3800c b&t hydraulic setup procedure - madill equipment€¦ · boom and stick ... *alternative...

095175- 3800C B&T Hydraulic Setup of 21

3800C B&T Hydraulic Setup Procedure

1. New Machine Startup Safety Check Procedure ........................................ 2

1.1. Hydraulic Oil ............................................................................................................. 2

1.2. Main Valve ................................................................................................................. 2

1.3. Pilot Circuit ................................................................................................................ 2

1.4. Engine......................................................................................................................... 2

2. Hydraulic Pressure Setting Procedure ...................................................... 3

2.1. Pilot System ................................................................................................................ 4

2.2. Make-Up Oil............................................................................................................... 5

2.3. Pump Compensator ................................................................................................... 5

2.4. Travel ......................................................................................................................... 6

2.5. Boom and Stick .......................................................................................................... 7

2.6. Swing .......................................................................................................................... 8

2.7. Travel Shift Point ....................................................................................................... 9

2.8. Pump Margin ............................................................................................................. 9

3. Grapple setup............................................................................................. 10

3.1. Tilt Cylinder ............................................................................................................. 10

3.2. Main Pressure Setting .............................................................................................. 10

3.3. Grapple Open/Close, Outriggers ............................................................................. 10

3.4. Grapple Rotate ......................................................................................................... 11

3.5. Load Sense Relief ..................................................................................................... 12

3.6. Proportional Control Handle................................................................................... 12

4. Cycle Time Setting Procedure .................................................................. 14

4.1. Cylinder Functions................................................................................................... 14

4.2. Swing ........................................................................................................................ 14

4.3. Travel ....................................................................................................................... 14

4.4. Cab & House ............................................................................................................ 14

4.5. Horsepower Adjustment (Travel Method) ............................................................. 18

4.6. Horsepower Adjustment (Stationary Method)....................................................... 18

APPENDIX A: Field Calibration ........................................................................ 19

Figure 1 - Pilot System .................................................................................................... 4 Figure 2 - Make Up Oil .................................................................................................... 5 Figure 3 - Main Pump Adjustments ................................................................................. 5 Figure 4 - Travel Cross Line Reliefs ................................................................................ 6 Figure 5 - Main Manifold .................................................................................................. 7 Figure 6 - Swing Two Stage Relief .................................................................................. 8 Figure 7 - Swing Motor Ports ........................................................................................... 9 Figure 8 - MBT Valve .................................................................................................... 11


1. New Machine Startup Safety Check Procedure

1.1. Hydraulic Oil • Ensure the cases of the swing motor and both travel motors are filled with

oil.

• Ensure the case of the main pump is filled with oil.

• Ensure the pilot pump suction is full of oil and the air is bled out of the line.

• Ensure the hydraulic oil reservoir has the correct level in it.

1.2. Main Valve • Loose the jam nut on the load sense relief and back out adjusting screw

several turns.

• Ensure that the screw engages by at least 4 (four) threads, then tighten the jam nut.

1.3. Pilot Circuit • Thread pilot relief valve screws out until they contact their internal stops,

then back in 1/2 turn

1.4. Engine • Install stop blocks on both sides to ensure machine is unable to travel.

• Ensure that the engine has the correct oil and coolant levels, and that the air filter element is in place.

• Prime fuel system, pull ECM breaker and crank engine over without firing until pump builds pressure.

• Push breaker in and start engine. Let idle for 30 seconds then shut down.

• Inspect machine for leaks. Check hydraulic and engine oil level and fill as required.

• Re-start engine and let idle for a few minutes, then check to ensure engine can be revved up to mid and high rpm.

• Slowly run functions to ensure air is out of system (keep eye on oil level while doing this).

• Shut off engine, check hydraulic and engine oil level and fill as required.

• Check machine for leaks.


2. Hydraulic Pressure Setting Procedure CAUTION: Ensure that all personnel are positioned in such a manner as to prevent injury if the machine were to move unexpectedly. Whenever possible place the front end of the machine on the ground. Ensure that swing brake is locked on by plugging and capping brake release line. Install travel stops to prevent machine from travelling.

