Propvalve e

Technical Manual
Proportional Valve Technology

Mobile Cranes
TECHNICAL TRAINING 11/1999

S. Weinberger
Technical Manual Proportional Valve Technology
Contents
Contents
General Notes 3 Measurements/Adjustments

Measurement Sequence 23
Instruction Data on AC535 24
General Function Adjustment of Proportional Amplifiers
Proportional Control Function on AC1600 4 translation of regulations from design dept. 25
Proportional Control Function on AC535 5 Adjustment of Proportional Amplifiers
CC/PC3800/4200 28
Components
Capacitor Module Type VT 11110 6 Action Charts
Stabilised Power Supply Module Type VT 11006 6 AC 665/AC 400 30
Joystick Type VT 10468 and VT 10406 7 AC 35 31
Joystick Type FSG 2000u 8 CC 1400 32
Joystick Type FSG 2000i, Connecting Diagram 9 CC 1800 34
Joystick Type FSG 2000i 10 CC 1400 35
Checking of Joysticks Type FSG 2000i 11 CC 12600 37
Proportional Amplifier Type VT 11032 13
Electric circuit diagrams are not included, please
Setting a Proportional Amplifier 20
use diagrams matching the crane serial number
Proportional Solenoid with Pressure Reducing Valve 21
you are working on.
y2PROPVALVE_E11.DOC TECHNICAL TRAINING SWR - 1

General Notes
Figure 1
Figure 2

General Notes
General Notes
Proportional valve technology is now an established concept in the field of hydraulic pilot control systems for mobile cranes. This
handbook will be a source of information for this technique.
A common sequence chart is shown in Figure 1.
Follow the course of the signal:
A voltage signal is connected to an amplifier and there converted to a current signal corresponding to the voltage level, e.g. 1mV
1mA.
This electric current signal is connected to a proportional solenoid with stroke to current or force to stroke relationship.
Proportionally with respect to this current, which is the input variable, the proportional solenoid generates force -or travel- as the
output variable.
This proportional solenoid is mounted on a proportional pressure control valve which again is connected -or directly mounted- on a
hydraulic control block.
According to the oncoming pressure, this control block is giving way for the oilflow to a hydraulic motor or cylinder resp.
For the consumer, a hydraulic motor or a hydraulic cylinder, that means that force and speed are influenced in a stepless manner.
At the same time is also controlled:
the change in volume flow with respect to time, i.e. acceleration or deceleration of revs. of a hydraulic motor or speed of a piston.
Proportional valves and proportional pumps also make freely programmable control possible.
Technical advantages of proportional devices are
continuously variable control of set-point values
simpler, more rapid movements
improvement of the switching process
controlled switching transition, pressure peaks thus avoided
thus extended service life
fewer and simpler valves, e.g. directional control valves
installation location optimised, thus more dynamic response of the control system
Corresponding amplifiers are assigned to the various proportional devices.
From Figure 2 various applications of proportional hydraulics can be seen, while we are using the pressure function (force) with
pressure reducing valves.

Components
Crane Voltage
General Function
Figure 3
of the proportional valve control with AC1600 type cranes
Power
24V Supply A power supply module is supplied with crane voltage
Capacitor
Module 15V
Module
it generates +15V and 15V, which are fed to a joystick (signal transmitter)
A capacitor module is wired parallel in the circuit to act as ripple filter.
The joystick generates a voltage signal corresponding to the deflection of its lever; this
voltage signal is connected to a proportional amplifier.
Joystick
10 Volt The range of signal value is from 0 to 10V, either positive or negative, depending on
direction of deflection of lever.
The proportional amplifier is also supplied with crane voltage for the purpose of op-
eration.
It recognises the difference of positive or negative voltage signal from the joystick,
Proportional converts this into a proportional current signal to its associated output which is con-
Set-Point Adjustment
Amplifier nected to a proportional solenoid.
The set-point adjustment also influences the proportional amplifier.
+A -B In this case, a voltage is delivered to the proportional amplifier with a potentiometer.
This voltage is the basis for the amplifier to process the current signal to the propor-
Proportional Proportional tional solenoid. If, for example, 60% of the possible voltage is set, the pressure pro-
Solenoid Solenoid duced by the pressure reducing valve can also only be 60% of the possible pressure.
Pressure Reducing Pressure Reducing The minimum and maximum current signals of the proportional amplifier can be set
Valve Valve independently of each other, e.g. 300mA and 900mA.
The proportional amplifier has further an adjustable ramp former. This forms a
slowly increasing or decreasing output signal from the input signal.
The durations of the increase or decrease of the output signal - the ramp - can be ad-
justed independently of each other.
b a This ramp cannot be influenced by moving the lever so as to oppose it or by rapidly
pulling or releasing it.
Control The proportional solenoid adjusts the piston of a pressure reducing valve proportion-
Block
ally with respect to the current and thus controls the pressure in the hydraulic pilot
circuit.
The hydraulic pilot pressure must be set

before a proportional amplifier is adjusted.
All adjusting work must be carried out in accordance with the
instructions of our design department.
Hydraulic New designed cranes do have proportional valve control systems without ca-
Motor pacitor and power supply modules resp. As this control system is continuously
improved, see corresponding electric circuit diagrams for details.
\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 4

Components
Block Circuit Diagram Function

Example: AC535 The joystick = signal transmitter is supplied with 24 Volt, in addi-
tion also the DC/DC converter, the amplifier and the deadman
switch. This switch must be operated to supply the amplifier on a
AUS - second terminal with 24 Volt; otherwise the amplifier will not oper-
DC/DC Con- ate.
F5 - 24 Volt verter The joystick produces a signal from 4 mA - at 1% of the lever action -
to 20 mA with a fully moved lever; this signal the setpoint is con-
Joystick 10 V nected to terminal 5 on the amplifier.
The amplifier however needs a voltage signal - max. 10,25 V,
10mV - for operation and this is produced with the resistors RLX,
0 - 20 mA R11A
RLY, RRX or RRY resp. wired in parallel.
The amplifier converts the set point signal into an operating current
Deadman- RLX, RLY, signal according to the force required from the proportional valve.
switch RRX, RRY
The maximum of this current signal may be reduced if required with
the rotating potentiometer of the set point reducer; herewith the hy-
10,25 V 8V
draulic pilot pressure and in sequence the operating speed is re-
duced.
Amplifier The current signal is at first jumping to 250 mA and thereafter
AI, AII, AIII
slowly increasing to a maximum of 800 mA. This value guarantees
control to the maximum of the according proportional valve.
250 - 800 mA 0 - 10 V
The current is pulsed to keep losses and thermal load to a minimum.
Pulse frequency is generated from a pulse generator, in the relation
Propvalve Setpoint- between switching on and off the value of the current is controlled.
YI, YII, YIII reducer The pulsed current works on the solenoid like a constant current.
If the current signal between amplifier and proportional solenoid

valve is > 1.3 A the amplifier or solenoid is defective.
The hydraulic pilot pressure must be set before a proportional
amplifier is adjusted.
All adjusting work must be carried out in accordance with the
instructions of our design department.

