4000 b&t hydraulic setup procedure - madillequipment.com

105978- 4000C B&T Hydraulic Setup of 20

4000 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. Main Pumps ..................................................................................................... 5 2.4. Fan ................................................................................................................... 6 2.5. Travel ............................................................................................................... 7 2.6. Travel Shift Point ............................................................................................. 8 2.7. Boom and Stick ............................................................................................... 9 2.8. Swing Pump .................................................................................................. 10 2.9. Factory Pressure Check ............................................................................... 10

3. Field set up for swing pump ..................................................................... 11 3.1. Pump Margin ................................................................................................. 11

4. Grapple setup............................................................................................. 12 4.1. Tilt Cylinder ................................................................................................... 12 4.2. Main Pressure Setting................................................................................... 12 4.3. Grapple Open/Close, Outriggers .................................................................. 12 4.4. Grapple Rotate .............................................................................................. 13 4.5. Load Sense Relief ......................................................................................... 13 4.6. Proportional Control Handle ........................................................................ 14

5. Cycle Time Setting Procedure .................................................................. 16 5.1. Cylinder Functions ........................................................................................ 16 5.2. Swing ............................................................................................................. 16 5.3. Travel ............................................................................................................. 16 5.4. Cab & House .................................................................................................. 16 5.5. Horsepower Adjustment (Travel Method) ................................................... 20 5.6. Horsepower Adjustment (Stationary Method) ............................................ 20

Figure 1 - Pilot System .................................................................................................. 4 Figure 2 - Make Up Oil ................................................................................................... 5 Figure 3 - Main Pump Adjustments .............................................................................. 5 Figure 4 - Fan Pump ...................................................................................................... 6 Figure 5 - Travel Cross Line Reliefs ............................................................................. 7 Figure 6 - Main Manifold ............................................................................................... 9 Figure 7 - Swing Pump Test Ports and Adjustments ................................................ 10 Figure 8 - MBT Valve ................................................................................................... 13


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 120F10 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


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. Main Pumps

Figure 3 - Main Pump Adjustments


2.4. Fan Install 1000 psi gauge into the test port on top of fan pump regulator.

Confirm standby pressure is 240-260 psi at HI idle. This must be checked with machine operating systems cold (before fan control is activated by any of the three temperature senders). Adjust as required.

Warm machine up to operating temperature.

Engage fan override mode.

Connect 6000 psi gauge into the test port on top of fan pump regulator.

Verify fan maximum pressure is 2950 psi. If required, adjust screw on end opposite solenoid.

Record max fan rpm for forward and reverse.

Figure 4 - Fan Pump


2.5. 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 5 - Travel Cross Line Reliefs


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

correctly. Set track back on the ground. Leave the switch in auto for this adjustment.

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

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

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

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

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

Ensure the travel stops are in place and engage left forward travel.

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


Figure 6 - Main Manifold

2.7. 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.

Stall stick in and set LS relief back to 4000 PSI


2.8. Swing Pump

Figure 7 - Swing Pump Test Ports and Adjustments

2.9. Factory Pressure Check Install test 600 psi gauge on G test port.

Set Engine at hi idle and confirm charge psi is 375 +/ – 25

Install 6000 psi test gauges on MA and MB test ports.

Swing cycle set the swing brake.

Set Engine at Hi idle.

Ease fully into right swing to ensure brake is holding.

Swing right and confirm pressure is set to 5450 =/-100 psi on the POR

Repeat procedure for Left swing.

Check swing cycle times and adjust if necessary See Figure 6.


3. Field set up for swing pump

Install 600 psi test gauge in G port.

Set engine to high idle.

Adjust charge pressure to 375 +/- 50 psi See figure 6 for test and adjustment points.

Install 6000 psi test gauges in MA and MB

Ease fully into right swing to ensure brake is holding.

Swing right and adjust pressure cut off to 5750 =/-100 psi see figure 6 for test and adjustment points.

Note if you cannot achieve 5750 on the PCO you may need adjust right cross line relief up to achieve 5750.

Swing right and adjust the high pressure cross line relief to crack at 5450.

