2850 s2 b&t hydraulic setup procedure - madill …...098320b 2850 s2 b&t hydraulic setup...

098320B 2850 S2 B&T Hydraulic Setup of 35

2850 S2 B&T Hydraulic Setup Procedure

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

Hydraulic Oil ............................................................................................................... 2 1.1. Main Valve ................................................................................................................. 2 1.2. Pilot Circuit & PRV ...................................................................................................... 2 1.3. Engine ........................................................................................................................ 2 1.4.

2. Hydraulic Pressure Setting Procedure ............................................................................ 3 Pressure Reducing Valve ........................................................................................... 4 2.1. Pilot System ............................................................................................................... 5 2.2. Make-Up Oil ............................................................................................................... 5 2.3. Travel ......................................................................................................................... 6 2.4. Boom and Stick .......................................................................................................... 7 2.5. Travel Shift Point ........................................................................................................ 7 2.6. Swing ......................................................................................................................... 8 2.7. Fan ........................................................................................................................... 10 2.8. Cab & House ............................................................................................................ 11 2.9.

Pump Margin ............................................................................................................ 12 2.10.3. Grapple setup.................................................................................................................. 13

Tilt Cylinder .............................................................................................................. 13 3.1. Main Pressure Setting .............................................................................................. 13 3.2. Grapple Open/Close, Outriggers ............................................................................... 13 3.3. Grapple Rotate Identification ..................................................................................... 14 3.4. Load Sense Relief .................................................................................................... 14 3.5. Proportional Control Handle ...................................................................................... 14 3.6.

4. Cycle Time Setting Procedure ........................................................................................ 18 Cylinder Functions .................................................................................................... 18 4.1. Swing ....................................................................................................................... 18 4.2. Travel ....................................................................................................................... 18 4.3. Fan ........................................................................................................................... 18 4.4. Cab & House ............................................................................................................ 19 4.5. Horsepower Adjustment (Travel Method) ................................................................. 22 4.6. Horsepower Adjustment (Stationary Method) ........................................................... 22 4.7.

Appendix A: Field Calibration ................................................................................................. 23 Appendix B: Fan Parameters .................................................................................................. 26

Figure 1 – Pressure Reducing Valve ........................................................................................ 4 Figure 2 - Pilot System .............................................................................................................. 5 Figure 3 - Make Up Oil ............................................................................................................... 5 Figure 4 – Track Drives ............................................................................................................. 6 Figure 5 - Main Manifold............................................................................................................ 6 Figure 6 - Swing Two Stage Relief ............................................................................................ 8 Figure 7 - Swing Motor Ports .................................................................................................... 9 Figure 8 – Priority Swing Valve................................................................................................. 9 Figure 9 – Fan Pump ............................................................................................................... 10 Figure 10 - Fan Solenoid block ............................................................................................... 11 Figure 11 – Main Pump Adjustments ..................................................................................... 11 Figure 12 - MBT Valve ............................................................................................................. 14


1. New Machine Startup Safety Check Procedure

Hydraulic Oil 1.1.• 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.

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

turns.

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

Pilot Circuit & PRV 1.3.• Thread pilot relief valve screw out until it contacts its internal stop, then back in

1/2 turn.

Engine 1.4.• Install stop blocks on both sides to disable machine 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 main 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 dropping pressure at the P test port. The engine will also load and the turbo may be heard to whine. Once 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 to be done at high idle.


Pressure Reducing Valve 2.1.• Start engine and set to high idle.

• To set PRV pressure, insert stopper in left forward travel.

• Engage left forward travel.

• Adjust PRV to 420 psi. Ensure pilot system relief pressure is high enough to achieve PRV setting of 420 psi.

Figure 1 – Pressure Reducing Valve

PRV PRESSURE ADJUSTMENT


Pilot System 2.2.• Start engine and set to high idle.

• Insert stopper in left forward travel.

• Engage left forward travel.

• Adjust pilot pressure to achieve 400 ± 10 psi in the pilot test port as shown in Figure 2.

Figure 2 - Pilot System

Make-Up Oil 2.3.• Start engine and set to high idle.

• Adjust make-up relief valve to 300 ±10 psi as shown in Figure 3.

Figure 3 - Make Up Oil

CHECK PILOT & PRV PRESSURE HERE

ADJUST PILOT PRESSURE HERE

ADJUST MAKE-UP PRESSURE HERE

CHECK MAKE-UP PRESSURE HERE


Travel 2.4.

Figure 4 – Track Drives

Figure 5 - Main Manifold


Boom and Stick 2.5.• Stall stick out and adjust the load sense relief to achieve 4800 psi in the P test

port. It may be necessary to increase setting of stick out port relief in order to achieve 4800 psi.

• Engage boom up and adjust the port relief (see Figure 5) to crack at 4800 psi.

• Repeat the procedure for the boom down port relief.

