- Muncie Power Products
Contents
1. ROAD 00 10000000 LBs XV 0000 00 0000000 ps 0000 Message Bar Jii OFF OFF LIQUID SPINNER Operation Messages Hot Oil This indicates the hydraulic oil has exceeded 186 degrees Fahrenheit Allow system to cool and take corrective action to eliminate source of over heating Cold Oil This indicates the hydraulic oil is below 34 degrees Fahrenheit Cold oil can be very viscous and cause performance issues Muncie recommends actuating a motor function and allowing the system to warm before performing any rigorous functions Low Oil This indicates the oil level is low Replenish oil level as needed Filter Bypass This indicates that the filter bypass switch has been tripped Change the filter element Filter Bypass This indicates that the filter bypass switch has been tripped Change the filter element Body Up This indicates that the body up switch has engaged Open Circuit Detected This indicates that a wire or connector has disconnected creating an open circuit condition Inspect wiring and correct Short Circuit Detected This indicates that an output wire is shorted to ground Please inspect wiring and correct Switched to GPS fallback groundspeed This message indicates that the groundspeed signal from the truck was lost Therefore the GPS signal will be used to calculate the speed of the truck ELECTRICAL GUIDE CONTROLLER ERRORS Hardware Related Messag2. Ground Spinner Auger Unloader I 2 Paster B save a j 4 Con High White Red Wire Pin Unloader Red Wire Pin 2 V ez Ton Pin 11 Red Vire Pin 3 Sprner White Pin 7 III Black Ground LOAD PRESSURE 4 POS PLUG PIN FUNCTION WIRE COLOR Ground Input Voltage Qutput Voltage PUMP PRESSURE 4 POS PLUG PIN FUNCTION WIRE COLOR Drange Pin 8 nput Voltage il lack Ground s Output Voltage Black Wire Black Ground SLAVE 12 POS PLUG FUNCTION WIRE COLOR Power Power Power Can High Can Low Ground Power Can High Can Low 5 Volt Input 5 Volt Red _ Green I CM Green Gray Red Wire MASTER 12 POS PLUG PIN FUNCTION WIRE COLOR Hot Oil Cold Oil Low Body Sensor 5 Volt Output Pump Pressure Load Pressure Pink Green Yellow Pink Pin 10 12015792 ee Green Pinu DIGITAL INPUT 6 POS PLUG PIN FUNCTION WIRE COLOR Hot Oil Digital 1 Cold Oil Digital 2 Low Oil Digital 3 Body Sensor Digital 4 Ground 22 ELECTRICAL GUIDE CONTROLLER ERRORS System Errors and messages will appear in the message bar These messages will include open circuits short circuits controller errors senor warnings and more Resolve the issue and depress the ok button to clear the message Consult factor for assistance TOTALS
3. PGP would display 1200 PSI and L S port would display 1000 PSI In this way the system will always attempt to sustain a differential or boost pressure of approximately 200 PSI FR1 Load sense drain orifice FR1 provides a controlled drain for the load sense pilot line Its function is to ensure that the pressure cannot be trapped in this pilot and result in EV1 not being able to fully open at low pressure when required Post Compensators EP1 EP2 EP3 and EP4 The post compensators ensure that all functions will operate simultaneously during low pump flow situations when the circuit requires more oil than the pump can provide The pilots of the post compensators are directly tied to the LS pressure network Each compensator will modulate flow by restricting or allowing flow to pass to achieve a constant differential This differential across all of the compensators allows all of the functions to work with each other to prevent any one function from coming to a complete stop HYDRAULIC EXPLANATION OF SPREADER CIRCUIT Proportional Valve SP3 Spinner flow control valve SP3 is a proportional solenoid flow control valve In its un energized state it provides a blocked path between the pump flow and the spinner work port When it is energized it provides an increasing orifice opening to flow as a result of increasing electric current to its solenoid coil Proportional Valve SP2 Auger Conveyor flow control valve SP2 is a proport
