Controller Installation and Adjustment Procedures For Models · 1 IP-A11071 Controller Installation and Adjustment Procedures For Models 0172326 0112567 If further assistance with

1

IP-A11071Controller Installation and

Adjustment Procedures For Models

0172326

0112567

If further assistance with the following procedures is required, please contact Snorkel’s Technical Service Department at 800-255-0317.

February 27, 2007

2

New Circuit Board Installation on Old Style Controller Housing

Remove the two screws from the cover plate. Set

cover plate aside.


cover plate aside.


cover plate aside.

Unplug pot connecdtor from

circuit board.

Remove the wire connectors from each of the two micro switches.

Remove the two screws from the circuit board mounting brackets and set screws to

one side as they will be needed for the mounting of the new circuit board.

Remove the two screws from the circuit board mounting brackets and set screws to

one side as they will be needed for the mounting of the new circuit board.

Remove old circuit board

and set aside.

3See Controller Adjustment Procedure for final adjustments of new circuit board.

New Circuit Board Installation on Old Style Controller Housing

Using the two saved mounting screws, align the two outer holes on the bottom of the new circuit board with the two holes on the

mounting brackets. Secure new circuit board as shown.

Re connect pot connector to new circuit board as shown.

Plug connector with the red and black wires in as shown.

Note: You will have one unused micro switch after the installation

of the new circuit board.

4

TB 37Things to check before adjusting drive controller:Check engine rpm’s for correct settings. Pump performance and Drive speeds will be greatly effected if engine rpm’s are not set correctly.

GM, 1.6 Liter (Gas) Hi-2800, Mid-2300, Low-1450 Rpm’s

Ford, VSG 413 Liter (Gas) Hi-3200, Mid-2400, Low-1100 Rpm’s

Kubota V1200-B (Diesel) Hi-3200, Low-1200/1500 Rpm’s

Toyota 4P (Gas) Hi 2800, Low 1000 Rpm's

Deutz F2L511 (Diesel) Hi 2800, Low 1200 Rpm's

Deutz F3L1011 (Diesel) Hi 2800, Low 1300 Rpm's

Wisconsin W4-1770 (Gas) Hi 2800, Low 1800 Rpm's

Check pressures on the variable displacement pump compensator. Main system pressure is 2800 psi and differential pressure is 300. Drive speeds can be greatly effected if differential pressure setting on the pump compensator is incorrect.

Check the stroke limiter on the backside of pump to see that it measures 11/16's of an inch including the jam nut. Not having the stroke limiter set correctly will cause drive speeds to be extremely slow and cause poor drive performance problems when trying to climb an incline.

5

TB 42 – 50Things to check before adjusting Drive Controller:Check engine rpm’s for correct settings. Drive speeds will be greatly effected if engine rpm’sare not set correctly.


Cummins Diesel 3.3 Hi 2550, Low - 1000 Rpm's

Ford Gas VSG 411, 1.1 Liter Hi - 2800, Mid - 2100, - Low - 1250 Rpm's

Ford Gas, Model VSG 413, 1.3 Liter Hi – 3200, Mid – 2400, Low – 1100 Rpm’s

Deutz Diesel, Model F3L1011F Hi – 2800, Low – 1300 Rpm’s

Check pressures on the pump compensator. Main system pressure is 2500 psi and stand-by pressure is between 300 – 400 psi. Drive speeds can be greatly effected if stand-by pressure setting on the pump compensator is incorrect.

Check the stroke limiter on the backside of pump to see that there is 11/16's of an inch of the adjusting screw showing including the jam nut. Turning this adjustment out more than 11/16's of an inch will cause the engine to bog down or in too far will starve the drive system of flow.

6

TB 42/50 - 42J – 47J With Simplified Hydraulic System:Things to check before adjusting Drive Controller:Check engine rpm’s for correct settings. Drive speeds will be greatly effected if enginerpm’s are not set correctly.


Cummins Diesel B3.3 Hi - 2650 - Mid - 1850 - Low -1000 Rpm's

Ford Gas LRG 425, 2.5Liter Hi - 2800 - Mid - 2000 - Low -1050 Rpm's

Deutz Diesel, Model F3L2011 Hi - 2800 - Mid - N/A - Low -1300 Rpm’sTB 37 and TB 42J

Deutz Diesel, Model F3L2011 Hi - 2650 - Mid - 2000 - Low -1200 Rpm’sTB 42 / 50 and TB 47J

Check pressures on the pump compensator. Main system pressure is 2500 – 3000 psi, and stand-by pressure is between 300 – 400 psi. Drive speeds can be greatly effected if stand-by pressure setting on the pump compensator is incorrect.