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

Travel Shift Point 2.6.• 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 right forward travel.

• Adjust load sense relief to achieve 3100 psi in the P 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 to read 500 psi at the M

port (turn out to increase pressure).

• 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.


Swing 2.7.

Figure 6 - Swing Two Stage Relief

DO NOT ADJUST THE SMALL HEX SCREW. THIS ADJUSTS THE TORQUE CONTROL FEATURE (See Figure 7)

• 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.

• Stall stick out and adjust the load sense relief to achieve 3900 psi in the LS2 test port.

• Ensure the brake is holding and engage swing left.

• Adjust the pressure compensator on the priority swing valve (refer to Figure 8) to 3900 psi on LS2 test port.

• Ensure the brake is holding and engage swing left and adjust the load sense relief to achieve 3600 psi in the LS2 test port.

• Adjust the high pressure swing left reliefs to achieve crack under the above conditions. Do the 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 1400 psi. Adjust the left drive down a bit, and then adjust the right drive down a bit further. Continue to "walk" the drives down until they are both at 1400 psi. The low setting can be adjusted between 1400-2400psi to suit operator preference.

• Reconnect swing pilot lines.

• Stall swing against brake and check to make sure that the main pump pressure is at the higher setting on LS2 test port (pilot lines not crossed).

• Adjust the pressure compensator on the priority swing valve (bottom) to 3300 psi on the LS2 test port.

• Stall stick out and adjust load sense relief to achieve 4500 psi in the P test port.


Figure 7 - Swing Motor Ports

Figure 8 – Priority Swing Valve

PRESSURE COMPENSATOR

ADJUSTMENT

TORQUE CONTROL

ADJUSTMENT


Fan 2.8.• 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 3500 psi. If required, adjust screw on end opposite solenoid.

• Record max fan rpm in Table 3.

Figure 9 – Fan Pump


Figure 10 - Fan Solenoid block

Cab & House 2.9.• Relief pressure should be 2500 ± 100 psi (factory set).

Figure 11 – Main Pump Adjustments

Fan Stand Still Solenoid Valve

Fan Reversing Solenoid Valve

B Port A Port

MARGIN

HORSEPOWER


Pump Margin 2.10.• Ensure correct track tension, and stall stick out. • Adjust the load sense relief to achieve 4500 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.

• Adjust margin pressure to 325 psi. • Re-check cycle time and adjust as required. If cycle time is adjusted, margin

must also be reset.

• Repeat as necessary.


3. Grapple Setup Ensure that make-up oil has been set before proceeding with grapple setup. Refer to Section 2.3.

Tilt Cylinder 3.1.• Stall stick out and adjust the load sense relief to achieve 2500 psi in the LS2 test

port.

• Engage tilt cylinder out and adjust the port relief (see Figure 5) to crack at 2500 psi.

• Stall stick out and adjust the load sense relief to achieve 3000 psi in the LS2 test port.

• Engage tilt cylinder in and adjust the port relief to crack at 3000 psi.

Main Pressure Setting 3.2.• 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.

Grapple Open/Close, Outriggers 3.3.• 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. (See Figure 12)

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


Figure 12 - MBT Valve

Grapple Rotate Identification 3.4.• Stall stick out and adjust LS relief to achieve 4500 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.

Load Sense Relief 3.5.

• Ensure travel stop is in place and engage right forward travel to confirm LS relief has been set to 4500psi in the P test port.

Proportional Control Handle 3.6.• 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 1600 rpm

Engine - no load - low RPM 900 rpm

Pressure Reducing Valve PRV manifold 420 ± 10 psi

Pilot pressure Cut-out Manifold 400 ± 10 psi

Makeup pressure Pilot Manifold 300 ± 10 psi

Fan Pressure Fan 3500 ± 20psi

Fan Standby Fan 260 ± 10psi

Main Pump - margin pressure Bottom Screw 325 ± 10 psi (2)

Boom up Top 4800 ± 50 psi

Boom down Bottom 4800 ± 50 psi

Stick out Bottom 4800 ± 50 psi

Stick in Top 4800 ± 50 psi

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

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

Swing left (first stage) Right 3300 ± 50 psi

Swing right (first stage) Left 3300 ± 50 psi

Swing left (second stage) 1400 ± 50 psi(1)

Swing right (second stage) 1400 ± 50 psi(1)

Swing compensator Bottom 3300 ± 50 psi

Left reverse travel Top 4800 ± 50 psi

Left forward travel Bottom 4800 ± 50 psi

Right reverse travel Top 4800 ± 50 psi

Right forward travel Bottom 4800 ± 50 psi

Travel Left Shift Point Travel Motor 3100 ± 50 psi

Travel Right Shift Point Travel Motor 3100 ± 50 psi

Load sense relief 4500 ± 50 psi

Full load engine RPM 1980 rpm

See grapple settings, next page

Table 1 - Machine Pressures 1) The low setting on the 2 stage swing relief is to be set at 1400 psi full flow as opposed to crack.

