Radio Remote - Tecnord Actuators
Contents
1. Actuator see dwrg 15 1002 013 B Loosen the 2 screws 32 to remove the plastic cover 28 Remove the 2 locking nuts 29 6 mm 1 4 hex Lift up the electronic cicuit board 33 and free the flying connector of the position transducer Loosen the 2 nuts 26 Lift up the plastic casing holding the 2 coils 25 and the electronic circuit board 33 in place Remove the 2 proportional cartridge valve 22 from their cavities 29 mm 1 1 8 hex Remove the plug 42 and the spring 43 to inspect the by pass valve 21 D Disassembly procedure of Position Transducer 9 see dwrg 15 1002 013 B Loosen the 2 mounting bolts 13 to remove the servo piston kit Loosen the 4 set screws 6 to remove the cover plate 7 and the gasket 8 Remove the press transducer 9 by sliding the electrical cable along the cavity in the manifold WARNING to reassembly make sure that the driving pin of the transducer matches the circular groove on the free end of shaft E Inspection and cleaning procedure of Proportional Valves 22 see dwrg 15 1002 013 B Check for correct perpendicularity of the cylindrical tube ass y deflections or distortions of the tube ass y will prevent the internal plunger from sliding free in response to electrical signals The internal POPPET SEAT arrangement must be free from contamination particles F Inspection and cleaning procedure of orifices S and by pass valve 21 see dwrg 12. again and insert the DIN connector marked 49 on the coil terminal Energize the coil by activating any lever of the control box the internal poppet must shift with an audible click blowing air from the lower bottom there must be no free passage through the side holes of the cage PRESSURE REDUCING VALVE Remove the cartridge from its cavity 26 mm 1 hex Push the internal spool upwards with the tip of a plastic stick to override the internal spring force and check if it slides free along the cage Inspect the O RINGs and the BK UPs TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 9 TECNORD A Inspection of pressure maintenance valve see dwrg 15 0202 056 EV49 SOLENOID OPERATED PILOT PRESSURE CUT OFF VALVE Remove the nut and the coil 19 mm 3 4 hex Remve the cartridge valve from its cavity 26 mm 1 hex Check for correct perpendicularity of the cylindrical tube ass y deflections or distortions of the tube prevent the internal plunger from sliding free in response to electrical signals Install the coil on the tube ass y again and insert the DIN connector marked 9 on the coil terminal Energize the coil by activating any lever of the control box the internal spool must shift with an audible click TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 10 TECNORD C Disassembly procedure of the Electro hydraulic proportional
3. angles of the joystick lever required to turn on the GREEN LED LV are equal on both sides of the NEUTRAL position TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 13 TECNORD 7 HYDRAULIC SCHEMATIC Tab IX Hydraulic schematic TECNORD Via Decorati al Valor Militare 41040 Baggiovara Modena Italy 14 Data 12 06 98 NOR D File MTW MLT CEY EV49 05 E DESCRIPTION A PRESSURE MAINTENANCE MANIFOLD BLOCK EL HYDRAULIC PROPORTIONAL ACTUATOR A i tl X VCP Pressure maintenance volve VPA B Proportional pressure control valve E V 49 Soloperated By Pass valve VBP Pilot operated By Passs valve FET Filter screen SP Servo piston VRP Pressure reducing valve GC Coupling EV 9 SoLoperated cut off valve TP Position transducer ECB Electronic circuit board T T E E DA x vea N N Pp 1 i
4. chassis leaving room around it for hoses connection Fix the actuators block B in the crane arranged point see Tab l Connect the forks at the end of the servo piston rods If co axial mechanical connections between servo pistons and transmission rods can be adopted these must be done leaving enough clearance for self alignment of matching parts After that move the Crane s manual levers back and forth and check for their free return to neutral as a result of a good alignment between matching parts Correct every deficiency that may cause mechanical drag WARNING do not attempt to connect the actuators block directly to the Crane s manual levers as this would limit the stroke of the directional valve spool and cause problems of slow return to neutral TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 5525 B HYDRAULIC CONNECTIONS Tab 1 Connections at block A REF DESIGNATION E Pump line inlet port S Return line to tank To the P port of directional control valve To the P port of inlet section B Pump pressure gauge port Pilot pressure gauge port Connections at manifold B Pp Pilot pressure inlet line Sp pilot pressure return line Pilot pressure reduced gauge port SIZE 1 2 BSP 1 2 BSP 1 2 BSP 1 4 BSP 1 4 BSP 1 4 BSP 1 4 BSp 1 4 BSP 1 4 BSP TECNORD REMARKS High pressure hose Low pressure hose High pressu