Check the stroke limiter on the backside of pump to see that there is 11/16's of an inch of the adjusting screw showing including the jam nut. Turning this adjustment out more than 11/16's of an inch will cause the engine to bog down or in too far will starve the drive system of flow.

7

TB 60 & PRO 66Things to check before adjusting drive controller:Check engine rpm’s for correct settings. Pump performance and Drive speeds will be greatly effected if engine rpm’s are not set correctly.


Ford, LRG-423, 2.3 Liter (Gas) Hi-2800, Mid-2000, Low-1250 Rpm’s

Ford, LRG-425, 2.5 Liter EFI (Gas)

Hi-2800, Mid-2200, Low-1400 Rpm’s

Deutz, F4L-1011 (Diesel) Hi-2650, Mid-2000, Low-1200 Rpm’s

Cummins, B3.3 (Diesel) Hi-2550, Mid-1850, Low-1000 Rpm’s

Continental, TM27 (Gas) Hi-2800, Mid-2000, Low-1000 Rpm’s

Check pressures on the variable displacement pump compensator. Main system pressure is 2500 psi and differential pressure is 375 - 400 psi. Drive speeds can be greatly effected if differential pressure setting on the pump compensator is incorrect.

Check the stroke limiter on the backside of pump to see that it is set at 11/16 of an inch. Not having the stroke limiter set correctly will cause drive speeds to be extremely slow and cause poor drive performance problems when trying to climb an incline.

8

TB 80/85J Things to check before adjusting drive controller:Check engine rpm’s for correct settings. Pump performance and Drive speeds will be greatly effected if engine rpm’s are not set correctly.

GM 2.4 Liter (Gas) Hi-2800, Mid-2300, Low-1450 Rpm’s

Ford, LRG-423, 2.3 Liter (Gas) High-2800, Mid-2000, Low-1250 Rpm’s

Ford, LRG-425, 2.5 Liter EFI (Gas) High-2800, Mid-2200, Low-1400 Rpm’s

Deutz, F4L-1011 (Diesel) High-2650, Mid-2000, Low-1200 Rpm’s

Deutz, F4L-2011 F (Diesel) High-2650, Mid-2000, Low-1200 Rpm’s

Cummins, B3.3 (Diesel) High-2550, Mid-1850, Low-1000 Rpm’s

Cummins, 4B3.9 (Diesel) High-2650, Mid-1850, Low-1000 Rpm’s

John Deere 4039D (Diesel) High-2650, Mid-1850, Low-1000 Rpm’s

Continental, TM27 (Gas) High-2800, Mid-2000, Low-1000 Rpm’s


Check the stroke limiter on the backside of pump to see that it is set to 11/16” from the back of the pump, including the jam nut. Having the stroke limiter set incorrectly can cause extremely slow or poor drive performance when trying to climb an incline.

Service Note: Some machines may be equipped with a Rexroth Pump. The stroke limiter should be set at 7/8” from the back of the pump, including the jam nut.

9

TB 80FA – 85JFA :Things to check before adjusting Drive Controller:

Check engine rpm’s for correct settings. Drive speeds will be greatly effected if engine rpm’s are not set correctly.

GM 2.4 Liter, (Gas) Hi-2800, Mid-2300, Low-1450 Rpm’s

Cummins Diesel 3.3 Hi - 2700, Mid - 1900, Low - 1050 Rpm's

Ford Gas LRG 425 Hi - 2850, Mid - 2050, Low - 1350 Rpm's

Deutz Diesel, Model F4L2011F Hi - 3200, Mid - 2400, Low - 1100 Rpm’s

Check pressures on the pump compensator. Main system pressure is 2700 - 2800 psi and stand-by pressure is between 375 – 400 psi. Drive speeds can be greatly affected if stand-by pressure setting on the pump compensator is incorrect. Check the stroke limiter on the backside of pump to see that there is 11/16's of an inch of the adjusting screw showing including the jam nut. Turning this adjustment out more than 11/16's of an inch will cause the engine to bog down or in too far will starve the drive system of flow.

10

TB 100-120-126 Things to check before adjusting drive controller:Check engine rpm’s for correct settings. Pump performance and Drive speeds will be greatly effected if engine rpm’s are not set correctly.

