original training document

TRAINING Epsilon

Customer specific questions

Original training document

2014/07

PALFINGER AG Franz-Wolfram-Scherer-Straße 24 5020 Salzburg / Austria www.palfinger.com

http://www.palfinger.com/

Index Customer specific questions

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Index

1 General........................................................................................... 4 1.1 Introduction and handling of this document ..................................... 4 1.2 Validity ............................................................................................ 4 1.3 Symbols in this document ............................................................... 4

2 The crane socket ........................................................................... 5 2.1 • General information to crane socket ............................................. 5 2.2 Measuring the column’s gap ........................................................... 7 2.3 Modification of the dead point ......................................................... 8

3 The column .................................................................................. 11

4 The boom system ........................................................................ 12 4.1 Main boom .................................................................................... 12 4.2 Outer boom ................................................................................... 12 4.3 Changing of the extension cylinder ............................................... 12 4.4 Changing the houses on double telescopic system ...................... 12 4.5 Mounting of extension boom system ............................................ 12

5 EPSLINK ...................................................................................... 15 5.1 General ......................................................................................... 15 5.2 Changing the outer boom hoses ................................................... 15

6 Trouble shooting ......................................................................... 16 6.1 General questions ......................................................................... 16 6.2 Crane lifting capacity is too low ..................................................... 18

Customer specific questions General

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1 General

1.1 Introduction and handling of this document

This PALFINGER training document is a technical description about systems on a loader crane. It will be expensed for PALFINGER trainings on loader cranes and should be a reference book for service and repair work.

These training documents have been produced for PALFINGER service workshops. An appropriate knowledge about the product and a basic education will be assumed.

1.2 Validity

This training document applies without any time limitation for the described system.

It is possible due to further developments that newer versions of this document are already available.

The respectively newest edition of this training document and further technical documents are available on the PALFINGER Extranet in the range PATIS-Online / service documents.

Registration can be done at https://www.palfinger.com

PALFINGER keeps the right to change the documents at any times without notice.

© Copyright by PALFINGER

Copying (also in Extracts) only after written permission from:

PALFINGER AG Franz-Wolfram-Scherer-Straße 24 A-5020 Salzburg/Austria

1.3 Symbols in this document

To make the document clearly structured and easily readable, important references, instructions and risks are highlighted by symbols and special words.

Caution!

Symbol and special word will be used for imminent danger. If the safety instructions are ignored, acute danger for life exists for the operator and others.

Attention!

Symbol and special word will be used for imminent danger. If the safety instructions are ignored, acute danger for life exists for the operator and others.

Note!

Symbol and special word will be used for a very important note which makes operation of the machine easier.

https://www.palfinger.com/

The crane socket Customer specific questions

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2 The crane socket

2.1 • General information to crane socket

The base, the column and the slewing cylinders are painted separately in the production process. To guarantee a trouble free assembling process, all red marked areas must be cleaned from paint, otherwise the small tolerances would not allow the assembling anymore. The radial gap between column and base is 0.15 to 0.3 mm at new cranes. This additionally avoids wearing and guarantees greasing and a good working performance for a long time.

From Epsolution series pos. 1 and 2 are only cleaned from colour. Undercoat will be not removed.

The base

Bush: When changing the glide bushes by any reason, they have to be built in the right way. Each strip (A) has a smooth and a rogh surface, the rough surface has to be outside when placing the strip in the base (it must touch the base). The smooth surface touches the column. Self-aligning roller bearing: The swivel joint roller bearing (B) is glued into the base, when remounting this bearing, it has to be glued into the base again!

Customer specific questions The crane socket

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2.1.1 End layer restrictor (Version 1)

If the piston reaches the end position in the slewing cylinders (see picture below) the oil flow is reduced. This reduces the operating speed. At the end position the flow finally becomes zero.

2.1.2 End layer restrictor (version 2)

Functionality is the same as on version 1. The big difference on this system is the screw for damping (Pos. 1). The screw is mounted from the inner side of the slewing cylinder.

1 Screw 2 Allen screw 3 Piston 4 Piston seal 5 Wide piston ring 6 Scraper ring Divided piston: In order to fit new sealing the piston can be dismantled in two parts by unscrewing the allen screws (Pos. 2). This simplifies the resealing of the piston.


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2.2 Measuring the column’s gap

During each crane service, the gap of the column should be measured to avoid damages caused by too big axial or radial gaps.

For the measuring of the axial as well as the radial gap following points are important:

Checking the axial gap:

Put the crane in the shown position, the boom system should not touch the ground.

Put the measuring instrument onto the base as shown below.

Lift the crane column by using an overhead crane with a force of approximately 1t.

Read out measured gap.

The axial gap must not exceed 3 mm.

If the gap is higher, immediately check, if the surclip ring on the bottom of the column is still in the right position.

