THE POWER OF PERFORMANCE

Hydraulic / electro-hydraulic limiting device

B7

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 setting
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder ref. 2. Setting points 1st test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref. 3. 2nd test: operation of the overload limiting device in the rear work area (supplementary jib not fitted). Valve concerned ref. 4 with FPI device OFF. 3rd test: operation of the overload limiting device in the rear work area (supplementary jib not fitted). Valve concerned ref. 5 with FPI device ON. 4th test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 6. 1 6

2 JIB

5 4

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
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder ref. 2.

2 JIB Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 3. 2nd test: operation of the overload limiting device in the rear work area (no supplementary jib applied). Valve concerned ref. 4. 3rd test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref.5. 5

1 3 4

THE POWER OF PERFORMANCE

33

Hydraulic / electro-hydraulic limiting device

B7

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
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1 or inside the jib cylinder ref. 2. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 3. 2nd test: operation of the overload limiting device in the rear work area (no supplementary jib applied). Valve concerned ref. 4 with FPI device OFF. 3rd test: operation of the overload limiting device with FPI ON (no supplementary jib applied). Valve concerned ref. 5. 4th test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref. 6. 2 JIB

5 4

4.21 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
The overload limiting device operates when the max. pressure value is reached inside the first boom cylinder ref. 1, the 2nd boom cylinder ref. 2, and the jib cylinder ref. 3. A higher pressure value inside the 2nd boom cylinder is allowed, respect to the 1st boom cylinder: valve ref.4 operates to compensate pressure values. Setting points 1st test: operation of the overload limiting device of the supplementary jib: Valve concerned ref. 5. 2nd test: operation of the overload limiting device in the rear work area (no supplementary jib applied). Valve concerned ref. 6 with FPI device OFF. 3rd test: operation of the overload limiting device with FPI connected (no supplementary jib applied). Valve concerned ref. 7. 4th test: operation of the overload limiting device in the front work area (no supplementary jib applied). Valve concerned ref. 8.

3 JIB 4 1 7 6 5 8

34

THE POWER OF PERFORMANCE

CONTROLBANKS B8

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

Controlbanks

B8

B.8.0 - HC-D3M Controlbank: technical improvements


A 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.

OIL SEEPAGE BETWEEN ELEMENTS Oil seepage between elements is caused by the large inner surface relative to the oil delivery channel. This surface 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.

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:

THE POWER OF PERFORMANCE

Controlbanks

B8

If an element has to be added to a controlbank or an element has to be replaced, you may have to deal with the following cases: - A new element is fitted to an old controlbank: this is not advantageous for the problem in question nor does it create problems of any type. - An old element is fitted to a new controlbank: this eliminates the benefit of the reduction in the push area only on the applied element. The other elements still benefit from the modifications that have been made. Oil leaKage on tHe element loweR plUg The following modifications have been made to solve the problem relative to oil leakage from the plug applied to the element lower part: - the material has been modified to be able to tighten it with a higher torque wrench setting - an o-ring with a composition more suitable for higher temperatures has been applied - the position of the o-ring on the plug has been modified along with its seat on the controlbank element - the plug threaded portion has been increased to prevent it from being unintentionally unscrewed because of dilatations.

new version

previous version

Both the Manufacturer and EFFER, are convinced that the technical solutions which have been found lead to the elimination of oil leakages: before making these modifications, a prototype has undergone a test cycle at 350 bar, consisting in the execution of 280, 000 working cycles lasting 1 second each. At the end of the test, the controlbank did not have any leakage. P.S. Since the beginning of April 2000 the manufacturer has also modified the closing plugs of the special valves and the general valve. Such modification has also been made on the HC-D4controlbank. The new plugs are interchangeable with the previous plugs and vice versa.

THE POWER OF PERFORMANCE

Controlbanks

B8

THE POWER OF PERFORMANCE

Proportional controlbank HAWE B8.1

type PSL 41-3


Features:
Max. working pressure Max. oil inlet capacity Standard supply voltage Supply voltage on request 420 bar 100 lt/min. 24 volt 12 volt

type PSL 52-3


Features:
Max. working pressure Max. oil inlet capacity Standard supply voltage Supply voltage on request 420 bar 200 lt/min 24 volt 12 volt

THE POWER OF PERFORMANCE

Controlbanks

B8.1

THE POWER OF PERFORMANCE

Controlbanks

B8.1

Operation
u When activating the hydraulic pump, the oil direct to the controlbank enters the first section, and if no lever
is selected, the oil exits to return into the oil tank, so preventing the hydraulic oil from passing through the controlbank.

u When moving a controlbank lever, only the quantity of oil required (depending on the design features arranged

for that specific function or on the shift of the lever performed by the operator) is delivered to the selected element. The exceeding quantity of oil always returns into the tank. 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. than the quantity the pump can deliver, the priority of operation is given to the functions that require a lower working pressure.

u This feature is guaranteed by the element compensator and by the inlet compensator. By moving two or

u When moving many levers simultaneously, so as to make the inlet compensator demand an oil flow higher

u This function allows to fit pumps with an oil flow higher than the data specified for the crane, thus increasing the operating speed remarkably and still without increasing the oil temperature, which turns to be insignificant with respect to the usual systems. (Ask the EFFER Technical Department about the max. pump size you may fit to a given crane model equipped with Hawe controlbank). u The most remarkable operational advantage lies in the fact that different manoeuvres can be performed at very
reduced speed but at the max. pressure allowed for each movement, differently from the usual controlbank.

NOTE: any operation carried out on the controlbank must be performed in the cleanest possible environment. Make sure impurities do not enter the controlbank. Even touching the components with very dirty hands may jeopardise the correct operation of the controlbank.

THE POWER OF PERFORMANCE

Controlbanks

B8.1

Identification of the parts PSL 41-3


1- Inlet element 2- Closing element

758-2 757-2

3- Lever element

4- Main pressure valve

761-2

760-2

5- Plug instead of check-relief valve

6- Check relief valve

762-2
THE POWER OF PERFORMANCE

Controlbanks
7- Radio control solenoid

B8.1

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

763-3

763-2

9- Inlet solenoid valve

10- Control lever

760-3 761-3

11- Control lever support 13- Controlbank tie rods

12- Rod return device

765-2 765-3

THE POWER OF PERFORMANCE

Controlbanks

B8.1

1 - Inlet element

The following main components are applied to the inlet element: 1.1 - 1.2 - 1.3 - 1.4 - 1.5 - 1.6 - Max. pressure control valve also called main valve. Inlet compensator Exhaust solenoid valve Pressure gauged screw to eliminate pressure peaks Coupling for pressure gauge 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 remarkable changes of the setting value can be obtained with small adjusting shifts. Should the valve be removed, when reassembling it, it is not necessary to apply Loctite as previously. In order to make the mounting of the valve easier, we recommend that you loosen the pressure adjusting screw completely. In this way, the inner spring will not affect the assembly. Obviously, it is necessary to set the valve when the assembly is completed. Tighten with torque wrench, set to 100 Nm.

10

THE POWER OF PERFORMANCE

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

B8.1

Fig. 1 1 2

parts inside the body of the inlet element

Fig. 2

Since 2007 the vibration damper (X) shown in fig.1 was modified inside the element body as in fig. 2. In addition to vibration damper (Y) , a spring (A) and a pin (B) were fitted to grant constant max. pressure to the main valve. All parts can be supplied as a whole spare part with EFFER code # 8990920 (complete main valve).

THE POWER OF PERFORMANCE

11

Controlbanks

B8.1

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. CAUTION: Always clean the components carefully before mounting the parts. 1 2 4 3 1 2 4 (cod.1932893H) 3

(cod.1932893) 5 l = 5,8 cm (cod.8991268)

5 l = 6,8 cm (cod.8991972)

12,2 mm

2 4 3

*
4
17,3 mm

l = 5,8 cm (cod.1932893) (cod.8991268)

l = 6,8 cm (cod.8991972)

(cod.1932893H)

feed with fixed displacement pump

feed with variable displacement pump

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

12

THE POWER OF PERFORMANCE

Controlbanks

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 manually, 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

THE POWER OF PERFORMANCE

13

Controlbanks

B8.1

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. avoiding fluid hammers in the hoses connecting the controlbank to the oil tank.

uThis screw with gauged inner ports for oil flow, is meant to shift the compensator towards the closing position, 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. and even the total crane outage.

u A clogged port in the screw may cause a reduction of the crane operating speed, or a lower max. pressure value, u When the replacement of the controlbank or of an inlet element is necessary, make sure that the original screw
type A keeps being fitted on the replacement part.