GM 2.4 Liter, (Gas) Hi-2800, Mid-2300, Low-1450 Rpm’s

Cummins, B3.3 (Diesel) High-2550, Mid-1850, Low-1000 Rpm’s

Cummins, 4B3.9 (Diesel) High-2650, Mid-1850, Low-1000 Rpm’s

John Deere 4039D (Diesel) High-2650, Mid-1850, Low-1000 Rpm’s

Continental, TM27 (Gas) High-2800, Mid-2000, Low-1000 Rpm’s


Check the stroke limiter on the backside of pump to see that it is set to 11/16” from the back of the pump NOT the jam nut. Having the stroke limiter set incorrectly can causeextremely slow or poor drive performance when trying to climb an incline.

Universal OEM ControllersThis circuit board is designed to be used for either the HPI or Hawe (60 Hz) or Enerpac / Apitech / Parker (33Hz) hydraulic proportional control valves with a slight modification to the circuit board. (see next page)

Service Note: The Universal OEM Circuit Board will replace OEM Circuit Boards P/N 3040393 and 3040394, 60 Hz used on HPI and Hawe Proportional Control Valves and P/N 3040518 33Hz circuit Boards used on Enerpac / Apitech / Parker Proportional control Valves.

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Universal OEM Circuit Board Adjustments

The new universal circuit board has a trim pot adjustment for each direction of handle movement that corresponds to the “A” or “B” connections on the circuit board terminal strip. (“A” , wire number 17 Forward Drive or “B”, wire number 18 Reverse Drive) The “Ramp” adjustment is for either direction of handle movement and turns off when controller hand is returned to center. Each trim pot has approximately 20 full turns of adjustment. Turning the trim pots CW will increase voltage for that direction and turning them CCW will decrease voltage for that direction. The following procedure will describe how to pre-set and make final adjustment to circuit board.

A Low Range

B Low Range

A Hi Range

B Hi Range

A Threshold

B Threshold

Ramp

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Voltage Checks on Potentiometer

The potentiometer regulates the voltage to the “A or B” terminals of the circuit board. Moving the joystick handle forward will increase voltage and moving it reverse will decrease voltage. To check the potentiometer for center, place the positive lead of your meter on the “Green” wire and put the black lead of your meter to a good machine ground. With the controller in the neutral position you should read approximately .20 volts. Moving the controller handle to the full on forward position you should read .35 volts, and moving the controller handle to the full reverse position you should read .05 volts.

Purple CCW or Forward

Orange CW or Reverse

Green CW or Wiper

R10k Ωpotentiometer

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Preset Procedure for Drive Controller:

1. Turn the Ramp trim pot 20 full turns (CCW).2. Turn the “A and B” Low Range Trim Pots CW 10 full turns.3. Place the ignition switch to on and start the engine. If machine is equipped with a Jib,

fully lower the Jib. Place the boom in its fully stowed position and fully Retract the boom in. Turn engine off, turn key switch back on.

4. Place Drive Range switch set to Hi and Foot switch down. 5. Move the control handle off center approximately 1½”. 6. Holding that position, adjust the “Threshold for that direction “A or B” trim pots counter

CW to obtain 2.5 to 3.5 volts. Return controller handle to center.

Verify there is 12 volt on the “R”. 1. Depress the foot switch.2. Move the controller handle full on.3. With the controller full on, adjust the “A and B” trim pots CW to obtain 7.5 to 9 volt

setting. Return controller handle to center.

Start engine and raise the boom up above horizontal. Turn engine off, and key switch back on.

Verify there is “No” voltage on the “R” . 1. Depress the foot switch.2. Move the controller handle full on. 3. With the controller full on, Adjust the “A and B” Low Range trim pot clock wise or CCW

to obtain 4.5 to 5.5 volt setting. Return controller handle to center.

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Drive Controller Final Adjustment:Before starting controller adjustment, make sure that the hydraulic oil is up to operating temperature 80° to 90°.

Mark off fifty feet. At the platform, place the Range Selector switch to “Hi”, Ignition switch on, Throttle switch to HI. Make sure that the “R” terminal on the drive circuit board has 12 volts on it. Start engine. Lower the boom below horizontal, lower jib boom to its stowed position and fully retracted the boom. At a rolling start, perform the following:

Threshold: Make sure after the “A (Forward) and B (Reverse)” Hi and Low range has been adjusted that the Threshold “A and B” both smooth starts and stops. (With controller handle full on, move controller handle approximately 1” from full on towards the off position. The drive function should start to slow down until handle reached approximately 1½” to center of controller or shuts off.)