NOTE: Hydraulic oil temperature must be 120°F±10 during entire adjustment procedure. To heat up the oil, lower the left and right travel forward port reliefs to just below the load sense setting, install stop blocks and stall travel. This will cause oil to flow over the port reliefs, quickly heating the oil. NOTE: To determine "crack" pressure, lower the relief setting until flow occurs. This will be heard as hissing or squealing from the relief and by a drop in pressure at the P test port. The engine will also load and the turbo may be heard to whine. After flow is present, raise the relief setting until flow just stops. The squeal should cease, and the engine should unload. Do not raise the setting too much, as the crack point may be exceeded and the relief set too high. Crack should be clearly audible as the relief screw is tightened or loosened and flow stops or starts. NOTE: All setup is done at high idle *Alternative method for blocking tracks: adjust brake pilot relief on the travel motor as shown in Figure 4. Verify that brake is holding once adjustment has been made.


2.1. Pilot System • Start engine and set to high idle.

• Adjust pilot pressure to achieve 450 ± 10 psi in the pilot test port as shown in Figure 1.

Figure 1 - Pilot System

PRES

CHECK PILOT

PRESSURE HERE

ADJUST PILOT

PRESSURE

HERE


2.2. Make-Up Oil • Start engine and set to high idle.

• Adjust make-up relief valve to 250 ±10 psi as shown in Figure 2.

Figure 2 - Make Up Oil

2.3. Pump Compensator • Adjust compensator screws on both main pumps (middle screw, see

Figure 3) all the way in and back out 1/2 turn.

Figure 3 - Main Pump Adjustments

MARGIN

COMPENSATOR

HORSEPOWER

ADJUST MAKE-UP PRESSURE HERE

CHECK MAKE-UP PRESSURE HERE


2.4. Travel • Increase setting of right forward travel cross line relief (see Figure 4) to

ensure no flow occurs when the function is stalled.

• Ensure travel stops are in place and engage right forward travel.

• Adjust the load sense relief to achieve 4300 psi in the P test port (see Figure 5).

• Engage right forward travel and adjust the cross-line relief to crack at 4300 psi.

• Repeat the procedure for right reverse travel. • Repeat the procedure for left forward and left reverse travel.

Figure 4 - Travel Cross Line Reliefs


Figure 5 - Main Manifold

2.5. Boom and Stick • Stall stick out and adjust the load sense relief to achieve 4300 psi in the P

test port. It may be necessary to increase setting of stick out port relief in order to achieve 4300 psi.

• Engage boom up and adjust the port relief (see Figure 5) to crack at 4300 psi.

• Repeat the procedure for the boom down port relief.

• Repeat the procedure for the stick in and stick out port reliefs.


2.6. Swing

Figure 6 - Swing Two Stage Relief

• Disconnect and cap all pilot lines from the swing motor reliefs. Be sure to label the lines for re-connection.

• Turn the low pressure sections all the way in on the swing reliefs (refer to Figure 6).

• Turn the high pressure sections all the way in on the swing reliefs.

• Ensure the track is blocked and engage left reverse travel with engine at high rpm.

• Adjust the load sense relief to achieve 4300 psi in the P test port.

• Ensure the brake is holding and engage swing left.

• Adjust the high pressure swing left reliefs to achieve crack under the above conditions. Adjust left drive first, then lower the right to just achieve crack, then raise slightly.

• Repeat the procedure for swing right.

• Adjust the low pressure swing left reliefs to achieve full flow at 2000 psi. Adjust the left drive down slightly, and then adjust the right drive down slightly further. Continue to "walk" the drives down until they are both at 2000 psi. The low setting can be adjusted between 1400-2400psi to suit operator preference.

• Repeat the procedure for swing right.

• Reconnect swing pilot lines.

• Stall swing against brake and check to make sure that main pump pressure is at the higher setting (pilot lines not crossed).


Figure 7 - Swing Motor Ports

2.7. Travel Shift Point • Lift a track in the air and make sure the low/auto switch is working

correctly. Leave the switch in auto for this adjustment.