CAUTION: Always clean the components carefully before mounting the parts. NOTE: It is advisable to avoid mounting screws type B on a controlbank supplied with screws type A (the type A of screw may generate a peak in the truck engine RPM , peak which wont last anyway more than few seconds at the very beginning of the lever operation, and which grants a much more constant boom operation).

A B
773

Screw A: EFFER code # 8991081 ( 9,6) high damping calibrated screw Screw B: EFFER code # 8991261 direct calibrated screw EFFER code # 8991154 since 2001 ( 9,3) Low damping calibrated screw

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

14

535
THE POWER OF PERFORMANCE

Controlbanks

B8.1

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). inside the controlbank.

u That letter indicates the point suitable for the application of a pressure gauge to detect the pressure values
However, it is necessary to point out some data related to the pressure gauge readings: A- When oil starts flowing to the controlbank, the pressure value on the pressure gauge is 15-18 bar. This is a standard value, indicating the pressure value necessary for the inner operation of the controlbank. Such value must not be added to the values listed in the crane set tables (i.e.: set at the values actually read on the gauge!) B- When performing a crane movement, the pressure gauge shows the pressure value necessary for that movement, until the max. setting value is reached. If the lever movement is interrupted, the pressure gauge indicator goes down slowly if compared to a traditional controlbank. Such fact is normal. C- If you need to set a check-relief valve with a setting value much lower that the main relief valves, you know already that youll first have to make a full end-stroke of the cylinder you are going to set, before proceeding with the setting. In doing this, youll notice that the pressure gauge first jumps to the setting value of the main relief valve (max.) and then starts dropping down to the setting value of the check-relief valve (See the photos). This fact is normal. Moreover, note that the value initially shown by the gauge is only a reading, while in reality such a pressure Adid never occur in the circuit related to the check-relief valve being set.

772

THE POWER OF PERFORMANCE

15

Controlbanks

B8.1

1.6 Pressure-reducing valve


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. 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). 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. CAUTION: Always clean the components carefully before mounting the parts. Y = 18,5 mm X = 7 mm

776776

775

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

16

THE POWER OF PERFORMANCE

Controlbanks

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

THE POWER OF PERFORMANCE

17

Controlbanks

B8.1

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

3.1 - 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)

3 1

5
18
THE POWER OF PERFORMANCE

Controlbanks
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)

B8.1

Lever: EFFER code # 8990896

8 6

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

O-rings are coded as follows: Controlbank, class 3 Gasket set, inlet element Gasket set, elements Controlbank, class 5 Gasket set, inlet element Gasket set, elements

EFFER code # 8990893 EFFER code # 8991260 EFFER code # 8991333 EFFER code # 8991334

THE POWER OF PERFORMANCE

19

Controlbanks

B8.1

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 controlbank can have max. 10 lever elements. material might cause oil leaks or worst break down.We list herebelow the code # of the tie rods, according to the different diameter and the number of element bodies of the controlbank: No. elements bodies
4 5 6 7 8 9 10

u In case of modifications, we recommend to always use original tie rods, as tie rods made up with unsuitable

Tie rod M 10 8991068 8991069 8991070 8991071 8991097 8991220 8991222

Tie rod M 8 8991072 8991073 8991074 8991075 8991098 8991219 8991221

Tightening torque necessary for the correct operation of the controlbank: PSL4
Tie rod M 8

PSL2

PSL5

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 30C after operation. Hydraulic sealing of the different body elements is assured by gaskets type O-ring:

Size 4,47 X 1,78 13,94 X 2,62 14 X 1,78 17,12 X 2,62

EFFER Code 8000500 8005600 8001500 8006000

20

THE POWER OF PERFORMANCE

Controlbanks

B8.1

u The cranes equipped by an FPI device, are provided on some functions/levers - with an element featuring a port (diameter 1/8 GAS) to connect it to the FPI device. It may happen that the same element body is fitted on cranes not supplied with the FPI device: in that case, the port is sealed with a plug. Should be necessary to replace an element body, we recommend to replace the whole lever element. For this spare part, you have to notify EFFER of the crane serial number and the function for which the lever element is intended, in addition to different element configurations, depending upon the type of inner spool. Three types of element body are available:
- arranged with two check relief valves on port A and B. - arranged with one check relief valve on port A and B. - without check-relief valves In the first case, see additional information in section 3.7. In the second case, the max. pressure value measured at both ports of the elements shall be equal to the setting value for the main relief valve. CAUTION: Always clean the components carefully before mounting the parts.

control bank without DMU

*
control bank for DMU NOTE: NB: Allinterno di questo c una sfera A FLIP-FLOP ball isblocchetto located inside the block. FLIP-FLOP. Se unimpurit impedisce lo st scorriIf impurities prevent ball sliding, the crane 1 boom mento della sfera, il primo braccio della gru non can not rise. esegue la manovra di salita. Note: On some crane models, a screwed block is fitted under the control bank element with 4 screws removable by a 6mm-socket head wrench -. This block is fitted to the elements enabled to those cylinders that require the presence of valves discharging pressure peaks in a timely way. These pressure peaks are caused by the movement of the crane in a poor progressive way. The regulating valve is set to a single value, higher than the setting of the special valves fitted to the hawe control bank element. In case of supply of the block as a spare part, the regulating valve above is supplied already set, and the register is sealed with lead. - The hydraulic tightness between the block and the control bank element is guaranteed by two gaskets. - In case the block has to be removed, it is recommended to lock the screws using a dynamometric wrench: torque wrench setting 9,5 Nm. WARNING: always clean the components with care before assembling.
THE POWER OF PERFORMANCE

21

Controlbanks

B8.1

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

2 1

22

THE POWER OF PERFORMANCE

Controlbanks

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

789

EFFER code # 8991263

THE POWER OF PERFORMANCE

23

Controlbanks

B8.1

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.

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 Different types of cursors are available also, depending on the max. rate of oil flow designed for the ports a

u The cursor shall slide freely inside the element body. In case the cursor has scratches due to impurities in the

oil, the smooth sliding of the cursor is jeopardised and it may be necessary to replace the cursor, or as we recommend, the whole lever element. If the cursor is removed from the inside of the element body, before fitting it, it is necessary to follow these indications: CURSOR (1) WITH LONGITUDINAL GROOVES: The grooves must be turned towards the closing element. CURSOR (2) WITH TWO LONGITUDINAL PORTS: The two ports must be turned towards the opposite side of the controlbank ports. (ports A and B). CAUTION: Always clean the components carefully before mounting the parts.
O = Oper Centre L = Closed Centre PORT A / B Code B = 1/2 1/2 Closed centre POTR A / B Code 8991233

O 80 140 o L 80 140
0

PORT A / B O-10/10 O-16 / 16 O-25 / 25

Code

8991226 L-25 / 25 8990833 B-16 / 25

8991227 L-40 / 40 8991155 R-40/80-40 8991469 8990758 L-16 / 16 8991232 R-40/63-40 8991471 8991137 L-63 / 63 8991133 8990921 8991099 8991228 8991111 8991112 8991110 8991229 8991150 8991230 8991231

80 14 0

O-40 / 40 O-63 / 63 O-80 / 80 O-16 / 25 O-25 / 40 O-40 / 63 O-40 / 80 O-25 / 16 O-40 / 25 O-63 / 40 O-80 / 40

2 A
24

A
THE POWER OF PERFORMANCE

Controlbanks

B8.1

3.5 Flip-flop valve


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.