See Drive Speed Chart below. Speed is achieved by adjusting the Hi and Low trim pots.3 MPH = 50’ in X Seconds (see chart, page 14)1 MPH = 50’ in X seconds (see chart, page 14)

High Range: Move the controller handle to the full on position. At a rolling start, time the machine within the fifty feet. Adjust the Hi Range ”A (Forward) and B (Reverse)” trim pot clockwise or counter clockwise as necessary to obtain the correct times as specified in the chart below.

Low Range or Dual Range: Elevate the boom above horizontal. Check the “R” terminal of the drive controller to see that it does not have 12 volts on it. Move the controller handle to the full on position. At a rolling start, time the machine within the fifty feet. Adjust the Low Range “A and B” trim pot clockwise or counter clockwise as necessary to obtain the correct times for Forward (A) and Reverse (B) as specified in the chart below. After the Low Range adjustment, lower the boom to its stowed position.

Ramp (Single Trim Pot): Is a time delay built into the circuit board for either the “A or B”direction. The more you turn the ramp trim pot clockwise, the more time delay you add to the machine response to controller movement. Turning the ramp trim pot counter clockwise de-creases ramp delay of controller response when moved. Adjust the ramp delay to achieve a 1 ½ to 2 second delay.

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Manual Over Ride

CW / CCWSWING

LIFT

DRIVE

Manual Over Ride

UP / DN

Manual Over Ride

FWD / REV

Spool Stop Adjustment

Manual Over Ride

Actuating Bolt Hole

Spool Stop Set Screw

Manual Over Ride

Actuating Bolt Hole


Swing & Lift Controller Adjustment:

The Spool Flow Stop Adjustments shown above, are located inside of each Manual Over Ride lever of the Hawe Proportional Control Valve. Before making any adjustments of the spool flow stop, verify the speeds by operating the lift and swing functions from the ground controls. When verifying the drive speeds, mark off 50 feet, and at a rolling start time drive within the 50 feet from the platform. Boom Lift UP / Down (Full Stowed boom to Full Elevated or Full Elevated boom to Full Stowed ) 40 to 45 seconds Swing CW / CCW (full rotation 360°) 60 to 65 secondsBoom Fully Retracted to Fully Extend 40 to 45 seconds Boom Fully Extended to Fully Retracted 25 to 30 seconds Jib Boom Up / Down 30 to 40 seconds (No adjustment, approximate time. If slower than approximate times listed, contact the Snorkel Service Department: 800-255-0317)zz

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Swing & Lift Controller Adjustment:

Manual Over Ride

CW / CCWSWING

LIFT

DRIVE

Manual Over Ride

UP / DN

Manual Over Ride

FWD / REV

Spool Stop Set Screw 2mm

One Located OnEach Side

Spool Stop AdjustmentSpool Stop

Adjustment2.5mm

Manual Over Ride

Actuating Bolt Hole

Manual Over Ride

Actuating Bolt Hole

NOTE: Adjustment of the Lift / Swing Spool Stops should only be done if one direction is moving faster than the other. Timing the unite from the ground control station will determine if an adjustment will be required. If an adjustment is required for the Lift or Swing Spool Stops, you will need two metric hex-keys, one 2mm and one 2.5mm. (see above pictures for locations) 1. Loosen the Spool Stop Set screw located on the L. H. or R. H. side of each manual over ride for the section to be adjusted using a 2mm hex-key. (see above pictures for locations) 2. This step will require a second person. Start engine form the ground control station and activate the system enable switch. Using a 35mm bolt approximately 2-3” long or a punch of approximately the same diameter and length, insert bolt into Manual Over Ride Actuating Bolt Hole. (see above picture) Facing the control valve, and moving the manual over ride lever to the left or the right will make the valve respond as follows:Moving the Manual Over Ride to the Left: Swing CCW, Boom UP, and Drive FWDMoving the Manual Over Ride to the Right: Swing CW, Boom Down, and Drive Reverse 3. Move the manual over ride in the slower direction. Using a 2.5mm hex-key, turning the hex screw in or CW will decrease spool movement for slower speed, turning the hex screw out or CCW will increase spool movement for faster speed. Only move the hex screw 1/8 to 1/4 “ at a time. Re-check the time of the slower function to see if the speed has increased to equal the faster direction. If not repeat step 3. If speeds are now approximately the same, re-tighten the spool stop set screw.