• Ensure travel stops are in place and engage left reverse travel.

• Adjust load sense relief to achieve 3100 psi in the P3 test port.

• Install 6000 psi gauge In the M port on the left motor (see Figure 4)

• Engage left reverse travel and adjust shift point screw (see Figure 4) to read 500 psi at the M port.

• Remove the gauge from left motor and install in right motor M port

• Ensure the travel stops are in place and engage right reverse travel.

• Adjust shift point screw to achieve 500 at M port. ***It is very important that both sides read the same pressure***

2.8. Pump Margin • Ensure correct track tension. • Ensure travel stops are in place and engage right forward travel. • Adjust the load sense relief to achieve 4000 psi in the P test port.


• Remove high pressure gauge and install differential gauge, HI to P test port and LO to LS test port.

• Remove travel stop from right side and use front end to position this track in the air. Engage right forward travel in low range.

• Set right forward low range cycle time as discussed in cycle time set up procedure.

• Disconnect outboard pump load sense line. Plug and cap. • Engage right forward travel and adjust margin pressure to achieve 325

psi. • Re-check cycle time and adjust as required. If cycle time is adjusted,

margin must also be reset. • Reconnect load sense line to rear pump and disconnect load sense line

from inboard pump plug and cap. • Engage right forward travel and adjust margin pressure on rear pump to

achieve 300 psi. Note: Do not readjust cycle time to spec as it will be slower, this is normal for rear pump.

• Reconnect load sense line.

3. Grapple setup Ensure that make-up oil has been set before proceeding with grapple setup. Refer to section 2.2.

3.1. Tilt Cylinder • Stall stick out and adjust the load sense relief to achieve 3000 psi in the

LS2 test port.

• Engage tilt cylinder out and adjust the port relief (see Figure 5) to crack at 3000 psi.

• Stall stick out and adjust the load sense relief to achieve 2500 psi in the LS2 test port.

• Engage tilt cylinder in and adjust the port relief to crack at 2500 psi.

3.2. Main Pressure Setting • Install a 6000psi gauge in the "P" test port on the main valve on the

machine. • Start engine and set to high idle.

• Engage right forward travel and set the LS relief to achieve 4700psi at the "P" test port, raising the LS relief and the travel motor cross port relief valves if required.

3.3. Grapple Open/Close, Outriggers • Stall stick out and adjust LS relief to achieve 4700 psi in the P test port. • Engage grapple close and adjust the port relief to crack at 4700 psi.

• Repeat the procedure for grapple open, left/right outrigger open/close.


Figure 8 - MBT Valve

3.4. Grapple Rotate • Stall stick out & adjust LS relief to achieve 4000 psi in the P test port.

• Bottom out the swing motor relief cartridges and back them out 1/2 turn (new production will have plugs, so this step is not necessary).

• Bottom out the relief cartridges on the control valve rotate section.

• Engage grapple rotate CW and adjust the pressure limiter to achieve 3200 psi. If valve has 2 limiters, one is CW and one is CCW. Both must be adjusted.

• Adjust the port relief to crack at 3200 psi.

• Repeat the procedure for rotate CCW.

• Lower the pressure limiter to achieve 2850 psi. The flow at the B-port relief should be reduced significantly but there will still be an audible hiss.


3.5. Load Sense Relief • Ensure travel stop is in place and engage right forward travel to confirm

LS relief has been set to 4000psi in the P test port.

3.6. Proportional Control Handle

• The following are the driver board settings that will provide optimal performance (See “Field Calibration” document, Appendix A, for details on how to modify these settings.):

Parameter Setting

1H 80 (DEFAULT)

1L 20 (DEFAULT)

2H 80 (DEFAULT)

2L 20 (DEFAULT)

1r 0.2

2r 0.2

co Cf (DEFAULT)

Fr 20 (DEFAULT)

cr 2

• If driver board displays a numerical value on power up instead of “P1” and does not allow menu navigation, follow the procedure below:

1. Disconnect inputs 2. Set “Input Mode Select” (Display “cr’) to “02” (See “Field

Calibration” document) 3. Save/Exit 4. Reconnect Inputs 5. Confirm “P1” is being displayed on power up

• This error occurs because the BNT is set up for two inputs and the driver board is set to receive only one input. This extra input, regardless of whether the second input button is being activated or not, will result in an error. The board has to be set to receive two inputs in order for the board to function correctly.