4. Flow Control for Contamination SP6 Check the Plumbing are the PLA and PLB ports plumbed backwards Check the Plow Down Relief for Contamination RV5 Check if the Plow Cylinder is leaking internally Check CV3 for Contamination blocking LS signal Check Cylinder Panel Harness Buttons should change from green to red when pushed Sync Truck Profile Check for Contamination in the plow down flow control SP6 Check for Contamination in the Plow Up Relief RV5 Check Load Holding Valve for Contamination CV 1 Check if the plow cylinder is leaking internally Decrease the maximum plow speed settings 25 ISSUE Plow Does Not Angle left or right Plow Angles Slow ISSUE Hoist Does Not Raise Hoist Raises but drifts down slowly Hoist Raises Slowly SA Telescopic Hoist Lowers Slowly Hoist Slams Down When Lowering 26 TROUBLESHOOTING PLOW ANGLE ISSUES POTENTIAL PROBLEMS Check the plow angle speeds in the controller Check the electrical circuit for opens and shorts Look for error messages Check crossover relief on Plow Check to see if quick disconnects are seated properly Check to see if quick disconnect manifold is held open debris Check EHPR1 Plow Right Pilot or EHPR2 Plow Left Pilot Check PE2 fo Contamination Check CV4 or CV5 for contamination Do the cylinder panel buttons change from green to red If not check the harness Sync Truck Profile Check the Controller Speed Settings Make sur
5. higher than the LS Gauge while a function is operating EV1 Plugged when used with a piston pump unloading pressure compensating cartridge EV1 is a normally closed two position two way pilot cartridge It can provide a low pressure path for pump flow to escape to tank This is its primary function when the pump is bypassing no functions operating The bypass pressure of the pump in this state will vary from about 20 60 PSI depending upon the pump flow This pressure will show at PGP The path to tank is opened by pump pressure being applied to the left side pilot of EV1 which forces the valve open The right side pilot line of EV1 is drained to tank through the TS3 when not engaged Electrically Actuated Main Relief Valve to allow the EV1 valve to open fully TS3 Electrically Actuated Main Relief Valve TS3 is a normally open two position two way solenoid operated relief valve When its solenoid is not energized it provides a drain path for the pilot pressure on the right side of EV1 This allows for pilot pressure on the left side of EV1 to push it open and expose a low pressure path for the pump flow to escape to tank TS3 Will energize whenever any function of the Advantage Plus is operating This closes the pilot drain on the right side of EV1 and that in turn causes EV1 to begin shutting off the pump flow escape to tank Pump flow is now forced to move toward the actuators as required If TS3 was energized by itself or manually ov
6. 1 Red 4 Cond Black 3 Cond DT06 4S PIN ASSIGNMENTS Green 3 Cond WIRE CONNECTION WIRE COLOR Green 4 Cond 1 DB15 Pin 4 Red 4 Cond DTMO6 6S Pin 4 DTM06 6S Pin 1 O N O G A OO N DT06 4S Pin DTO6 4S Pin 4 White 4 Cond 2 15 11 Black 4 Cond DT06 4S Pin 2 Black 4 Cond 3 DB15 Pin 9 DTM06 6S Pin 3 Green 4 Cond Red 2 Cond 4 DB15 10 DTMO6 68 Pin 2 White 4 Cond Black 2 Cond CABLE LENGTHS CABLE TYPE LENGTH INCHES 23 ELECTRICAL GUIDE SLAVE HARNESS 1 amp 12 i l d Slav J O Sst 1 Hols Dom Orange Pin 7 Holst Up Yellow Pin 6 ne me Black Ground Block Ground mes Hoist IM Relief Pink Green 8 T Black round Plow Down White Pin 2 TIE wy Black Ground iT e Up Tan Pin AZ Black Ground Plow DN Relief a Plow Right _ Purple 5 Gray Pin 3 Black Ground Black Ground SLAVE 12 POS PLUG FUNCTION WIRE GOLOR Plow Up Tan Pump Down White Plow Down Relief Gray Plow Left Blue Plow Right Purple Hoist Up Yellow Hoist Down Orange Hoist Down Relief Pink Green Plug Plug Plug Plug 20 ELECTRICAL GUIDE MASTER SLAVE HARNESS MASTER 12 POS PLUG FUNCTION WIRE COLOR Battery Power To Power Stud Relay Control Can High Can Low
