multifunction hydraulic bank mod09
Contents
1. i Gaskets kit includes all O Rings A5000430010 of the module Complete module 12V with 43650 connectors and CIAP91C connecting rods Complete module 24V with 43650 connectors and CIAP92C connecting rods Complete module 12V without 43650 connectors and CIAP91R connecting rods Complete module 24V without 43650 connectors and CIAP92R connecting rods R Cap for closing unused holes of PTCI9 the manifold NR a a s a e A e 2 o i 2 M c Page 9 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual 6 1 After sale service If you cannot solve the problem also with the help of the examples included in this manual is necessary to call exclusively to the installer This one can contact our after sale service providing us the following information e Type of system e Serial number of the system look chapter 5 e Possible special characteristics of the system look chapter 5 e Accurate description of the problem in which conditions the problem show itself and when it s started to show The manufacturer after sales service can be contacted by telephone by internet or by fax and only the installers can exclusively use it The telephone after sale service is active every working day in office timetable Only a competent technician after he tried to solve the problem by telephone and after he has estimated the type of the defect can authorise the shipment for the repair or the even2. crane circuit be sure to connect directly the exhaust to the oil tank without filters or other links look figure 8 and 9 Figure 7 Figure 8 Figure 9 HYDRAULIC MINI PUMP UNIT g EXHAUST DIRECT TO THE OIL TANK TO VALVE CONTROL ROD Example of hydraulic connection Example of hydraulic connection with counter to pressure block with mini pump unit If there is air inside the circuit the piston does not move itself smoothly it does not move or it bumps After you have done the hydraulic connections supply the system and make some manoeuvres with all pistons to guarantee the oil fulfil of the cylinders and the exit of the air already inside the hydraulic circuit 2 4 Electrical connections The proportional solenoids have a DIN43650 connector The winding is connected between the connector pole 1 and 2 The ground pole is not used When it is powered the solenoid A the piston will move inside when it is powered the solenoid B the piston will move outside look figure 10 The piston stroke is determined by the value of current absorbed by the solenoid The piston moves itself from the zero position to the longest position outside or inside when the solenoid absorbs the greatest current value look data sheet Figure 10 Page 6 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual 2 5 Rules for a correct and safe installation a Do not make welding with the hydraulic bank mounted Dismount the bank
3. levers in the zero position when you exceed the loading capacity you have to verify the rods are sturdy enough to avoid deformations It must be possible to reach the screws that fix the brackets on the dual control rods to verify the clamping In the back of the hydraulic bank must exist the necessary space to unscrew the stay bolts and and unthread the module to replace it The connectors of the solenoids must be reached simply it is easier to verify when a problem occurs In case that the distance between centres of the rods is not the same of the modules it is anyway possible to mount the system paying attention to place the bank centred with the rods you have to match the position of the central modules with the central rods to distribute the difference of distance between centres of all modules The maximum value of the two axis distance is Compensation of difference between centers max allowed deviation 20 mm about 20 mm look figure 2 Be sure that the pistons of the bank are all aligned to the middle of their stroke zero position mount the brackets on the rods without tighten the screws link the piston forks to the brackets and block them with the spring pins Figure 3 Tighten the screws locking all them at least two times and after this tighten the lock nuts look figure 3 Page 4 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual The coupling between the pistons and th
4. Multifunction Hydraulic Bank MODO9 Installer and user manual MULTIFUNCTION HYDRAULIC BANK MODOQY INSTALLER AND USER MANUAL CE marked product in accordance with 89 336 EEC e 89 392 EEC directives Page 1 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual UE act ee carats gcc ite en ete nett na nce cece ce ge et oe stg see vats E se ingoveeph eee ecakioo eet eebaeee ee vane eaeeeareaeee 2 Ts AIM Met ENO A IN et eta sc nccaereeen em E e meecteadouncentensieene 3 Dol Produc AC SCM ON sorser aa S Er a Ea i debewessstausGisiesvsdtadstu ide nd aanetineidvene OS 3 Mee alila SSC APO HOM EE N EN A E ET E T EET N EEN I E E S EEEE E AE EE TE 3 To Typical OW ANON S eeens E E ESEE E E E E ie Er E 3 2 INSTALLATION srein E E EEE E 4 P FECT E E EE E E E PE A E E E E E E E E S AE E E EE 4 22 Mechanic alins taNo e E eee eee ean eee ee reer 4 23 WAV OF AMMIG CONIC CON S eraspena E AE SE SNE dE rA a RAE FEET NE a AE 5 2 4 NTIS OLN neccen 0G tres oie ec et os mete rere cert eco es veneer e a aeere trate ectorceaees 6 2 5 Rules for a correct and safe installation cisisccsncsseecsessacsedesune destesasesussususedvavevedsiavasv ave sus tlavevbesesssccesdsavesduesevedsiasedavesaveebiestiess 7 SNANTENANCE aara S E E E 7 A TROUBLE SHOOTING asses erence ia Eere a tse ESEETO EE EET EAEE AEE ERESSE EEEE AA EEEE AEEA suede SEESE ESEESE EEEa 8 D OCGRAPPING mene ne te iee n E ER ETRE A E EEE EE ee a REE eee eee eee 8 0 OGPARE PARTS LIST sserrsi irsin