Components
Capacitor Module, Type VT 11110 Stabilised Power Supply Module

(Power Pack), Type VT 11006
This unit is connected parallel to the power supply module
and serves as ripple filter. is supplied with crane voltage and feeds the joystick (=
This components arre snapped in on rails and are used only in signal transmitter) with stabilised 15V, galvanically
cranes with Rexroth joysticks isolated from input voltage.
Terminals The unit has reverse voltage protection and an on-
Input Terminals Output indication with LED.
+24V Crane voltage X1 X4 +24V to Power pack It is not proofed for continuous short-circuit. Thus, if one
0 X2 X5 0 output voltage is overloaded, the second one is automati-
0 (24V) X3 X6 0
cally reduced with it.
Terminals
Measurements
Input Terminal Output
Terminal Reference Desired - result
+24V Crane voltage X1 X4 15V
X1 towards Crane minus 24 V Supply voltage
0 (+24V) X2 X5 0 (15V) Reference/zero
X1 towards X3 24 V Supply voltage
n.c. X3 X6 +15V
X1 towards X4 0V
X3 towards Crane minus 0V
Measure with the Multimeter
This module has no reverse voltage protection, Minus pole Plus pole Desired
it will get damaged if terminals are wrongly connected. Do
not connect or disconnect no terminal when it is energised, to crane minus to X1 24 V
on X2 to X1 24 V Crane voltage
on X5 to X4 15 V Supply of joystick
on X5 to X6 + 15 V Supply of joystick

Components
This units are mechanically very complicated built and are used in AC1600 type
Joystick Figure 4 cranes only. Changing to joysticks of more recent design is possible only with exten-
sive rewiring work.
Electronic Signal Transmitter
Types VT 10468 and VT 10406 resp. They have one -X = VT 10468- or
Manufacturer: Mannesmann Rexroth two operating directions -X and Y = VT 10406-.
The mark of the direction is stamped on top side of the mounting
flange.
Supply is 15V from the stabilised power supply module.
The output signal is processed according to operating direction:
+ or -, 0 to 10V;
Level Direction Output Amplifier output
XA forward 0 to +10V B X12
XB backwards 0 to 10V A X10
YC to the left 0 to +10V B X12
YD to the right 0 to 10V A X10
X- and Y-directions can be driven simultaneously - diagonally.
The lever travel in each operating direction is 20:
after approximately 1% of the latter, one directional contact
switches per axis half;
after approximately 10%, the downstream-connected proportional
amplifier starts to transmit a current signal to the proportional
solenoid
The unit has two cable harnesses. One of these is screened and con-
tents the
15V supply lines
0 to 10V signal lines
earth line for the housing.
The second, non-screened cable harness contents the
24V supply lines, directional signal lines and deadman's contact
lines.
Cable colours and assignment can be found in the applicable circuit
diagram.
Components
Type FSG 2000u = voltage output signal 0 to 10V

Joystick (Manufacturer: FSG-Berlin)
Type FSG 2000u Figure 5
This unit simplifies the construction of the control system as
it does need neither a power supply module nor a capacitor
module.
Crane Voltage is connected directly to this unit where it is
with induction transferred to a voltage signal, + or , 0 to
10Volt.
So far it is installed in TC/CC/PC 3800/4200 and CC 6400 type
cranes.
Identification number and voltage signal output +/10Volt is
marked on a sticker on the unit!
Changing to joysticks of more recent design is possible only

with extensive rewiring work.

Components
Type FSG 2000i = signal output 0 - 20mAmp

Joystick FSG 2000i Figure 6 (Manufacturer: FSG-Berlin)
Connecting Diagram
We use 3 variants of this joystick. It simplifies construction of
the control system as it does need neither a power supply
module nor a capacitor module.
Crane voltage is connected directly to this unit where moving
of the joystick is transferring it to a current signal, either + or
, 0 to 20mAmp. As the amplifier needs a voltage signal, this
current signal is modified with a parallel wired trimming po-
tentiometer to produce the required voltage signal.
This version was selected for improved protection against in-
terfierence and safer signal transmission.
So far it is installed in AC665 and CC/TC1400 type cranes.
Identification number and current signal output +/0 to 20
mAmp is marked on a sticker on the unit!
Changing to joysticks of an older design is possible only with

extensive rewiring work.

Components
Connecting Diagram Figure 7 Connecting Diagram Figure 8

Joystick FSG 2000i Joystick FSG 2000i

Components
5. Zero contact
Checking of Joysticks Type FSG 2000 i set multimeter to resistance range and connect poles to terminals
6 and 7, operate joystick:
Crane Functions
after the click of the microswitch the resistance must drop to 0
CC1400/CC2800/CC12600/ X and Y-level, deadman switch, two 6. Manually operated switches
CC3800/AC665/AC535 switches, vibrating pin set multimeter to resistance range and connect poles to terminals
CC1400/CC2800/CC3800/ Y1 and Y2-level, deadman switch, two 15/16 for deadman switch, terminals 17/18 for left switch and ter-
CC12600 switches, vibrating pin minals 18/19 for right switch:
after operating the according switch the resistance must drop
CC12600/CC2800/CC3800 Y-level, deadman switch, two switches, to 0
vibrating pin
7. Vibrating pin (rotating indicator)
CC3800 Y-level, round joystick check with very short supply (tip) of 24 volt to terminals 13 and
14.
Joystick with one or two Y-levels

1. To check for correct outputs disconnect the joystick from the con-
trol circuit and provide 24 volt to terminals 1 (+) and 2 ();
2. Signal output
set multimeter to DC-current range and connect (+) pole to termi-
nal 3, () pole to terminal 4:
operate joystick, current must rise from zero to 20 mA
3. Direction contacts
set multimeter to DC-voltage range and connect (+) pole to termi-
nal 2, () pole to terminal 9:
operate joystick, after the click of the microswitch voltage must
rise from zero to 24 volt (supply voltage),
repeat with () pole on terminal 10, move joystick vice-versa, the
same result is required
4. disconnect the temporarily made voltage supply for checking zero
position switch and all other switches.

