999 SERVICE MANUAL
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM CALIBRATION
PROCEDURES
To ensure proper operation of the crane functions, the
charge pressures, pressure senders, pump control system,
and pump pressures must be properly calibrated. Calibration
screens are provided to assist in the calibration process.
Front
Console
Display
Scroll
Up-Down
Rocker
Limit Bypass
Switch
8.
Once all items are calibrated, turn crane mode switch
CLOCKWISE to SELECT position to turn off calibration
sequence. Cursor (*) will disappear from screen.
Each calibration item is assigned a number in the binary
system (power of two). After running a calibration check,
outputs that are on (active) for any item, are added together.
To identify the active items, find the binary number displayed
on the screen in the first column of Table 2-9. All shaded
boxes to the right of the of the number indicate active items
(items that failed calibration). Troubleshoot the particular
system to determine the cause of the fault.
If the number displayed on the screen is 0, there are no
active items (all items passed calibration).
Calibration Procedures
Pressure Sender
Crane
Mode
Switch
The pressure sender screen (Figure 2-9) indicates if each
systems pressure sender null (0) is within 0.65 1.35 volts.
A1182
FIGURE 2-8
Accessing Calibration Screens
WARNING
Moving Load Hazard!
With engine running, crane functions (drums, boom hoist,
swing, travel) can operate unexpectedly while system
components are being calibrated.
To prevent crane functions from moving:
Turn park on for all crane functions.
To access calibration screens, proceed as follows. See
Figure 2-8 for location of controls.
1.
Select and confirm Setup mode to activate calibration
program.
2.
Turn bypass switch clockwise and hold and scroll up to
access diagnostic screens.
3.
Scroll up or down to HYD SYSTEM CHECK in display.
4.
Turn crane mode switch CLOCKWISE to SELECT
position. A cursor (*) will appear next to item being
calibrated.
5.
Scroll up or down to desired calibration screen.
6.
Turn crane mode switch COUNTERCLOCKWISE to
CONFIRM position to start calibration of selected item.
7.
Once selected item is calibrated, repeat steps 3 6 for
next item.
The pressure senders must be calibrated at the following
intervals:
When a new programmable controller is installed.
When a new CPU board is installed.
When a new controller chip is installed.
When a pump is replaced.
When a pump control (EDC or PCP) is replaced.
When a pressure sender is replaced.
When displayed pressure is not correct.
Every 6 months.
To calibrate the pressure senders, proceed as follows:
1.
Access calibration screen (see Accessing Calibration
Screens procedure).
2.
Stop engine (leave ignition and cab power switches on).
It is normal for yellow operating limits light to come on
during this procedure.
3.
Calibration will not start if engine is running or will stop if
engine is started during calibration.
4.
When calibration starts, percent (%) of completion is
displayed on screen.
5.
Check binary number in screen when calibration is
done:
a.
If 0 appears, all items have passed.
b.
If any number other then 0 appears, use Table 2-9 to
determine which items have failed.
2-9
HYDRAULIC SYSTEM
999 SERVICE MANUAL
Binary
Number
HYD SYSTEM CHECK
* PRES SENDER 0% 15
Percent
Complete
Binary
Number
Calibration Item
Binary
Number
Binary
Number
HYD SYSTEM CHECK
* CHARGE PRES
15
Binary
Number
Calibration Item
Binary
Number
Calibration Item
Front Drum
16
Swing Left 1
Rear Drum
32
Travel Right
Calibration Item
Front Drum
16
Swing Left
Boom Hoist
64
Travel Left
Rear Drum
32
Travel Right
Swing Right
128
Accessory System
Boom Hoist
64
Travel Left
Swing Right
128
Accessory System
Same Pump as Swing Right
FIGURE 2-10
FIGURE 2-9
Charge Pressure
The charge pressure screen (Figure 2-10) indicates if each
systems charge pressure is within 275 400 psi (19 27
bar), as monitored by the computer.
Charge pressure should be checked at the following
intervals:
When a new programmable controller is installed.
When a new CPU board is installed.
When a new controller chip is installed.
When a pump is replaced.
When a pump control (EDC or PCP) is replaced.
Every 6 months.
Control System
The control system calibration screen (Figure 2-11) indicates
whether the pump center is within the allowable range for
each pumps Electric Displacement Control (EDC). The
allowable range is 5 25% pump command signal for hoist
pumps, and 2.5 20% in each direction for swing.
Control system calibration must be performed at the
following intervals:
When a new programmable controller is installed.
When a new CPU board is installed.
When a new controller chip is installed.
When a pump is replaced.
When a pump control (EDC or PCP) is replaced.
When there is a noticeable time increase to engage a
crane function when handle is moved from off.