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

780

3.6 Element compensator


required by the operator who is activating a lever of the controlbank.

u Each lever element is fitted with a compensator, meant to call from the inlet compensator the quantity of oil

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

THE POWER OF PERFORMANCE

25

Controlbanks

B8.1

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

X
792

Y
791

4 4 1a 3a 2 1 3

790

26

THE POWER OF PERFORMANCE

Controlbanks

B8.1

3.8 Radio remote control solenoid

manual control lever a double electric solenoid is fitted (of proportional type). 12-volt Solenoid EFFER code # 8991215 24-volt Solenoid EFFER code # 8990569 A sole double-coil solenoid allows driving the lever in both directions: forward and backward. The solenoid is connected electrically to three wires: the connection at the point 1 is common to the two movements of the lever, with negative polarity. NOTE: HAWE controlbank is electrically powered, therefore, for any check, fit an ammeter on connecction 2 or 3. The ammeter values will depend on the manupilator stroke.

u When one of the levers of the controlbank is moved by the radio remote control, on the opposite side of the

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). screwdriver.

uTo remove the valves (3) extract the inner part of the valve (4) (yellow) and unscrew the valve body with a

CAUTION: Always clean the components carefully before mounting the parts. NOTE: The inner valve (4) shall run smoothly, under the pressure of the spring. Manually check the correct operation of the inner valve.

2 2 1 3

793

EFFER code # 8991125 , crane without DMU


797

EFFER code # 8991473 , crane with DMU

THE POWER OF PERFORMANCE

27

Controlbanks

B8.1

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

894

28

THE POWER OF PERFORMANCE

Controlbanks

B8.1

3.9 Load moment limit solenoid (L.S.)


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 Some safety devices installed on the crane, such as for example the load limiting device, the winch end stroke,

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 Coil 24 volt code # 8991284 code # 8990589 Max. absorption: 1.4 A. 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.

800

798

A
THE POWER OF PERFORMANCE

B
29

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

B8.1

The movement to be locked (and its direction) is determined by Effer when designing the matching of a controlbank to a given crane model. The electric connections to the solenoid are the following: 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. 1 2 3

u When the solenoid is electrically activated, a pin (3) comes out the solenoid and drives a piston (4/5) inside
the lever element. Only when that piston is pushed, may the hydraulic oil run out the ports of the lever element.

u If both the ports of the controlbank are to be controlled, two pistons (4) are to be fitted, whereas if just one port

of the controlbank has to be controlled, a pin (5) shall then be fit into the seat of the corresponding port NOT to be controlled, instead of the piston. NOTE: On controlbanks fitted to cranes delivered until the end of 1999, it may happen that the pin (3) fitted into the solenoid, is worn out at both its ends, due to the electric signal induced by constant ON-OFF switching. The deformation will cause a slowdown of the movement. Therefore, we recommend that you check the pin length at least once a year.

A
4

5
799

3
Copper gasket 12x16x1,5
800

4 5
803

3
17,517,6

30

THE POWER OF PERFORMANCE

Controlbanks

B8.1

u When extracting the piston or the pin from their seat, it is essential to remove the gasket (6) type O-ring first. In
order to avoid damaging it, use a small nail to remove it from its seat. With sharp-nose pliers, extract the pistons (4-5) from the seat.

u The solenoid is fitted with two pins having a cylindrical point in the centre. If the solenoid is not activated

electrically, by pushing that point with a shaped tool, or simpler with a nail, the solenoid acts as if it was powered, and allows the oil to run out the port of the controlbank when the control lever is activated manually.

882

Copper gasket 12x16x1,5

THE POWER OF PERFORMANCE

31

Controlbanks

B8.1

u For some lever elements, according to the Effer design, the L.S. solenoid may be not provided. In such a case the
corresponding ports are sealed by a plate secured by three Allen screws adjustable by a 8-mm open wrench. Two pins are located under the plate, and their hydraulic sealing is assured by two gaskets, type O-ring, similar to the gaskets mentioned above. EFFER code # 8991224 sealing plate complete with fastening screws, gaskets and pins.

798

802

805

32

THE POWER OF PERFORMANCE

Controlbanks

B8.1
3 / Remedy

4 - Troubleshooting
1 / Trouble 2 / Cause 1 A - No crane motion is 2.1- Inlet compensator stuck in 3.1- See section 1.2 regarding the indications possible, although the closed position because of for the removal of the inlet compensator, hydraulic pump operimpurities. and its working ates perfectly. 2.2 - No electric supply to the inlet 3.2- To check the operation of the solenoid solenoid valve. valve, supply voltage to the valve by connecting it to a wire applied directly to the truck batteries. In this way, you find out if the trouble comes from the electric connection of the crane or from the coil of the solenoid valve. 2.3 - Solenoid valve coil burnt 3.3 - If the coil of the solenoid valve is faulty, to fold the crane anyway, press the cylindric point in the centre of the solenoid, as described in section 1.3.

2.4 - The gauged screw to eliminate 3.4 - Remove the gauged screw and clean the pressure peaks on the drain line ports with an air jet. For additional informais clogged. tion, see section 1.4. 1 B -The crane does not per- 2.1- The pin fitted to the L.S. sole- 3.1- Check pin size according to the instructions form a specific movenoid is damaged. in section 3.9; if necessary, make a test by ment, when activating removing a pin from another solenoid. the lever of controlbank. The L.S. solenoid is fitted on the lever 2.2- The L.S. solenoid controlling 3.2- Connect a cable to the batteries of the a specific movement does not truck, with negative polarity applied to point element. get any electric supply. 1, and positive polarity to points 2 and 3. Then, verify if the trouble comes from the electric connection of the crane or from the solenoid. 2.3- The L.S. solenoid controlling 3.3 - If the solenoid is faulty, in order to perform the inhibited manoeuvre so as to fold the a specific movement is damaged. crane, press the cylindric point in the centre of the solenoid, as described in section 3.9. 2.1- The inlet compensator doesnt 3.1- Damaged compensator or seat, not allow1 C - All crane movements perform a complete stroke. ing the compensator to slide smoothly, see are slow section 1.2. 2.2- Gauged screw to eliminate 3.2- Remove the pressure gauged screw and hammers in the drain line, parclean the ports with an air jet. For additional tially clogged. information, see section1.4.

THE POWER OF PERFORMANCE

33

Controlbanks
1 / Trouble 2 / Cause 3 / Remedy

B8.1

1 D - A crane movement 2.1- Flip-flop valve related to that 3.1- Remove the flip-flop valve and clean the can be performed at low specific lever element does not seat with an air jet. For additional informaspeed only slide smoothly in its seat. tion, see section 3.4.

1 E- A lever of the control- 2.1- The fault may come from a 3.1- Replace the electric connection of the trouble in the electronic system solenoid related to the movement not bank does not move when activated by the of the radio remote control, or performed, with a connection related to radio remote control the solenoid of the controla working movement: if the trouble is still bank. . present, replace the remote control activator - see section 3.8 -. If the lever works, the cause may be in the radio remote control system or in the wire. 1 F - The crane does not 2.1- The pressure reducing valve 3.1- Remove the pressure reducing valve, clean is stuck with an air jet, then fit it. operate by the radio remote control, but only For additional information, see section 1.6. in manual. 1 G - The max. pressure 2.1- The main relief valve is dirty 3.1- Remove the main valve - see section 1.1or faulty and check that the small semispheric-head valve can not be depiston is free from impurities or surface tected anymore by the scores. Otherwise, fit a new valve. controlbank.

34

THE POWER OF PERFORMANCE

Controlbanks

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.

245

The elements of the PSL 52-3 control bank, as well as the connecting rods of the joining elements and the closing element are the same as those used for the PSL 41-3 version. EFFER code # 8991626 : Complete inlet element of size 5 fitted to inlet elements of size 3 EFFER code # 8991790 : Complete inlet element of size 5 fitted to inlet elements of size 3

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 5.9 - Inlet compensator

5.2 5.9 5.8

5.7 5.1 5.4 5.6

249

5.5

248

THE POWER OF PERFORMANCE

35

Controlbanks

B8.1

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.

4 2
792

1 3

u The check-relief valve can be easily identified by the presence of a cylindrical-head nut, adjustable by a 12-mm
Allen wrench, and of a counternut adjustable by a 13-mm Allen wrench -. Inside the valve there is a spring (1): act on the screw (2) that pushes the spring, by a 3-mm Allen wrench, so as to change the valve setting value. During working, if the valve set pressure is reached, the tapered pin (3) under the spring moves so as to let the oil flow towards the drain line, interrupting the crane movement.

u External hydraulic sealing is assured by copper washers (4) of the following size: 8 x 12 x 2 code # 8991234.
CAUTION: Always clean the components carefully before mounting the parts.

36

THE POWER OF PERFORMANCE

Controlbanks

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.

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

X = 7 mm

Y = 18,5 mm

775

THE POWER OF PERFORMANCE

37

Controlbanks

B8.1

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.

