Section 6.1 Implement Circuit - General System General: TF Configuration... 6.1.3 TB Configurations... 6.1.5 Implement Pump Breakdown... 6.1.6 Operational Description: General... 6.1.7 Compensator Control... 6.1.7 Standby Condition... 6.1.8 On-Stroke Condition... 6.1.9 Pressure Compensation... 6.1.10 Implement Control Valve: Description... 6.1.11 LS90 Operation... 6.1.11 L90LS Valve Cross-Section... 6.1.12 K220 Valve Cross-Section... 6.1.13 Form T011 6.1.1 Implement Circuit - General
T0026 Figure 1: Simplified TF 830 Implement Circuit Diagram (Typical) Implement Circuit - General 6.1.2 Form T011
General - TF Configurations (See Figure 1) The TimberPro TF 830 implement circuit is a closed center hydraulic system. The system uses state-of-the-art components such as a load sensing axial piston pump, radial piston motors, and pressure compensated (electriccontrolled-pilot operated) control valves. The main components in the system are: 1) 60 gal. (227 litre) hydraulic oil tank for storage and cooling of the hydraulic oil. See Section 3.2 in this manual for important information on the hydraulic tank and its components. 2) 100-mesh implement suction strainer w/ magnetic stem. 3) Suction line shut-off valve. 4) Rexroth AA11VO145 95 gpm (360 litres) variable displacement axial piston implement pump with pressure flow compensating capabilities. 5) VOAC 5-section main control valve with load sensing and flow compensation capabilities. All sections are electric-controlled-pilot operated. 6) Load sense orifice (.024). This orfice is located in the #6 connector turned into the PL port on the mid inlet section of the control valve. 7) High pressure, double acting cylinders and radial piston motors. 8) 14-port rotary manifold for 360 continuous rotation swing. In the implement circuit it provides the hydraulic link to the steer cylinders located in the rear frame. 9) Rexroth AA2FE series fixed displacement, bi-directional, piston motor mated to a Lohamnn GFB-72 planetary reduction gearbox with a wet mult-disc brake and anti-cavitation manifold. 10) 130 psi (1,03 Mpa) return line check valve. To create back pressure in the system to help with Anti-Cavatation on the Swing Motor. This check valve is located inside the end cap of the Voac control valve. 11) High capacity oil cooler with a 120-140 F (49-60 C) thermal bypass and 50 psi (3,45 kpa) back pressure bypass. 12) Return and case drain filters in the hydraulic tank. See Section 3.2 in this manual for important information on the hydraulic tank and its components. 13) Fixed displacement, bi-directional, gear motors that turn the cooling fans for the engine radiator and hydraulic oil cooler. 14) Charge and Fan Drive Manifold. This manifold is supplied oil from the charge pump and controls the oil cooler fans, the radiator fan and also regulates and filters the charge oil being supplied to the wheel drive pump. 15) Charge pump. The charge pump is a 52cc gear pump that supplies oil to the wheel drive pump charge circuit and supplies oil for the radiator and cooler fans. 16) Lower Pressure Supply manifold provides high pressure from the implement pump to the lower manifold. 17) Lower Manifold is used to operate things like the brakes, gear box, motor shift, differential lock, frame lock and is also used to flush hot oil from the wheel drive motors. Form T011 6.1.3 Implement Circuit - General
T0027 Figure 2: Simplified TB 630 Implement Circuit Diagram Implement Circuit - General 6.1.4 Form T011
General - TB Configurations (See Figure 1) The TimberPro TB 630 implement circuit is a closed center hydraulic system. The system uses state-of-the-art components such as a load sensing axial piston pump, radial piston motors, and pressure compensated (electriccontrolled-pilot operated) control valves. The main components in the system are: 1) 60 gal. (227 litre) hydraulic oil tank for storage and cooling of the hydraulic oil. See Section 3.2 in this manual for important information on the hydraulic tank and its components. 2) 100-mesh implement suction strainer w/ magnetic stem. 3) Suction line shut-off valve. 4) Rexroth AA11VO145 95 gpm (360 litres) variable displacement axial piston implement pump with pressure flow compensating capabilities. 5) VOAC main control valves with load sensing and flow compensation capabilities. All sections are electric-controlled-pilot operated. 