5. machine function is activated either for safety purposes and for eliminating any flow restriction through the VCP valve when all the electro hydraulic remote control actuators are disengaged As soon as one of the directions control valves is partially shifted to move the applied load pressure builds up in the system in order to limit the maximum working pressure of the actuators to 250 psi a PRESSURE REDUCING VALVE VRP is provided Safety first of all the INLET SECTION a incorporates a SOLENOID OPERATED 3 WAY VALVE EV49 to cut off the pilot pressure any time the remote control joysticks are disengaged PROPORTIONAL ACTUATOR B CONTROL FUNCTIONS The pilot pressure Pp coming from the INLET SECTION A feeds the PROPORTIONAL VALVES VPA and VPB The function of these valves is to generate a variable pressure in response to a pulse width modulated PWM current signal alternatively fed to the coils via the electronic circuit board ECB This variable pressure is active on the ends of the servo piston SP connected to the spool of each sectional valve as the servo piston moves the position trnsducer TP generates a feed back signal to provide the desired control characteristic in response to a given deflection angle of the remote control joystick TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy nb TECNORD 4 INSTALLATION Tab 1 A INSTALLATION OF ELECTRO HYDRAULIC PARTS Fix manifold A on the
6. 5 1002 013 B Inspect the orifices S 0 8 mm 0 031 dia visible on the middle step of prop valve cavities Remove contaminants by means of a needle or compressed air Inspect the PILOT OPERATED BY PASS VALVE 21 by sliding the poppet in its cavity TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 11 TECNORD G Inspection of electrical connections see dwrg 15 1002 013 B Inspect the soldered terminals on coils 25 Inspect the three MALE FEMALE connectors on the electronic circuit board 33 Inspect the three soldered connections on the position transducer 9 Check the Input signal from the cable or radio joystick control lever Tab Il Page 14 If available insert the special test connector between the DIN flying plug and the fixed socket of the actuator and connect a volt meter in scale DURING VOLTAGE to test With the joystick at rest the reading must be 0 00 Volt By rotating the corresponding joystick slightly off of center the reading should change from 0 00 to 6 00Volt nominal value 10 in one direction and from 0 00 to 2 00Volt in the other direction Adjusting the maximum stroke of the servo piston by means of trimmers T2 and T4 Tab Il Page 14 The optimum calibration of max stroke is attained when the maximum deflection angle of the joystick control lever corresponds to the maximum stroke of the directional valve spool driven by the
7. DURES The User of the Remote Control must be properly trained on how to use the equipment The Manufacturer warrants that at the time of delivery the REMOTE CONTROL is free of defects in material and manufacture and will conform substancially to the Manufacturer s specifications It is the Purchaser s responsibility to determine the suitaility of the REMOTE CONTROL for an specific application and to insure that it is installed and guarded in accordance with all State Local Private Safety and Health Regulations Codes and Standards If the Remote Control will be used in a safety critical applications the Customer must undertake appropriate testing and evaluation to prevent injury of the Final user Changes or modifications not expressely approved by the Manufacturer could void the User s authority to operate the equipment The Manufacturer is constantly aiming at the improvement of the System for what concerns its efficiency eprformances and durability Therefore it is possible that some parts or components are changed without notice TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy i dia TECNORD 2 PARTS DESCRIPTION Mod MLT CEY has been designed to remotely control the functions of Truck Mounted Cranes and other types of Machines equipped with directional hydraulic control valves Mod MLT CEY can be attached to the transmission rods of the Crane manual control lonkage without