7. 2 23 Or TENO M M V 24 System 25 27 Controller Panel 27 HYDRAULIC SPECIFICATIONS HYDRAULIC PRESSURE SETTINGS FUNCTION DESIGNATION PSI Main Relief Boost Spreader Plow Up Plow Down Hoist Up Hoist Down FUNGTION MAX FLOW RATES Inlet Flow Plow Up Plow Down Plow Angle Hoist Up Hoist Down opinner Auger RANGE PSI 1500 3600 0 500 300 3500 300 3600 0 1700 300 3600 0 3000 DIFFERENTIAL PSI ADJUSTED Electically Mechanically Mechanically Mechanically Electically Mechanically Electically HYDRAULIC PORT DESIGNATIONS mg II DESIGNATION FUNGTION FUNCTION SIZE SAE Hoist Raise Tank Hoist Lower Tank 2 Angle Left Auger Angle Right Auger reverse Spreader Return Pump Gauge Port Spinner Pump Pressure Transducer 04 Modified Plow Up Load Sense Pressure Transducer 04 Modified Plow Down Plow Raise Pressure Transducer 04 HYDRAULIC CARTRIDGE DESIGNATIONS FUNCTIONS AND PART NUMBERS FR1 RV1 TS3 CV1 SP4 TS2 CV3 DESIG PART NUMBER NXRV0820A0NC05 02 NXRV0822A0N26 NXRV1022A0N35 NXRV0822A0N26 NXRV0822A0N13 NNXRV0822A0N26 NXTS1036A0N00 NXTS1036CONO NXTS3820AMONOO NXCV08200N10 N
8. ADVANTAGE SD Service Manual Rev 1 TABLE OF GONTENTS OST O E 3 919 c RTT 4 bio je ae OEE O E E E E E E 5 Cartridge Designations Functions and Part Numbers 6 7 C 8 ____ _ 9 Solenoid Shit SeQUENCE ia e Mm mmm 9 Explanation of Unloading Circuit Emm 10 Explanation of Spreader 8 geji PE 11 Explanation ot PIOW E 12 Explanation of Plow Down O 13 Explanation ot Hoist CIRCUS TET 13 I M 14 Configuring System from Open to Closed nennen nnne nnn nnn 15 Installation of Plow Pressure Release Manifold nana 16 i e igle Mai e PR m 17 RO ICA WENG AS SIJO TE EET 17 miisieiQe ilsio dec 18 Electrical Joystick EN 19 Electrical Slave Ics Ne TET 20 Electrical TUE 21 EEC TCL Controller BITODS 2
9. EEDBACK PULSES PER SEC FEEDBACK SENSOR Open Loop Open loop typically refers to the conveyor or pre wet function Open loop simply means that electrical feedback isn t required Today with the use of cartridge valves and current control feedback sensors really aren t required however they can provide more precision The advantage plus has the capability to do either open or closed loop Open Circuit Detection The Advantage Plus Controller has built in diagnostics that detect when a solenoid is unplugged When this occurs the controller will generate an error code on the screen and a button cylinder function or display spreader function will flash Many of our competitors have test lights at the valve to indicate that the electrical connection is connected and firing However our buttons provide real time feedback by turning from green to red to indicate that an output is connected and actuated Digital Input Digital inputs are simply on or off switches that are connected to the system Digital inputs include oil level float switches body up switches hot oil switches cold oil temperature switches and filter bypass switches Analog Input These are inputs that generate a proportional 0 5 volt signal In the Advantage Plus analog inputs include the pressure transducers that measure the hydraulic pressures PWM input These inputs provide a pulsed signal either square or sine Examples of PWM signals include speedometer sensor
10. XCV04200N05 NXCV04200N05 NXCV08200N25 NXCV04200N05 NXCV10200N15 NXCV10200N15 NXCV04200N05 NXCV04200N05 NXCVD10 NXSP0820MON00 FUNCTION Boost Pressure Plow Angle Left Relief Spreader Relief Hoist Raise Relief Plow Raise Relief Plow Angle Right Relief Hoise Lower CTRL Plow Lower CTRL Main Relief Plow Lift Check Valve Plow Lower Check Valve Plow Check Valve Body Check Valve LS Check Valve Auger Check valve Spinner Check Valve Hoist Lower Check Valve Hoist Raise Check Valve Check Valve Disc Plow Raise HYDRAULIC CARTRIDGE DESIGNATIONS FUNCTIONS AND PART NUMBERS SP2 SP3 SP4 SP5 SP6 SP7 ORF1 ORF2 ORF3 ORF4 EP1 Ep EP3 EP4 FR1 EV1 CL1 GL2 BLK Not Shown PART NUMBER NXSP1020AMONOO NXSP1020MONO0 NXSPO8200N00 NXSPO820MONO0 NXSPO8200N00 NXSP1057C0N00 NX6101025 NX6101025 NX6101025 NX6101025 NXEP08350N10 NXEP10S350N10 NXEP10S350N10 NXEP10S350N10 NXFRO820FON 0 20 NXEV128340N010 COIL 4303612 COIL 4303712 BLOCK 7620110 NX6108080 FUNCTION Auger Spinner CTRL Hoist Raise Hoist Lower Plow Lower Plow Angle Orifice Plugs Orifice Plugs Orifice Plugs Orifice Plugs Plow Compensator Hoist Compensator Auger Compensator Spinner Compensator LS Drain Cartridge Unloader Coil 1 Coil 2 PT PGP HYDRAULIC EXPLANATION OF PRESSURES Pump PSI The pump pressure Indicates the inlet pressure from the pump This pressure will always be approximately 200 PSI higher than the load sense pres