5. SHEET single section 800 1800 mA 12V Working PWM current 350 1000 mA 24V weigh Overall dimensions mm 200 W x 160 H x 35 D Blow by max MANIFOLD A B C TYPE mm mm mm 4 functions 6 functions 8 functions RESU GATE aorrevirokronivo iyore rores TeSt DY roerei ae Page 11 di 12
6. also when you have to weld on the rods or on the bearing b If itis possible orient the solenoid power cables downward so the rain do not reach the connector c Fix carefully the connectors verifying the correct position of the gaskets Use only the supplied screws or screws with the same length If you fasten too much the screws the connectors can be damaged d Mount a steel cover sheet or other material that covers the zone of the connectors in order to avoid that the rain goes directly into the connectors look figure 11 e The cover must be easily removable for the operations of inspection and eventual maintenance on hydraulic modules f The cover must leave enough space for the circulation of the air necessary for the cooling of the modules g Do not wash with jets under pressure and do not dip the equipment in water Figure 11 h Avoid the contact with corrosive solvents i Do not execute operations with the bank electrically supplied or under pressure HYDRAULIC j Use exclusively mineral oil avoiding vegetable oils or other mixtures The use of not suitable oil in the system damages the gaskets k It is necessary to mount on the main hydraulic circuit of the crane a safety dump valve BYPASS normally opened in derivation between the pump delivery and the exhaust that maintains without pressure the system when no manoeuvre is executed Every time that a solenoid of the hydraulic bank is supplied
7. be solved following the suggestions and the executing tests indicated in the following table Breakdowns Possible causes and remedies Supplying any solenoid of the Very low pressure or the oil does not arrive to the modules verify the oil pressure on the hydraulic bank the pistons do not delivery pipe with a gauge it must be at least 15 BAR max 30 BAR or verify that move or they are very slow to start disconnecting the pipe physically the oil comes out when someone makes a to move manouvre If the oil comes out slowly check the state of the oil and of the delivery filter Check that the exhaust pipe of the hydraulic modules is connected directly to the oil tank without filters or too much long pipes It is impossible to regulate the The cartridge is dirty the component parts of the cartridge associated to the irregular proportionality of one or more manoeuvre are obstructed from impurity that slow down the operation Dismount and manoeuvres clean up the cartridge in order to solve the problem and install a filter on the delivery pipe to avoid again the same problem A lever of the distributor remains Uncouple the fork from the bracket on the dual control rod and verify that the defect blocked on maximum opening on does not come from the distributor one side or on the other side oe Set sete tis Impurity in the hydraulic circuit dismount and clean up the module cartridges or change the whole module and mount a delivery f
8. d up The Imin current is the required value to start to move the piston the Imax current is the required value to move the piston to the full stroke For other current values between Imin and Imax the piston will stop in an intermediate position proportional to the current value When the current of the proportional solenoid is missed the piston will come back to the central position by only the returning action of the internal and the manual distributor springs 1 3 Typical applications This type of hydraulic bank can be used to remotely control manual hydraulic distributors with a lower stroke than the module stroke look technical data sheet it is designed to be coupled to the dual control rods It is not allowed to use this block in systems with climatic electric hydraulic and mechanical specifications different from the ones listed in the technical data sheet The system cannot be used in environment that needs explosion proof specifications Page 3 di 12 LL Multifunction Hydraulic Bank MODO9 Installer and user manual 2 INSTALLATION 2 1 Preface The installation of the hydraulic bank must be done by prepared technicians and by appropriately equipped workshops following what is described in this manual Check the packaging state after received the hydraulic bank and verify the inside material state If it appears damaged by shocks or drops happened during the transport please check all the compon
9. e A E e Ea E E 9 CLAR Ie SENE gt eo E A T E re 10 CAN E e E E E E eo es ces ene E ede EE E A EE 10 7 TECHNICAL DATA SHEET single section cccccccceeesceceeseseeeeeeesaeeeeecesaeeeescsuseeesceseeeeecesseeecsesaeeeeceeeeeeesaseeesssaeeeeseneeeeeeas 11 MANUFACTURER DECLARATION aan ese ceeceteenrten ccacnceice cenoernnseacedesoeoscionayoettaleesanadeacsan ice a Pinea ai ia e i aS aE 12 The paragraphs marked with this symbol contain information to follow carefully in order to avoid situations of potential danger for people or things This symbol appears in the handbook in order to signal paragraphs containing information to follow scrupulously in order to guarantee the correct operation and a long operating life of the equipment This manual must be always joined to the hydraulic bank for adjusting repairing and maintenance works at equipped workshops Store it accurately for consultations in case of technical troubles or further changes to electric and hydraulic system No part of this publication may be reproduced without the prior written permission Version 1 0 Page 2 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual 1 INTRODUCTION 1 1 Product description Dear Customer thank you to have chosen a ATS product The hydraulic bank described in this manual is an electrohydraulic system that coupled with a manual hydraulic distributor allows itself to be controlled remotely The bank is made up of a