8. Manitowoc Boom Trucks Radio Remote Tecnord Actuators For C Series Cranes Installation e Service Manitowoc Boom Trucks Inc 3000 S Austin Ave Georgetown TX 78627 1609 Sales 512 942 3000 Sales Fax 512 863 3776 Service 512 942 3000 Service Fax 512 942 3094 Web Site www manitowocbt com Tecnord C Series A Qanitowoc Company February 2002 TECNORD SERVOCOMANDI E REGOLAZIONE MULTIDROM MLT CEY FBK Multi function electro hydraulic proportional control system Special configuration for installation on the trasmission rods of truck mounted cranes 22 0 mm 0 86 Long stroke version Installation and Service Manual MANITOWOC series TE CNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy Tel 39 059 51 00 01 Fax 39 059 51 13 57 E mail tecnord tecnord com TECNORD INDEX Introduction Parts description System layout Principle of operation Installation System start up procedures Inspection and maintenance procedures TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy cha TECNORD 1 INTRODUCTION This Manual has been compiled by TECNORD to provide the basic information on how to use Mod MLT CEY FBK Electro Hydraulic remote Control System and how to proceed with its maintenance Before using this equipment carefully read this Manual with particular reference to Paragraph 5 SYSTEM START UP PROCE
9. Pp Po ill 7 S BN S S sh C E FT Pel sai SPA sa yr 1 UL VPB Il Il LID 0203 029 i ie IR Eey SP PIL DIS Hgh cP A 9 RS ML N RPM FLT PD 87 E qeu E S
10. RCONNECTING CABLE TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy pa TECNORD 5 SYSTEM START UP Place a low pressure gauge 60 bar 1000psi on the MP port at thee inlet section A of the actuator block Start the engine and engage the PTO Fold out the crane by means of its manual control levers in order to prevent hazardous movements in case of erratic start up operation of the remote control Turn on the remote control system Radio configuration turn the key switch on the command switch to REMOTE turn on the power switch of the transmitter unit see original radio instr Turn one of the remote control levers slightly off the centre approx 10 the pressure reading on the Pressure Gauge at Port MPR must fail between 16 and 20 bar 230 to 285 psi Turn the control lever to its maximum rotation angle the manual lever of the directional valve must proportionally reach the end of its stroke Make sure that the pressure reading on the Pressure Gauge at Port MPR does not exceed 21 bar 300 psi WARNING before moving away to operate the machine from a remote post stand in front of the manual control levers of the directional control valve and check if the commands excerted on the levers of the remote control box are correctly executed by the electr hydraulic proportional actuators with respect to the following working conditions the position control characteristics
11. inhibiting the manual controllability of the equipment The system consists of ELECTRO HYDRAULIC PARTS to install on the original hydraulic equipment suitable to be controlled with cable and radio systems ELECTRO HYDRAULIC PARTS These parts are common to both CABLE and RADIO versions see Tab l A Inlet section with pressure maintenance valve VCP solenoid operated dump valve EV49 pressure reducing valve VRP and solenoid operated pilot pressure cut off valve EV49 B Electro hydraulic proportional actuator with closed loop control of the servo piston stroke and built in electronic circuit board and mounting flange C Connecting adaptor between ACTUATOR and TRANSMISSION ROD ELECTICAL JUNCTION BOX D Base connector with pre wired output harness to valves battery and accessories TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy TECNORD 3 PRINCIPLE OF OPERATION Tab 1 PRESSURE MAINTENANCE VALVE A AND PILOT PRESSURE SPECIFICATIONS TECNORD Mod MLT CE Electro hydraulic Remote control requires a pilot pressure of 18 bar 250 psi In most cases where used with fixed displacement pumps and open center valves this pilot pressure is attained by directing oil through a spring loaded pressure maintenance valve VCP lodged in manifold A to insure 18 bar 250 psi at all times Manifold A also carries a 2 WAY NORMALLY OPEN VENTING VALVE EV49 whose function is to dump oil to tank when no