11. ctric current to its solenoid coil RV4 Upside Hoist Pressure Relief This is an adjustable relief valve that protects the cap side of the Hoist cylinder This is set at the factory at 2600 PSI The only time it will allow oil to drain back to tank is if the pressure reaches 2500 Pol HYDRAULIC EXPLANATION OF HOIST DOWN CIRCUIT Hoist Down Relief The TS1 valve is a two position three way proportional pressure valve IL serves multiple functions In its non energized state it provides a constant 100 PSI of down force on the rod side of the hoist cylinder When the hoist is raising the oil from the rod side of the cylinder is drained back through this valve This valve is energized when lowering a DA hoist cylinder Its purpose is to provide an adjustable pressure down force to the rod side of the cylinder The pressure setting of this valve is adjustable as a function of electrical current Maximum setting 1000 PSI CV10 and CV11 CV10 and CV11 are back to back check valves Their purpose is to communicate the higher of the two hoist pressures back to the RV1 boost pressure relief CV6 Hoist Shuttle Cartridge Load Holding Check The purpose of this valve is to hold the hoist suspended in the air after oil has passed through the SP4 HYDRAULIC CONFIGURING SYSTEM FROM OPEN TO CLOSED CENTER Instructions 1 Locate the RV1 cavity and remove Hydraforce P N RV08 20A 0 NC 05 02 2 Replace with NXCP08 20 N 3 W
12. d in an appropriate location and not reading temperatures from the exhaust 3 Contact Muncie for Lens replacement 1 Verify that the appropriate connector is plugged into the transducer receptacle 2 Verify that the pin of the connector are seated properly 1 Replace the Pressure Transducer ISO 9001 JE Muncie Muncie Power Products Inc Member of the Interpump Hydraulics Group Power General Offices and Distributon Center P O Box 548 Muncie IN 47308 0548 lex 765 284 7721 FAX 765 284 6991 E mail infomunciepower com PAA s gt DNV Products Web site http www munciepower com Drive Products Exclusive Agents for Canada ISO Certified by an Accredited Registrar SP15 04 Muncie Power Products Inc 2015
13. e plumbing is not restricting flow Is Pump Undersized need more displacement Check Boost Pressure Setting Sync Truck Profile HOIST ISSUES POTENTIAL PROBLEMS Check the Controller Speed Settings Check the Hoist Down Manual Override SP5 or Additional SP Check the Hoist Down Flow Control for Contamination SP5 or additonal SP Check the Plumbing are the HA and HB ports plumbed backwards Check the Hoist up Relief for Contamination RV4 Check if the Plow Cylinder is leaking internally Check the flow control for contamination SP5 or Additional SP Check the hoist upside relief RV4 for contamination Check the load holding check valve for contamination CV6 Check the Controllers Speed Settings Check the pump displacement May need larger displacement pump Check Boost Pressure Relief Setting Should be set at 200 PSI Did we check the controller speed settings Verify that hoist isolation plug is installed Is T2 routed directly to the Reservoir Did we install a second SP16 in the CP2 cavity to lower the hoist Turn the Hoist Max Speeds Down on the controller Spinner Does Not Operate Auger Conveyor Does Not Operate TROUBLESHOOTING SPREADER ISSUES POTENTIAL PROBLEMS Check the Controllers Speed Settings Check the Plumbing Are we deadheading the function Check the guick disconnects If the function operates when switch motors could have faulty motor Check the Spreader Relief Valve for contamination Chec