10. e rods to move must have less play possible in the movement direction axial to use all the useful stroke of the pistons without death zones On the other hand it is required the presence of certain play in the other direction transversal The play is obtained by the brackets slots or using the opening of the fork The pistons must be stressed only in the axial direction A transversal loading of the pistons may block them and quickly wear out the gaskets The distributor levers after the assembly of the modules and with themselves switched off must remain aligned Pulling the distributor levers by hand the rods must move freely without show hardening When you release the levers they must return to the centre immediately unhesitatingly If the levers return to the centre slowly it can be necessary substitute the distributor recall springs with a more strong type contact the manufacturer of the distributor If you want to connect the hydraulic bank directly on the rear exit of the distributor don t couple the forks front to front but use always a bracket and connect the fork to a slot look example figure 4 CORRECT The connection does not Pierced allows bracket movements in this direction i Module piston FABER COM Module piston FABER COM tof Forks front rear exit of rear exit o the distributor the distributor connected Figure 4 2 3 Hydraulic connections The multifunction bank must be hydraulically sup
11. ent parts If you suspect the presence of problems keep in touch with the manufacturer before the installation on the vehicle to choose between the change or the reparation of the damaged parts The hydraulic modules bank is heavy and must be handled with care paying attention to do not shocking it or putting it violently on the ground Little imperceptible dents could compromise the good working It could be greasy due to the oil left inside during the testing phase so it is essential to wear gloves and working clothes when you handle it The installation of the hydraulic bank is not particularly difficult but to guarantee a good working system we recommend to follow carefully what is described afterwards in this manual Install all the safety systems required and do not exclude the already existing ones following respective manufacturer s instructions 2 2 Mechanical installation Locate on the crane the position where you ll mount the hydraulic bank The rules used to choose the right position are as follows The manifold must be mounted mostly in horizontal position Other positions can be used but they are not recommended because it makes difficult to bleed air from the hydraulic circuit The manifold must be fixed to the crane frame and not to the truck frame The bearing must not bend too much when the pistons work on the dual control rods If the crane has an hydraulic overload system used to bring forcedly the distributor
12. ilter The defect is not written in this list Identify the type of the problem electric or hydraulic Disconnect the connector on the module that shows the defect if the defect exists again then there is an hydraulic problem if the defect disappears there is an electrical problem Try to exchange the connector of a working module with ones of a defective module if the defect moves the cause is not in the module 5 SCRAPPING In case of shipment of the hydraulic bank to the manufacturer for a checking use possibly the original packaging or one that offers a good protection against external things and between the same parts inside the box If for change or scrapping it is decided to take apart the equipment from the truck take care of the oil that come out from the hydraulic circuit and get rid of it with the other components following the current norms in an authorised centre Page 8 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual 6 SPARE PARTS LIST The only available spare parts for the hydraulic bank are listed in the following table If are damaged other parts please contact the supplier DESCRIPTION CODE A2000710040 12v A2000710041 24v Female connector DIN 43650 A2001300020 2p T Cartridge with O Rings A5000310010 PIP4409 4F 40 PIP6409 6F 40 PIP8409 8F 40 PIP4469 4F 46 PIP6469 6F 46 PIP8469 8F 46 Manifold functions interaxis PIP4509 4F 50 PIP6509 6F 50
13. in order to move the distributor levers also the safety valve has to be supplied that closing itself will send the main system under pressure Such valve has to be supplied also when someone manually use the hydraulic distributor of the crane The manufacturer does not answer for the damages caused to the system and from the system in case it has not been respected these elementary norms of emergency 3 MAINTENANCE To guarantee a good work and in safety conditions of the hydraulic bank the user must do a periodical check on the bank itself and on the other accessories installed on the system You have to verify BEFORE EACH WORK SESSION The perfect running of the safety valve with the system under pressure but without electric power valve not supplied A moving a manual distributor lever the crane must not move PERIODICALLY based on the effective use The perfect running of the hydraulic bank and of the installed accessories on the system The state of the oil filter The filter must be cleaned and if it is very dirty it must be replaced The oil level of the hydraulic pump unit if present The state of the electrical wires connected to the hydraulic bank The presence of rust Page 7 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual 4 TROUBLE SHOOTING Here we describe the most common cases of bad working Before contact the after sale service please check if the breakdown can
