TMS800E Hyd Press Set Proc

Copy Printed 11/26/2008. To confirm status of revision check the Engineering Design Standards – Lotus Notes database.
Printed Copy is Uncontrolled

Number: 80006679
ENGINEERING Revision Number: #
SPECIFICATION Revision Date: 26AUG08
Page 1 OF 20
TMS800E07 PRESSURE SETTING PROCEDURES

OBJECTIVE
To assist personnel in properly checking, adjusting and setting the hydraulic systems pressures.
EQUIPMENT
Required pressure gauge (1) three dial gauge 0-5000 PSI (0-34.5 MPa). (1) Parker Diagnostic Quick
Disconnect p/n PD240.
PROCEDURE INDEX
Procedure Title Page
Pressure Setting Table 3
A. To Check/Set the Main Directional Control Valve, Hoist(s), Lift and Telescope 4-5
Counterweight Removal/Cab Tilt Pressures
B. To Check/Set the Outrigger/swing Circuit Pressure 5-6
C. To Check/Set the Oil Cooler and Air Conditioner Motor Pressure 6
D. To check/Set the Charge Air Cooler Pressure 6
E. To Check/Set the Front Steer Pressure 6-7
F. To Check/Set the Swing Brake Release Pressure 7
G. To Check/Set the Pilot Supply Pressure 7
H. To Check/Set the Piston Pump ΔP Pressure 7
I. To Check/Set the Center Front Stabilizer Pressure 8
J. Procedure for setting Threshold on Electronic Controllers 8-9
K. Procedure for setting Threshold and Max on Swing brake pedal 9
Figures 1 – 9 10-19
Revision Record 20
Proprietary and confidential information: this document and subject matter contained are and at all times shall be the sole and exclusive property of Manitowoc,
Inc., who reserves all rights to the subject matter herein contained. This copy is loaned subject to the agreement and condition that it or the subject matter contained
shall not be disclosed, in whole or in part, to any other party, that it will be kept confidential and that it shall not be copied in any form or in any way disseminated
without the express written permission of Manitowoc, Inc. Acceptance of the copy shall be construed as acceptance of the forgoing condition.
Number: 80006679
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Notes:
• When checking the directional control valve relief settings, unless otherwise specified, start with the
engine at idle RPM and move the controller to its fully stroked position. Then slowly accelerate the
engine to the specified RPM. Read gauge and make adjustment to specified setting.
• When checking the outrigger relief valve setting, start with the engine at idle RPM, activate and
hold the extend or retract switch as specified. Slowly accelerate the engine to the specified RPM.
Read gauge and make adjustment as required.
• The number after GP (gage port) corresponds to the gage port number on the hydraulic schematic
i.e. GP1 through GP10.
Number: 80006679
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Valve Pressure Setting Table

Reservoir oil temperature to be approx. 120° F
VALVE TO BE SET PRESSURE TOLERANCE GAUGE PORT (GPX) &

SETTING PSI (MPa) ADJUSTMENT LOCATION
PSI (MPa)
Hoist (s) & Lift Pressure Setting 4000 (27.6 ) ± 50 (0.4 ) GP2 Superstructure mounted Main
directional control valve load sense
relief valve (see figure #1)
Telescope Extend Pressure 2600 (17.9) ± 50 (0.4 ) GP5 Superstructure mounted Main
Setting directional control valve port relief
valve (see figure #2)
Telescope Retract Pressure 3460 (23.8) ± 50 (0.4 ) GP5 Superstructure mounted Main
Setting directional control valve port relief
valve (see figure #2)
Outrigger Extend/Retract and 3100 (21.4) ± 50 (0.4 ) GP7 Carrier mounted Outrigger
Swing Left/Right Pressure Setting Control Manifold (see figure #6)
Hydraulic Oil Cooler Motor and 2000 (13.8 ) ± 50 (0.4 ) GP10 Carrier mounted Motor Control
Air Conditioner Motor Pressure Manifold (see figure #4)
Setting
Engine Charge Air Cooler 3200 (22.1) ± 50 (0.4 ) GP6 Carrier mounted charge air
Pressure setting cooler manifold. (see figure #5)
Steer Pressure Setting 2175 (15.0 ) ± 50 (0.4 ) GP8 Carrier mounted Power Steering
Assembly (see figure #7)
Swing Brake Supply Pressure 250- 275 See Range GP4 Superstructure mounted
Setting (1.7- 2.1) Accessory with swing directional
control valve (see figure #1)
Pilot Supply Pressure Setting 400- 450 See Range GP3 Superstructure mounted
(2.8- 3.1) Accessory with swing directional
control valve (see figure #1)
Counterweight Removal 2500 (17.2) ± 50 (0.8 ) GP2 Superstructure mounted
Extend/Retract & Cab Tilt Accessory with swing directional
Relief Pressure Setting control valve (see figure #1)
Pump ΔP Pressure Setting 325 – 400 See Range GP2 Carrier mounted Piston pump
(2.2 – 2.8) (see figure #9)
Center Front Stabilizer Relief 175- 225 See Range GP9 Carrier mounted @ inlet to
Setting (1.2 – 1.6) center front stabilizer relief valve
(see figure #8)
Number: 80006679
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A. Procedure for checking/setting the main directional control valve for hoist(s) & boom lift.