6) Load sense orifice (.024). This orfice is located in the #6 connector turned into the PL port on the mid inlet section of the control valve. 7) High pressure, double acting cylinders and radial piston motors. 8) 14-port rotary manifold for 360 continuous rotation swing. In the implement circuit it provides the hydraulic link to the steer cylinders located in the rear frame. 9) Rexroth AA2FE series fixed displacement, bi-directional, piston motor mated to a Lohamnn GFB-72 planetary reduction gearbox with a wet mult-disc brake and anti-cavitation manifold. 10) 130 psi (1,03 Mpa) return line check valve. To create back pressure in the system to help with Anti-Cavatation on the Swing Motor. This check valve is located inside the end cap of the Voac control valve. 11) High capacity oil cooler with a 120-140 F (49-60 C) thermal bypass and 50 psi (3,45 kpa) back pressure bypass. 12) Return and case drain filters in the hydraulic tank. See Section 3.2 in this manual for important information on the hydraulic tank and its components. 13) Fixed displacement, bi-directional, gear motors that turn the cooling fans for the engine radiator and hydraulic oil cooler. 14) Charge and Fan Drive Manifold. This manifold is supplied oil from the charge pump and controls the oil cooler fans, the radiator fan and also regulates and filters the charge oil being supplied to the wheel drive pump. 15) Charge pump piggy-back mounted to the implement pump. The charge pump is a 52cc gear pump that supplies oil to the wheel drive pump charge circuit and supplies oil for the radiator and cooler fans. 16) Lower Manifold Supply pump piggy-back mounted to the Charge pump. The Lower Manifold Supply pump is a 10cc gear pump and supplies oil that is used in the lower manifold. 17) Lower Manifold is used to operate things like the brakes, gear box, motor shift, differential lock, frame lock and is also used to flush hot oil from the wheel drive motors. Form T011 6.1.5 Implement Circuit - General
POR Pressure Adjustment Standby Pressure Adjustment Case Drain Suction Inlet Pump Compensator Rexroth AAV11O Series Pump P Pressure Manifold (Connection for P port pressure to control valve & optional clam bunk, and mono-block brake manifold) 00702 Figure 3: Implement Pump Breakdown Implement Circuit - General 6.1.6 Form T011
Load Sense From Valve Standby Pressure Adjust (Load Sensing) Maximum Pressure Limiting (POR) 00705 Figure 4: Pump Compensator Control Operational Description General The implement hydraulic system uses a Rexroth AA11VO series hydraulic pump. This is a variable displacement piston pump with a load sensing, pressure limiting compensator control. Compensator Control (See Figure 4) The compensator control has three main oil galleries that connect to the pump at its mounting base. The first gallery (Ref #1) vents to tank via the pump case. The second gallery (Ref #2) connects to the pump s large control piston. The third gallery (Ref #3) is the P pressure connection. P pressure is the pressure seen at the outlet of the pump and at the pumps small control piston (bias stem). Each spool has a mechanical spring force applied at one end (Ref #6). The amount of spring force can be changed by turning an adjustment setscrew (Ref #7) IN or OUT to preload the spring. Turning the adjustment screw IN increases spring preload, requiring more force at the opposite end of the spool to overcome the spring. Turning the adjustment screw OUT decreases spring preload, requiring less force at the opposite end of the spool to overcome the spring. Both spools are open on the opposite end to P pressure. P pressure provides the hydraulic force used to overcome the mechanical spring force. Inside the compensator control are two spools; stand-by (Ref #4), and pressure limiting, (Ref #5). Form T011 6.1.7 Implement Circuit - General
