proportional valve block nordhydraulic rs 210 b8 · 2015. 5. 7. · controlbanks nordhydraulic...

Specifications: Max. working pressure 350 bar / continuous working

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

Standard supply voltage 24 volt (22÷30 volt)

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

Proportional valve block Nordhydraulic RS 210

THE POWER OF PERFORMANCE

B8.3

RS 210

Controlbanks Nordhydraulic


84

B8.3 Controlbanks Nordhydraulic

Controlbanks Nordhydraulic Controlbanks Nordhydraulic


85

B8.3

1 - Introduction u Even if this hydraulic valve block is not a compensated proportional valve block, it is particularly appreciated for its motion sensitivity.

Specifications:

it is a modular valve block, max. 10 elements, suitable for hydraulic oil operation with temperatures from -15° C to +80° C.

Specifications:

Max. working pressure: 350 bar / continuous working

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

Standard supply voltage 24 volt (22 ÷ 30 volt)

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

At the valve block inlet there is a compensator.

94

37

AG 1/2”

T1G 1/2”

AG 1/2”

T2G 1/2”

BG 1/2”

BG 1/2”

37

7035

42 11356

,590

45

5025

9(4X

)

22 36,54339,5 434343

27



86


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

u Valve block gasket kit

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

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

B

A

A



87

B8.3

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

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

On this type of head it is not possible to carry out a carry-over connection in order to feed another valve block.

The main head is provided with the following components:

2.1 master valve

2.2 compensator

2.3 unloading solenoid valve

2.3 2.1

2.2



88


2.1 Master valve

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

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

Effer Code of complete master valve 8991590

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

2.1



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B8.3

2.2 Compensator

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

Effer Code of complete compensator 8991593.

2.2



90


2.3 Unloading solenoid valve

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

Effer Code of 12 Volt solenoid valve 8991591

Effer Code of 24 Volt solenoid valve 8991506

Effer Code of cap provided with gaskets 8991592

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

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

2.3



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B8.3

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

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

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

A

A

BB

3



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

Element Cod. Effer

Rotation lever element (CE) Cod. Effer 8991513

Rotation lever element (not CE) Cod. Effer 8991514

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

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

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

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

Extension lever element (CE) Cod. Effer 8991517

Extension lever element (not CE) Cod. Effer 8991518

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

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

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

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

Winch lever element (CE) Cod. Effer 8991521

Winch lever element (not CE) Cod. Effer 8991522

Rotor/bucket lever element Cod. Effer 8991524

Rotation lever element (CE) Cod. Effer 8991513

Rotation lever element (not CE) Cod. Effer 8991514

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

3.1

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

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

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



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

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

A valve with all single components is shown below.

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

200 - 240 bar Effer code 8991532

240 - 300 bar Effer code 8991533

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



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3.2 Lever support

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

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

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

3.3 Stem return device

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

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

Effer code of complete stem return device 8991509.

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

Effer code of complete stem return device 8991510.

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

3.2

1

2



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B8.3

3.4 Non return valves

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

The above valves can be disassembled only after remo-ving the valve block element and after removing the lever support and the stem return device.

To remove the non return valve use a M5 screw to be used as an extractor.

Effer code of non return valve complete with gaskets 8991596.

4 - Closing element

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

3.43.4

A B

4



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

Tie rod kit Cod. Effer

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

NOTE: The kit includes the screw nut/washer.

6 - Microswitches for DMU

6

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

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



97

B8.3

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

Effer code of non-magnetic wrench 8991588.

The sensor shall be removed in the following operating sequence:

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

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

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

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

NOTE: each microswitch is connected with its sensor.

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



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7 - Mechanic microswitch adjustment and replacementu Two types of microswitches located on cranes where the DMU load limiting device is fitted, signal the positioning of the inner slider to the DMU.- electronic microswitch: Effer code 8991508 (refer to paragraph 6). - mechanic microswitch: Effer code 9395656KN.

