ADVANTAGE + - Muncie Power Products
Contents
1. Load 0000 PSI Main Relief Ramp 50 HYDRAULIC CONFIGURING SYSTEM FROM SA TELESCOPIC TO DA HOIST CP3 Instructions 1 Locate the CP2 cavity and remove Hydraforce P N CP16 20N 2 Locate the CP3 cavity and reinstall the CP16 20N cartridge removed in step 1 3 Install an SP16 20 into the CP2 cavity 5 16 20 0 12 4 Verify that the configuration file has been set for a SA telescopic hoist cylinder 5 Plug the appropriate electrical output into the newly installed SP16 20 Wire Color Orange The additional electrical hoist output will be a part of the standard wire harness even if unused We will coil this additional output if unused 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 tank 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 ELECTRICAL GUIDE WIRING ASS2. RV10 22A 0 N 35 XX NXRV08 20A 0 NC 05 02 NX6101025 NX6101025 NX6101025 NX6101025 16 567 0 4303712 FR08 20F 0 N 0 20 NXEV16 S34 0 N 10 FUNCTION Main Relief Hoist Downside Relief Plow Downside Relief Hoist Raise Hoist Lower Plow Lower Auger Spinner Plow Raise Plow Raise Relief Hoist Raise Relief Spreader Relief Clipper Relief Boost Pressure Relief Orifice Orifice Orifice Orifice Plow Angle Spool Coil LS Drain Cartridge Unloader HYDRAULIC CARTRIDGE DESIGNATIONS FUNCTIONS AND PART NUMBERS LOC Front Top Right Top Top Top Top Top Right Top Top Top Front Front Front Front Front Front Right Left Front DESIG EP2 EP1 EP3 4 EH2 0 6 0 8 0 9 0 1 0 2 0 3 0 4 0 5 0 7 0 10 0 11 CP3 CP2 CP1 CB1 CB2 PART NUMBER 16 535 0 40 10 535 0 10 10 535 0 10 10 535 0 10 NXEHPR98 T33 0 N 12ER NXEHPR98 T33 0 N 12ER NXCV16 20 0 n 05 NXCV10 20 0 N 15 NXCV10 20 0 N 15 NXCV10 20 0 N 05 NXCV06 B20 0 5 NXCVO6 B20 0 5 NXCV08 B20 0 4 NXCV08 B20 0 4 NXCV08 B20 0 4 NXCV08 B20 0 4 NXCV08 B20 0 4 NX6103116 NXCP16 20 N NXCP12 4L N NXCBEA LAN NXCBEA LAN FUNCTION Compensator Compensator Compensator Compensator Plow Right Pilot Ctrl Plow Left Pilot Ctrl Hoist Load Hold Check Spreader Check Spreader Check Check Valve Load Sense Check Load Sense Check Load Sense Check Load Sense Check Load Sen
3. When RV1 has a load sense pressure applied to its right side which is communicated from the array of LS check valves CV2 CV3 4 CV5 CV7 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 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 com
4. Slowly 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 Hoist Slams Down When Lowering Turn the Hoist Max Speeds Down on the controller 28 ADVANTAGE PLUS SYSTEM TROUBLESHOOTING SPREADER ISSUES ISSUE POTENTIAL PROBLEMS Spinner Does Not Operate Auger Conveyor Does Not Operate Check the Controllers Speed Settings Check the Plumbing Are we deadheading the function Check the quick disconnects If the function operates when switch motors could have faulty motor Check the Spreader Relief Valve for contamination Check 9 is LS signal being relayed back to boost pressure valve Check CV10 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 CV10 is LS signal being relayed back to boost pressure valve SYSTEM IS OVERHEATING POTENTIAL PROBLEMS System is Getting Hot 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 tha
5. WIRE CONNECTION WIRE COLOR PINNUMBER WIRE CONNECTION WIRE COLOR 1 1 DB15 Pin 8 Green 3 Cond 2 DTMO6 68 Pin 2 Red 3 Cond 2 DB15 Pin 2 Red 3 Cond 3 u 3 0706 45 Pin 3 Resistor Red 2 Cond Red Resistor 4 DTO6 4S Pin 1 Red 4 Cond 4 DT06 4S Resistor Black 2 Cond Black Resistor 5 5 DB15 Pin7 Black 3 Cond 6 6 7 DTMO6 6S Pin4 Black 3 Cond DT06 4S PIN ASSIGNMENTS 8 06 65 Pin 1 Green 3 Cond Mul Pb AAN WIRE COLOR 9 0706 45 Pin Green 4 Cond DB15 Pin 4 Red 4 Cond 10 DT06 4S Pin 4 White 4 Cond DB15 Pin 11 Black 4 Cond 11 DTO6 4S Pin 2 Black 4 Cond DB15 Pin 9 DTMO6 6S Pin 3 Green 4 Cond Red 2 Cond 12 DB15 Pin 10 0 06 65 Pin 2 White 4 Cond Black 2 Cond 13 CABLE LENGTHS 14 CABLE TYPE LENGTH INCHES 15 4 Cond 23 2 Cond 9 3 Cond 26 21 ELECTRICAL GUIDE SLAVE HARNESS APWH4A Deia 1 d Slove Yellow Pin 6 mS TEN Pink Green Pin 8 Black Ground i Plow Down White Pin 2 Black Ground E Tan Pin 1 Plow Up Plow Right p PI Black Ground m e7 Purple Pn 5 lje Black Ground Gray Pin 3 Black Ground m Black Ground SLAVE 12 POS PLUG PIN FUNCTION WIRE COLOR B 1 Plow Up Tan B 2 Pump Down White B 3 Plow Down Relief Gray B 4 Plow Left Blue B 5 Plow Right Purple B 6 Hoist Up Yellow B 7