To set hoist(s) & boom lift;
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ the GP2
port of the swing and accessory manifold (see figure #1).
2. Assure piston pump “P” max (see figure #9) factory setting is correct. Loosen the jam nut on the “P” max
adjusting screw and turn it “in” until it SOFTLY seats or bottoms out. Then back the adjusting screw “out” ¼
to ½ turn and lock in place with jam nut. This will ensure that full system pressure of 4000 PSI can be
obtained in step #4.
3. If the lift cylinder is not installed, plug the extend hose (the larger of the two). If lift cylinder is installed, omit
this step and continue to step #3.
4. Start engine and throttle up to full RPM (see notes). Feather into the boom lift controller to full controller
stroke (Up or down) and hold. If the boom is installed, boom up to max elevation and hold or boom down to
minimum elevation and hold. Adjust the load sense relief valve “in” to increase or “out” to decrease so that a
gauge pressure reading of 4000 ±50 PSI is achieved (see figure #9).
5. Stop engine and remove the diagnostic couplers from the test nipples.
To set the telescope extend and retract;
Extend:
6. If the boom is not installed, install a pressure check diagnostic quick disconnect (Parker PD240) with gauge
onto test nipple @ the GP5 port @ the inlet of the main directional control valve (see figure #2).
7. Cap hose (the larger of the two) running from port A, telescope section of the main directional control valve
to the cylinder port block at the back of the base section.
8. Start engine and throttle up to full RPM (see notes). Attempt to telescope OUT by feathering into the
controller to full controller stroke. Adjust the work port relief valve “in” to increase or “out” to decrease so
that a gauge pressure reading of 2600 ±50 PSI is achieved (see figure #2).
9. If the boom is installed, start engine and throttle up to full RPM (see notes). Telescope out to fully extend
the boom and hold. Adjust the work port relief valve “in” to increase or “out” to decrease so that a gauge
pressure reading of 2600 ±50 PSI is achieved (see figure #2).
10. Stop engine and remove pressure gauge and re-connect plumbing.
Number: 80006679
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Retract:
11. If the boom is not installed, install a pressure check diagnostic quick disconnect (Parker PD240) with gauge
onto test nipple @ the GP5 port @ the inlet of the main directional control valve (see figure #2).
12. Cap hose (the smaller of the two) running from port B, telescope section of the main directional control
valve to the cylinder port block at the back of the base section.
13. Start engine and throttle up to full RPM (see notes). Attempt to telescope IN by feathering into the
controller to full controller stroke. Adjust the work port relief valve “in” to increase or “out” to decrease so
that a gauge pressure reading of 3460 ±50 PSI is achieved (see figure #2).
14. If the boom is installed, start engine and throttle up to full RPM. Telescope in to fully retract the boom and
hold. Adjust the work port relief valve “in” to increase or “out” to decrease so that a gauge pressure reading
of 3460 ±50 PSI is achieved (see figure #2).
15. Stop engine and remove pressure gauge and re-connect plumbing.
To set the cab tilt and the counterweight removal pressure;
16. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ the GP2
port of the swing and accessory manifold (see figure #1).
17. If the lift cylinder is not installed, plug the extend hose (the larger of the two). If lift cylinder is installed, omit
this step and continue to step #3.
18. Start engine and throttle up to full RPM (see notes). Select and hold the cab tilt switch on the
superstructure cab right arm rest in the “down” position and adjust the load sense relief valve of the
counterweight removal and cab tilt directional control valve “in” to increase or “out” to decrease so that a
gauge pressure reading of 2500 ±50 PSI is achieved (see figure #3).