Components
Joystick with X- and Y-levels Notes

1. To check for correct outputs disconnect the joystick and provide 24
volt to terminals 1 (+) and 2 ();
2. Signal output
set multimeter to DC-current range and connect () pole to termi-
nal 4, (+) pole to terminal 3 for Y-level and 5 for X-level:
operate joystick accordingly, current must rise from zero to 20 mA
3. Direction contacts
set multimeter to DC-voltage range and connect (+) pole to termi-
nal 2, () pole first to terminal 9, than 10, 11 and 121 and always
operate joystick:
after the click of the microswitch voltage must rise from zero
to 24 volt (supply voltage), the same result is required for each
terminal
4. Disconnect the temporarily made voltage supply for checking zero
position switch and all other switches!
5. Zero contact
set multimeter to resistance range and connect poles to terminals
6 and 7, operate joystick:
after the click of the microswitch the resistance must drop to 0
6. Manually operated switches
set multimeter to resistance range and connect poles to terminals
15/16 for deadman switch, terminals 17/18 for left switch and ter-
minals 18/19 for right switch:
after operating the according switch the resistance must drop
to 0
7. Vibrating pin (rotating indicator)
check with very short supply (tip) of 24 volt to terminals
13 and 14.

Components
Proportional Amplifier Type VT 11032 Figure 9 A proportional amplifier

used in AC1600/CC/PC3800/4200 converts the set-point value signal coming from joystick into a cur-
rent signal corresponding to the force required by the proportional
solenoid.
The maximum current signal may be reduced with the set-point
adjuster in such a manner that the maximum pressure and thus the
working speed are also reduced.
Maximum reduction is reached with maximum voltage signal (10V),
from the set point adjuster.
The integrated ramp former
forms a gradually increasing or decreasing output signal (the ramp)
from a jump-in set-point value.
The durations of increase and decrease can be set independently of
each other.
The control is thus adapted to the requirements of crane functions.
After transfering the voltage on the set point adjuster this unit is
changeable to amplifier VT11165 which is the actual type used.
VT 11165 gives maximum reduction with zero voltage signal from
set point adjustment.
Some precautions
Connect or disconnect terminals only in de-energised state
Measurements with multimeter in DC-position
Distance to operated radio equipment at least 1 meter
Reference minus is raised +9 V against minus of supply
voltage
No jumper lead between reference minus and supply minus
If the maximum current output exceeds 1.3 Amp amplifier or

proportional solenoid is defective.
For setting, follow the instructions of our design department.

Components
Proportional Amplifier Type VT 11032

used on AC1600/CC/PC3800/4200 Figure 10 LED/Poti Function/Setting
1 LED power, green on = 24V supply
2 LED H2, yellow on = 24V supply, or malfunction if move-
ment activated
off = movement activated
flashing = short circuit in cable to propor-
tional solenoid
3 LED B, yellow on after 10% lever travel direction XA/YC,
forward/left
4 LED A, yellow on after 10% lever travel direction XB/YD,
backwards/right
5 Poti R11 ramp time move in direction XB/YD,
backwards/right
6 Poti R12 ramp time releasing direction XB/YD,
backwards/right
7 Poti R2 min. current, direction XB/YD,
backwards/right
8 Poti R1 max. current, direction XB/YD,
backwards/right
9 Poti R14 ramp time releasing direction XA/YC,
forward/left
10 Poti R4 min. current, direction XA/YC,
forward/left
11 Poti R13 ramp time move in direction XA/YC,
forward/left
12 Poti R3 max. current, direction XA/YC,
forward/left

Components

used on AC1600/CC/PC3800/4200 Figure 11 Terminals Function
X1 +24V supply, UB for solenoids
X2 0 (+24V)
X3 24V, Proportional output A enabled - XA/YC,
backwards/right
X4 GND - measuring point
X5 10V Signal from joystick
X6 Set-point adjustment, input 0 to 10V, 10V max.
speed reduction
X7 +24V, UB amplifier
X8 24V Proportional output B enabled - direction
XA/YC, forward/left
X9 not connected
X10 + Proportional output A, direction XB/YD,
backwards/right
X11 0 Proportional output A
X12 + Proportional output B, direction XA/YC,
forward/left
X13 0 Proportional output B
X14 not connected
X15 not connected
X16 not connected
X17 +24V signal output B to relay in crane electrics
X18 +24V signal output A to relay in crane electrics

Components
The unit converts the set-point value signal coming from the
Proportional Amplifier Type VT 11165 Figure 12
signal transmitter into a current signal corresponding to the
used on AC665/AC535/CC1400/1800/CC12600 force required by the proportional solenoid.
The maximum current signal can be reduced with the set-point
adjuster (potentiometer) so that pilot pressure and thus working
speed are also reduced.
The integrated ramp generator
produces a slowly, gradually increasing or decreasing output
signal (the ramp) from a step input signal.
The gradient (ramp time) of increase and decrease can be set
independently of each other.
The control is thus adapted to requirements of crane functions.
The difference between types VT 11165 and VT 11032 is in the
design of the set-point adjuster:
VT 11165 gives maximum reduction with zero voltage signal,
while
VT 11032 gives maximum reduction with maximum voltage sig-
nal (10V).
Therefore the units are not interchangeable without extensive
changes in the wiring
Some precautions
Connect or disconnect terminals only in de-energised state
Measurements with multimeter in DC-position
Distance to operated radio equipment at least 1 meter
If maximum output current is >1.3Amp:

amplifier or proportional solenoid is defective.
For setting, follow the instructions of our design department.