Repeat the procedure for swing left.

Swing right and adjust the PCO back to 5450.

Adjust the swing cycle times using adjustments on figure 6.

3.1. 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.


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

4.1. 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.

4.2. 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.

4.3. 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

4.4. 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.

4.5. 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.


4.6. 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:________________ Table 1 - Machine Pressures

FUNCTION LOCATION SETTING ACTUAL

Engine - no load - high RPM 1650 rpm

Engine - no load - medium RPM 1275 rpm

Engine - no load - low RPM 750rpm

Engine - full load - max RPM 1500 rpm

Engine - full load - boost 25-30 psi

Pilot pressure Pilot manifold 450 ± 10 psi

Grapple make up oil Pilot manifold 125 ± 10 psi (2)

Fan Pressure Fan Pump 2950 ± 50 psi

Fan Standby Fan Pump 450 ± 10 psi

Front pump margin pressure Right screw 325 ± 10 psi (1)

Rear pump margin pressure Right screw 300 ± 10 psi (1)

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 Pump right cross line Top 5750 ± 50 psi

Swing Pump left cross line Bottom 5750 ± 50 psi

Swing Pump PCO Pump 5450± 50 psi

Swing Pump charge Pump 375 ± 50 psi

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

Travel Shift Point travel motor 3100 ± 50 psi

Load sense relief main manifold 4000 ± 50 psi

1)

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

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


5. Cycle Time Setting Procedure

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

Table 3.

5.2. Swing

Adjust screws on swing pump controller to achieve cycle times shown in Table 3. Use caution to ensure that the cycle time is not exceeded.

5.3. 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.

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


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

Table 2 - Machine Cycle Times

FUNCTION LIMIT

SCREW LOCATION

LIMIT SCREW

DIM. (INCHES)

CYCLE TIME

(SECONDS)

ACTUAL TIME

(SECONDS)

Swing left B Swing Pump 25 (1)

Swing right A Swing Pump 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 0.551 (3) 25 ( 3 revs)

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

Left forward - high travel Motor 0.551 (3) 25 ( 3 revs)

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

Right reverse - high travel Motor 0.551 (3) 25 ( 3 revs)

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

Right forward - high travel Motor 0.551 (3) 25 ( 3 revs)

House open Bottom Right 0.248 23

House close Bottom Left 0.229 19

Cab operate Top Right 0.265 45

Cab transport Top Left 0.278 49

Fan Forward Temperature Control Mode

2000 RPM

Fan Reverse 1200 Max

Fan Override Mode 2020RPM

Record grapple settings on following page

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)

Dimension shown is for 100mm screw, for 90mm screw dimension is 0.422


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


5.5. Horsepower Adjustment (Travel Method) Connect a laptop to the engine and load Volvo 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, lift attachment clear off the ground and apply forward travel, cycle full boom up and stick out with fan on full (Override). Adjust BODAS parameter I min to achieve 88% to 90% load at 1650 RPM with approx. 24 to 25 psi of boost (164 to 174 kPa)

Repeat the above and add right swing. Check HP, should be 93% load.

When horsepower adjustment up is needed, lower I min parameter down from 225 to 200 range. NOTE: Should not need to go below 200.

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

5.6. Horsepower Adjustment (Stationary Method) Connect a laptop to engine diagnostic plug and load Volvo 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, Install track stopper and stall right forward travel, lift boom and attachment clear off the ground, cycle boom up and stick out with fan on full (Override). Adjust BODAS parameter I min to achieve 88% to 90% load at 1650 RPM with approx. 24 to 25 psi of boost (164 to 174 kPa)

Repeat the above and add right swing. Check HP, should be 93% load.

When horsepower adjustment up is needed, lower I min parameter down from 225 to 200 range. NOTE: Should not need to go below 200.

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

*NOTE: For 4000 machine do not touch the HP screws*

Record actual pull down rpm: Record actual boost pressure:

***Note: Turning adjustment screw in increases load, out reduces load.***

4000 b&t hydraulic setup procedure - madillequipment.com

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