771

5.5 Plug
u This plug is required for the execution of the works on the inlet element. The hydraulic tightness in outer part
is guaranteed by an ERMETO G1/4 gasket, Effer code # 8991476.

38

THE POWER OF PERFORMANCE

Controlbanks

B8.1

5.6 LS connection
u The hole located under to this plug is related to the hydraulic connection of the LS pipeline, which is provided 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.

THE POWER OF PERFORMANCE

39

Controlbanks

B8.1

5.8 Plug
u This plug is required for the execution of the works on the inlet element. The hydraulic tightness in outer part
is guaranteed by an ERMETO G1/4 gasket, Effer code # 8991476.

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. CAUTION: Always clean the components carefully before mounting the parts. 5 1 4

40

THE POWER OF PERFORMANCE

Controlbanks

B8.1

6 - Coupling with DMU


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 wont provide - the validation to the solenoid valve located at the control bank inlet to convey the oil to the control bank element, thus allowing - or not allowing - the execution of the manoeuvre.

237

236

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

241

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.

THE POWER OF PERFORMANCE

41

Controlbanks

B8.1

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 point or the lever neutral position 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 andOUT 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 magnet inside the metal cylinder, once disassembled. If the OUT Aled 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.

42

THE POWER OF PERFORMANCE

Controlbanks
The microswitch is operated by a magnetic rod, connected to the control bank spool.

B8.1

IMPORTANT: The amagnetic rod loses its magnetic characteristics if put in contact with metallic bodies. To disassemble the rod, which is necessary in order to remove the cursor from the element, a socket wrench 10mm wrench hexagon, made with amagnetic material is required. (This socket wrench Effer code # 8991472 is available from Effer). N.B. When the rod is disassembled, the position of the nut must not be changed with respect to the amagnetic rod, to avoid losing rod centering with respect to the microswitch. In case the element spool has to be replaced, apply the magnetic rod on the crane to the new spool.

THE POWER OF PERFORMANCE

43

Controlbanks

B8.1

7 - HAWE Proportional controlbank: variable displacement pump


u
The inlet compensator comes with a spring inside - see section 1.2 -. This spring is removed in the version of controlbank for variable displacement pump and replaced by a pin of the size shown in the drawing below. Cylinder EFFER Code # 1932893 36,7 36,8 mm 10,6 10,7 mm r =1mm steel Cylinder EFFER Code # 1932893H 54,7 54,8 mm 10,6 10,7 mm r =1mm acciaio

a)

Control bank type PSL 41-3 (elements of size 3)

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 differentiates an operation with fixed pump from an operation with variable displacement pump. u

feeding by fixed displacement pump

feeding by variable displacement pump

A hydraulic connection marked L.S. - diameter 1/4 Gas - is also located on the inlet element. The line to this connection goes to the variable displacement pump. We recommend a diameter of the line of 1/4 GAS-type. The L.S. signal from the controlbank is meant to call from the pump only that portion of oil flow required by the levers being activated from the operator. The max. oil flow remains of course the max. one available from the pump. When no of the controlbank is activated, no pressure will be found on this circuit.

LS

44

THE POWER OF PERFORMANCE

Controlbanks
u Control bank type PSL 52-3 (elements of size 3)

B8.1

In the version of control bank setup for operation with fixed delivery pump, a plug A1 located under the screw A. - The hydraulic tightness toward the outer part is guaranteed by a copper washer having the following size: M8x12x2 mm, Effer code # 8991234 To perform the transformation of a control bank type PSL 52-3 from operation with fixed delivery pump into operation with variable delivery pump, proceed as follows: 1) Unloosen the screw ref. A and remove the inner screw A1. 2) Under the screw B, fit the screw A1. 3) Under the screw A, apply the screw C Effer code # 8991430 (with central hole 0,6). Required material: number 1 Code 8991430

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.

A1 C A B

A1

LS

THE POWER OF PERFORMANCE

45

Controlbanks
u Control bank type PSL 52-5 (elements of size 5)

B8.1

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.

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

3) Unscrew the screw D and place the dowel B previously removed.

4) Tighten the screw D. Required material: number 1 Code 8991430

D B

46

THE POWER OF PERFORMANCE

Controlbanks
A hydraulic connection marked L.S. - diameter 1/4 Gas - is also located on the inlet element.

B8.1

The line to this connection goes to the variable displacement pump. We recommend a diameter of the line of 1/4 GAS-type. The L.S. signal from the controlbank is meant to call from the pump only that portion of oil flow required by the levers being activated from the operator. The max. oil flow remains of course the max. one available from the pump. When no of the controlbank is activated, no pressure will be found on this circuit.

LS

7.1 Maximum working pressure setting


When you fit a variable delivery pump to a crane, the maximum operating pressure value of the crane is adjusted by the maximum pressure valve fitted to the pump. The variable delivery pump has two adjusting points: 1) STAND-BY pressure 2) MAXIMUM WORKING pressure 1) STAND-BY pressure Even when no crane control lever is operated, the variable delivery pump, conveys a little oil amount to the crane hydraulic circuit. When one control bank lever is operated, this oil amount is conveyed by the control bank to the pump to move the inner plate so that there is the required oil amount in the crane hydraulic circuit to handle the crane. If the pressure gauge is fitted to the LS hydraulic line (joining the LS connection to the control bank with the LS junction on the pump) a setting value relating to the pressure inside this pipe is detected. By way of example, manufacturers of variable delivery pumps recommend setting the pressure at a value of 30-35 V. max. 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 respondquickly to the displacement of the control bank lever.

V. max. PUMP

THE POWER OF PERFORMANCE

47

Controlbanks

B8.1

2) MAXIMUM WORKING pressure A variable delivery pump feature is that it automatically does not convey oil anymore to the crane circuit when the provided maximum pressure value is reached thus preventing oil from overheating. From this you may understand that the setting of the crane maximum working pressure is assigned to the main overpressure valve fitted to the pump. If a pressure gauge is fitted to control bank connection P, the maximum overpressure valve setting value is detected. NOT KNOWING if this value is limited by the control bank valve operation, or by the valve fitted to the pump, the first step is, when the truck engine is not started yet, to increase the main valve setting by around 35-40 bar: you can have this increase by screwing up the adjuster by a half turn. In this way the valve fitted to the control bank is used only as a further safety, and you must set the overpressure valve fitted to the pump at the value indicated on the specific crane hydraulic diagrams.

CRANES WITH ELECTRO-HYDRAULIC FPI DEVICE 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 increase 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.

V. max. (A)

V. max. pump

48

THE POWER OF PERFORMANCE

Controlbanks
ADDITION OF HYDRAULIC USERS ON A HYDRAULIC CIRCUIT WITH VARIABLE DELIVERY PUMP

B8.1

The previous chapters explained that the variable delivery pump conveys oil to crane hydraulic control, then to the various cylinders that handle the crane, only when it receives a signal by the control bank. Otherwise, the pump conveys only a small oil amount, at a very low pressure value that does not allow the crane to be handled. The application of more users on a hydraulic circuit supplied by a variable delivery pump, requires a signal of oil demand to be sent to the pump whenever you want to operate the added user. The diagram below shows the application of a user: In addition to diverter (1) whose task is to divert oil to the added control bank, you must fit a FLIP-FLOP valve (2) and a flow regulator (3) The function of the flow regulator is to send to the pump, through the connection carried out on LS hydraulic line with the application of the flip-flop valve, a signal that determines the pump displacement , that is the maximum oil delivery that you want the added user to have at its disposal: the more the flow regulator is closed, the less oil will reach the added user. The above is true in case the control bank of the added user is not proportional, that is when you do not have the LS signal at disposal. In this specific case, during the use of the added user, the variable delivery pump turns into a fixed delivery pump, losing the advantages of self-adjustment according to the demanded oil amount.