Components
Proportional Amplifier Type VT 11165 Figure 13

used on AC665/AC535/CC1400/1800/CC12600 Pos LED/Poti Function/Setting
1 LED power, green on = 24V supply
2 LED H2, yellow on = 24V supply, or malfunction if
movement activated,
off = movement activated
flashing = short circuit in cable to pro-
portional solenoid
3 LED B, yellow on after 10% lever travel direction
X-/Y-, backwards/left
4 LED A, yellow on after 10% lever travel direction
X+/Y+, forward/right
5 Poti R11 ramp time move in direction X+/Y+,
forward/right
6 Poti R12 ramp time releasing direction X+/Y+,
forward/right
7 Poti R2 min. current, direction X+/Y+,
forward/right
8 Poti R1 max. current, direction X+/Y+,
forward/right
9 Poti R14 ramp time releasing direction X-/Y-,
backwards/left
10 Poti R4 min. current, direction X-/Y-,
backwards/left
11 Poti R13 ramp time move in direction X-/Y-,
backwards/left
12 Poti R3 max. current, direction X-/Y-,
backwards/left

Components

used on AC665/AC535/TC/CC1400/1800/CC12600 Figure 14 Terminals Function
X1 +24V Supply, UB for Solenoids
X2 0 (+24V)
X3 Proportional output A enabled - X+/Y+, back-
wards/right, 24V
X4 GND - Measuring Point, Crane Minus
X5 Input 10V from Joystick
X6 Set-point Adjustment, Input 0 to 10V, 0V max.
Speed Reduction
X7 +24V, UB Amplifier
X8 Proportional Output B enabled - Direction X-/Y-,
forward/left, 24V
X9 n.c.
X10 + Proportional Output A, Direction X+/Y+,
backwards/right
X11 0 Proportional Output A
X12 + Proportional Output B, Direction X-/Y-,
forward/left
X13 0 Proportional Output B
X14 Ramp Adjustment, n.c. on Slewing Control
X15 0 (+24V), Crane Minus
X16 n.c.
X17 +24V Signal Output B to Relay in Crane Electrics,
n.c. on Slewing
X18 +24V Signal Output A to Relay in Crane Electrics,
n.c. on Slewing

Components
Proportional Amplifier Type VT 11550 Figure 15 this amplifier converts the set-point value signal coming from
used on CC/TC1400/1800 the signal transmitter into a current signal corresponding to the
force required by the proportional solenoid.
The unit is not interchangeable with other type

amplifiers!
Terminals Function
X1 +24V supply, UB solenoids
X2 0 (+24V)
X3 Switched Output B, 24V
X4 GND - measuring point
X5 Signal Input 10V from Joystick
X6 24V Operating Voltage for Amplifier
X7 - Proportional output B, direction X-/Y-,
forward/left
X8 + Proportional output A, direction X+/Y+,
backwards/right
X9 Switched Output A, 24V
X10 not connected
X11 24V Input Interlock
X12 not connected
This amplifier does not need an earth-return wiring of the

proportional solenoid while others do need this.

Components
Setting a Proportional Amplifier

Type VT 11032/VT 11165 Please Note:
Some precautions Amplifier VT 11032
Make sure that hydraulic circuits have no malfunction, i.e. Signal of setpoint value adjustment
setting of pilot pressure must be according to hydraulic cir- 10V for max reduction and
cuit diagram of crane and hydraulic oil in operating tem- 0V for no reduction
perature = 50C!
Adjustment of the setpoint reducing poti
Connect or disconnect terminals only in de-energised state On cranes with powerpack type VT 11006 trimmer and potis are
Distance from radio equipment at least one meter supplied with minus from this unit, accordingly the multimeter
has to be connected!
Measurements with multimeter in DC-position Reference minus is terminal X5 on power pack.
An electric circuit must be closed to check adjusted voltages.
Setting
Amplifier VT 11165
1. Ensure that pots for the ramp (T/down - T/up) are not
on min (left stop position). The ramp former is con- Signal of setpoint value adjustment
nected upstream of the electronics for the proportional 0V for max reduction and
10V for no reduction
outputs and malfunction may possibly follow
2. Check function of set-point adjustment and turn pots to

max. position
3. Set min and max pilot control pressure using pots R1 to
R4 in accordance with instructions 455 649 40a or wir-
ing diagram of crane resp.
4. Set time ramp in accordance with instructions
455 649 40a or wiring diagram of crane resp.
5. Check pilot control pressure again and correct if neces-
sary as stated in #3. Keep on doing this until pressure
stayes on required level

Components
Proportional Solenoid Figure 16 Proportional Solenoids

are the connecting link between electronics and hydraulics.
Proportional solenoids are d.c. solenoids.
From the input variable electric current
they produce, proportionally,
the output variables force and travel.
We use
force-controlled solenoids with a defined force/current
behaviour.
There are also travel-controlled solenoids having an
analoguous travel/current behaviour.
Force-Controlled Solenoids
In this case, the magnetic force is controlled by changes in the
current without the armature of the solenoid executing any
substantial travel.
The magnetic force and magnetic current are kept constant by
the feedback of current to an electronic amplifier, also when
the resistance of the solenoid changes, e.g. as a result of tem-
perature influences.
When the current remains constant, the magnetic current and
magnetic force remain constant over a travel of approximately
1.5mm, see (Figure 15).
We use force-controlled solenoids connected to proportional
pressure reducing valves, where the magnetic force is con-
verted to hydraulic pressure.
A proportional solenoid is a controllable d.c. solenoid operat-
ing in oil.
Proportional solenoids must be bled before initial operation!

Components
Proportional Solenoid Type DRE 4 K Figure 17 Function

with Pressure Reducing Valve It reduces the pressure at connection A proportionally with
respect to the solenoid current and largely independently of
pressure at connection P.
The pressure at connection A acts via a piston, against the
magnetic force. In de-energised state, a spring on the piston
switches connection A - T.
Coil resistance is
12 ohm at 20C
18 ohm at 70C
Proportional solenoids must be bled prior to operation.

If the signal current between proportional solenoid and
amplifier is >1.3A then amplifier or solenoid is defective.

Measurements and Adjustments
Setting Instructions
Measurements
with malfunctions in the electronic system for AC535
for telescopic boom cranes 455 649 40/3, Page 1 - 3
Switch off voltage. Switch it on again after about 2 minutes. If this has not
for lattice boom cranes 552 530 40/, Page 26
rectified the malfunction, continue to check in the following sequence:
1. Check all belonging fuses, if you find failures check for short circuit
2. At cranes with power supply module, check supply of crane voltage
first, then + and 15V supply to the joystick Remember always:
at cranes without power supply module check 24 Volt supply to joy- Hydraulic pressure is adjusted with help
stick of the current signal from the amplifier
3. At the proportional amplifier check supply voltage on all terminals, to the proportional solenoid.
switches and relays according to electric circuit diagram, then
4. Supply to set-point reducer (potentiometer) and its signal to amplifier
5. Supply to joystick and signal from same to amplifier
6. Current signal and lines from amplifier to proportional solenoid
7. On proportional solenoid check for short-circuits and coil resistance:
12 at 20 celsius, 18 at 70 celsius.
If the signal current between proportional solenoid and

amplifier is >1.3A then amplifier or solenoid is defective.
For easy measurements use adapters on proportional
solenoids.