Standby Condition When all functions are in neutral, oil flow to the main control valve port P is blocked. In this pump standby condition P pressure on one side of the standby (load sensing) spool overcomes the mechanical spring force on the other side of the spool. This forces the spool to shift thus allowing P pressure past the spool to the large control piston. The pressure on the large control piston forces it to shift, overcoming the small control piston (bias stem) and moving the swash plate to the de-stroke position. By adjusting the spring tension exerted against the standby spool, the standby pressure will be increased or decreased. Standby pressure is the minimum pressure required to maintain control of the pump. TF820 standby pressure is set at 400 PSI (2,75 Mpa). 00706 Figure 5: Implement Pump Compensator Control - Standby Condition Implement Circuit - General 6.1.8 Form T011
On-Stroke Condition The main control valve and implement pump are tied together with a load sense signal line. When a function is activated the control valve induces a load sense signal to the spring side of the standby (load sensing) spool. The load sense pressure adds to the existing spring force which in turn overcomes P pressure on the other side of the spool. This forces the standby spool to shift thus venting the large control piston to the hydraulic tank through the pump case drain. With the large control piston vented to tank, P pressure on the small control piston (bias stem) moves the swash plate to it s on-stroke position. The strength of the load sense signal from the control valve determines how much pressure will be required to do the work. 00707 Figure 6: Implement Pump Compensator Control - On-Stroke Condition Form T011 6.1.9 Implement Circuit - General
Pressure Compensation To limit maximum implement system pressure the pump uses an adjustable pressure compensator (also called pressure limiting or pressure override<por>). POR pressure is set at 3000 PSI (20,6 Mpa), for the TF and TS configurations, or 3800 PSI (26,2 Mpa) for the TB configuration. Pressure compensation is done at the pump compensator with a pressure limiting (POR) spool. On one side of the pressure limiting spool is adjustable spring force. On the other side of the spool is P pressure. When P pressure overcomes the spring force the spool shifts, routing P pressure past the spool to the large control piston. This pressure on the large control piston forces it to shift, overcoming the small control piston (bias stem) and moving the swash plate to the minimum displacement position. The pump in this position would produce only enough flow to maintain the maximum system pressure. 00708 Figure 7: Implement Pump Compensator Control - Pressure Compensation Implement Circuit - General 6.1.10 Form T011
Implement Control Valve Description The Timberpro T800 utilizes a VOAC L90LS or K220 series directional control valve. The valve is a stackable proportional, load sensing and flow compensated, closed center valve. The valve is controlled with proportional, electric-over-hydraulic controls. L90LS Operation NOTE: Operation of the K220 valve used on the TB configuration is very similar in operation to the L90LS valve used on the TF and TB configurations. By breaking the VOAC valve down into its three major components (Mid inlet section, end section, and spool section) it will be easier to understand. Inlet Section The inlet section is where the pump connections are made. These connections are the load sense line and pump pressure line and tank. A direct acting main safety relief is also incorporated into the inlet section to protect the valve and pump from pressure spikes. This relief is a cartridge style relief that is factory preset at 4350 PSI (300 bar) and is not adjustable. End Section Internal pilot pressure supply is a valve function built into the end section. The end section is fitted with a non-adjustable pilot pressure reducing valve factory preset at 320 PSI (22 bar). This gives an internal pilot supply for the electro-hydraulic pilot caps to shift the main valve spools. For safety reasons, the pilot pressure reducing valve is equipped with a separate non-adjustable safety relief factory preset at 500 PSI (35 bar). Also incorporated into the end section is a pilot oil filter equipped with a bypass. The filter protects internal pilot circuit from contamination. Four ports are used in the end section. 