Preset Procedure for Swing/Lift Controller:Preset Voltage Table:

Function Ramp Threshold High Range Low Range Measure AtTerminal

Swing 15 Turns “CCW” 3.5 – 4 volts 7 – 8 volts N/A CW # 24CCW # 23

Lift 15 Turns “CCW” 3.5 – 4 volts 7 – 8 volts N/A UP # 22DN # 23

Final Adjustment for Swing / Lift Controller:1.Start the engine.2.Operate the controller and adjust the threshold trim pot as necessary to produce smooth starts and stops with a minimum dead band.Note: The LED’s must come on before motion starts and must still be on after motion stops.1.Move controller to full on and check for maximum speed in seconds per the chart. Note: If the speed listed can not be obtained with the controller handle full on, increase the high range voltage. If an increase in output voltage occurs with no increase in speed or the function speed is faster than shown, this is an indication that the corresponding spool stop requires adjustment. For information on adjusting spool stop (s), see HPI Valve Adjustment for Swing & Lift Speeds.).1.Recheck the threshold movement. If a large change in high range voltage, 1/2 volt or more was necessary, will normally effect the threshold voltage adjustment.2.Turn the ramp time trim pot CW 3 – 4 turns.3.Move the controller handle quickly to 3/4 full travel and note function response. Continue to adjust ramp time until a gradual response is obtained without excessive time delay.

Final Adjustment Table:

Threshold High Range Dual Range Ramp Time

Swing / Lift Operate function, adjust for smooth starts and stops

***

Operate function full on, turn to

CCW until function starts to

slow, Then CW ½turn

N/A Turn 3 – 4 turns CW. Operate function and

adjust for controlled

acceleration without dead

band

Swing One revolutionCW or CCW

60 - 65 secondsfull 360°

Lift40 – 45 second

UP or Down

17

18

Hi Range: Boom stowed and fully retracted, range switch set to Hi, Machine Speed, at a Rolling Start, 50’ = in X sec.

Low Range: Elevate Boom above horizontal, range switch set to Low, MachineSpeed, at a Rolling Start, 50’ = in X sec.

“X” = machine actual speed at a rolling in 50’

Hi Range Low Range

ATB 60 / AB60J 10 -11 sec. 4x4

48-53 sec.55-60 sec.

TB 37 / 42 & 42J / 47J / 50 / 60 / 66J 11 -14 sec.4x4

32-37 sec.45-60 sec.

TB 80 11 -14 sec. 55-60 sec.

TB 85J 11 -14 sec. 55-70 sec.

TB 85J FA 11-24 sec. 55-60 sec

TB 100J / 120 / 126J60-75 sec. one revolution of wheel

10 -12 sec. 30-37 sec.

Lift/Swing/Drive Voltage Pre-Sets

A or BTHRESHOLD

A or BHI RANGE

A or BLOW RANGE

FORWARD 2.5 TO 3.5 VOLTS 7.5 TO 9 VOLTS

4.5 TO 5.5 VOLTS

REVERSE 2.5 TO 3.5 VOLTS 7.5 TO 9 VOLTS

4.5 TO 5.5 VOLTS

UP 2.5 TO 3.5 VOLTS 7.5 TO 9 VOLTS

4.5 TO 5.5 VOLTS

DOWN 2.5 TO 3.5 VOLTS 7.5 TO 9 VOLTS

4.5 TO 5.5 VOLTS

CW 2.5 TO 3.5 VOLTS 7.5 TO 9 VOLTS

4.5 TO 5.5 VOLTS

CCW 2.5 TO 3.5 VOLTS 7.5 TO 9 VOLTS

4.5 TO 5.5 VOLTS

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SERVICE NOTES:

1. On both A and B Low Range trim pots, turn adjustment screws 10 full turns clockwise. (On models TB 37,42,42J, 47J, 420 and 50, Low Range is not used for Lift/Swing low speed. After preset of 10 turns on both trim pots, precede to the Hi Range adjustment.) On these machines low is, however, used for elevated drive speeds.

2. Preset both the A and B Threshold trim pots. The controller handle must be moved at least 1½ inches off center or until machine is just barely starts to creep and adjust per above chart.

3. Move controller handle to full on and adjust the A and B Hi Range trim pots per above chart.

4. Elevate the boom above horizontal or extend out past 4’ for Drive/Lift/Swing. Move controller handle full on and adjust Low range trim pot. (Low Range Trim Pot only applies to models TB 80, 85J, TB 80, 85J FA, Lift/Swing/Drive and TB100, 120 and 126 Swing/Drive only. Remove wire #122 from “R” terminal of controller and adjust the Low Range trim pot.)

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Checking Lift/Swing Speeds From The Ground Controls

Always verify your ground control speeds first, before attempting a controller adjustment.

Lift/Swing speeds should be checked from the ground control, not form the platform. At the proportional control valve for lift/swing, each section has spool stops that limits the travel of the main spool.