Amplifiers on AC535 Above mentioned data may differ with different

Adjustment of resistors and ramp time cranes and must be corrected if necessary.
Especially the pressure setting on the pressure re-
Crane- Amplifier Valve Adjusted Value Ramp Time lief valve DBV for the lowering brake valve of the
Function Prop DB-V PSt VTele raising falling telescopic boom cylinders must be adjusted accord-
ing to the retracting speed.
Slewing Gear A III
right Output B Y III 2 7 - 23 bar 2,5 s R13 2) 1,5 s R14 2) If the set value differs to much from the listed value
left Output A Y III 1 7 - 23 bar 2,5 s R11 2) 1,5 s R12 2) contact the design dept.
Hoist I AI
raise Output A YI 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
lower Output B YI 5,5 - 27 bar 1 s R13 2) (ext. ~ 1,2 s)
Remember always:
Hoist 2 A II Hydraulic pressure is adjusted with help
raise
lower
Output A
Output B
Y II
Y II
5,5 - 27 bar
5,5 - 27 bar
1 s R11 2)
1 s R13 2)
0,5 s R12 2)
(ext. ~ 1,2 s) of the current signal from the amplifier
to the proportional solenoid.
Derricking Circuit 1 AI
raise Output A YI 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
lower Output B YI 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
Derricking Circuit 2 A II
raise Output A Y II 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
lower Output B Y II 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
Telescopic Boom
Circuit 1 AI
extend Output A YI 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
retract Output B YI 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
D28 (~18 bar) 0,2 - 0,25 m/s 1)
pinning R35 12 bar
locking R35.3 10,5 bar
Telescopic Boom
Circuit 2 A II
extend Output A Y II 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
retract Output B Y II 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
D28 (~18 bar) 0,2 - 0,25 m/s 1)
pinning R35 12 bar
locking R35.3 10,5 bar
1) Normal speed
2) Resistors in Amplifier
Source: e-anw_01.doc/8315
Adjustment of Proportional Amplifiers 3. minimal pressure P min with minimal current

(Translation of adjustment regulations Nr. 455 649 40a from design operate joystick only until LED of according channel is just swit-
dept.) ching on and hold joystick in this position
adjust according pot to prescribed pressure
Preparation left turn decrease current right turn increase current
Connect amperemeter into plusline of according proportional so- 4. maximal pressure P max with maximal current
lenoid valve operate joystick into corresponding direction and hold it in the
with solenoid A: end position
between terminal 10 on amplifier and + of solenoid valve adjust according pot to prescribed pressure
with solenoid B: left turn decrease current right turn increase current
between terminal 12 on amplifier and + of solenoid valve Abnormalities
Connect pressure gauge to according pressure check connection
If there is no possibility to connect a pressure gauge the basic
Turn set point adjuster to position 4 adjustment should be:
Carry out adjustment for each solenoid valve as follows: for minimal current 300 mA
for maximal current 900 mA
The pilot pressure is to be adjusted with help of the current bet-
ween amplifier and solenoid valve. The current of 900 mA guarantees the complete control of the ac-
cording proportional solenoid valve. Thereby is the possibility
1. increasing time ramp
that the sensitive response of the control lever is influenced be-
quickly operate joystick from neutral into one operating direction
cause the maximal value is reached earlyer and the control range
and hold it in the end position watch amperemeter accordingly
is only a small part of possible movement of the control lever. In
and with help of a watch check the time between start of the mi-
this case the control range may be influenced with help of the set
nimal current-output until the maximal current output is re-
point adjuster. If the full speed is needed however the rotating
ached.
pot of the set point adjuster must be turned into position 4 again.
adjust according pot to prescribed time
left turn decrease time right turn increase time On the slewing gear there are no hydraulic check points provided.
Here the current must be adjusted to values as described above.
2. decreasing time ramp
quickly operate joystick from the end position to neutral Attention: if the maximal current is higher than 1.3 A the ampli-
watch amperemeter accordingly and with help of a watch check fier or the proportional valve might be defective.
the time
adjust according pot to prescribed time
left turn decrease time right turn increase time

Securing of the adjusted values

If all amplifiers are adjusted, they are to be secured with labels.
This labels are to be signed from the adjuster with name and
date.
The adjusted/measured values are to be written on the labels on
the inside of the door of the terminal box X2.
If an amplifier was changed the new values must also be written
onto the label. A new label must be sticked on if needed.
Order number of label: 455 648 48

Function Amplifier Propvalve Checkpoint P min I min P max I max T up T down Remarks
Hoist 1 raising B 215.1 Y215.2 19 6 bar --- 26 bar --- 2 sec 1.5 sec -
Hoist 1 lowering B 215.1 Y215.1 23 6 bar --- 26 bar --- 2 sec 1.5 sec 1
Hoist 2 raising B 216.1 Y 216.2 20 5 bar --- 26 bar --- 2 sec 1.5 sec 1
Hoist 2 lowering B 216.1 Y 216.1 24 6 bar --- 26 bar --- 2 sec 1.5 sec 1
Tele extend B 217.1 Y 217.1 21 6 bar --- 26 bar --- 0 sec 0 sec 3
Tele retract B 217.1 Y 217.2 26 6 bar --- 26 bar --- 0 sec 0 sec 3
Luffing Cylinder B 218.1 Y 218.1 21 6 bar --- 26 bar --- 2 sec 1.5 sec -
raising
Luffing Cyl. lowering B 218.1 Y 218.2 25 6 bar --- 26 bar --- 2 sec 1.5 sec -
Slewing right B 219.1 Y 219.1 --- --- 300 mA --- 800 mA 3 sec 3 sec 2
Slewing left B 219.1 Y 219.2 --- --- 300 mA --- 800 mA 3 sec 3 sec 2
Remarks
1: to reach maximal speed the sensitivity is influenced; with normal operation use set point aduster
2: no pressure checkpoints provided
3: time ramps not required