1) T2B - Return oil to tank. 2) T3B - Oil supply for the frame lock circuit 3) LSP - Load sense drain 4) P2 - Auxiliary pressure port that supplies the mono-block valve Spool Section (See Figure 8) The spool section consists of a body, 4-way main spool, compensator spool, port relief valves, and electric proportional solenoids. The electric proportional solenoids (Ref #6 & #7) are controlled by a proportional current signal from the IQAN digital control system. As the current to the solenoids changes, the valve produces a pilot signal proportional to the current supplied. This changing pilot pressure pushes the 4-way main spool (Ref #2) in either the A or B direction. Not only is direction determined, but also how far the spool travels. Primary load sense is connected through the timed drillings in the main spool (Ref #4). When the main spool shifts the load sense will communicate with the work ports. The load sense signal travels to the pump control through the section shuttle valve (not shown). These shuttles are hardened seats located between each section. The series of shuttles allow only the load sense signal from the section with the highest pressure to reach the pump. The load sense signal also travels into the spring chamber (Ref #9) of the section compensator spool (Ref #10). The compensator spool spring and the section s load sense pressure maintain a constant pressure across the main spool. Having a constant pressure drop across the main spool allows the section to deliver oil flow that is proportional to the main spool position. Port reliefs (Ref #3 & #5) are also used on all sections. The port reliefs on standard machines are set at 4060PSI (280 bar). All port reliefs have an anti-cavitation feature. The system tank line has a 130 PSI (9 bar) back pressure check valve. The back pressure check valve causes the oil flow through the anti-cavitation checks to maintain back pressure on all components. Form T011 6.1.11 Implement Circuit - General
1) Spool Stop 2) 4-Way Main Spool 3) A Port Relief 4) Load Sense Communication Hole 5) B Port Relief 6) A Solenoid Coil 7) B Solenoid Coil 8) LS Dampening Orifice 9) Compensator Spring 10) Compensator Spool 11) Centering Spring 12) Cover 13) Proportional Solenoid Orifice 00601 Figure 8: Implement Control Valve Spool Section Cut-Away - LS90 Implement Circuit - General 6.1.12 Form T011
1) Spool Stop 2) Main Work Spool 3) A Port Relief 4) Load Sense Communication Hole 5) B Port Relief 6) A Solenoid Coil 7) B Solenoid Coil 8) Proportional Solenoid Orifice 9) Compensator Spool 10) Cover T0837 Figure 9: Implement Control Valve Spool Section Cut-Away - K220 Form T011 6.1.13 Implement Circuit - General
Implement Circuit - General 6.1.14 Form T011
Section 6.2 Implement Circuit - Tests & Adjustments Safety Information.... 6.2.2 Tools Required... 6.2.2 Implement Pump Stand-by Pressure... 6.2.3 Implement Pump POR Pressure... 6.2.5 Implement Pump Case Pressure... 6.2.6 Implement Pump Case Flow... 6.2.7 Swing Charge Pressure... 6.2.8 Swing Pump POR Pressure... 6.2.9 Swing Pump Null... 6.2.10 Disc Saw Pump Stand-by.... 6.2.12 Disc Saw Pump POR... 6.2.13 Form T012 6.2.1 Implement Circuit - Tests & Adjustments
Safety information You must read and understand the warnings and basic safety rules, found in Group-1 of the Operation & Maintenance manual, before performing any operation, test or adjustment procedures. Tools Required Tachometer 0-60 psi (0-1000 kpa) pressure gauge 0-600 psi (0-5 Mpa) pressure gauge 0-10,000 psi (0-80 Mpa) pressure gauge 9/16, 11/16, 3/4, 13/16, 1-1/4, & 1-3/8 wrenches 13mm wrench 4mm allen wrench PN# 15437, #12 ORS cap PN# 15869, quick-couple adapter PN# 18838, #6 ORS plug PN# 18839, #6 ORS cap Gauge test hose #12 ORBM - #4 JICM adapter Calibrated container - 10 gallons (38 litres) Stop watch The operator or another mechanic may be required to operate a control while a pressure reading is being taken. 00015 Diesel exhaust fumes contain elements that are hazardous to your health. Always run engine in a well ventilated area. If in an enclosed space, vent exhaust to the outside. NOTE: Each machine is shipped from the factory with at least one 600 psi and one 10,000 psi gauge with quick-couple adapters. The gauges can be found in the machine Up-Time Kit. 00017 At operating temperature, the engine, exhaust system components, cooling system components and hydraulic system components are HOT. Any contact can cause severe burns. Implement Circuit - Tests & Adjustments 6.2.2 Form T012