14. erridden without any other system valves functioning the pressure at PGP would be approximately 200 PSI to 300 PSI The L S port would not show pressure In addition the TS3 valve is used as the main relief It is an electrically adjustable relief that can be adjusted up to a maximum setting of 3600 PSI RV1 Plugged when used with a piston pump Boost Pressure Relief Valve RV1 s purpose is to raise the differential or boost pressure between PGP and LS by a margin of approximately 200 to 300 PSI It comes into play when TS1 is energized At that point the pilot pressure on the right side of EV1 can only drain through RV1 RV1 s internal bias spring is set for 200 PSI That means the pressure of EV1 s pilots both sides must build to at least 200 PSI before the right side pilot can drain through RV1 and allow EV1 to begin to open This boost pressure is required to allow flow to get through other cartridge valves in the system to operate functions When RV1 has a load sense pressure applied to its right side which is communicated from the array of LS check valves CV2 CV3 CVD10 CV7 CV10 CV11 etc this will add to the pressure required for EV1 to drain its right side pilot and open For example if the load sense pressure for a spreader motor is 1000 PSI this will be added to the 200 PSI spring bias pressure of RV1 Now EV1 cannot begin to open its path to tank until the pump pressure has achieved something slightly higher than 1200 PSI
15. es No Master Module Found Master Module not detected upon startup Check wiring and correct Master Lost Master Module disconnected after startup Check wiring and correct Slave Lost Slave Module disconnected after startup Check wiring and correct Motor Mod Lost Motor Module disconnected after startup Check wiring and correct Panel Lost Cylinder Panel disconnected after startup Check wiring and correct Liquid Feedback Sensor Failure flow turbine not detected Check wiring and correct If not utilizing flow turbine switch to open loop setting in calibration menu Lost auger feedback feedback sensor not detected Check wiring and correct If not utilizing feedback sensor switch to open loop setting in calibration menu Panel Faults Found Configuration Display Corruption Configuration file corrupted Please contact Muncie and check wiring on controller so that it is connected to ignition triggered shutdown Processor was reset forcibly This error indicates an unexpected system crash If problem persists please contact Muncie Panel Comm Fault This message indicates a processor communication error Try resetting the controller If problem persists contact Muncie 23 GLOSSARY OF TERMS Post Compensation Post compensation is synonymous with flow sharing This feature allows all of the hydraulic functions to operate simultaneously during low pump flow scenarios Remember that without post co
16. ing us to draw less horsepower Open Center Open center refers to valve types Open center valves are used with fixed displacement pumps gear and allow the flow to dump back to tank during system bypass Without a designated passage to tank the flow would constantly bleed over relief Closed Center Closed center refers to valve types Closed center valves are used with variable displacement pumps piston These valves do not offer a passage to tank Instead the variable displacement pump de strokes preventing it from generating flow Keep in mind that the piston pump destrokes when the LS signal is at O PSI Closed Loop Closed loop is typically referencing the functionality of the conveyor or pre wet function Years before the use of cartridge valves and current control closed loop control was required to achieve consistent hydraulic performance Specifically stack valves have excessive hysteresis and overshoot By placing a feedback sensor on the auger shaft we can measure how many revolutions per minute the shaft spins Knowing the RPM we can then modulate our current to achieve our desired output Simply put if we dial in 200 Lbs mile and the valve opens up too much the feedback sensor will recognize the inconsistency and readjust the signal to the valve to limit the flow to accomplish the desired setpoint SETPOINT CONTROLLER a OUTPUT VALVE HYDRAULIC FLOW HYDRAULIC MOTOR RPM WORK AUGER CONVEYOR Wed 38nSv3W ELECTRICAL F