19. Stop engine and remove the diagnostic couplers from the test nipples.
B. Procedure for checking/setting the outrigger/swing pressures.
1. Install a pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple at GP7 port
of the outrigger control manifold (see figure #6).
2. Start Engine and throttle up to full RPM (see notes). Select and hold either the outrigger “extend” or “retract”
switch on the cab dash. Adjust the pressure reducing valve integrated in the outrigger control manifold “in”
to increase or “out” to decrease so that a gauge pressure of 3100 ±50 PSI is achieved (see figure #6).
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3. Stop engine. Remove the diagnostic coupler.
C. Procedure for checking/setting the oil cooler and air conditioner motor pressure.
1. With engine off, Install a pressure check diagnostic coupler (Parker PD240) with gauge onto the diagnostic
nipple at GP10 port of the motor control manifold (see figure #4).
2. Disconnect and cap hose running from the A2 port of the motor control manifold to hydraulic swivel port #6
(see figure #4).
3. Start engine and throttle up to 1500 RPM (see notes). With the oil cooler motor off adjust relief valve in the
motor control manifold “in” to increase or “out” to decrease so that a gauge pressure of 2000 ±50 PSI is
achieved (see figure #4).
4. Stop engine. Remove diagnostic couplers and re-connect plumbing.
D. Procedure for checking/setting the engine charge air cooler pressure.
1. With engine off, install a pressure check diagnostic quick disconnect (Parker PD240) with gauge onto
diagnostic nipple at GP6 of the charge air cooler control manifold (see figure #5).
2. Disconnect and cap hose running from the A port of the control manifold to the cooler motor inlet (see figure
#5).
3. Remove electrical connector from solenoid valve Y945 on the charge air cooler manifold.
(see figure #5)
4. Start engine and throttle up to 1500 RPM (see notes). Adjust the relief valve in the motor control
manifold “in” to increase or “out” to decrease so that a gauge pressure of 3200 ±50 PSI is achieved (see
figure #5)
5. Stop engine. Remove diagnostic couplers and re-connect plumbing.
E. Procedure for checking/setting the front steer pressure.
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple GP8 port @
the inlet of the power steering gear box (see figure #7a).
2. Disconnect and plug steer hose as shown (see figure #7c).
3. Start engine and throttle up to full RPM (see notes). Fully turn the steering wheel to left or right.
Adjust the priority flow relief valve in the pump (see figure #7b) “in” to increase or “out” to decrease so that a
gauge pressure of 2175 ±50 PSI is achieved.
Number: 80006679
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CAUTION! To prevent pump damage/failure due to heat build up, run the engine at full RPM in this
configuration for a maximum of 15 seconds to 30 seconds..
4. Stop engine. Remove diagnostic couplers.
F. Procedure for checking/setting the swing brake release pressure.
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ GP4B port
of the swing and accessory manifold. Unplug connectors containing wires 50 with 1475. Plug connector
containing wire 50 into the solenoid where wire 1475 was. (See figure #1 for location).
2. Start engine and idle, release swing brake and adjust the swing brake pressure reducing valve “in” to
increase or “out” to decrease so that a gauge pressure of 250-275 PSI is achieved. Then place connectors
back to their original positions. (see figure #1).
3. If adjustment can’t obtain the setting in step #2, stop engine and install a pressure check diagnostic quick
disconnect (Parker PD240) with gauge onto the test nipple @ the GP2 at the accessory manifold valve
(see figure #1). Follow procedure H to set and then repeat this step.
G. Procedure for checking/setting the pilot supply pressure.
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ GP3 port
of the swing and accessory manifold (see figure #1).
2. Start engine and @ idle RPM, lower left armrest, depress and hold the cab tilt lower switch, adjust the
controller pressure reducing valve of the swing and accessory manifold “in” to increase or “out” to decrease
so that the gauge pressure of 400-450 PSI is achieved (see figure #1).
H. Procedures for checking/setting the piston pump ΔP.
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ GP2 port
of the swing and accessory manifold (see figure #1).
2. Start engine and @ idle RPM, adjust the piston pump (ΔP) differential pressure adjusting screw “in” to
increase or “out” to decrease so that a gauge reading of 325 - 400 PSI is achieved (see figure #9).