Implement Pump Stand-By Pressure Specification: 400-425 psi (28 bar) Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at idle Procedure: 1. Ensure the hydraulics are at correct operating temperature. Figure 1: Disconnect Load Sense Line (Typical) 00589 2. Open the rear gullwing guard to access the swing pump. 3. Use the 13/16 wrench to disconnect the implement pump s load sense line were it connects to the load sense shuttle valve. See Figure 1. NOTE: The load sense must be disconnected before testing or adjusting the implement pump stand-by pressure. This prevents false readings from the control valve interacting with the pump. 3. Plug the Hose, but leave the pump open to atmosphere. 4. Start the engine and run at idle. 5. Connect the 600 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 2. NOTE: Only install a 600 psi pressure gauge after the engine is running. If the gauge is installed before the engine is started it can be damaged. 6. Read the pressure gauge, the implement pump stand-by pressure should be set at 400-425 psi (28 bar). If implement pump stand-by pressure setting is correct, go to step #11. If adjustment is required, continue with step #7. 7. Use the 13mm wrench to loosen the jam nut on the stand-by pressure adjustment setscrew. See Figure 3. 8. Use the 4mm allen wrench to turn the adjustment setscrew. T0026 Figure 2: Implement Pump Pressure Gauge Port Tap Turning the adjustment setscrew CLOCKWISE increases the pressure setting. Turning the setscrew COUNTER-CLOCKWISE decreases the pressure setting. Form T012 6.2.3 Implement Circuit - Tests & Adjustments
00676 Stand-By Pressure Figure 3: Implement Pump Stand-By Pressure Adjustment 9. Read the pressure gauge and adjust pressure setting as required. 10. After the correct pressure setting is made, tighten the jam nut to lock the setscrew. 11. Remove the pressure gauge and shut down the engine. 12. Re-connect the load sense line removed in step #3. NOTE: It is not necessary to bleed the load sense line because the pump is vented internally. 13. Close and secure the rear engine guard. Implement Circuit - Tests & Adjustments 6.2.4 Form T012
Implement Pump POR Pressure Specification: 3800 +/- 50 psi (262 +/- 3.5 bar) NOTE: The settings listed above are standard settings for most TimberPro machines. Some specialized machines with special attachments can require these settings to be different. Please contact your TimberPro dealer if you have any question on the setting of your machine. Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at high idle (approx. 1200 RPM). Procedure: 1. Ensure the hydraulics are at correct operating temperature. 2. Open the rear gullwing guard to access the swing pump. 3. Connect the 10,000 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 2. 4. Start engine and increase engine throttle to high idle (approx. 1200 RPM). 5. Instruct the operator or another mechanic to bottom out an implement function while you read the pressure gauge, implement pump POR pressure should be set at specification. (Because different function have different pressure settings make sure and select a function (stick boom) that has a main relief setting higher than the implement pump POR.) 00676 See Figure 5. 8. Use the 4 mm allen wrench to turn the adjustment setscrew. Turning the adjustment setscrew CLOCKWISE increases the pressure setting. Turning the setscrew COUNTER-CLOCKWISE decreases the pressure setting. 9. Instruct the operator or another mechanic to bottom out an implement function while you read the pressure gauge, implement pump POR pressure should be set at specification. (Because different function have different pressure settings make sure and select a function (stick boom) that has a main relief setting higher than the implement pump POR.) 10. After the correct pressure setting is made, tighten the jam nut to lock the setscrew. 11. Shut down the engine. POR Pressure Figure 5: Implement Pump POR Pressure Adjustment 12. Remove the pressure gauge then close and secure all access panels and guards. 6. If implement pump POR pressure setting is correct, go to step #10. If adjustment is required, continue with step #7. 7. Use the 13 mm wrench to loosen the jam nut on the POR pressure adjustment setscrew. Form T012 6.2.5 Implement Circuit - Tests & Adjustments