Every 6 months.
To check charge pressure, proceed as follows:
1.
Start engine and run at low idle.
2.
Access calibration screen (see Accessing Calibration
Screens procedure).
To check control system calibration, proceed as follows:
3.
Screen indicates state of charge pressure:
1.
Access calibration screen (see Accessing Calibration
Screens procedure).
a.
If 0 appears, charge pressure is okay for all items.
2.
b.
If any number other then 0 appears, use Table 2-9 to
determine which items are not within specified
charge pressure.
Turn PARK ON for all crane functions (drums, boom
hoist, swing, travel).
3.
Start engine and run at high idle. It is normal for yellow
operating limits light to come on during this procedure.
Calibration will not start if engine is not running at
high idle. Calibration will stop if engine speed is
decreased during calibration.
2-10
4.
When calibration starts, percent (%) of completion is
displayed on screen.
5.
It takes approximately 2 minutes to complete check.
999 SERVICE MANUAL
6.
HYDRAULIC SYSTEM
Check binary number in screen when calibration is
done:
a.
If 0 appears, all items have passed.
b.
If any number other then 0 appears, use Table 2-9 to
determine which items have failed.
HYD SYSTEM CHECK
* CONTROL CAL 0% 15
Binary
Number
To check pump pressure calibration, proceed as follows:
1.
Access calibration screen (see Accessing Calibration
Screens procedure).
2.
Turn PARK ON for all crane functions (drums, boom
hoist, swing, travel).
3.
Start engine and run at:
HIGH IDLE, field personnel.
1,500 rpm, MCC assembly personnel when
checking out a new crane
Percent
Complete
Binary
Number
Swing Right
Swing Left 1
Front Drum
Rear Drum
16
Boom Hoist
32
Auxiliary Drum (in butt)
Testing will not start if engine is not running
faster than 900 rpm.
4.
Calibration will not start if engine is not running.
Calibration will stop if engine speed is decreased during
calibration.
5.
When calibration starts, the percent (%) of completion is
displayed on screen.
6.
Check binary number in screen when calibration is
done:
Calibration Item
Same Pump as Swing Right
a.
If 0 appears, all items have passed.
b.
If any number other then 0 appears, use Table 2-9 to
determine which items have failed.
FIGURE 2-11
Pump Pressure
The pump pressure screen (Figure 2-12) cycles through the
hoist pumps to make sure each pump is capable of
producing 6,000 psi (414 bar).
Pump pressure calibration must be performed at the
following intervals:
HYD SYSTEM CHECK
* PUMP PRES
0% 15
Binary
Number
Percent
Complete
Binary
Number
Calibration Item
When a new programmable controller is installed.
Front Drum
When a new CPU board is installed.
Rear Drum
When a new controller chip is installed.
Boom Hoist
When a pump is replaced.
Auxiliary Drum
16
Travel Right
When a pump control (EDC or PCP) is replaced.
32
Travel Left
When displayed pressure is not correct.
Every 6 months.
FIGURE 2-12
2-11
HYDRAULIC SYSTEM
2-12
44
87
45
88
46
89
47
90
48
91
49
92
50
93
51
94
52
95
10
53
96
11
54
97
12
55
98
13
56
99
14
57
100
15
58
101
16
59
102
17
60
103
18
61
104
19
62
105
20
63
106
21
64
107
22
65
108
23
66
109
24
67
110
25
68
111
26
69
112
27
70
113
28
71
114
29
72
115
30
73
116
31
74
117
32
75
118
33
76
119
34
77
120
35
78
121
36
79
122
37
80
123
38
81
124
39
82
125
40
83
126
41
84
127
42
85
128
43
86
129
128
32
64
16
4
8
128
32
64
16
4
8
128
32
64
16
4
8
Binary System
Table 2-9
999 SERVICE MANUAL
999 SERVICE MANUAL
HYDRAULIC SYSTEM
130
173
216
131
174
217
132
175
218
133
176
219
134
177
220
135
178
221
136
179
222
137
180
223
138
181
224
139
182
225
140
183
226
141
184
227
142
185
228
143
186
229
144
187
230
145
188
231
146
189
232
147
190
233
148
191
234
149
192
235
150
193
236
151
194
237
152
195
238
153
196
239
154
197
240
155
198
241
156
199
242
157
200
243
158
201
244
159
202
245
160
203
246
161
204
247
162
205
248
163
206
249
164
207
250
165
208
251
166
209
252
167
210
253
168
211
254
169
212
255
170
213
171
214
172
215
128
32
64
16
4
8
128
32
64
16
4
8
128
32
64
16
4
8
Table 2-9 Binary System (continued)
2-13