Checking of radial gap:

Put the crane in the shown position, the boom system should not touch the ground. The telescopic nose should be approx. 10cm over the ground.

Connect the measuring instrument as shown below. The feeler should be right in the centre of the splash-water protection.

Lower the main boom and press the crane boom system against the ground with a pressure of approximately 50 bar (therefore connect a pressure gauge to the emergency valve). Take 4 measurements, every 90 degrees of slewing angle.

The radial gap must not exceed 1,5 mm. If it is

bigger, the glide bush must be replaced.


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2.3 Modification of the dead point

2.3.1 Version 1

Take out the pressure from the slewing cylinders.

Drain oil from the base and take off the cover of the self-aligning roller bearing.

On ON ROAD cranes dismount the end layer limitation (slewing cylinder). Measure the dimension “X” of the racks, as shown in the picture.

On OFF ROAD cranes dismount the slewing cylinders on one side of the base.

Demount the boom system and take the surclip ring out of the bottom of the base. Then lift the column.

Turn the column to the required position and mount it again. Pay attention to the following points:

1. The self-aligning roller bearing must be glued into the base.

2. The inner and the outer ring of the bearing must be parallel, otherwise the bearing may break.

3. Doublechek the position of the teeth of slewing racks by controlling the position “X”.

4. If a rack turns, bring it back to the correct position. Perhaps it is necessary, on ON ROAD, to dismount one slewing cylinder tube.

The further Steps have to be carried out in opposite way of dismantling.

Finally, the hose package must be repositioned according to the new dead point (see point 1.3)


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2.3.2 Version 2 (only with end layer restrictor version 2)

Take out the pressure from the slewing cylinders.

Drain the oil of the base.

Dismount all slewing cylinders

Dismount one piston on each rack (Pos. 1 + 2).

Dismount the racks by turning the column in direction A.

Turn the column to the desired dead point.

Mount the racks by turning the column in direction B.


Finally, the hose package must be repositioned according to the new dead point (see point 1.3)


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2.3.3 Measuring of the slewing gap

Drive function „slewing“ several times from dead point to dead point.

Boom position as shown on the sketch.

Switch off hydraulic pump.

Mark column and base (Pos. 3).

Move boom system by hand.

The gap must not exceed 8 mm (Pos. 3)!

The measured gap is the summery of hydraulic- gap (main control valve, hoses. Air,…) and mechanical gap (bearing, racks,...). If the gap is too big the problem is mostly in the hydraulic system.

The column Customer specific questions

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3 The column

When changing the hose package, do it as shown:

Slew the crane to the dead point which is furthest away from the filter (Pos 3).

Dead point with shortest way (Pos. 1) is wrong.

Mount the hoses not twisted and parallel (Pos. 5) from filter to dead point (Pos. 2).

Twisted hoses (Pos. 4) reduce the hose length!

The hose package must lie under the main boom cylinder (Pos. 7).

A wrong position of the hose package (Pos. 6) reduces the hose length!

Hose package needs space between crane and assembled parts (Pos. 12).

Guide plate (Pos. 10) prevents a wear for example through mounting bolts.

Wrong assembling (Pos. 9, 11) increases the wear on the hose package.

Mount every 0,5m cable ties on the hose package.

Test hose package on the whole slewing area.

Dismount cable ties and fit protection hose.

Customer specific questions The boom system

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4 The boom system

4.1 Main boom

4.1.1 Changing the hoses on a Z-boom

Open the hose on it’s fitting (A) and pull the loose end through the rear mounting opening on the boom

Open the hose bracket (B)

Connect the new hose (C) to the fitting of the defective hose (A)

Remove the old hose by pulling both hoses through the boom from side (B)

Connect the bracket (B) and finally the fitting (A) of the new hose.

4.2 Outer boom

4.2.1 Advantages of the double telescopic system

The extension booms are operated by one cylinder and the help of two chains. So it get’s the double speed compared to the single boom system. Furthermore, the inside laid hoses are protected better.

The boom system Customer specific questions

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4.3 Changing of the extension cylinder

The changing of the extension cylinder is in chapter M5-6 explained.Changing of hoses on double telescopic system.

4.4 Changing of hoses on double telescopic system.

The hose change is detailed explained in chapter M5-6 as well as in the operator’s manual. The process is also shown in a video, which is available from EPSILON.

Customer specific questions The boom system

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4.5 Mounting of the extension boom system

The telescopic boom change is detailed explained in chapter M5-6. To explain the internal position of the hoses consider following sketches.