L.S.
Flip-flop valve Oil diverter tap

EFFER code # 8850217

added use

Flow regulator valve EFFER code # 8853750

THE POWER OF PERFORMANCE

49

Controlbanks

B8.1

50

THE POWER OF PERFORMANCE

Proportional controlbank DANFOSS - PVG 32 B8.2

PVG 32

Features:
Maximum working pressure 350 bar, continuous work Inlet maximum oil flow rate: Standard supply voltage Supply voltage on request 150 l/min with variable displacement pump 140 l/min with fixed displacement pump 24 volt (22 30 volt) 12 volt (11 15 volt)

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

52

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

Operation
u As soon as the hydraulic pump is operated, the oil conveyed to the control bank enters the first section and,
if no control lever is operated, it goes out of the section and goes back to the oil tank. Therefore the hydraulic oil does not pass through the control bank. u When a control bank lever is operated, only the demanded amount of oil (amount which is demanded either by the project data established by EFFER for that specific function, or by the displacement of the lever set by the operator) is deviated towards the operated element. The surplus part of oil always goes back to the tank without passing through the control bank. u This functionality is ensured by the element compensator and by the inlet compensator. If two or several control bank levers are operated at the same time, the various compensators of the single elements send their oil demand to the inlet compensator: the compensator positions itself so as the sum of the demanded oil continues until the whole pump oil flow rate is ended. In case several levers are operated at the same time, demanding the inlet compensator for more oil than the pump can supply, the functions requiring less operational pressure will be operated in priority. This functionality allows fitting pumps whose displacement is able to convey an oil amount that is higher than the one recommended by EFFER on the specifications of the various cranes; it also raises the operating speed considerably and creates an increase of oil temperature that is however irrelevant compared to a traditional system. (Contact the Technical Service for the data item concerning the maximum oil flow rate that can be conveyed to the control bank, according to the crane type). u The most important operating advantage is that, unlike what occurs with a traditional control bank, it is possible to perform several manoeuvres at the same time, also at very reduced speed, but at the maximum pressure allowed for the single movements. u Does not require oil drain hoses. NB: All operations carried out on the control bank must be performed under perfectly clean conditions. Make sure not to make impurities enter the control bank. In case of deposit of impurities if you only touch the control bank components with very dirty hands, the control bank correct operation may be jeopardized.

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

THE POWER OF PERFORMANCE

53

Controlbanks SAUER-DANFOSS

B8.2

Identification OF SAUER-DANFOSS PVG 32 Model components


1- Inlet element 2- Control bank element 3- Closing element 4- Assembly tie rod kit

1 3 4

4
54

4
THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

1- Inlet element
Complete inlet element (EFFER Code 8991453) The following main components are fitted to the inlet element: 1.1 - Maximum pressure control valve generally referred to as main valve. 1.2 - Inlet compensator 1.3 - Unloading solenoid valve 1.4 - Additional pressure gauge connection 1.5 - L.S. hydraulic connection 1.6 - Pressure reducing valve to supply electro-hydraulic controls

1.4 1.2

1.1 1.6

1.3 1.5 1.4

1.3

1.1

1.6
1.2
Kit complete with all seals on the inlet element - EFFER code 8990712

1.5

THE POWER OF PERFORMANCE

55

Controlbanks SAUER-DANFOSS

B8.2

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 hexagon. The hexagon is 6 mm in size. The hydraulic sealing towards the outside is ensured by a 9x2 O-ring type seal. EFFER cod 8991567 Ref. 1. The adjustment of the maximum pressure value is carried out by acting on the cheese-headed screw Ref. 2. If the screw is turned clockwise the setting value increases, if it is turned counterclockwise the setting value decreases. 1 complete turn increases the setting value by 100 bar. Maximum setting allowed by the control bank: 350 bar.

WARNING: The increase of the setting beyond the project values is an operation that may entail serious hazards for safety. NB: It is recommended to carry out small movements of the screw while keeping the achieved setting value constantly monitored. WARNING: Always clean the components carefully before assembly.

u A filter is fitted inside the element, under the main valve. A 6-mm socket wrench is required to disassemble this

filter. This filter Ref. 3, does not require special maintenance: it is recommended to clean it only in case of serious troubles such as the truck pump breaking.

1.1

2 1

56

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

1.2 Inlet compensator


It is possible to remove the compensator only after removing the tie rod spacer Ref. 1. Please note that this spacer has a tapered shape and can be removed towards the control bank side. Therefore to disassemble the compensator it is necessary to disassemble the head from the control bank. u Using a M6 screw the bushing complete with the O-ring type seal Ref. 2 can be removed. Please note that a considerable force must be applied to remove the Ref. 5. NB: Pressure that the internal spring exerts on compensator causes the compensator to move when loosening the screws. It is therefore recommended to keep the plug in its position this operation can be carried out with the pressure of a hand - to avoid that the plug is damaged or falls to the ground. u The compensator has to flow freely inside the seat, and the small oil holes have to be free from impurities. The compensator perfect operation is achieved when it flows freely inside its seat, and when it is free from significantly deep marks on the surface. u The dowel Ref. 4 is screwed inside the compensator Ref. 3. This is a special dowel, with a small 1-mm hole in its center. A 3-mm setscrew wrench is required to disassemble this dowel. It is recommended to disassemble this dowel if a through cleaning of the compensator is required, because of its malfunction. If the malfunction is caused by impurities that clog oil passage, this may cause all crane movements to be slowed down until the entire crane stops. u The compensator Ref. 3 cannot be supplied as a single spare-part: we recommend replacing the whole inlet element in case it has deep marks, as its seat will be certainly damaged too. u The only case when disassembling, cleaning or replacing the compensator can be useful, is to cope with an emergency that may arise temporarily on the field. WARNING: Always clean the components carefully before assembly.

u The inlet compensator is fitted under a plastic plug, located on the side opposite to the solenoid valve.

1.2

3 4 2 5

THE POWER OF PERFORMANCE

57

Controlbanks SAUER-DANFOSS

B8.2

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 1 2

1.3

58

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

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 pressure 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 maximum. 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.

1.4

1.5 Hydraulic connection for L.S.


side. In case a variable delivery pump is fitted, the hydraulic pipe that conveys the oil demand signal to the pump compensator, must be connected to this connection.

u A connection called L.S. is provided on the inlet element

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.

1.5
59

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

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 maintain 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.

WARNING: Always clean the components carefully before assembly.

1.6

60

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

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

2.8 2.6

2.1 2.6

2.2

2.7

2.3 2.4 2.5


THE POWER OF PERFORMANCE

61

Controlbanks SAUER-DANFOSS

B8.2

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: O-RING 5 X 2 O-RING 16 X 2.5 O-RING 10 X 2.5

N. 2 N. 4 N. 1

N.B: With the Effer Code 8990717 a kit including all seals fitted to the element is supplied.

u In case you need to replace a control bank element we recommend fitting a complete lever element. For this
spare-part, communicate the crane serial number and the function for which the lever element is intended to EFFER. Two types of pressure control valves can be fitted to the element body: a) valve that controls the pressure maximum value sent inside the cylinder - active pressure. b) valve that controls the pressure maximum value allowed inside a cylinder, due to crane performance increase carried out with any movement - passive pressure. In the light of the above, three element types can be supplied: - element prearranged for two maximum pressure adjusting valves on A and B ports (n. 2 valves a). - element prearranged for two maximum pressure adjusting valves on A and B ports and two shockproof/anticavitation valves (n. 2 valves b) - element not prearranged for pressure adjusting valves (n. 2 valves a) + n. 2 valves b) WARNING Always clean the components carefully before assembly.

2.1

A
a

a
THE POWER OF PERFORMANCE

62

Controlbanks SAUER-DANFOSS

B8.2

2.2 Mechanical lever control


Note: The return device of the stem is built in the spool and is represented 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 setscrew 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 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 supplied. 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 required. 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.

2.2
3 4 3 2 5 1

5 4

THE POWER OF PERFORMANCE

63

Controlbanks SAUER-DANFOSS

B8.2

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 communicate the crane serial number to EFFER and also specify the movement that the specific spool controls. The spool has to flow freely inside the element body. If there are marks on the spool due to the use of the crane with impurities in oil, this may hinder the spool free sliding: if this is case, it is necessary to replace it; for replacement we recommend fitting a complete element. The following parts are fitted to the two ends of the spool: a plug on one side, and a stem return device on the other. The drawing shows the mechanical composition of the completely assembled spool. Ref. 2: Stem return spring. WARNING: Always clean the components carefully before assembly.