Example: Swing is faster one direction than the other. This could indicate that the spool stops are out of adjustment or if you’ve recently installed a new PWM Module and haven’t set it yet. See PWM Module Adjustment procedure on page 25.

AB60J Times

T/T Swing CW/CCW

85-95 sec.

Main Boom UP 40-45 sec.

Main Boom Down

40-50 sec.

Riser Boom UP 24-30 sec.

Riser Boom Down

16-20 sec.

Jib Boom UP 9-12 sec

Jib Boom Down 7-13 sec.

Extend 30-38 sec.

Retract 30-38 sec.

TB37 Times

T/T Swing CW/CCW

95-105 sec.


Main Boom Down

45-55 sec.

Extend 25-40 sec.

Retract 25-40 sec.

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TB42J Times

T/T Swing CW/CCW

95-105 sec.


Main Boom Down

45-55 sec.



Extend 25-40 sec.

Retract 25-40 sec.

TB47J Times

T/T Swing CW/CCW

60-65 sec.


Main Boom Down

40-45 sec.



Extend 40-45 sec.

Retract 25-30 sec.

TB 60 – TB 66J Times

T/T Swing CW/CCW

85-95 sec.


Main Boom Down

40-50 sec.



Extend 60-70 sec.

Retract 35-40 sec.

TB 42 / 420 / 50 Times

T/T Swing CW/CCW

60-65 sec.


Main Boom Down 40-45 sec.

Extend TB 42/420TB 50

40-45 sec.30-40 sec.

Retract TB 42/420TB 50

25-30 sec.30-40 sec.

22

TB 80 / TB 85J FA Times

T/T Swing CW/CCW Fast 90-100 sec.

Main Boom UP FastSlow

65-75 sec.86-106 sec.

Main Boom Down FastSlow

60-70 sec.93-113 sec.

Jib Boom UP (TB 85JFA Only) 25-35 sec

Jib Boom Down (TB 85JFA Only)

25-35 sec.

Extend 80-90 sec.

Retract 60-70 sec.

TB 80 / TB 85J Times

T/T Swing CW/CCW Fast 90-100 sec.

Main Boom UP Fast Slow 86-106 sec.

65-75 sec.

Main Boom Down FastSlow

60-70 sec.93-113 sec.

Jib Boom UP sec

Jib Boom Down sec.

Extend 80-90 sec.

Retract 60-70 sec.

23

TB 100 / 120 / 126J Times

T/T Swing CW/CCW Mid 160-200 sec.

Main Boom UP Fast 60-80 sec.

Main Boom Down Fast 65-90 sec.

Jib Boom UP 8-13 sec.


Extend 80-100 sec.

Retract 80-100 sec.

24

Swing & Lift Control Valve Adjustment:Before adjusting the Lift or Swing controller for speeds at the platform, actual Lift or Swing speeds should be verified from the ground control as speeds for Swing and Lift are set by spool stops located on the Enerpac / Apitech / Parker proportional control valves. The preset voltages should provide enough voltage to achieve full spool travel for maximum speeds. Setting the voltages excessively high, can produce “High End” dead band, (When controller handle position changes without a corresponding change in the functions speed).

Swing Speed Adjustment on Apitech Proportional Control Valve:

Apitech Proportional Control Valve Location

This is the manual spool stop. The top screw adjusts the C2 (CCW) function and the bottom screw adjusts the C1 (CW) function. Do not over tighten jam nut as damage could occur to spool manual stop.

Turn spool stop clockwise until swing stops. Turn spool stop counter clockwise to obtain proper swing speed, 90 to 100 seconds in a full 360° with the boom fully retracted. Check both directions to insure your times are close to the same in both directions. If you cannot get the speed the same in both directions you may have to do a centering adjustment. See procedure page 9.

25

Swing Speed Adjustment on ApitechProportional Control Valve (continued):

This is the centering null adjustment screw for swing ONLY. If the swing speed is faster one direction than the other you can adjust the centering of the spool.Warning: The centering null adjustment can be adjusted to far where the machine will swing as soon as you step on the foot switch or hold up on the ground control switch.