6. 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 CONTROLLER OUTPUT N VALVE HYDRAULIC FLOW HYDRAULIC MOTOR RPM WORK gt AUGER CONVEYOR x m D o E 2 ELECTRICAL FEEDBACK 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
7. 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 electric 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 2500 PSI The only time it will allow oil to drain back to tank is if the pressure reaches 2500 PSI HYDRAULIC EXPLANATION OF HOIST DOWN CIRCUIT Hoist Down Relief The TS1 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 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 si
8. 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 sensors 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 26 ADVANTAGE PLUS SYSTEM TROUBLESHOOTING HF88298 14 ISSUE POTENTIAL PROBLEMS Electronics do not power System Powered but nothing operated hydraulically Verify that the PTO is engaged Is Pump Producing Flow 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 ch
9. 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 overridden 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 3000 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
10. ADVANTAGE Service Manual Rev 1 TABLE OF CONTENTS HYDRAULIC Hydraulic Specifications silla 4 BON DESNE an e ees 5 Cartridge Designations Functions Part NUuMmbers 8 6 7 misi eie a ANG fue t 8 Explanauomnof PIessileS els Cu 9 Se lee 9 Hyeraulic Circuit EXPO sureste elena 10 14 Mechanical Locked Plow Conf ia 15 Open Center to Closed Center Conve zus ne 16 Configuring for SA Telescopic Hoist Cylinders sitas ee 17 Plow Pressure Release Manifold 4 4 4 44444040 18 ELECTRICAL System Wining ASSIGNMENTS a A O ATA TNE ria 19 System Block EIER ne 20 JOVSICK HAMES ETT 21 Slave Nh A Po 22 Masters Slave Harmess soria aei pis 23 Wes quje ig nn a DEO 24 25 GENERAL cn PP uud 26 Troubleshooting Guido a a 27 29 HYDRAULIC SPECIFICATIONS HYDRAULIC PRESSURE SETTINGS FUNCTION DESIGNATION DEFAULT PSI RANGE PSI ADJUSTED Main Relief TS3 2200 1500 3000 Electically Clipper Relief RV2 1600 300 3500 Mechanically B
11. Brown B 5 5 Volt Output Red B 6 Pump Pressure Gray B 7 Load Pressure Green B 8 B 9 B 10 Ground Speed Pink B 11 Temperature Sensor Green B 12 Ignition Yellow Pin 10 SS DIGITAL INPUT 6 POS PLUG FUNCTION WIRE COLOR Low Oil Digital 3 Body Sensor Digital 4 Ground 24 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 AIR TOTALS PUMP TEMP 00 Les est 0000 TEMP 00 0000000GALS PSI 0000 Message Bar OK Jii OFF OFF LBS MILEPARTZ 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 Body Up This indicates that t
12. Certified by an Accredited Registrar SP15 03 Muncie Power Products Inc 2015
13. Hoist Down Orange B 8 Hoist Down Relief Pink Green B 9 Plug B 10 Plug B 11 Plug B 12 Plug 22 ELECTRICAL GUIDE MASTER SLAVE HARNESS APWH5A MASTER 12 POS PLUG FUNCTION WIRE COLOR A 1 Battery Power Red A 2 To Power Stud Red A 3 Relay Control Red 4 Can High White A 5 Can Low Blue A 6 Ground Black Spinner White A 8 Auger Orange A 9 Plug A 10 Plug A 11 Unloader Tan A 12 Plug Unlooder e7 Ton Pin 11 p Black Ground Spinner rz Pin 7 mea Black Ground range Pin 8 teli Black Ground Con High White Red Wire Pin 1 Red Wire Pin 2 Red Vire Pin 3 LOAD PRESSURE 4 POS PLUG PIN FUNCTION WIRE COLOR Ground 2 Voltage Red 3 Plug 4 Output Voltage Green PUMP PRESSURE 4 POS PLUG PIN FUNCTION WIRE COLOR 1 Ground Black 2 Input Voltage Red 3 Plug 4 Output Voltage Gray Black Wire Black Ground SLAVE 12 POS PLUG FUNCTION WIRE COLOR Power A2 Power A3 Power 4 Can High A5 Can Low 6 Ground 7 Power 8 Can High 9 Can Low A11 A 12 5VoltInput Red Red Red White Blue Black Red Green White Plug Plug Red _5 Volt Red Green MASTER 12 POS PLUG FUNCTION WIRE COLOR B 1 Hot Oil White B 2 Cold Oil Green B 3 Low Red B 4 Body Sensor
14. IGNMENTS 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 Connect to Battery Ground Pink Wire Connect to Speedometer Input Orange Wire When applicable Connect to pre wet valve or pump Source Current A mE Power CAN Gray Harness Route into Cab o 5 o Black Connect to Battery Ground Red Connect to 12VDC Battery a e o am Yellow Connect to 12VDC Ignition Pink Connect to Speedometer Input Orange Connect to Pre Wet ELECTRICAL GUIDE ki E 5 F or dl gt or Oe a B H a o amp 3 3 a al 5 5 iu amp a E 5 x z 5 5 cu m INPUTS OUTPUTS OUTPUTS OUTPUTS CAM INPUTS INPUTS DIGITAL INPUTS 9 can INPUTS vi NALOS INPUTS CAN EUS CAN BUS GROUND GROUND LIQUID MOD L2WDC POWER 12WDC_ POWER MASTER MOD SLAVE MOD OPTIONAL GROUND SPREADER ievnCc POWER PANEL CAN BUS CYLINDER JOYSTICK PANEL ELECTRICAL GUIDE JOYSTICK HARNESS APWH3A 4 Cond 22 AWG Cable SEs 07 06 69 3 Cond 22 AWG Cable DB15 PIN ASSIGNMENTS DTMO6 6S PIN ASSIGNMENTS PIN NUMBER