Z 2 1

2.3

64

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS
Listed below are the Effer codes of the spools that are mainly fitted to the cranes:

B8.2

EFFER Code 8991568 8991569 8991570 8991571 8991486 8991572 8991573 8990469 8990442 8990443 8991574 8991575 8991576 8991577 8991578

Code 157B7002 157B7021 157B7022 157B7024 157B7135 157B7062 157B7072 157B7121 157B7122 157B7123 157B7172 157B7421 157B7502 157B9505 157B9591

Description 40 - l/min. Spool in closed center 25 - l/min. Spool in closed center 40 - l/min. Spool in closed center 100 - l/min. Spool in closed center 5-l/min. Spool in open center con pressure control on ports A and B (PC -> AB) 40-l/min. Spool in closed center with pressure control on port A (PC -> A) and flow rate control on port B 40-l/min. Spool in closed center with pressure control on port B (PC -> B) and flow rate control on port A 25 - l/min. Spool in open center 40 - l/min. Spool in open center 65 - l/min. Spool in open center 40-l/min. Spool in open center with pressure control on port B (PC -> B) and flow rate control on port A 25-l/min. Spool with B closed and A in T 40-l/min. Spool with A closed and B in T 40/100 - l/min. Differential spool in open center Differential 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 Differential 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 Differential 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

8991579

157B9592

8991580

157B9641

THE POWER OF PERFORMANCE

65

Controlbanks SAUER-DANFOSS

B8.2
3

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.

2.4

u The valve Ref. 3 cannot be removed; correct operation

is achieved when the ball moves freely pushed by a light air blow.

2 1

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 operator 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.

2.5

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.

66

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

2.6 Special pressure adjusting valves


u In the preceding paragraph we mentioned the possibility 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 carried out with any movement passive pressure. - The presence of these valves is a project data item.

a) Active pressure control valve u 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 valve u 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

b
4

THE POWER OF PERFORMANCE

67

Controlbanks SAUER-DANFOSS

B8.2

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
8990151 8990152 8990329 8990330 8990150 8990328 8990149 8990147 8990148

Setting
125 140 150 160 210 250 280 300 320

68

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2
2.7
1

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 complete 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.

THE POWER OF PERFORMANCE

69

Controlbanks SAUER-DANFOSS

B8.2
2.8

2.8 Radiocontrol coil


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 8991643 B) 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 8991642 C) For cranes on which the DMU load control device is present, without radiocontrol: 12-24 volt coil EFFER code 8991457 Note: 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.

u In case a control bank lever is operated by a radiocontrol, a

2 2
Radio control electric connection

(Black connector)

DMU electric connection

Radio control electric connection (Grey connector)

DMU electric connection (no radiocontrol)

DMU

V bat V bat +

70

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

Note: When turning off the radiocontrol, if a movement of the control bank lever is noticed (movement related to the mechanical zero) act on the regulation placed in the coil rear part, using a 2.5-mm setscrew wrench. The correct adjustment is obtained when the control bank lever maintains its position if an ON-OFF is executed on the radiocontrol.

THE POWER OF PERFORMANCE

71

Controlbanks SAUER-DANFOSS

B8.2

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.
Stabilizers

HPCO SPOOL
fixed delivery pump

HPCO SPOOL

variable delivery pump

See note 3 in the following page

Crane

This control bank element has an inner slider which can have three positions: 1) It conveys oil to the control bank, to allow crane to be handled 2) It conveys oil outside, to feed the hydraulic system of the stabilisers 3) This is a neutral position: the oil is conveyed to drainage, and inhibits any hydraulic handling During the normal work of the crane, the operation of the slider inside the element is carried out electrically. The electric module code 8991920 has two electrical coils inside. When these coils are electrically energized, they move the slider to one direction or to another.

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.

72

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

Note 1: If the crane, where the HPCO function is provided, is also equipped with the DMU3000, it is not equipped with the unloading solenoid valve (NEM) connected to the operating stops imposed by DMU Note2: If the crane, where the HPCO function is provided, is also equipped with a radio control, it is not provided with the unloading solenoid valve connected to radio control operation. Nota3: If you want to fit a variable delivery pump to the crane where the HPCO function is provided, a spool must be placed inside the element (code 8991934 ) along with a single pipe between control bank connection LS and the hydraulic pump connection LS. In addition to what mentioned above, it is necessary to carrry out the operation of 5.

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 5.0 x 2.0 n. 4 O-rings 5.0 x 2.0 With the EFFER code 8990717 you can buy the complete kit of seals ensuring the closing element hydraulic sealing.

THE POWER OF PERFORMANCE

73

Controlbanks SAUER-DANFOSS

B8.2

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 5 6 8 9 10 8991561 8990439 8990440 8990441 8990492 8991562 8991563

Torque wrench setting necessary for the control bank correct operation: 22Nm N.B.: A tie rod kit includes the supply of: 3 tie rods 6 nuts 6 washers

74

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

5 - Variable displacement pump installation


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

range the crane control bank and the hydraulic system, as better explained below, to be supplied by a variable displacement hydraulic pump (variable oil flow rate to control bank, depending on the demand from the manoeuvre that is being performed).

u On request, EFFER can prear-

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 diameter.

LS

0,8 1 mm

Note: In case of use of a variable displacement pump, a non constant movement of the cylinders operating the crane booms, called pendulum effect, may occur; please note that this can result from the instability of the tilted pump plate. In case of troubles as described above, a pipe fitting has to be connected to the end of the hose connected to the control bank LS connection, on the connection side with the hydraulic pump; the pipe fitting oil passage must be 0.8 1 mm.

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

THE POWER OF PERFORMANCE

75

Controlbanks SAUER-DANFOSS

B8.2

ment change, from fixed flow pump into variable displacement pump.

u Below are the drawings concerning the inlet ele-

Fixed 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.

1
Variable displacement pump

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

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

76

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

STANDARD Version with


fixed displacement pump T P

VARIABLE DISPLACEMENT pump version


In case in addition to the crane control bank, another control bank has to be supplied by the variable displacement pump, (i.e.: for crane stabilizers) also the valve Ref. A and Ref. B has to be installed as shown in the diagram of the following page.

LS

Flip flop valve EFFER Code 8850217

Flow regulator EFFER Code 8853750

NOTE: References A and components to be added.

are

. LS signal connected to the


crane control bank.

THE POWER OF PERFORMANCE

77

Controlbanks SAUER-DANFOSS

B8.2

5.1 Variable displacement pump setting instructions


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 pressure 2) MAXIMUM WORKING pressure 1) STAND-BY pressure Even when no crane control lever is operated, the variable delivery pump, conveys a little oil amount to the crane hydraulic circuit. When one control bank lever is operated, this oil amount is conveyed by the control bank to the pump to move the inner plate so that there is the required oil amount in the crane hydraulic circuit to handle the crane. If the pressure gauge is fitted to the LS hydraulic line (joining the LS connection to the control bank with the LS junction on the pump) a setting value relating to the pressure inside this pipe is detected. By way of example, manufacturers of variable delivery pumps recommend setting the pressure at a value of 30-35 bar. Please note that this pressure value, although very low, creates an increase in hydraulic oil temperature when no control bank lever is operated. Having said that, the proper setting value is the minimum value at which the crane movements respond quickly to the displacement of the control bank lever. 2) MAXIMUM WORKING pressure a variable delivery pump feature is that it automatically does not convey oil anymore to the crane circuit when the provided maximum pressure value is reached thus preventing oil from overheating. From this you may understand that the setting of the crane maximum working pressure is assigned to the main overpressure valve fitted to the pump. If a pressure gauge is fitted to control bank connection P, the maximum overpressure valve setting value is detected. NOT KNOWING if this value is limited by the control bank valve operation, or by the valve fitted to the pump, the first step is, when the truck engine is not started yet, to increase the main valve setting by around 35-40 bar: you can have this increase by screwing up the adjuster by a half turn. In this way the valve fitted to the control bank is used only as a further safety, and you must set the overpressure valve fitted to the pump at the value indicated on the specific crane hydraulic diagrams.