Implement Pump Case Drain Pressure Specification: Maximum 35 psig (2.4 bar) allowed. Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at full throttle (approx. 2000 RPM). Implement pump pressure at specification. Procedure: 1. Produce a gauge test hose that will allow you to tee in a 60 psi (4 bar) gauge to the #12 ORFS connector that will be installed into the implement pump case drain port. 2. Ensure the hydraulics are at correct operating temperature. 3. Open the rear gullwing guard to access the swing pump. Be sure the pump case is full of oil before starting the machine otherwise catastrophic damage to the pump will occur. 6. Start engine and run at full throttle. 7. Instruct the operator or another mechanic to bottom out an implement function and hold it for a full minute while you observe the pressure gauge. The implement pump case drain pressure should not exceed specification. If the specification is exceeded, look for conditions that would increase backpressure in the case drain circuit such as a plugged case drain filter element, failing component, etc. 8. After completing the test, cycle all implement functions for a least 2-minutes to cool the hydraulics down. 9. Shutdown the engine and remove the adapter tee that was installed for testing. 10. Close and secure the rear engine guard. 4. Locate and remove the implement pump case drain hose and connector and tee in a fitting and 60 psi (4 bar) gauge. 5. Install the gauge test hose and pressure gauge to the case drain port adapter. Implement Circuit - Tests & Adjustments 6.2.6 Form T012
Implement Pump Case Drain Flow Specification: New or rebuilt - Maximum 4.6 gpm (17,5 litres) allowed. Used - Maximum 5.8 gpm (22 litres) allowed. Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at full throttle (approx 2000 RPM). Implement pump pressure at specification. Procedure: 1. Ensure the hydraulics are at correct operating temperature. 2. Open the rear gullwing guard to access the swing pump. Be sure the pump case is full of oil before starting the machine otherwise catastrophic damage to the pump will occur. 5. Start engine and run at full throttle. Immediately have the operator or another mechanic bottom out an implement function and hold it for a full minute. 6. After one minute, deactivate the implement function and shutdown the engine. 7. Remove implement pump case drain hose from the container and re-connect it to the hydraulic tank. 8. Cycle all implement functions for a least 2-minutes to cool the hydraulics down. 9. Measure the oil in the container. If the amount exceeds specification, the implement pump is worn or failing and may have to be replaced. 10. Close and secure the rear engine guard. 3. Use the 1-1/4 and 1-3/8 wrenches to remove the implement pump case drain line at the hydraulic tank. Cap the fitting to prevent contaminates from entering the hydraulic system. 4. Place the open end of the case drain hose into the calibrated container. Form T012 6.2.7 Implement Circuit - Tests & Adjustments
Swing Drive Charge Pressure Specification: DO NOT set charge pressure above 450 psig (31 bar). Overheating of the circuit and damage to the system can result. 425 psig (29.3 bar) Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. T00026 Figure 6: Swing Drive Charge Pressure Gauge Port Tap Engine operating at high idle (approx. 1500 RPM). Procedure: 1. Ensure the hydraulics are at correct operating temperature. 2. Start the engine and run at low idle. 3. Connect the 600 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 6. NOTE: Only install a 600 psi pressure gauge after the engine is running. If the gauge is installed before the engine is started it can be damaged. 6. Increase engine throttle to high idle (approx. 1500 RPM). 7. Read the pressure gauge, the Swing Drive charge pressure should be set at 425 psig (29.3 bar). If Swing Drive charge pressure setting is correct, go to step #10. If adjustment is required, continue with step #8. T00026 Figure 7: Swing Drive Charge Pressure Manifold 9. Locate the large charge pressure relief cartridge. See Figure 2. Use the 9/16 wrench and 5/32 allen wrench to loosen the jam nut. Turning the adjustment setscrew CLOCKWISE increases the pressure setting. Turning the setscrew COUNTER-CLOCKWISE decreases the pressure setting. 10. Read the pressure gauge, re-adjust pressure setting as required. After the correct pressure setting is made, tighten the jam nut to lock adjustment setting. 11. Shut down the engine. Remove the pressure gauge and secure the rear engine guard. 8. Open the rear engine guard and locate the Charge pressure manifold assembly. See Figure 7. Implement Circuit - Tests & Adjustments 6.2.8 Form T012