12. of the actuators must be smooth stable and repeatable when one function at a time is engaged only the corresponding manual control lever must respond while all the other levers must steadily remain at rest when two or more functions are engaged at the same time no mutual interaction must esult in the position control characteristics of the corresponding manual control levers EMERGENCY PUSH BUTTON push the red palm button on the control box in order to stop the electrical power to the circuit TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 8 TECNORD 6 INSPECTION AND MAINTENANCE PROCEDURES A Inspection of pressure maintenance valve A see dwrg 15 0202 056 VCP PRESSURE MAINTENANCE CARTRIDGE VALVE Remove the hex cap 34 mm 1 5 16 hex and remove the 2 co axial springs Make sure that at least one shim is placed underneath the springs In order to INCREASE DECREASE the pilot pressure by 2 bar 30 psi at a time ADD ELIMINATE one shim at a time Check for free movement of the valves spool in its cage NORMALLY OPEN SOLENOID OPERATED VENTING VALVE Remove the nut and the coil 19 mm 3 4 hex Remove the cartridge valve from its cavity 26 mm 1 hex Check the correct perpendicularity of the cylindrical tube ass y deflections or distortions of the tube prevent the internal plunger from sliding fre in response to electrical signals Install the oil on the tube ass y
13. re hose High pressure hose High pressure gauge 800 bar 4500 psi Low pressure gauge 60 bar 1000psi High pressure hose Max 2 mt 6 ft long The line must be driven to tank separately in order to avoid back pressure effects on the servo pistons Low pressure gauge 0 60 bar 0 1000psi TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy RB s TECNORD C ELECTRICAL CONNECTIONS Tab 1 Install the JUNCTION BOX D max 1 5 mt 5 ft away from the actuators block make sure that the open end of the black sheath grouping all the output cables is placed upside down to prevent water from entering the junction box Make sure that the output DIN connectors are properly tightened with rubber seals installed between the plug and the socket Do not leave DIN plugs hanging disconnected to prevent water and moisture from oxidating contacts and wires REF COLOUR DESIGNATION REMARKS Blue Positive 12 VDC Brown Negative This wire must be connected to the negative pole of the battery DO NOT USE THE VEHICLE FRAME AS DIN Plug Dump valve EV49 at block A DIN Plug Pilot pressure cut off valve at block Proportional actuators Radio Remote Control The RECEIVER UNT will be connected to the junction box D through a multi core cable with MALE FEMALE plugs The wiring schematic of the junction box D corresponds to the flying MALE connector of the RECEIVER INTE
14. servo piston of the proportional actuator This condition is monitored by the YELLOW LED called LG which should TURN ON one at a time when the servo piston reaches the end of its stroke in one direction to insure the full flow condition and then TURN OFF by releasing the joystick lever just a few degrees to insure that dead band around the maximum stroke is limited The trimmer T2 is provided for EXTEND direction The trimmer T4 is provided for RETRACT direction Turn trimmer T2 T4 clockwise to increase the actuator stroke for a given joystick angle Turn trimmer T2 T4 counter clockwise to decrease the actuator stroke TECNORD Via Decorati al Valor Militare 3 41040 Baggiovara Modena Italy 12 TECNORD L Adjusting the symmetry of the neutral position dead band by means of trimmer T5 Tab Il Page 14 Because the overall mechanical and electrical tolerances the dead band across the 0 position of the control lever might not be symmetrical The symmetry of the dead band can be adjusted by means of trimmer T5 according to the following logic if the symmetry error causes the actuator to RETRACT as soon as the joystick lever is moved off of center then trimmer T5 must be rotated COUNTER CLOCKWISE if the symmetry error causes the actuator to EXTEND as soon as the joystick lever is moved off of center then trimmer T5 must be rotated CLOCKWISE the optimum calibration is reached when the deflection
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