15. Lower SA SP5 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 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
16. de of the cylinder The pressure setting of this valve is adjustable as a function of electrical current Maximum setting 1000 PSI CP2 Provisional Cavity This cavity can be used to populate another SP valve in order to achieve faster hoist lower speeds CV7 and CV11 CV7 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 HYDRAULIC CONFIGURATIONS Mechanically Locked Plow To allow the plow angle to free wheel for a mechanically locked plow perform the following 1 Locate CB1 and CB2 valves shown above 2 Loosen the lock nut and use the appropriate Allen to turn both stems fully CW This will take the pressure setting from 2750 PSI to 200 PSI 3 Tighten the lock nut 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 8 20 3 Within 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 7 7777 PWM Freq 77 PWM Freq G2 m Main Relief Press Transducer Pump 0000 PSI
17. e 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 allowing 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 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
18. eck 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 ISSUE POTENTIAL PROBLEMS Plow Does Not Raise Plow Raises Slowly and Drifts Back Down Plow Slams Down Check the Controllers Speed Settings Check the Plow Down Manual Override SP6 Check the Plow Down 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 Oylinder 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 CV1 Check if the plow cylinder is leaking internally Decrease the maximum plow speed settings 27 ADVANTAGE PLUS SYSTEM TROUBLESHOOTING PLOW ANGLE ISSUES ISSUE POTENTIAL PROBLEMS Plow Does Not Angle left or right Check the plow angle speeds in the controller Check the electrical ci
19. he 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 Messages 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
20. ing orifice opening to flow as a result of increasing electric current to its solenoid coil HYDRAULIC EXPLANATION OF PLOW DOWN CIRCUIT 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 adjustable 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 2000 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 8 2 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 PLOW DOWN CIRCUIT SP4 Hoist Raise Flow Control SP4 is an electrically actuated proportional two position two way valve During its non energized state it
21. ing to a complete stop RV2 Clipper Relief The purpose ofthis valve is to provide redundant pressure protection and clip any pressure spikes that occur due to load shocks Therefore when a shock load occurs within the system this relief will clip any pressure beyond its set point 10 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 proportional 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 Spreader Pressure Relief 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 sp
22. 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 25 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 compensation 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 equally 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 th
23. oost RV1 200 0 500 Mechanically Spreader RV3 1600 300 3500 Mechanically Plow Up RV5 2000 300 3500 Mechanically Plow Down TS2 600 0 1000 Electically Hoist Up RV4 2500 300 3500 Mechanically Hoist Down TS1 600 0 1000 Electically FUNCTION MAX FLOW RATES DIFFERENTIAL PSI Inlet Flow 50 GPM 200 Plow Up 15 GPM 200 Plow Down 23 GPM 200 Plow Angle 23 GPM 200 Hoist Up 32 GPM 200 Hoist Down 32 GPM 200 Spinner 15 GPM 200 Auger 15 GPM 200 HYDRAULIC PORT DESIGNATIONS DESIGNATION FUNCTION SIZE SAE PLA Plow Up 10 PLB Plow Down 10 P Pump 16 PAA Plow Left 10 PAB Plow Right 10 HB Hoist Down 12 A Auger 10 B Auger Reverse Spreader Return 10 LS Load Sense 4 S Spinner 10 HA Hoist Up 12 Route to Tank Return Port 16 If manifold is configured for a SA telescopic hoist cylinder connect this port directly to an open port on the reservoir If manifold is configured for a DA hoist cylinder this port can be used as a return port HYDRAULIC AND PART NUMBERS FUNCTIONS CARTRIDGE DESIGNATIONS EP2 gt CV4 DESIG TS3 51 52 5 4 5 5 5 6 SP2 SP3 SP1 RV5 RV4 RV3 RV2 RV1 OR1 OR2 OR3 OR4 PE2 CL1 FR1 PART NUMBER NXTS38 20AM 0 N 00 NXTS12 36C 0 N 0 TS10 36C 0 N 0 NXSP16 20M 0 N 00 NXSP16 20M 0 N 00 NXSP12 20M 0 N 00 NXSP10 20AM 0 N 00 NXSP10 20M 0 N 00 NXSP10 20M 0 N 00 NXRV10 22A 0 RV10 22A 0 NC 05 02 RV10 22A 0 N 35 XX