17. ional solenoid flow control valve In its non energized state it provides a blocked path between the pump flow and the auger conveyor work port When it is energized it provides an increasing orifice opening to flow as a result of increasing electric current to its solenoid coil Relief Valve RV3 Spreader Pressure Relief RV3 limits the pressure of the spreader motor circuits It is located in the pilot load sense line of the spreader work ports It ultimately limits the pressure at the RV1 and therefore EV1 which opens to dump pump flow to tank RV3 is adjustable Its pressure setting will be displayed at the LSGP if a spreader motor load exceeds the relief setting or a blockage of a spreader work port occurs CV8 8 CV9 CV8 and CV9 are back to back check valves Their purpose is to communicate the higher of the two spreader motor pressures of the hoist circuit back to the RV1 boost pressure relief HYDRAULIC EXPLANATION OF PLOW CIRCUIT SP7 Plow Angle Directional Control Valve SP7 has a neutral position and two actuated positions The actuated positions alternately switch the tank and pressure lines connected to the cylinders to provide opposing angle directions This valve is known as a motor spool therefore in its normal position it blocks the pump flow from passing However it allows the pressure from the counterbalance valves to drain back to tank CVD10 Check Valve This valve allows the LS signal from the plow angle ci
18. ithin the control panel configuration menu a Locate the Pump Type Selection in the Global Settings Menu b Toggle the box and change from gear to piston pump Global Settings Pg 3 Pump Type GearPump PWM Freq G1 TS PWM Freq G2 Main Relief Press Transducer Pump 0000 PSI Load 0000 PSI _ Main Relief Ramp 50 HYDRAULIC PLOW PRESSURE RELEASE MANIFOLD INSTALLATION Purpose This manifold is intended to relieve pressure within the plow angle lines It allows easier connection between quick disconnect fittings Operation Instruction Pull actuators to relieve pressure within the plow angle circuit Installation Instructions 1 Locate the T Port Route back to port T2 or the B port 2 Locate the PAA Port Route to the PAA port on the Main Hydraulic Manifold 3 Locate the PAB Port Route to the PAB port on the Main Hydraulic Manifold 4 Locate the PAA1 Port Route to the plow left cylinder 5 Locate the PAB1 Port Route to the plow right cylinder Quick Disconnect Angle RT Quick Disconnect Angle LT PAA Angle LT PAB Angle RT AED a v Tank ELECTRICAL GUIDE WIRING ASSIGNMENTS Gray Jacketed Cable This cable supplies the controller with power ground and CAN connection Red Wire Connect to 12VDC Battery with a 20A fused connection Yellow Wire Ignition Power Connect to a fused ignition power source Black Wire Co
19. k C V9 is LS signal being relayed back to boost pressure valve Check CV7 is the LS signal being relayed back to boost pressure valve Check the controllers speed settings Check the Plumbing Are we deadheading the function Check the quick Disconnects Swapping supply to spinner could have faulty motor Check the Spreader Relief Valve for contamination Check CV8 is LS signal being relayed back to boost pressure valve Check CV7 is LS signal being relayed back to boost pressure valve SYSTEM IS OVERHEATING System is Getting Hot POTENTIAL PROBLEMS 1 Check the standby pressure Contamination in LS Drain 2 Check pressure with motors engaged Bad Quick Disconnect 3 Verify that we do not have excess pump flow 4 Verify that the low oil cold oil sensor isn t plugged into the wrong input ISSUE Air Road Temp Sensor Not Functioning Air Road Temp Sensors are Incorrect PSI Not Displayed on Controller Incorrect PSI Shown on Controller CONTROLLER ERROR MESSAGES 1 Verify that a sensor is installed and wired correctly 2 make sure that the system is configured for this sensor must be factory configured 3 Check the Power and Ground Connections of the sensor 4 Verify that all of the pins are in the correct locations and seated correctly in their housing 5 Verify that the lens cover was removed after installation 1 Try Calibrating the Sensor to the Controller 2 Verify the Air Road Temp Sensor is mounte