26

Apitech Valve Section Identification

Pulsar (Black) 33Hz – P/N 6010653 (Drive, Lift Swing Only)

Pulsar (Blue) 63Hz – P/N 6010845 (EXT / RET Only)

Low Drive, 14 GPM Fwd or Rev, 33Hz

PulsarWith Manual Over

Rides

Swing, 7 GPM CW or CCW, 33Hz

PulsarWith Manual Over

Rides

Ext / Ret, 7. GPM Ret and 11.5 GPM Ext, Blue 63Hz Pulsar With Manual

Over Rides

Lift / Lower, 5 GPM Lift and 5.5 GPM Lower,

33Hz Pulsar With Manual Over Rides

High Drive, 14 GPM Fwd or Rev,

33Hz PulsarWith Manual Over

Rides

27

Pulse Width Modulation Module or PWM Module

Not Used

Threshold

Speed

Control Wires for PWM ModuleBlack = Ground # 3

Red = 12 volts # 67AYellow = Wiper from rheostat # 174Purple = Voltage to rheostat # 175Gray = Ground to rheostat # 173Blue = PWM signal to Lift/Swing

toggle switch # 172

Speed Rheostat

Pulse Width Modulation Module is located behind the Ground Control panel. The PWM module sends a pulsing signal through the Speed Rheostat located on the ground control panel. The speed rheostat regulates the PWM signal from fast to slow to the pulsars on the Apitech proportional control valve for the Lift and Swing functions. If a new PWM module is installed, it will require setting so the lift speeds will be correct from the ground control station.

PWM Module Adjustment:1.Turn Speed trim pot on PWM module full on clockwise. (Trim pot only has ½to ¾ turns of adjustment. Do not over adjust trim pot as damage can occur.)

2.Rotate the speed rheostat knob on ground control panel to the fast position and then rotate the rheostat knob form to the 10:00 position from fast.

28

29

PWM Module Adjustment (continued):3. Using the Boom Up control switch at the ground control, adjust the threshold trim pot on PWM module until the boom just starts to move. Rotate the speed rheostat from fast to slow checking for metering control with out excessive dead band.

4. Rotate the Speed rheostat to the Fast position. Place the boom in the fully stowed position. Time the boom through it full range of movement. From fully stowed to fully elevated should be 65 to 75 seconds and fully elevated to fully stowed should be 60 to70 seconds. If lift speeds are to fast, turn the Speed trim pot counter clockwise to decrease boom speed.

The Jib function is a non-proportional function. The approximate “Lift and Lower”times are 25 – 35 seconds.

Service Tips:

Lift and Swing will not work from ground control station but will from platform.Check rheostat positionCheck signal from PWM Module (#172) to Lift/Swing switches

When moving the rheostat at the ground control from fast to slow and lift or swing stops, replace the rheostat.

30

Hawe Three-Section Proportional Control ValveFrom Platform L. H Side

To read the pressure limiters settings, install a 0-5000 psi gauge at the pump compensator test port.

For Lower and Lift, dead head the lower and raise functions to read the pressure limiters setting.

For Reverse and Forward drive, remove the outboard hose as indicated above, plug the hose and cap the port. Deadhead the drive both forward and reverse to read the limiters settings. Reconnect the hose when finished.

Note: For two wheel drive units adjust relief’s to 2500 PSI, on four wheel drive units set relief’s to 2800 PSI.

The Inlet Relief is Factory set at 3600 psi (No Adjustment Required). It provides protection for the Hawe Proportional Control Valve from damage in the event of extremely high pressures produced when a pump compensator fails.

P/N 6019057

LOWER 650 PSI

SWING

LIFT

DRIVE

LIFT 2500 PSI

DRIVE REV See Note

DRIVE FWD See Note

INLET RELIEF 3600 PSIFACTORY SET

REMOVE THIS HOSEFOR PRESSURE TEST

31

Hawe Three-Section Proportional Control Valve

Service Note

LOWER 650 PSI

SWING

LIFT

DRIVE

LIFT 2500 PSI

DRIVE REV See Note

DRIVE FWD See Note

INLET RELIEF 3600 PSIFACTORY SET

If a relief adjustment is required, you will need a machined ¼”drive, 12mm, 12 point, deep socket turned to 16mm diameter by 32mm long. This will allow loosing and tightening of the jam nuts of the relief (s).

32

Spool Stop Adjustment and Manual Over Rides

The Spool Flow Stop Adjustments shown above, are located inside of each Manual Over Ride lever of the Hawe Proportional Control Valve. Before making any adjustments of the spool flow stop, verify the speeds by operating the lift and swing functions from the ground controls. When verifying the drive speeds, mark off 50 feet, and at a rolling start time drive within the 50 feet.

For 3 MPH = 50’ in 11 to 14 seconds, Boom Down and Fully Retracted, Range in Hi, and Hi Engine Rpm's.