LS
78

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

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 centimetres per cycle there are two possibilities: You need to buy a special fitting EFFER code 8991498, Ref. 1 and insert it into the M hole located on the control bank inlet element. A hose recommended gas diameter Ref. 2-, has to be applied to this fitting. On oil delivery coming from truck pump and from the emergency hand pump, there must be some check valves Ref. 3 and to the oil deliveries of the truck pump Ref. 4 and of the emergency hand pump Ref. 5 . N.B. The flip-flop valve, fitted to the hydraulic branch that connects the truck pump to the control bank, must have a size to ensure that the whole oil capacity is conveyed by the truck pump.

u a) Automatic system

2 3 4

3 5

THE POWER OF PERFORMANCE

79

Controlbanks SAUER-DANFOSS
u b) Manual system

B8.2

You need to buy a special tap EFFER code 8991541, Ref. 6 and insert it into the control bank connection M. Check valves Ref. 7 have to be located on the oil delivery coming from the truck pump and on the delivery coming from the emergency hand pump. - To operate the crane using the hand pump the tap must be closed. - To operate the crane using the truck pump the tap must be open.

N.B. The flip-flop valve, fitted to the hydraulic branch that connects the truck pump to the control bank, must have a size to ensure that the whole oil capacity is conveyed by the truck pump.

6 6

LS

80

THE POWER OF PERFORMANCE

Controlbanks SAUER-DANFOSS

B8.2

7 - Troubleshooting
1 / Problems 2 / Causes 3 / Solutions 1A. The crane does not 2.1 Main valve locked by impurities. 3.1 See paragraph 1.1 for main valve disasexecute any movement sembly and reset. although it is certain that the hydraulic pump is per2.2 Inlet compensator locked in its 3.2 See paragraph 1.2 for its disassembly fectly working. closed position by impurities. and operation. Moreover check that the special dowel is free from impurities. 2.3 Unloading solenoid valve not 3.3 To check the solenoid valve operation, powered or burnt. it can be powered using a cable connected to the batteries. In this way, you will see if the problem is in the crane connection or in the coil. To be able to refold the crane, operate the mechanical emergency applied on the coils as described in paragraph 1.3. 1B. The crane does not ex- 2.4 If fitted, special pressure adjusting 3.4 See paragraph 2.4 for its disassembly ecute a specific movement valve clogged by impurities. and operation. although it is certain that the control bank levers and inner spool are not 2.5 The flip-flop valve does not pres- 3.5 To clean the flip-flop valve refer to chaplocked mechanically. surise the signals because of the ter 2.4, concerning disassembly.. presence of impurities.

1C. It is no longer possible 2.6 Electrical problem in the module 3.6 Module replacement. For replacement to operate a movement relative to a movement. refer to chapter 2.8. using the radiocontrol. 1D. It is no longer possible to 2.7 Pressure reducing valve clogged 3.7 Clean the pressure reducing valve operate movements using by impurities. and replace. For disassembly refer to the radiocontrol but it is chapter 1.5. working manually.

THE POWER OF PERFORMANCE

81

Controlbanks SAUER-DANFOSS

B8.2

82

THE POWER OF PERFORMANCE

Proportional valve block Nordhydraulic RS 210 B8.3

RS 210

Specifications: Max. working pressure


Max. inlet oil delivery: Standard supply voltage

350 bar / continuous working 70 l/min with fixed displacement pump 24 volt (2230 volt)

Supply voltage on request 12 volt (1115 volt)

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

B8.3

84

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

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.

94

37

A G 1/2 T1 G 1/2

A G 1/2 T2 G 1/2

45 25

70

56,5 90 113

35

42

37

27

B G 1/2 22 39,5 43 43 43 43 36,5

Specifications: Max. working pressure: Max. inlet oil pressure: Standard supply voltage Supply voltage on request 350 bar / continuous working 70 l/min with fixed displacement pump 24 volt (22 30 volt) 12 volt (11 15 volt)

At the valve block inlet there is a compensator.

9(4X) B G 1/2

50

THE POWER OF PERFORMANCE

85

Controlbanks Nordhydraulic

B8.3

When the truck is operating and once the hydraulic pump has been operated, only a 25 l/ oil delivery circulates inside the valve block elements. The oil in excess with respect to this value returns to the oil tank. As a consequence, during small movements of the crane booms, the element spool shall paralyse only a small quantity of oil, thus obtaining optimum operating sensitivity. In case the lever shifting or different simultaneous movements require an oil delivery higher than 25 l, the compensator sends the required oil delivery up to the maximum level sent by the pump. All element spools have a pre-set maximum delivery: this value is pre-set by Effer during design.

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.

A A B

86

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

B8.3

2 - Main head
u The type of main head used by Effer requires the coupling for the oil sent by
the pump (P1 = GAS) and the coupling for the connection to the oil tank (T4 = GAS). On this type of head it is not possible to carry out a carry-over connection in order to feed another valve block. The main head is provided with the following components: 2.1 master valve 2.2 compensator 2.3 unloading solenoid valve

2.3 2.2

2.1

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

THE POWER OF PERFORMANCE

87

Controlbanks Nordhydraulic

B8.3

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.

2.1

Effer Code of complete master valve 8991590

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

88

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

B8.3

2.2 Compensator
u The compensator does not need any adjustment. It can
be easily removed in order to carry out inside cleaning operations that are necessary, in case the crane does not move at maximum speed.

Effer Code of complete compensator 8991593.

2.2

THE POWER OF PERFORMANCE

89

Controlbanks Nordhydraulic

B8.3

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

90

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

B8.3

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

A A

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

3
Consequently, each lever element has a specific order Effer code: this code corresponds to the basic supply, without the microswitch that activates the DMU 2000 load control device.

THE POWER OF PERFORMANCE

91

Controlbanks Nordhydraulic
Element Rotation lever element (CE) Rotation lever element (not CE) 1st boom lever element (CE) 1st boom lever element (not CE) 2nd boom lever element (CE) 2nd boom lever element (not CE) Extension lever element (CE) Extension lever element (not CE) Addit. jib lever element (CE) Addit. jib lever element (not CE) Addit. extension lever element (CE) Addit. extension lever element (not CE) Winch lever element (CE) Winch lever element (not CE) Rotor/bucket lever element Rotation lever element (CE) Rotation lever element (not CE) Cod. Effer Cod. Effer 8991513 Cod. Effer 8991514 Cod. Effer 8991515 Cod. Effer 8991516 Cod. Effer 8991525 Cod. Effer 8991526 Cod. Effer 8991517 Cod. Effer 8991518 Cod. Effer 8991519 Cod. Effer 8991520 Cod. Effer 8991517 Cod. Effer 8991518 Cod. Effer 8991521 Cod. Effer 8991522 Cod. Effer 8991524 Cod. Effer 8991513 Cod. Effer 8991514

B8.3

The supplied elements are complete with operating lever and sealing gaskets.

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


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.

3.1
92
THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic
The cap can be removed by means of a 10 mm Allen wrench.

B8.3

u In case you want to disassemble the inside components of the pressure reducing valve, loosen the adjusting device completely, extract it by means of long nose pliers.

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 reducing valve. Effer code 8991595.

THE POWER OF PERFORMANCE

93

Controlbanks Nordhydraulic

B8.3

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.

3.2

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.

94

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

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 removing the valve block element and after removing the lever support and the stem return device. To remove the non return valve use a M5 screw to be used as an extractor. Effer code of non return valve complete with gaskets 8991596.

3.4

3.4

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

4
THE POWER OF PERFORMANCE

95

Controlbanks Nordhydraulic

B8.3

5 - Valve block connection tie rods


u 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 Tie rod kit for 5 levers Tie rod kit for 6 levers Tie rod kit for 7 levers Tie rod kit for 8 levers

8991500 8991501 8991502 8991503 8991504

NOTE: The kit includes the screw nut/washer.

6 - Microswitches for DMU


u The cranes with DMU load limiting device are provided - 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.

6
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.

96

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic

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.