Adjustment of Proportional Amplifiers

B215; B216; B217; B218; B219 and B220 CC/PC 3800/4200
Electric Circuit Diagram 552 530 40, Page 26/29
Terminal Designation Function
X1 UL Load voltage (Supply Amplifier)
X2 0V GND Operating Voltage (0 +24UV)
X3 UFA Release Solenoid 1, Joystick position X- or Y-
X4 GND GND + 15 Volt
X5 US Signal Voltage 0...+10 V X+/Y+; 0...-10 V X-/Y-;
X6 USV Set Point Adjustment 0...+10 Volt
X7 UV Operating Voltage +24 Volt
X8 UFB Release Solenoid 2, Joystick position X+ or Y+
X9 USX Malfunction
X10 +UPA + Proportional Output Solenoid 1; X-/Y-;
X11 -UPA - Proportional Output Solenoid 1; X-/Y-;
X12 +UPB + Proportional Output Solenoid 2; X+/Y+;
X13 -UPB - Proportional Output Solenoid 2; X+/Y+;
X14 URT External Ramptime (n.c.)
X15 URT External Ramptime (n.c.)
X16 UT Test Voltage
X17 UAB Digital Output Solenoid 2; X+/Y+, 24 V at 1 to 100% movement of Joystick
X18 UAA Digital Output Solenoid 1; X+/Y+, 24 V at 1 to 100% movement of Joystick

Adjustment Figures for Proportional Amplifiers

Electric Circuit Diagram 552 530 40 Page 26/29
Output A Output B
Designation/ Imin Imax T up T down Imin Imax T up T down
Function (mAmp) (mAmp) (sec) (sec) (mAmp) (mAmp) (sec) (sec)
V215
Hoist 1 Circuit P2 250 800 1.5 1.5 250 800 1.5 1.5
V216
Hoist 2 Circuit P1 250 800 1.5 1.5 250 800 1.5 1.5
V217.1
Travel left crawler 250 800 1.5 1.5 250 800 1.5 1.5
Circuit P2
V217.2
Travel right crawler 250 800 1.5 1.5 250 800 1.5 1.5
Circuit P1
V218
* W1/W2 Circuit P1 250 800 1.5 1.5 250 800 1.5 1.5
V219.1
E -*W1-SL Circuit P2 250 800 1.5 1.5 250 800 1.5 1.5
V219.2
E-W1/W2-S Circuit P3.1 250 800 1.5 1.5 250 800 1.5 1.5
V219.4
Slewing Circuit P3.2 250 800 3.0 3.0 250 800 3.0 3.0
V220
Superstructure Cyl 250 800 1.5 1.5 250 800 1.5 1.5
Backstops Circuit P1
* W1/W2 = Luffing gear in rear boom (main boom mast)

* W1-SL = Luffing gear in front boom (main boom superlift)

Action Charts
AC665/AC400
AC665/AC400 Operational Diagram
Operational Diagram Crane voltage Hoist, Luffing and Telescopic
Crane voltage Slewing Gear Boom
10 V
RV Joystick 4.7 k
Joystick 2k
0 - 20 mA 0 - 20 mA
4.7 k Ramp
10V supply for set-point reducers

R11, R121, RIII and R35
RIII Function Function

0 - 10 V 4.7 k 0 - 10 V
Crane voltage is connected to a joystick Crane voltage is connected to a joystick
which is producing a current signal which is producing a current signal
corresponding to the movement of its control corresponding to the movement of its control
RLX lever. This current signal is converted to
Prop-Amplifier lever. This current signal is converted to
1k voltage with an 1k potentiometer and Prop-Amplifier
voltage with an 1k potentiometer and
connected to a proportional amplifier. From 1k
there the amplified signal is connected to a connected to a proportional amplifier. From
prop. solenoid valve which is directly there the amplified signal is connected to a
mounted on a hydraulic control block. This prop. solenoid valve which is controlling the
proportional solenoid valve is reducing the hydraulic pressure in the pilot control circuit
pressure in the pilot circuit corresponding to affecting the control of hydraulic pumps I
2 Prop-Valves, the signal from the joystick. and/or II. This signal is corresponding to the
left & right turn
Prop-Valves signal from the joystick.
Checking & Adjustment
operate joystick full stroke into one direction Checking & Adjustment
and check on X5 of amplifier: 10 V must operate joystick full stroke into one direction
Controlblock be the reading, + or depending on direction and check on X5 of amplifier: 10 V must
of control lever.
be the reading, + or depending on direction
Voltage to be adjusted with 1 k pot.
of control lever.
Joystick in neutral 0 V., The ramptime is
Voltage to be adjusted with 1 k pot.
adjusted with a 4.7 k pot which is supplied
with 10 V from an adjustable 2 k pot. Joystick in neutral 0 V.
Hydraulic
The ramptime is adjusted with a
Pump
4.7 k pot which is supplied with 10 V
Hydraulic from an adjustable 2 k pot.
Motor

Action Charts
AC 535 AC535
Opera t ion a l Dia gr a m Operational Diagram
Crane voltage Slewin g Gea r Crane voltage Hoist, Luffing and
Telescopic Boom
10 V
Joystick 2k
0 - 20 mA Joystick 4.7 k
0 - 20 mA
4.7 k Ramp
10 V
Function
0 - 10 V Function
4.7 k Crane voltage is connected to a joystick
0 - 10 V Crane voltage is connected to a joystick
which is producing a current signal
corresponding to the movement of its control which is producing a current signal
Prop-Amplifier lever. This current signal is converted to corresponding to the movement of its control
1k voltage with an 1k potentiometer and Prop-Amplifier lever. This current signal is converted to
connected to a proportional amplifier. From voltage with an 1k potentiometer and
1k
there the amplified signal is connected to a connected to a proportional amplifier. From
prop. solenoid valve which is directly there the amplified signal is connected to a
mounted on a hydraulic control block. This prop. solenoid valve which is controlling the
proportional solenoid valve is reducing the hydraulic pressure in the pilot control circuit
pressure in the pilot circuit corresponding to affecting the control of hydraulic pumps I
2 Prop-Valves, the signal from the joystick.
left & right turn and/or II. This signal is corresponding to the
Prop-Valves signal from the joystick.
operate joystick full stroke into one direction Checking & Adjustment
and check on X5 of amplifier: 10 V must operate joystick full stroke into one direction
Controlblock be the reading, + or depending on direction and check on X5 of amplifier: 10 V must
of control lever. be the reading, + or depending on direction
Voltage to be adjusted with 1 k pot. of control lever.
Joystick in neutral 0 V. The ramptime is Voltage to be adjusted with 1 k pot.
adjusted with a 4.7 k pot which is supplied Joystick in neutral 0 V.
with 8 V from an adjustable 2 k pot. Hydraulic
The ramptime is adjusted with a
Pump
4.7 k pot which is supplied with 10 V
from an adjustable 2 k pot.
Hydraulic
Motor

Action Charts
CC1400
Operating Diagram
CC1400 Slewing
Operating Diagram Crane Voltage
Crane Voltage Derricking/Luffing/
Crawlers