For 1 MPH = 50’ in 33 to 38 seconds, Boom Elevated above Horizontal and/or Extended out approximately 6’, Range switch in Low, and Low or Mid Engine Rpm's. (Note: Some early production units were built using the F3L2011F Deutz Diesel, using a throttle solenoid for high and low engine rpm,s. Later production uses the Addco Actuator system On both the Deutz F3L2011F and the Cummins 3.3 diesel engines. See engine RPM adjustment.)

Boom Lift UP / Down (Full Stowed boom to Full Elevated or Full Elevated boom to Full Stowed ) 40 to 45 seconds

Swing CW / CCW (full rotation 360°) 60 to 65 seconds

Boom Fully Retracted to Fully Extend 40 to 45 seconds

Boom Fully Extended to Fully Retracted 25 to 30 seconds

Jib Boom Up / Down 30 to 40 seconds

Manual Over RideCW / CCW

SWING

LIFT

DRIVE

Manual Over RideUP / DN

Manual Over RideFWD / REV



Manual Over RideActuating Bolt Hole

Spool Stop Set ScrewOne on each side of the

manual over ride.


33

Spool Stop Adjustment and Manual Over Rides

NOTE: Adjustment of the Lift / Swing Spool Stops should only be done if one direction is moving faster than the other.

Timing the unit from the ground control station will determine if an adjustment will be required.

If an adjustment is required for the Lift or Swing Spool Stops, you will need two metric hex-keys, one 2mm and one 2.5mm. (see above pictures for locations)

1. Loosen the Spool Stop Set screw located on the L. H. side of each manual override for the section to be adjusted using a 2mm hex-key. (see above pictures for locations) When adjustment is complete, use a small amount of Loctite to secure the set screw.

2. This step will require a second person. Start engine form the ground control station and activate the system enable switch. Using a 35mm bolt approximately 2-3” long or a punch of approximately the same diameter and length, insert bolt into Manual Override Actuating Bolt Hole. (see above picture) Facing the control valve, and moving the manual override lever to the left or the right will make the valve respond as follows:

Moving the Manual Override to the Left: Swing CCW, Boom UP, and Drive FWD

Moving the Manual Override to the Right: Swing CW, Boom Down, and Drive Reverse

3. Move the manual override in the slower direction. Using a 2.5mm hex-key, turning the hex screw in or CW will decrease spool movement for slower speed, turning the hex screw out or CCW will increase spool movement for faster speed. Only move the hex screw 1/8 to 1/4 “ at a time. Re-check the time of the slower function to see if the speed has increased to equal the faster direction. If not repeat step 3. If speeds are now approximately the same, re-tighten the spool stop set screw.

SWING

LIFT

DRIVE

Manual Over RideCW / CCW

Manual Over RideUP / DN

Manual Over RideFWD / REV



Spool Stop Adjustment2.5mm

Spool Stop Set Screw 2mm


34

Hawe Service Tips•Stand-by pressure is very critical to the smooth operation of this valve. If we are seeing an oscillation in the boom functions it is a good idea to make sure the stand-by pressure on the machine is between 350 to 400 psi. (jerky boom movement or the same effects of a bad accumulator.)

•In very cold weather if the functions are slow or sluggish one option is to put a second tank line from the “T” port on top of the valve, directly to the hydraulic tank. If this problem goes on for an extended period of time without being fixed it is possible that you may blow the handle section seals. Hawe recommends that if this happens that you replace the whole handle section instead of trying to replace the seals.

•Under normal operation, if we have slow or sluggish operation and by moving the manual override the operation is responsive and of normal speed. The “GAP” filter may be plugged. Remove the gap filter from the “M” port clean and re-install.

•Shuttle valve location under the port plate, once the port plate is removed you will see a small brass fitting with a screwdriver slot in it. Remove this fitting taking caution not to damage the o-rings on this fitting. Once this fitting is out the shuttle ball will be in the cavity. The size of the shuttle ball is approximately 3mm (1/8”).

•If the valve is disassembled the thru bolts will need to have a torque value of, 17 ft/lbs (23Nm) for the larger bolts and 7ft/lbs (9.5Nm) for the small bolt.

•The cross port relief’s have no external adjustments. They are factory set using shims for spring pressure.

•The relief valves are not a cartridge type, if you remove the adjustment screw you will have access to the spring and seat. If you believe you have a relief valve problem, back the relief valve off, run that function, then reset the pressure. The relief valves will leak oil if the cap is not put back on after setting the pressure.

Documents

Controller Installation and Adjustment Procedures For Models · 1 IP-A11071 Controller Installation and Adjustment Procedures For Models 0172326 0112567 If further assistance with