THE POWER OF PERFORMANCE

97

Controlbanks Nordhydraulic

B8.3

7 - Mechanic microswitch adjustment and replacement


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.
b

u Two types of microswitches located on cranes where the DMU

NB: Cranes manufactured in early 2005 are provided with mee chanic microswitches. Therefore, upon request of spare parts, we can only supply mechanic microswitches. The different sizes of the two types of microswitches c d do not make it possible to fit a mechanic microswitch next to electronic microswitches: should an electronic microswitch need to be 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 components A) Microswitch support complete with two microswitches with their securing screws and washers B) Microswitch operating cam complete with two dowels (M6x6) for fastening and one dowel (M5x10) for adjustment. C) Plastic material bushing complete with gaskets D) Side closing plate E) Upper protection plug

u Equipment necessary for setup

Electric 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

7.1 Procedure for proper assembly


The 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). 2) Disconnect the electric cables connected to the electronic microswitch. It is advised to take note of the cable lay-out in order to reconnect 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 adjustment of the microswitch starting from the element which is hardest to reach, i.e. the one which is closer to the stabiliser.
x

98

THE POWER OF PERFORMANCE

Controlbanks Nordhydraulic
3) Grease the two O-rings located on the bushing (c) and insert it in the slider and in the special housing on the rod return device cap.
c

B8.3

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.

b a

6) Fix microswitch support (a) to the control bank with suitable washers and socket head screws using a 5-mm Allen wrench and extension to provide a higher torque wrench setting. The use of washers is advisable but not biding. After the mechanic microswitch is secured to the block it will have an angulated position of approximately 30 on the left side with respect to the vertical axis

M6

M5

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 positioned in the neutral point, the two pilot lights are turned on. To adjust the cam position better with respect to the two microswitches, you can use the dowel fitted to the cam rear end. Obviously, when adjusting, always apply a slight pressure on the cam in the direction of the control bank to avoid any contact between the adjusting dowel and the cam support shaft. After having carried out this first centring, slightly tighten the two dowels which lock the cam to the centring pin.
THE POWER OF PERFORMANCE

99

Controlbanks Nordhydraulic
3) Do small movements with the control lever in the two directions: the two pilot lights are turned off when the relative microswitch is operated by the cam. If the two pilot lights do not turn off symmetrically with respect to the central position of the cam, change the position of the cam with respect to the microswitches by acting on the rear dowel (by screwing or unscrewing it). 4) When the symmetry of the cam with respect to the two microswitches is achieved, check the stroke, the control bank slider the and the cam do before the two pilot lights are turned off . If they turn off too early a signal may be conveyed to the DMU that a lever of the control bank is not positioned in the central area. Therefore a faulty state occurs. If they turn off too late a flow of oil occurs inside the hydraulic cylinders without the proper initial proportionality, and therefore the movement will start abruptly 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
v

B8.3
a

support (a). By loosening the two screws it is possible to change the height of the two microswitches, or it is possible 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 microswitches to prevent the vibrations from moving it from its position. 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 -.
d

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

100

THE POWER OF PERFORMANCE

F.P.I. DEVICE B9

Service Manual

Rev.

07-2008

GB

THE POWER OF PERFORMANCE

F.P.I. Device

B9

THE POWER OF PERFORMANCE

F.P.I. Device

B9

1 - Description
The F.P.I device referred to is fitted only to certain crane models and has an electro-hydraulic operation. The operation of this device is intentional, that is it is the worker who decides when using it. The operation may take place either by operating the key switch, placed near the manual control station or through a switch on the button panel of the radio control. In both cases the operation of the device is accompanied by lighting of a warning light, placed next to the two switches described above. The use of F. P. I. device involves: a reduced crane boom handling speed, (first boom, second boom and jib if fitted)

u u

A higher pressure value inside the crane hydraulic circuit. 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 retraction, 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.

THE POWER OF PERFORMANCE

F.P.I. Device

B9

2 - Functioning principle
The F.P.I. device works by reducing the dynamic effects on crane structure due to load movements. The valve Ref. 1 deducts a portion of the oil sent to the compensators of each controlbank element (for those elements controlling the crane booms), thus reducing the internal stroke of the spool inside the element, which results in the end in a limited operating speed of the crane. The solenoid valve applied on the unit is electrically powered when the F.P.I. device turns ON.

Ref. 1

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. 2

THE POWER OF PERFORMANCE

F.P.I. Device
INCREASE 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 pressure value relating to crane operation with the device off - the crane pressure value with FPI=OFFThe pressure value with the device turned on, the crane pressure value with FPI=ON- is adjusted by the main valve fitted to the control bank.

B9

THE POWER OF PERFORMANCE

F.P.I. Device

B9

3- Valves
3.1 F.P.I. valve
Two 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 ADJUSTING SCREW

PRESSURE ADJUSTING SCREW

SPEED ADJUSTING SCREW

SPEED ADJUSTING SCREW

THE POWER OF PERFORMANCE

F.P.I. Device

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 whenever the F.P.I. device is switched ON. Note: the a.m. parts # are related to a 24 VOLT power supply

4 - Settings

PRESSURE ADJUSTING SCREW

u The holding valves on booms cylinders of F.P.I. cranes have a specic setting, obviously higher than the one designed for the same crane model without F.P.I., since they must keep the oil inside the barrel with a higher load (i.e.: pressure) applied to the crane.. u As explained above, when the F.P.I. is switched on, a higher pressure is available in the crane circuit. The working pressure is controlled: by the F.P.I. valve (when the F.P.I. is off ), while the (higher) pressure value is controlled by the main relief valve of the controlbank when the F.P.I. is on.
Setting points

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 information see chapter Load limiter

THE POWER OF PERFORMANCE

F.P.I. Device

B9

5 - Tunings
u Any fine tuning of the crane circuit shall always be carried out with the F.P.I. switched on and with an oil temperature of at least 25 C (by lower temperatures, the booms speed might be much slower).
Crane operational speeds, with the F.P.I. switched on, shall correspond to the values listed in the hydraulic diagrams of the corresponding crane model. Note: when willing to increase the cylinder outlet speed, unfasten the register screw on the F.P.I. valve while to decrease the speed fasten the same. We recommend to fasten the registers screws by fine tunings since even a small portion of revolution generates big speed changes.

5.1 F.P.I. valve tunings

ELECTRIC CONNECTOR

E50

ADJUSTING SCREW OUTER BOOM SPEED

ADJUSTING SCREW STANDARD CRANE GENERAL PRESSURE

ADJUSTING SCREW MAIN BOOM SPEED

ADJUSTING SCREW FLY-JIB SPEED

u After having verified the stroke times of the booms cylinders, we recommend to carry out a complete movement until the cylinder end-stroke for each of the set cylinders so as to verify that the check-relief valves are set according to the tables.

THE POWER OF PERFORMANCE

F.P.I. Device

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 activation 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.

ELECTRIC CONNECTOR

E51

PRESSURE ADJUSTING SCREW

u Turn the screw clockwise to increase pressure and crane operating range. Otherwise, turn the screw counterclockwise to decrease pressure and to reduce crane operating range.
In order to change the load limiting device operation point, we recommend you to read chapter 4 for the correct operating sequence.

THE POWER OF PERFORMANCE

F.P.I. Device

B9

6 - Operating instructions
As already explained, the F.P.I. device can be activated by turning the key switch near the manual control table or through the radio remote control board. On both cases, when activated, the yellow lamp on the main electric board lights up.

Important The device can be switched OFF only by the same unit of activation. So, if you switch it on from the radiocontroller, you may switch it off only from the radio-controller again.

u The F.P.I. device can be activated only if the crane boom operates within the 180 max. stability area (rear side of truck cab). The device can not be activated when the crane operates in the 180 truck front area. u The F.P.I. device will cut out automatically if the crane slewing reaches the front work area, and will cut in automatically
when the crane slewing to operate again in the rear work area.

u The F.P.I. device switched on through the radio remote control, will cut out automatically if the crane electric system is turned OFF. u
The F.P.I. device can be switched ON/OFF even during crane operation, with or without load applied.

u The lifting capacity of the crane with the F.P.I. device OFF cuts by 10% restect to the load diagram. It means that, with the same load applied, the crane outreach at the moment of the Overload Safety Device operation will be less than the value reported on the crane load diagram. u If the Overload Safety Device operates with the F.P.I .device ON, crane movements controlled by the Overload Safety Device will stop. In order to perform any manoeuvre, it is necessary:
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.

10

THE POWER OF PERFORMANCE

F.P.I. Device

B9

7 - Electric connections
The following instructions refer to some relevant electric connections.

ply).

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

Relay for the activation of the F.P.I. device energized by the radio signal. The relay is electrically energized by the wire connected to clamp 38.

K 50

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.

E 50 E 51

THE POWER OF PERFORMANCE

11

F.P.I. Device

B9

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.

8 - Maintenance
The F.P.I. valve doesnt need any specific maintenance: the filters on the inlet of the specific controlbank elements are designed for 100 microns and therefore should never be obstructed considering that the crane circuit has a 25 microns high-pressure filter.

12

THE POWER OF PERFORMANCE