Double telescope (old):

A Telescopic boom 1 B Telescopic boom 2 C Outer boom tubing D Lower guide roller E Front chain roller F Rear chain roller G Hose roller H Chain I Upper guide roller J Side guide plates K Lower guide plates

EPSCOPE:

A Telescopic boom 1 B Telescopic boom 2 C Outer boom tubing D Lower guide roller E Front chain roller F Rear chain roller G Hose roller H Chain I Upper guide roller J Side guide plates K Rear cover L Front cover M Chain greasing

EPSLINK Customer specific questions

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5 EPSLINK

5.1 General

EPSLINK is a patented link-swing damper-rotator combination designed by Epsilon.

5.2 Changing the outer boom hoses

Pull out fixation (Pos. 2) from hole A (Pos. 3). Therefore the fitting (Pos. 1) is loose.

Pull out a little bit the fitting with the mounted hoses. Fit the fixation in hole B (Pos.4).

Dismount the hose (Pos. 6) from fitting and Rotator. The dismount of the protection cover (Pos. 5) is not necessary.

During the mounting of the new hose following points have to be considered:

The hoses must have the right length, prescribed from Epsilon.

It is not allowed to mount the hoses twisted.

Fixation of the hoses with cable ties is not allowed.

Hose must be mounted close together.


1 Fitting 2 Fixation 3 Hole A 4 Hole B 5 Protection cover 6 Link hose

Customer specific questions Trouble shooting

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6 Trouble shooting

6.1 General questions

Bouncing or shocking movements

Reason: Air in the hydraulic system

Too less hydraulic oil in the tank Check system for leakages, refill tank, air-bleed the system

Pump defective. Change or repair pump. Refill tank. Air bleed the system.

Wrong oil type or oil too old. Check oil for foam building, eventually change oil. Air-bleed the system.

Hydraulik problem in the control valve Bring the machine to an authorised workshop.

Poor controllability, no fine movements possible

Reason: Oil flow too high, pump capacitiy too high

Pump defective Bring the machine to an authorised workshop.

Rpm of the truck engine too high. Reduce rpm.

Working speed decreases even at raising rpm.

Reason: Restriction in the oil flow

Suction filter is polluted Check filter, if necessary replace filter cartridge.

Pump defective. Check pump and repair in case of a fault. Refill oil level and air-bleed the system.

Condensation water is frozen in the suction line Warm up suction line carefully.

Crane does not lift mentioned load

Reason: Overload system switches too early

Overload valve set wrong. Bring the machine to an authorised workshop.

Pump defective. Bring the machine to an authorised workshop

Boom starts to sink down under load

Reason: Leakages in the hydraulic system

Leakages in the piping Check for leakages and repair them

Cylinder not tight or holding valve not tight. Bring the machine to an authorised workshop

Holding valve setting wrong. Bring the machine to an authorised workshop.

Crane lifts much more than the mentioned load

Reason: Overload system does not work

Valve settings are wrong Bring the machine to an authorised workshop.

Crane makes „cracking“ noises during operation

Reason: Mechanical parts are damaged

Bad maintenance, no greasing, deformed parts Bring the machine to an authorised workshop. In case of damaged parts, parts must be replaced.

Crane makes „squeezing“ noises during operation

Reason: Dry bearings

Trouble shooting Customer specific questions

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Bad maintenace (greasing) Immediately grease dry bearings.

Crane is too slow

Reason: Wrong rpm

Wrong or defective pump

Wrong transmission ration at the PTO

Customer has recently change the crane to a bigger model

(e.g. from E110Z to E140Z) bigger cylinders = less speed

Many leakages in a short time

Reason: too high oil flow

Hydraulic oil is too hot (high flow, high back pressure, wrong mounted cooler)

Manipulated valves

Rotation movements are too fast

Reason: MS-valve mounted instead of a check valve at the valve section (F130CF, H170CF). Attention: additional heating!

When using more functions at a time, one function moves too slow

Reason: Add pretension valves at the fast functions.

Attention: additional heating!

Customer specific questions Trouble shooting

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6.2 Crane lifting capacity is too low

All cranes are adjusted from Epsilon with a load according to the lifting capacity shield. Pressure adjustments from the installation company are absolute not necessary and not allowed.

Type shield / Lifting diagram

Boom position for lifting capacity test

The following reasons may be responsible for too low lifting capacity:

Oil temperature is not normal (40°C – max.60°C)

Inadmissible back pressure

Wrong oil flow

Defective main relief or port relief valve

Untight cylinder

If none of these reasons is true, contact EPSILON. In case the EPSILON factory allows a resetting of the valves, the form A1 must be filled out and returned to EPSILON. The workshop is responsible for the new settings of the crane.

Most often reasons for complaints concerning lifting capacity:

Customer compares single with double extension boom system

Customer used to have a single extension boom system and tries now to lift the similar load at the max. outreach of a double extension boom system.

Problem: less lifting capacity at higher own weight (with similar lifiting capacity).

original training document

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