Turn rotating potentiometer to position
5, then operate joystick full stroke into
Function one direction and check on X5 of
Crane voltage is connected to a proportional amplifier: reading must
joystick which is producing a current Joystick be 10 volt, + or depending on
Joystick signal corresponding to the movement 0 - 20 mA direction of joystick operation.
0 - 20 mA of its control lever. This current signal Voltage to be adjusted with 500-
is converted to voltage with an 1 k potentiometer.
potentiometer and connected to a Joystick in neutral = 0 volt.
proportional amplifier. From there the
amplified signal is connected to a
prop. solenoid valve which is directly
mounted on a hydraulic control block.
0-10V This proportional solenoid valve is Rot. Pot
reducing the pressure in the pilot
circuit corresponding to the signal 0 -10 V
Prop-Amplifier from the joystick.
Prop-Amplifier
1k Checking & Adjustment 470
operate joystick full stroke into one
direction and check on X5 of
amplifier: 10 V must be the
reading, + or depending on direction
of control lever.
Voltage to be adjusted with
Prop-
1 k-potentiometer. 500
Prop- Solenoid
Solenoid Valve Joystick in neutral 0 V. 0-10V Valve
Controlblock
Controlblock
Hydraulic
Motor
Hydraulic
Motor
Action Charts
CC1400
CC1400 Operating Diagram
Crane Voltage Hoist 1 & 2 raising
Operating Diagram
Crane Voltage Hoist 1 & 2 raising
22...32 VDC
Joystick 1. Signal from joystick to prop-
22...32 VDC Function
Crane voltage is connected to 0 - 20 mA amplifier:
Joystick 12...14 VDC
0 - 20 mA joystick, amplifiers and voltage turn rotating potentiometer to
12...14 VDC converter. The current signal from position 5, operate joystick full
the joystick is changed to a voltage stroke into direction raising and
1k
signal with a potentiometer; 1k check on X5 of amplifier:
After a 10% part of joystick 10 volt must be the reading,
movement the amplifier is 10 V Voltage to be adjusted with 1k-
operating a relay (K1) which is K1 potentiometer.
connecting the signal from joystick Joystick in neutral 0 volt.
K1 to a second amplifier, which to 1 - 10 V 4.7k After a 10% part of joystick
follow is operating a relay to movement the amplifier is
1 - 10 V operate the prop. solenoid valve on 0 to -10 V
operating a relay (K1) which is
0 to -10 V the control block (black/white- 5 Rot. Pot connecting the signal from joystick
5
control) to a second amplifier, which to
Rot. Pot Control of hydraulic pump is Prop- Prop-
Amplifier Amplifier follow is operating a relay to
Prop- Prop- according to position of joystick operate the prop. solenoid valve on
Amplifier Amplifier and position of rotating the control block (black/white-
potentiometer. This rotating control)
potentiometer is supplied with K1
K1 power from an voltage reducer and Relay 2. Supply and Signal for rotating
Relay an additional potentiometer. potentiometer:
Proportional solenoid valve turn rotating potentiometer to
for adjustment of pump has position 5 and adjust voltage on
Relay Prop-
ground-return wiring to prop. input of same to 10 volt, using
Prop- Solenoid Valve
Relay amplifier 1k-potentiometer. Control range
Solenoid Valve from rotating potentiometer to
amplifier is 10 volt to 1 volt.
Proportional solenoid valve
for adjustment of pump has
Prop- ground-return wiring to amplifier
Prop- Solenoid Valve
Solenoid Valve
Controlblock
Controlblock
Hydraulic
Pump
Hydraulic
Hydraulic Hydraulic Motor
Motor Pump

Action Charts
Crane Voltage CC1800 CC1800

Crane Voltage
24V Operating Diagram
Fuse 24V Operating Diagram
Hoist 1 & 2 raising Fuse
Hoist 1 & 2 lowering
Joystick B216/B215
22...32 VDC Joystick B216/B215
Y-Level Checking and Adjustment
Y-Level 22...32
Y+ = +0 - 20mA
Y- = -0 - 20 mA
1. Supply and signal of Y+ = +0 - 20mA VDC Checking and Adjustment
12...14 VDC
rotating potentiometer on Y- = -0 - 20 mA 12...14 V 1. Supply and signal of rotating
lh armrest console: DC potentiometer on lh armrest
R200 turn rotating R200 console:
1K/.75W 1K/ turn rotating potentiometer to
potentiometer to position
5 and set voltage on input R216 .75W position 5 and set voltage on
10V input of same to 10 volt, using
of same to 10 volt, using 1K/1W
10 1K potentiometer.
see 1K potentiometer. V
R220B1 Signal range to terminal X6 of
electrical Signal range to terminal proportional amplifier is 10 volt
circuit R220A1
X6 of proportional 10 - 1 V to 1 volt.
R216 + 0 - 10 V Rotating
diagram amplifier is 10 volt to 1 2. Check on terminal X6 of
1K/1W R220B1 Prop-Amplifier Potentiometer
R220A1 volt. N216/ 4.7K proportional amplifier:
Prop-Amplifier voltage signal from rotating
Rotating 2. Check on terminal X6 N215
10 - 1 V Potentiometer N220B/ potentiometer.
of proportional amplifier: N220A
+ 0 - 10 V 4.7K
voltage signal from
Prop-Amplifier Prop-Amplifier rotating potentiometer.
N216/ N220B/
N215 N220A
Prop.
Solenoid
see for connections Valve Y15.1/Y16.1
electrical see and operation of for connections and
circuit electrical relays see Controlblock operation of relays
diagram circuit electrical circuit Y15.4 see electrical circuit
diagram Y16.4 diagram
diagram
Prop.
Solenoid Valve Prop.
Y15.2/Y16.2 Solenoid Y20.1 Lowering Prop.
Valve Y20.2 brake Solenoid Y20.1
valve Valve Y20.2
Controlblock
Hydraulic
Hydraulic motor
pump P1 Hydraulic
P2.1 pump P1
Hydraulic
P2.1
motor

Action Charts
CC1400 CC1400
Operating Diagram Operating Diagram
Crane Voltage Hoist 1 & 2 lowering Crane Voltage Hoist 1 & 2 lowering
22...32 VDC Function