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


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

FUNCTION RELIEF

LOCATION SETTING ACTUAL

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 (V86546) Grapple Head MAX

Rotate CW at cross-port relief (V86546) Grapple Head 3200 ± 50 psi(2)

Rotate CW at pressure limiter (V86546) Grapple Head 2850 ± 50 psi(2)

Rotate CCW at motor (V86546) Grapple Head MAX

Rotate CCW at cross-port relief (V86546) Grapple Head 3200 ± 50 psi(2)

Rotate CCW at pressure limiter (V86546) Grapple Head 2850 ± 50 psi(2)

Table 2 - B&T Pressures


4. Cycle Time Setting Procedure

Cylinder Functions 4.1.• Adjust spool stops on cylinder valves to achieve cycle times shown in Table 3.

Swing 4.2.• 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.

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

low range. • Adjust spool stop on travel valve to achieve low cycle time shown in Table 3.

• Switch to high range. Check and record cycle.

• Repeat procedure for right reverse.

• Repeat procedure for left forward and left reverse.

Fan 4.4.

4.4.1. Override

• Install reflective tape on fan hub.

• Activate fan override with switch in cab.

• Measure fan rpm with tachometer.

• If pressure is set correctly fan speed should be between o 1700-1800rpm (forward) o 1200-1300rpm (reverse)


4.4.2. Temperature Controlled

• To check temperature controlled fan speed the system must be hot enough to bring the fan on full or the parameters can be lowered to bring fan on full.

• To lower parameters connect to fan controller using Bodas software. Go to parameter display/edit, menu 1, sensor 2. This is the engine temperature parameter. Lower the temp 2 min to 50 and temp 2 max to 55.

• Measure fan rpm with tachometer.

• If adjustment is required go to parameter display/edit, menu 1, fan 1 and adjust Imin fan1. Fewer milliamps equal more speed. Normal setting is 10 mA.

Final Imin Setting (forward)_____________

• Manually purge the fan and measure reverse rpm with tachometer.

• If adjustment is required go to parameter display/edit, menu 3, reverse 1 and adjust Imin. Fewer milliamps equal more speed. Normal setting varies, but a good starting point is 260 mA.

Final Imin Setting (reverse)_____________

• Reset sensor 2, temp 2 min to 87 and temp 2 max to 96.

Cab & House 4.5.

• 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 Bottom 0.415

25 (1)

Swing Right Top 0.426 25 (1)

Boom Up Bottom

0.135 9.0 (2)

Boom Down Top

0.182 8.0 (2)

Stick In Bottom 0.195 6.3

Stick Out Top 0.205 7.0

Left Reverse Low Travel Top 0.180 44s ( 3 revs)

Left Reverse High Travel 25s ( 3 revs)

Left Forward Low Travel Bottom 0.180 44s ( 3 revs)

Left Forward High Travel 25s ( 3 revs)

Right Reverse Low Travel Top 0.180 44s ( 3 revs)

Right Reverse High Travel 25s ( 3 revs)

Right Forward Low Travel

Bottom 0.180 44s ( 3 revs)

Right Forward High Travel 25s ( 3 revs)

House Open Bottom Right 6-3/4 turns 23

House Close Bottom Left 7-1/4 turns 19

Cab Operate Top Right 4 turns 34

Cab Transport Top Left 5 turns 49

Fan Forward Temperature Control Mode 1700-1800 rpm (3)

Fan Reverse 1200-1300 rpm (3)

Fan Override Mode Max RPM (4)

Record grapple settings on following page Table 3 - 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) See Section 4.4 for fan setup 4) See Section 2.8 for fan max rpm setup


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 0.242 2.5

Tilt cylinder in (grapple out)

Top 0.170 2.5

Grapple rotate left Grapple Head

13.5 (3 revs)

Grapple rotate 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


Horsepower Adjustment (Travel Method) 4.6.• Connect laptop to engine diagnostic port and load Cummins 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.

• Stall stick out, travel forward in low range and boom up. Adjust HP screws to achieve 1980-1990 rpm, 100% load and with approx. 24 psi (50 in Hg) of boost.

Horsepower Adjustment (Stationary Method) 4.7.• Connect laptop to engine diagnostic port and load Cummins 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.

• Install track stop in left forward travel, stall travel, lift boom and attachment clear off ground, cycle boom up and stick out. Adjust HP screws to achieve 1980-1990 rpm, 100% load with approx. 24 psi (50 in Hg) boost.

Record actual pull down rpm: Record actual boost pressure:

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


Appendix A: Field Calibration


Appendix B: Fan Parameters

Parameter tree 1:


Fan Parameter Tree 1


Parameter tree 2:


Parameter tree 3:

2850 s2 b&t hydraulic setup procedure - madill …...098320b 2850 s2 b&t hydraulic setup...

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