Swing Pump POR Pressure Specification: 3350 psig (230 bar) Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine at high idle (approx. 1500 RPM). Swing Pump charge pressure and charge spike relief set to specification. Procedure: Figure 8: Swing Pump Pressure Gauge Port Tap Operating the Swing Drives over relief produces extreme heat that can damage hydraulic system components. Expedite all pressure readings and adjustments. 1. Ensure the hydraulics are at correct operating temperature. 2. Position the boom close to the machine and chain the boom to the frame of the machine to stop the machine from swinging. Make sure to use a chain heavy enough to safely stop the machine from swinging. 6. Locate the POR relief on the Swing Pump. See Figure 9. Use the 13mm wrench and 4mm allen wrench to loosen the jam nut on the POR relief adjustment setscrew. 7. On your signal, have the operator or another mechanic apply the swing function while you set the POR relief to 3350 psig (230 bar). Turning the adjustment setscrew CLOCKWISE increases the pressure setting. Turning the setscrew COUNTER-CLOCKWISE decreases the pressure setting. 3. Connect the 10,000 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 8. 4. Instruct the operator or another mechanic to start the engine and run at high idle (approx. 1500 RPM). 5. On your signal, have the operator or another mechanic apply the swing function while you set the POR relief to 3350 psig (230 bar). If Swing Pump POR pressure is correct, go to step #11. If an adjustment is required, continue with step #7. Figure 9: Swing Drive POR Relief 00675 Form T012 6.2.9 Implement Circuit - Tests & Adjustments
8. After the correct pressure setting is made, hold the adjustment setscrew stationary and tighten the jamnut to hold the pressure setting. 9. Shut down the engine and remove the pressure gauge. 10. Shut down the engine. Swing Pump Null Specification: Obtain the lowest possible pressure between ports X1 and X2 with the jumper hose installed. Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at idle Procedure: 1. Ensure the hydraulics are at correct operating temperature. 2. Position the boom close to the machine and chain the boom to the frame of the machine to stop the machine from swinging. Make sure to use a chain heavy enough to safely stop the machine from swinging. 3. Open the rear gullwing guard to access the swing pump. 4. Using the 3/16 allen wrench, remove the plugs from ports X1 and X2. See Figure 11. Install the #6 ORBM adapters into the ports. 5. Connect the 24 (61cm) jumper hose between ports X1 and X2. 6. Start the engine and run at idle. The engine will remain running throughout the procedure. 7. Connect the 10,000 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap on the Swing Pump. See Figure 10. 8. The mechanical null adjustment is made with a large setscrew in the control piston cover. See Figure 13. Use the 24mm wrench and 8mm allen wrench, to loosen the jamnut and turn the adjustment setscrew in and out until the gauge reads the lowest possible pressure. NOTE: The lowest pressure reading indicates when the control piston is in the centered null position. 9. Remove the 10,000 psi gauge and install the 600 psi gauge in its place. Repeat step #8 to make the final adjustment. 10. Remove the 600 psi gauge and install the 10,000 psi gauge in its place. 00582 Figure 10: Swing Pump Pressure Gauge Port Tap The hydraulic null adjustment is made with an eccentric pin and should not be turned more than 90 from center (as indicated by a notch on the adjustment screw), otherwise damage to the eccentric pin could result. 11. The hydraulic null adjustment is made with a small setscrew on top of the stroke control. See Figure 11. Use the 13 mm wrench and 4 mm allen wrench, to loosen the jam nut and turn the adjustment setscrew in and out until the gauge reads the lowest possible pressure. NOTE: The lowest pressure reading indicates when the control spool is in the centered null position. 12. Remove the 10,000 psi gauge and install the Implement Circuit - Tests & Adjustments 6.2.10 Form T012