20. le as a function of electrical current RV5 Upside Pressure Relief This is an adjustable relief valve that protects the cap side of the plow cylinder This is set at the factory at 1300 PSI The valve will only open if the pressure at the cylinder reaches 2000 PSI CV1 Load Holding Check The purpose of CV1 is to hold the plow in the up position after oil has passed through the SP1 cartridge It will not allow oil to back feedback through the SP1 CV3 amp CV2 CV3 and CV2 are back to back check valves Their purpose is to communicate load sense pressures of the plow circuit back to the RV1 boost pressure relief EXPLANATION OF HOIST CIRCUIT SP4 Hoist Down Relief SP4 is an electrically actuated proportional two position two way valve During its non energized state it blocks pump flow from reaching the hoist cylinder When energized it provides an increasing orifice opening to flow as a result of increasing electric current to its solenoid coil Its function is to raise the hoist When this valve opens it allows oil to flow from the pump to the cap side of the cylinder SP5 Hoist Lower Flow Control SP5 is an electrically actuated proportional two position two way valve Its function is to lower the hoist During its non energized state it blocks the oil from draining from the cap end of the cylinder back to tank When energized it provides an increasing orifice opening to flow as a result of increasing ele
21. mpensation oil takes the path of least resistance Flow sharing modulates downstream pressures in order to keep everything operating During low flow scenarios all of the functions may reduce their speeds egually but all functions should stay operating Pre Compensation This feature does not allow for flow sharing Simply put this feature provides stable Flow as pressure fluctuates in a system However during low pump flow scenarios an output may completely stop since the flow will take the path of least resistance Voltage Compensation This is a method to control the electrical outputs from the controller Essentially the controller maintains a constant voltage at the output on the controller This is the most cost effective method at controlling a proportional solenoid however it is not the most precise method As the solenoid coil heats it s resistance increases which changes the performance of the valve Current Compensation This is another method to control the electrical output from a controller Although this is a more expensive method it is the most precise method As the coil heats and the resistance changes the controller allows the output to increase the voltage to compensate and keep the output current consistent Load Sense Load sensing was developed to improve the efficiency of a circuit All of our manifolds incorporate LS sensing technology Load sensing allows the system to build the pressure that the circuit requires allow
22. nnect to Battery Ground Pink Wire Connect to Speedometer Input Orange Wire When applicable Connect to pre wet valve or pump Source Current Power CAN Gray Harness Route into Cab Black Connect to Battery Ground Red Connect to 12VDC Battery Yellow Connect to 12VDC Ignition Pink Connect to Speedometer Input Orange Connect to Pre Wet 17 ELECTRICAL GUIDE m 2 z ge Li LJ Or vi Z zx LJ noz S lt O H H e MM gt 5 LJ Lr M n m su PWM INPUTS OUTPUTS OUTPUTS OUTPUTS AN INPUTS _ INPUTS DIGITAL INPUTS can INPUTS vi INPUTS CAN BUS CAN BUS GROUND GROUND LIGUIB HOP IPVDC POWER 12vDC POWER MASTER MOD SLAVE MOD OPTIONAL AN BUS m GROUND SPREADER l2VDC POWER PANEL CAN BUS nm CYLINDER JOYSTICK PANEL ELECTRICAL GUIDE JOYSTICK HARNESS 4 Cond 22 AWG Cable YT EE pr06 4s 2 Cond 22 AWG Cable EFEN 3 Cond 22 AWG Cable DTMO6 68 DB15 PIN ASSIGNMENTS DTM06 6S PIN ASSIGNMENTS PIN NUMBER WIRE CONNECTION WIRE COLOR PINNUMBER WIRE CONNECTION WIRE COLOR DB15 Pin 8 Green 3 Cond DB15 Pin 2 Red 3 Cond DTO6 4S Pin 3 Resistor Red 2 Cond Red Resistor DT06 4S Resistor Black 2 Cond Black Resistor DB15 Pin7 Black 3 Cond DTMO6 6S Pin 2 Red 3 Cond DTO6 4S Pin