24. rcuit 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 Plow Angles Slow Check the Controller Speed Settings Make sure plumbing is not restricting flow Is Pump Undersized need more displacement Check Boost Pressure Setting Sync Truck Profile HOIST ISSUES ISSUE POTENTIAL PROBLEMS Hoist Does Not Raise 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 Hoist Raises but drifts down slowly 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 Hoist Raises Slowly 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 SA Telescopic Hoist Lowers
25. reader work port occurs CV8 amp CV9 CV8 and 9 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 CP1 Auger Reverse Cavity This cavity can be populated with a solenoid actuated 2 position 2 way cartridge to reverse the auger flow HYDRAULIC EXPLANATION OF PLOW CIRCUIT PE2 Plow Angle Directional Control Valve PE2 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 Plow Angle Pilot Controls EH1 and EH2 Pilot pressure control valves EH1 and EH2 are solenoid operated pilot valves Their purpose is to provide hydraulic pilot shifting force to move the PE2 spool that in turn provide directional control of the plow angle When an EH valve is energized it completes a path from the pump to the end of the PE directional control Two EH valves are used for each PE valve One actuates the PE to angle left and the other actuates the PE spool to angle right The EH valves use very little to no flow since they are pilot controls When the EH valves are not energized they drain any residual pre
26. se Check Load Sense Check Load Sense Check Hoist Isolation Cavity Hoist Lower Check Aug Rev Cavity Plug Plow Lt Counterbalance Plow Rt Counterbalance LOC Top Right Top Top Front Front Left Top Front Top Front Front Front Front Front Front Front Left Top Top Front Front HYDRAULIC EXLANATION 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 pressure 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 require a boost between 200 and 300 PSI The boost pressure is required 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 TS3 SP2 Auger 1755 8129 Plow Raise TS3 SP1 Plow Lower DA IS3YESE6HIS2 Plow Lower SA SP6 Plow Left TS3 EHPR2 Plow Right TS3 EHPR1 Dump Raise 53 SP2 Dump Lower DA TS3 SP5 TS1 Dump
27. ssure from the actuation ends of the PE valves Plow Angle Counterbalance Valves CB1 and CB2 The plow angle counterbalance valves provide several functions First they provide crossover relief or cushion control for the plow angle cylinders They prevent the circuit from being damaged by shock loads At 2750 PSI they will relieve pressure and drain to tank In addition they are zero leakage valves that prevent any sort of induced backpressure to unintentionally elevate the LS pressure network These valves are piloted open when the directional control shifts CV4 and CV5 Check Valves These valves allow the LS signal from the plow angle circuit to be relayed back to the RV1 However they prevent the LS signal from back feeding They only allow 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 increas
28. t the low oil cold oil sensor isn t plugged into the wrong input CONTROLLER ERROR MESSAGES Air Road Temp Sensor Not Functioning Air Road Temp Sensors are Incorrect PSI Not Displayed on Controller Incorrect PSI Shown on Controller 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 mounted 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 29 NOTES NOTES ISO 9001 2 Muncie Power Products Inc Member of the Interpump Hydraulics Group i 8 Power General Offices and Distributon Center P O Box 548 Muncie 47308 0548 765 284 7721 FAX 765 284 6991 E mail info munciepower com a DNV Certification Inc INTERPUMP GROUP Products Web site http www munciepower com Drive Products Exclusive Agents for Canada ISO
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