22...32 VDC
Joystick The current signal from the
Joystick
0 - 20 mA joystick is changed to a
0 - 20 mA Checking & Adjustment
12...14 VDC voltage signal with a 1. Signal from joystick to prop-
12...14 VDC
potentiometer; amplifier:
Pump adjustment is carried operate joystick full stroke into
out with rotating 1k direction lowering and check on
potentiometer on lh-side X5 of amplifier:
armrest console. + 10 V must be the reading.
Proportional solenoid valve 1k Voltage to be adjusted with 1k-
10 V
for adjustment of pump has potentiometer.
ground-return wiring to Joystick in neutral 0 volt.
amplifier
2. Supply and Signal for rotating
1 - 10 V 1 - 10 V 4.7k potentiometer:
turn rotating potentiometer to
+ 0 -10 V + 0 -10 V position 5 and adjust voltage on
Rot. Pot input of same and on X5 of
5 5 6
Prop- Prop- Prop- amplifier to 10 volt, using 1k-
Prop-
Amplifier Amplifier Amplifier potentiometer. Control range from
Amplifier Rot. Pot
rotating potentiometer to amplifier
is 10 volt to 1 volt.
Proportional solenoid valve
ground-return wiring to amplifier.
Prop- Prop-
Solenoid Valve Solenoid Valve
Prop- Prop-
Solenoid Valve
Solenoid Valve
Controlblock Controlblock
Hydraulic
Hydraulic Hydraulic Hydraulic
Motor
Pump Motor Pump

Action Charts
CC1400
Operating Diagram
Crane Voltage Hydraulic Pump
Adjustment
22...32 VDC
12...14 VDC
1. Supply and signal of rotating
potentiometer on lh armrest
console:
1k turn rotating potentiometer to
position 5 and set voltage on input
of potentiometer to 10 volt, using
10 V 1k potentiometer. Control range
to proportional amplifier X6 10
volt to 1 volt.
4.7k Proportional solenoid valve
ground-return wiring to amplifier.
Rot. Pot
10- 1 V
6
Proportional-
Amplifier
Prop-
Solenoid Valve
Hydraulic
Pump

Action Charts
CC 12600
Operating Diagram
Hoists and Travel Gear
Crane Voltage CC 12600
Crane Voltage 22...32VDC Operating Diagram
Slewing
12...14VDC
Signal processing to the
proportional amplifier
Cranevoltage is connected to the Joystick 1k
22...32VDC joystick which is sending a current 0 20 mA
Joystick signal corresponding to its +10V
0 20 mA excursion; this is converted with the
12...14VDC 1 k pot into voltage. From the 4.7k rot. Pot
amplifier a current signal is
0 10 V
connected to the prop-solenoid
valve which is reducing the 0 10 V
1k hydraulic pressure in the pilot
0 10 V system accordingly.
The amplifier switches also the 1k
+10V 24V-signal for the relays which to Prop-Amplifier
Signal processing to the proportional
follow are switching the amplifier
Prop-Amplifier black/white solenoid valves. A = 10V B = +10V Cranevoltage is connected to the joystick
1k With the voltage converter and the 0V/24V which is sending a current signal
1 k pot 10 Volt are constantly 0V/24V corresponding to its excursion; this is
A = 10V B = +10V 0 V/24 V connected to the terminal of the 200 900mA converted with the 1 k pot into voltage.
command value input as the speed From the amplifier a current signal is
0 V/24 V 200 900mA connected to the prop-solenoid valve which
control is carried out with the pump
adjustment. Prop- Prop- is reducing the hydraulic pressure in the pilot
Valve Valve system accordingly.
Prop-Valve Prop-Ventil The amplifier switches also the 24V-signal
Prop-Valve
for the relays which to follow are switching
the black/white solenoid valves.
Voltage converter and 1 k pot are
generating 10 Volt which are used from the
4.7 k pot to adjust the command value
Checks/Adjustments
signal.
Operate joystick to its full stroke and check on
Checks/Adjustments Hint:
amplifier terminal X5 10 Volt is required there,
Operate joystick to its full stroke and in the control line between joystick and
+ oder , according to direction of excursion of
check on amplifier terminal X5 10 Volt joystick; this voltage is to be adjusted with the 1
amplifier is a chain of relays installed which
is required there, are not shown on this diagram for
k pot. simplification.
+ oder , according to direction of Joystick in neutral = 0 Volt.
excursion of joystick; this voltage is to be
adjusted with the 1 k pot.
Joystick in neutral = 0 Volt.

Propvalve e

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Propvalve e

Transféré par

Droits d'auteur :

Formats disponibles

Technical Manual

Proportional Valve Technology

TECHNICAL TRAINING 11/1999

General Notes 3 Measurements/Adjustments

y2PROPVALVE_E11.DOC TECHNICAL TRAINING SWR - 1

y2PROPVALVE_E11.DOC TECHNICAL TRAINING SWR - 2

y2PROPVALVE_E11.DOC TECHNICAL TRAINING SWR - 3

The hydraulic pilot pressure must be set

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 4

Block Circuit Diagram Function

If the current signal between amplifier and proportional solenoid

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 5

Capacitor Module, Type VT 11110 Stabilised Power Supply Module

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 6

Type FSG 2000u = voltage output signal 0 to 10V

Changing to joysticks of more recent design is possible only

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 8

Type FSG 2000i = signal output 0 - 20mAmp

Changing to joysticks of an older design is possible only with

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 9

Connecting Diagram Figure 7 Connecting Diagram Figure 8

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 10

Joystick with one or two Y-levels

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 11

Joystick with X- and Y-levels Notes

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 12

Proportional Amplifier Type VT 11032 Figure 9 A proportional amplifier

If the maximum current output exceeds 1.3 Amp amplifier or

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 13

Proportional Amplifier Type VT 11032

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 14

Proportional Amplifier Type VT 11032

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 15

If maximum output current is >1.3Amp:

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 16

Proportional Amplifier Type VT 11165 Figure 13

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 17

Proportional Amplifier Type VT 11165

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 18

The unit is not interchangeable with other type

This amplifier does not need an earth-return wiring of the

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 19

Setting a Proportional Amplifier

2. Check function of set-point adjustment and turn pots to

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 20

Proportional Solenoid Figure 16 Proportional Solenoids

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 21

Proportional Solenoid Type DRE 4 K Figure 17 Function

Proportional solenoids must be bled prior to operation.

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 22

If the signal current between proportional solenoid and

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 23

Amplifiers on AC535 Above mentioned data may differ with different

Adjustment of Proportional Amplifiers 3. minimal pressure P min with minimal current

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 25

Securing of the adjusted values

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 26

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 27

Adjustment of Proportional Amplifiers

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 28

Adjustment Figures for Proportional Amplifiers

* W1/W2 = Luffing gear in rear boom (main boom mast)

\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 29

10V supply for set-point reducers