Port X2 Port X1 Hydraulic Null Adjustment Setscrew Mechanical Null Adjustment Setscrew 00675 Figure 11: Hydrostatic Pump Null Adjustments 600 psi gauge in its place. Repeat step #11 to make the final adjustment. 13. Shut-down engine and remove jumper hose, fittings, and gauge. 14. Procedure complete. Form T012 6.2.11 Implement Circuit - Tests & Adjustments
Disc Saw Pump Stand-By Pressure Specification: 145-200 psig (10-13.8 bar) Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at idle Tools Required: 17 mm wrench 3/16 Allen wrench 3 mm Allen wrench 0-600 psi (0-41.37 bar) pressure gauge Procedure: 1. Be sure the disc saw circuit switch on the right Joystick Pod is in the OFF position so that the disc saw blade does not start during the procedure. See Figure 6. 2. Open the rear gullwing guard to access the disc saw pump. 3. Install the gauge at the disc saw pump pressure output block See Figure 12. 4. Start the engine and run at low idle. Figure 12: Disc Saw Circuit ON and OFF Switch If the disc saw stand-by pressure setting is correct, go to step #12. If adjustment is required, continue with step #9. 9. Locate the stand-by pressure adjustment setscrew on the disc saw pump compensator. See Figure 13. 10. Use the 17 mm wrench to remove the protective acorn nut. Use the 3 mm Allen wrench to hold the adjustment setscrew stationary while loosening the jamnut with the 17 mm wrench. 11. Turn the adjustment setscrew out COUNTERCLOCKWISE until the gauge reads about 100 psig (690 kpa), then in CLOCKWISE until the gauge reads the correct pressure of 145-200 psig (10-13.8 bar). Gauge Port T00051 5. Ensure the hydraulics are at correct operating temperature. 6. Connect the 600 PSI pressure gauge to the gauge test hose. 7. Increase engine throttle to 1500 RPM. 8. Read the pressure gauge. The disc saw stand-by pressure should be set at 145-200 psig (10-13.8 bar). Stand-By Pressure 00531 Figure 13: Stand-by Pressure Gauge Installation (Typical) Implement Circuit - Tests & Adjustments 6.2.12 Form T012
Tighten the jamnut to lock in the adjustment. See Figure 13. Gauge Port 12. Shut-down the engine and remove the gauge test hose and pressure gauge. 13. Close and secure the rear gullwing guard. 14. Procedure complete. Disc Saw Pump POR Pressure Tools Required: 17 mm wrench 3 mm Allen wrench Specification: 3950 psig (272 bar) Test Standards: Hydraulics at operating temperature of 140 F (60 C) or greater. Engine operating at 1250-1500 RPM. POR Pressure 2. Open the rear gullwing guard to access the disc saw pump. 3. Start the engine and run at low idle. 4. Ensure the hydraulics are at correct operating temperature. 00531 Figure 15: POR Pressure Gauge Installation (Typical) 5. In order to get an accurate compensator pressure reading, the cutting disc must be pinned to prevent rotation. See the disc saw attachment manual for this procedure. 6. Increase engine speed to full throttle. Procedure: 1. Be sure the disc saw circuit switch on the right Joystick Pod is in the OFF position so that the disc saw blade does not start during the procedure. See Figure 14. Flying objects and moving parts can cause serious personal injury or death. Keep clear of disc saw cutting attachment when in operation. 7. Turn the disc saw circuit ON to signal the disc saw to come on-stroke. See Figure 14. 8. Read the pressure gauge mounted in the cab on the front left dash panel. See Figure 7. The disc saw POR pressure should be set at 3800 psig (262 bar). If the disc saw POR pressure setting is correct, go to step #12. If adjustment is required, continue with step #9. Form T012 T00051 Figure 14: Disc Saw Circuit ON and OFF Switch 6.2.13 9. Locate the compensator pressure adjustment setscrew on the disc saw pump Implement Circuit - Tests & Adjustments
compensator. See Figure 15. 10. Use the 17 mm wrench to remove the protective acorn nut. Use the 3 mm Allen wrench to hold the adjustment setscrew stationary while loosening the jamnut with the 17 mm wrench. 11. Turn the adjustment setscrew out COUNTERCLOCKWISE until the gauge reads about 3200 psig (220.6 bar), then in CLOCKWISE until the gauge reads the correct pressure of 3950 psig (272 bar). Tighten the jamnut to lock in the adjustment. See Figure 9. 12. Shut-down the engine. 13. Close and secure the swing-out pump access guard. 14. Procedure complete. Implement Circuit - Tests & Adjustments 6.2.14 Form T012