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

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

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

a

e

c

b

d

x

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

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

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

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

Remove the electronic microswitches from the control bank.

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



99

B8.3

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

4) Introduce the cam (b) in the microswitch support (a), ensuring the proper position (the grooved side facing up and the slider housing hole on the insertion side). Now push the cam until it is against the support edge.

5) Put a drop of “Loctite 222” on the two M6x6 dowels and on the M5X10 dowel and insert them in the appropriate housings located on the cam. Slightly screw the dowels, making sure they do not obstruct the slider housing hole.

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

7.2 Procedure for proper adjustment

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

2) First, position the cam (b) in the central area with respect to the two microswitches: neutral point. With the cam correctly po-sitioned in the neutral point, the two pilot lights are turned on. To adjust the cam position better with respect to the two micros-witches, you can use the dowel fitted to the cam rear end. Obvi-ously, when adjusting, always apply a slight pressure on the cam in the direction of the control bank to avoid any contact between the adjusting dowel and the cam support shaft. After having car-ried out this first centring, slightly tighten the two dowels which lock the cam to the centring pin.

M6 M5

c

b

a

a



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B8.3

3) Do small movements with the control lever in the two directions: the two pilot lights are turned off when the relative microswitch is operated by the cam. If the two pilot lights do not turn off symmetrically with respect to the central position of the cam, change the position of the cam with respect to the microswitches by acting on the rear dowel (by screwing or unscrewing it).

4) When the symmetry of the cam with respect to the two microswitches is achieved, check the stroke, the control bank slider the and the cam do before the two pilot lights are turned off . If they turn off too early a signal may be conveyed to the DMU that a lever of the control bank is not positioned in the central area. Therefore a faulty state occurs. If they turn off too late a flow of oil occurs inside the hydraulic cylinders without the proper initial proportionality, and therefore the movement will start abruptly

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

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

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

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

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

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

v

v

d

b

a

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

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

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

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

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

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


B9F.P.I. DEVICE

Service Manual 07-2008 GB Rev. 2

F.P.I. Device


�

B9 F.P.I. Device

F.P.I. Device F.P.I. Device


�

B9

1 - Description The F.P.I device referred to is fitted only to certain crane models and has an electro-hydraulic operation.

The operation of this device is intentional, that is it is the worker who decides when using it. The operation may take place either by operating the key switch, placed near the manual control station or through a switch on the button panel of the radio control. In both cases the operation of the device is accompanied by lighting of a warn-ing light, placed next to the two switches described above.

The use of F. P. I. device involves:

a reduced crane boom handling speed, (first boom, second boom and jib – if fitted)

u A higher pressure value inside the crane hydraulic circuit.

u Crane performance features that are consistent with the reported data in load diagrams .

This type of device is present only in combination with HAWE-type proportional control banks.

Working with the crane:

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

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

F.P.I. Device


�

B9 F.P.I. Device

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

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

Ref. 1

Ref. 2



�

B9INCREASE IN THE MAXIMUM PRESSURE VALUE AVAILABLE FOR LIFTING

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

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

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

F.P.I. Device


�

B9 F.P.I. Device

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

1) EFFER part # 8866722 B for basic cranes

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

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

SPEED ADJUSTINGSCREWSPEED

ADJUSTINGSCREW

PRESSUREADJUSTINGSCREW

SPEEDADJUSTINGSCREW

1 2



�

B9

3.2 Overload Safety Device pressure increase valve

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

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

PRESSURE ADJUSTINGSCREW

� - Settingsu The holding valves on booms cylinders of F.P.I. cranes have a specific setting, obviously higher than the one designed for the same crane model without F.P.I., since they must keep the oil inside the barrel with a higher load (i.e.: pressure) applied to the crane..u Asexplainedabove,whentheF.P.I.isswitchedon,ahigherpressureisavailableinthecranecircuit.Theworkingpressureiscontrolled:bytheF.P.I.valve(whentheF.P.I.isoff ),whilethe(higher)pressurevalueiscontrolledbythemainreliefvalveofthecontrolbankwhentheF.P.I.ison.