Machine Pressures Serial No:_____________ Performed By:_______________ Date:________________

FUNCTION LOCATION SETTING ACTUAL

Engine - no load - high RPM 2000 rpm

Engine - no load - medium RPM 1275 rpm

Engine - no load - low RPM 750rpm

Engine - economy mode 1750 rpm

Engine - full load - max RPM 1900 rpm

Engine - full load - boost 25-30 psi

Pilot pressure cutout manifold 450 ± 10 psi

Grapple rotate pilot manifold 1000 ± 10 psi (3)

Front pump compensator centre screw bottom, then out ½ turn

Rear pump compensator centre screw bottom, then out ½ turn

Front pump margin pressure left screw 325 ± 10 psi (2)

Rear pump margin pressure left screw 300 ± 10 psi (2)

Boom up top 4300 ± 50 psi

Boom down bottom 4300 ± 50 psi

Stick out bottom 4300 ± 50 psi

Stick in top 4300 ± 50 psi

Swing left (first stage) right 4300 ± 50 psi

Swing right (first stage) left 4300 ± 50 psi

Swing left (second stage) 2000 ± 50 psi(1)

Swing right (second stage) 2000 ± 50 psi(1)

Left reverse travel bottom 4300 ± 50 psi

Left forward travel top 4300 ± 50 psi

Right reverse travel bottom 4300 ± 50 psi

Right forward travel top 4300 ± 50 psi

Load sense relief main manifold 4000 ± 50 psi

Table 1 - Machine Pressures

1) The low setting on the two stage swing relief is to be set at 2000 psi full flow as opposed to crack. See pressure set up procedure for more details.

2) Margin is dependent on cycle time. See cycle time set up procedure for more details.

3) Minimum base setting, must be adjusted to manufacture's specification once grapple is installed.


4. Cycle Time Setting Procedure

4.1. Cylinder Functions • Adjust spool stops on cylinder valves to achieve cycle times shown in

Table 3.

4.2. Swing • Adjust spool stops on swing valve to achieve cycle times shown in Table

3. Use caution to ensure that the cycle time is not exceeded.

4.3. Travel • Position front end of machine to raise one track in the air and run left

reverse in low range. • Adjust spool stop on travel valve to achieve low cycle time shown in Table

3. • Switch to auto (allowing motor to shift in to high range) and check cycle

time. • Adjust minimum displacement screw on motor to achieve cycle time

shown in Table 2. • Check left forward (no adjustment should be necessary). • Repeat procedure for right reverse and forward.

4.4. Cab & House • Adjust flow control to achieve cycle time shown in Table 3.


Machine Cycle Times Serial No:_____________ Performed By:______________ Date:____________

FUNCTION LIMIT

SCREW LOCATION

LIMIT SCREW

DIM. (INCHES)

CYCLE TIME

(SECONDS)

ACTUAL TIME

(SECONDS)

Swing left B Bottom 0.400 25 (1)

Swing right A Top 0.400 25 (1)

Boom up - LH & RH valves Bottom 0.135 9.0 (2)

Boom down - LH & RH valves Top 0.182 8.0 (2)

Stick in - LH & RH valves Bottom 0.195 6.3

Stick out - LH & RH valves Top 0.205 7.0

Left reverse - low travel Top 0.180 44 ( 3 revs)

Left reverse - high travel Motor 0.422 25 ( 3 revs)

Left forward - low travel Bottom 0.180 44 ( 3 revs)

Left forward - high travel Motor 0.422 25 ( 3 revs)

Right reverse - low travel Top 0.180 44 ( 3 revs)

Right reverse - high travel Motor 0.422 25 ( 3 revs)

Right forward - low travel Bottom 0.180 44 ( 3 revs)

Right forward - high travel Motor 0.422 25 ( 3 revs)