14. manifold with mounted on as much sections modules as the movements to activate All the modules are identical and they are fixed to the manifold with four screws stay Each module works as stand alone RING NUT COIL POWER Each module is made up of a hydraulic cylinder CONNECTOR van commanded by two proportional valves with mechanical feedback look figure 1 The coupling of the hydraulic bank pistons to the manual distributor already mounted on the machine is done by brackets to screw on the dual control rods which have to be coupled with the forks mounted on each piston CARTRIDGE It is possible to connect the forks to a different HEXAGONAL leverage system as long as is guaranteed with HEAD SCREWS right slots an enough play to prevent stress in different direction than the axial one MANIFOLD CYLINDER Figure 1 1 2 Working description Each module of hydraulic bank has to push or pull the lever of the linked manual distributor To make his work the hydraulic bank must be connected to an hydraulic circuit and to an electronic control system with PWM current output The movement of the piston and the opening of the linked function of the manual distributor is proportional to the value of the current supplied to one of the proportional solenoids to be powered up one each time When the hydraulic circuit is under pressure the piston will move in a direction or in the other one depending on which solenoid is powere
15. plied with a low pressure look data sheet The hydraulic connections can be obtained from the main crane hydraulic circuit using a counter pressure block or from an independent hydraulic pump unit suggested In both cases it is required to install a filter of a nominal value of at least 10 micron Figure 5 Figure 6 CORRECT POSITION NOT RECOMMENDED POSITION If you use the hydraulic pump unit it has to be mounted in a higher position compared to the hydraulic bank If this is not possible leave an exhaust pipe of at least 10 cm upside before the downward curve to the oil tank this to avoid the entrance of air from the exhaust hole in the hydraulic circuit when you use the distributor manually look figure 5 and 6 The oil inlet for the hydraulic bank delivery is marked with the letter V the oil outlet exhaust is marked with the letter L look figure 7 Pay attention when you make the hydraulic connections If you exchange the inlet with the outlet the piston movement becomes uncontrollable Page 5 di 12 LL LL LL Multifunction Hydraulic Bank MODO9 Installer and user manual It is not possible to connect the inlet and the outlet pipe into the same manifold Delivery V header It is suggested to use the 1 4 connectors on the front side The pipes used for the links must be suitable for this type of use and must carry the current ON pressures If you mount a counter pressure block on the main
16. s indicated on the manual and especially referring to the installation safety use and maintenance indications Moreover this warranty does not include compensation for the equipment inefficiency or stop periods of the machines e The equipment will be repaired in FABER COM s r l or in the nearest After Sale Authorised Centre Costs and risks of transport from and to the assistance centre will be at customer charge Please consider that all costs referring to equipment repair and or change as for instance but not only this FABER COM s r l people travelling expenses will be completely at customer charge f Every defective piece replaced not under warranty will become ownership of the customer g Every defective piece replaced under warranty will become ownership of the manufacturer h For assistance or requests without a well precise fault and for installation or explanation of system use rules already explained in the manual all costs are at buyer charge i If demanded for all repaired components will be given a copy of the technical relation with problem description and added or replaced materials If the repair is not possible or could be more expensive than the sale price of the new component the sales department will contact the customer for a new offer and the defective material will be sent back without repair it Page 10 di 12 Multifunction Hydraulic Bank MODO9 Installer and user manual 7 TECHNICAL DATA
17. tual shipment of a replacement part We will accept rendered material only if it has been authorised in advance and it has been shipped CARRIAGE FREE if not agreed in a different way The repaired material will be sent back CARRIAGE FORWARD The rendered material must be sent comprehensive of all the component parts screws O R brackets forks lock nuts etc In case of technician exit for a repair to the user it will be always debited beyond to a fixed right of call expenses of travel based on the current kilometric rates and the time used for the repair 6 2 Warranty The manufacturer guarantees the good working of the equipment of own production for a period of 12 twelve months from the date of purchase certified by the invoice at the specified conditions below a The warranty includes of course the change or the free repair of the parts of the equipment that have production defects and not damages due to bad maintenance or improper use of the equipment b The manufacturer can decide unquestionably on any issue about complaints and defects c In the hypothesis of improper use or bad maintenance and or in case of violation of the equipment from users not authorised by manufacturer the customer will loose all rights of assistance under warranty d The manufacturer has no responsibility for eventual damages that directly or indirectly could arrive from people or things for the missed observance of all instruction
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