Settingpoints

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

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

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

F.P.I. Device


�

B9 F.P.I. Device

� - Tunings5.1 F.P.I. valve tuningsu Any fine tuning of the crane circuit shall always be carried out with the F.P.I. switched on and with an oil temperature of at least 25 °C (by lower temperatures, the booms speed might be much slower).

Crane operational speeds, with the F.P.I. switched on, shall correspond to the values listed in the hydraulic diagrams of the corresponding crane model.

Note: when willing to increase the cylinder outlet speed, unfasten the register screw on the F.P.I. valve while to decrease the speed fasten the same.

We recommend to fasten the registers screws by fine tunings since even a small portion of revolution generates big speed changes.

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

ADJUSTING SCREW

ADJUSTING SCREW

ADJUSTING SCREWADJUSTING SCREW

OUTER BOOM SPEED

FLY-JIB SPEED

MAIN BOOM SPEEDSTANDARD CRANE

GENERAL PRESSURE

ELECTRIC CONNECTOR E50



9

B9

5.2 Adjusting the activation point of the Overload Safety Device

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

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

PRESSURE ADJUSTING SCREW

ELECTRIC CONNECTOR

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

In order to change the load limiting device operation point, we recommend you to read chapter 4 for the correct operating sequence.

E51

F.P.I. Device


10

B9 F.P.I. Device

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

Important

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

u The F.P.I. device can be activated only if the crane boom operates within the 180° max. stability area (rear side of truck cab). The device can not be activated when the crane operates in the 180° truck front area.

u The F.P.I. device will cut out automatically if the crane slewing reaches the front work area, and will cut in automatically

when the crane slewing to operate again in the rear work area.

u The F.P.I. device switched on through the radio remote control, will cut out automatically if the crane electric system is turned OFF.

u The F.P.I. device can be switched ON/OFF even during crane operation, with or without load applied.

u The lifting capacity of the crane with the F.P.I. device OFF cuts by 10% restect to the load diagram. It means that, with the same load applied, the crane outreach at the moment of the Overload Safety Device operation will be less than the value reported on the crane load diagram.

u If the Overload Safety Device operates with the F.P.I .device ON, crane movements controlled by the Over-load Safety Device will stop. In order to perform any manoeuvre, it is necessary:

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

b - to start a manoeuvre of extension retraction until the Overload Safety Device alarm stops sounding.

c -At this step, the crane lifting capacity has increased and you may keep on manoeuvring, with more lifting capacity available.

u When activating the function “SNAIL” with the F.P.I. device switched ON, crane boom movements slow down further. If the “SNAIL” speed has been set very slow this could actually make the whole crane not move at anymore. We reccommend you do not use this function with the F.P.I. device switched ON.

u The F.P.I. device can control the decrease of the boom working speed correctly only when oil temperature in the hydraulic circuit reaches at least 25 °C. By lower temperatures, the booms speed might be a bit faster.



11

B9

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

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

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

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

u Clamp 50: two electric wires activating the two F.P.I. device solenoid valves are attached to one side of this clamp..

The electric connectors of the two solenoid valves are marked with the numbers of the following parts:

E50: F.P.I. solenoid valve

E51: solenoid valve for Overload Safety Device pressure increase.

K 50

E 50

E 51

F.P.I. Device


1�

B9

� - MaintenanceThe F.P.I. valve doesn’t need any specific maintenance: the filters on the inlet of the specific controlbank elements are designed for 100 microns and therefore should never be obstructed considering that the crane circuit has a 25 microns high-pressure filter.

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

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

SA50: (EFFER spare part # 9394725).

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

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

proportional valve block nordhydraulic rs 210 b8 · 2015. 5. 7. · controlbanks nordhydraulic...

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