House open Bottom Right 0.248 23

House close Bottom Left 0.229 19

Cab operate Top Right 0.265 34

Cab transport Top Left 0.278 49

Record grapple settings on following page

Table 2 - Machine Cycle Times

1)

Three revolutions from a standing start, heel crowded in and 10 feet off ground 2)

From ground to full sweep, stick fully extended and heel fully tilted back 3)

Note base setting and use manufacture's specifications for final set up


B&T Pressures Serial No:_____________ Performed By:_______________ Date:________________

FUNCTION RELIEF

LOCATION SETTING ACTUAL

Tilt cylinder out (grapple in) Top 2500 ± 50 psi

Tilt cylinder in (grapple out) Bottom 3000 ± 50 psi

Grapple jaw open Grapple Head 4700 ± 50 psi

Grapple jaw close Grapple Head 4700 ± 50 psi

L.H. outrigger down Grapple Head 4700 ± 50 psi

L.H. outrigger up Grapple Head 4700 ± 50 psi

R.H. outrigger down Grapple Head 4700 ± 50 psi

R.H. outrigger up Grapple Head 4700 ± 50 psi

Rotate CW at motor Grapple Head MAX

Rotate CW at cross-port relief Grapple Head 3200 ± 50 psi(2)

Rotate CW at pressure limiter Grapple Head 2850 ± 50 psi(2)

Rotate CCW at motor Grapple Head MAX

Rotate CCW at cross-port relief Grapple Head 3200 ± 50 psi(2)

Rotate CCW at pressure limiter Grapple Head 2850 ± 50 psi(2)

Table 3 - B&T Pressures


B&T Cycle Times Serial No:_____________ Performed By:______________ Date:____________ While setting grapple head cycle times, stall out stick in to bring up the machine pressure.

FUNCTION LIMIT SCREW

LOCATION

LIMIT SCREW DIM.

(INCHES)

CYCLE TIME

(SECONDS)

ACTUAL TIME

(SECONDS)

Tilt cylinder out (grapple in)

Bottom 2.5

Tilt cylinder in (grapple out)

Top 2.5

Grapple rotate left Grapple Head

13.5 (3 revs)

Grapple rotate right right

Grapple Head

13.5 (3 revs)

Grapple close Grapple Head

1.5

Grapple open Grapple Head

1.5

L.H. outrigger down Grapple Head

1.7

L.H. outrigger up Grapple Head

1.25

R.H. outrigger down Grapple Head

1.7

R.H. outrigger up Grapple Head 1.25

Table 4 - B&T Cycle Times


4.5. Horsepower Adjustment (Travel Method) • Connect a laptop or Pro-Link to engine diagnostic plug and load Detroit

Diesel software. Monitor load percent, engine rpm and turbo boost.

• Set engine to high idle.

• Make sure hydraulic oil temp is 120°F + 10° for the duration of the test.

• Apply swing brake, stall swing, stall stick out, travel forward in low range and boom up. Adjust HP screws to achieve 1900 rpm (100rpm pull down), 100% load and with approx 25 to 30 psi of boost.

• When a horsepower adjustment is needed make sure both pumps are adjusted an equal amount, usually less than one flat on the adjustment screws.

4.6. Horsepower Adjustment (Stationary Method) • Connect a laptop or Pro-Link to engine diagnostic plug and load Detroit

Diesel software. Monitor load percent, engine rpm and turbo boost

• Set engine to high idle

• Make sure hydraulic oil temp is 120°F + 10° for the duration of the test.

• Apply swing brake, stall swing, lift boom and attachment clear off ground, cycle boom up and stick out and adjust hp screws to achieve 100% load and 1900 rpm with 25 to 30 psi boost.

• When a horsepower adjustment is needed make sure both pumps are adjusted an equal amount, usually less than one flat on the adjustment screws.

Record actual pull down rpm: Record actual boost pressure: ***Note: Turning adjustment screw in increases load, out reduces load.***


APPENDIX A: Field Calibration

3800c b&t hydraulic setup procedure - madill equipment€¦ · boom and stick ... *alternative...

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