23. rcuit to be relayed back to the RV1 However it will prevent the LS signal from back feeding It only allows oil to travel in one direction Plow Raise Flow Control SP1 SP1 is an electrically actuated proportional two position two way valve During its non energized state it blocks pump flow from reaching the plow lift cylinder When energized it provides an increasing orifice opening to flow as a result of increasing electric current to its solenoid coil When this valve opens it allows oil to flow from the pump to the cap side of the cylinder Plow Lower Flow Control SP6 SP6 is an electrically actuated proportional two position two way valve During its non energized state it blocks the oil from draining from the cap end of the cylinder back to tank When energized it provides an increasing orifice opening to flow as a result of increasing electric current to its solenoid coil HYDRAULIC EXPLANATION OF PLOW DOWN GIRGUIT Plow Down Relief The TS2 valve is a two position three way proportional pressure valve It serves multiple functions In its non energized state it provides a constant 100 PSI of down force on the rod side of the cylinder When the plow is raising the oil from the rod side of the cylinder is drained back through this valve This valve is energized when lowering a DA cylinder Its purpose is to provide an adjustable pressure to the rod side of the cylinder The pressure setting of this valve is adjustab
24. s IR temperature sensors and feedback sensors CAN inputs These are inputs that are connected to out CAN BUS network Typically these will have a power ground CAN Hi and CAN Lo connections Examples of these connections include IR temperature sensors 24 ADVANTAGE PLUS SYSTEM TROUBLESHOOTING ISSUE HF96083 14 POTENTIAL PROBLEMS System Powered but nothing operated hydraulically Verify that the PTO is engaged Is Pump Producing Flow Electronics do not power ISSUE Plow Does Not Raise Plow Raises Slowly and Drifts Back Down Plow Slams Down Contamination in Unloader Compensator EV1 Contamination In Boost Relief RV1 Contamination in Main Relief TS3 Boost Pressure Relief is set too low RV1 If using piston pump check stand by settings on pump If using piston pump make sure LS line is routed back to appropriate port Check to see if modules are recognized If not check CAN connection Verify that Modules are Plugged into harness Verify that Controller has been programmed with system profile Check to see if ignition input is connected to 12VDC Check Power and Ground Connections Check Fuse Check to make sure the master module is plugged in If applicable check the ignition source fuse on the truck Check the relay and connections located within the enclosure PLOW LIFT ISSUES POTENTIAL PROBLEMS Check the Controllers Speed Settings Check the Plow Down Manual Override SP6 Check the Plow Down
25. sure This pressure will never exceed the main relief setting Load Sense PSI The Load Sense PSI indicates the pressure communicated from the hydraulic load With no functions operating the LS pressure should be 0 PSI There will only be a LS pressure if a function is operating Boost Differential Pressure The boost or differential pressure is the difference between the Pump and the Load Sense Pressures Typical load sense hydraulic systems reguire a boost between 200 and 300 PSI The boost pressure is reguired to overcome the pressure drop across the valves Using a gear pump the boost pressure is set using the boost pressure cartridge Using a Piston Pump the boost pressure is adjusted at the pump SOLENOID SHIFT SEQUENCE Spinner SP3 od Auger SP2 TS3 Plow Raise SP1 TS3 Plow Lower DA TS2 SP6 TS3 Plow Lower SA SP6 TS3 Plow Left 57 Plow Right SP7 TS3 Dump Raise SP4 53 Dump Lower DA 152 SP5 153 Dump Lower SA SP5 153 HYDRAULIC EXPLANATION OF UNLOADING CIRCUIT Pump Gage Port PGP Indicates the inlet pressure from the pump This pressure will be approximately 200 to 300 PSI higher than the Load Sense pressure Load Sense LS2 Indicates the pressure of the load If more than one function is operating the higher load pressure will be observed There will only be a pressure from the LS port if a function is operating Remember the Pump Gauge will display a pressure approximately 200 PSI
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