Number: 80006679
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I. Procedure for checking/setting the Center Front Stabilizer Pressure.
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ GP9 @
the inlet of the center front stabilizer relief valve (see figure #8).
2. Extend the center front stabilizer to the ground and hold switch. Adjust the relief valve ”in” to increase or
“out” to decrease so that a gauge reading of 175 – 225 PSI is achieved (see figure #8).
J. Procedure for setting Threshold on Electronic controllers.
1. Attach test fitting and pressure gage in the Pilot End Caps one at a time at GPA for Main Hoist Up,
GPB for Aux Hoist Up, GPC Tele Retract, GPD Lift Down (see figure #2), GPA and GPB Swing Left
and Right (see figure #1).
Eprom Window
Set
Output Window
Value Window
File Down-Load
Save All
2. Attach laptop to diagnostic connector in cab and bring up the eprom settings (shown in the Figure
above). Arrange windows so you can view the eprom window & Output Window values.
3. Start engine and run at @ idle rpm’s, make sure to lower left armrest.
4. End caps for function ports GPA, GPB, GPC and GPD (see figure #2) move joystick to full on for the
function, monitor the pressure gage and adjust the Max down counts to reach 295psi then a just to
300psi +0/–5psi. Match the counts for the opposite side for Main hoist down and Aux hoist down, Lift
up and Tele ext. (No test Fittings)
5. End caps for function ports GPA and GPB (see figure #1) move joystick to full on for the function,
monitor the pressure gage and adjust the Max up or down on the counts to reach 275psi +5/-0psi.
Number: 80006679
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6. Setting the starting threshold for each function. Start with GPA Main Hoist Up (see figure #2). View the
pressure gage and move the joystick just off center for Main Hoist in the up position. Watch the
pressure gage, move until it reaches approx 100 PSI hold it there and look at the value for Main Hoist
up in the Output Window. If the pressure goes over 100 PSI back the value down. To change the
value double click the value you want to change in the Eprom Window and the value window will turn
blue. Enter the value for the Main hoist up and select “Set” and change the Main Hoist down with the
same settings. Repeat again and make sure that it does not exceed 100 PSI. Do not change the
default settings for the MAX. Repeat this process for ports GPB, GPC, GPD (see figure #2) and GPA,
GPB (see figure #1) and enter values to respected function. Make sure to select SAVE ALL after
completing the entered value settings.
7. After setting all of the functions and selecting save all, select the File Down-Load button. Save the file
in a folder under the model designation (TMS875E07). Name the file as follows:
(Sales order number_Date). Sample: (123456_2006aug17)
K. Procedure for setting Threshold and Max on Swing brake pedal
1. Attach laptop to diagnostic connector in cab and bring up the eprom settings (shown in the Figure in
section J.). Arrange windows so you can view the eprom window & Output Window values
2 Set swing brake center percentage X & Y counts to 500. Attach test fitting and pressure gage GP4
(see in figure #1) port with engine running at idle. Fully depress swing brake pedal. Monitor the press
gage and adjust the swing brake solenoid Max counts to reach 245 psi. Then raise the counts up to
reach 250psi.To set swing brake solenoid threshold. Slowly depress swing brake pedal down until you
reach 25psi on the gage. Then looking at the swing brake output value, set the swing brake solenoid
threshold 5 counts lower then the output value.
Number: 80006679
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See Procedure G
GPB
GP2
See Procedure F
controller
GP4
Wire
Wire
50
1475
GP
GP3
Figure #1
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Procedure A
Tele Extend Port Relief
GPA GPB GPC GPD
Procedure A
Load Sense Relief Valve
Procedure A
Telescope Extend
GP5
Procedure A
Tele Retract Port Relief
Figure 2
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Procedure A
Cab Tilt/Counterweight Removal
Load Sense Relief Valve
Figure #3
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Procedure C
Motor Control Manifold
(Oil Cooler & Air Conditioning)
Relief Valve
GP10
A2 Port
Figure 4
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Procedure D
Charge Air Cooler
Relief Valve
Y945
GP6
Port A
Figure #5
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GP7
Procedure B
Outrigger & Swing Relief Valve
Figure #6
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Figure #7a
Procedure E
Priority Flow
Relief Adjustment
Figure #7b
Procedure E
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Disconnect hose
From tube & plug
Hose using a
7447060609 &
7447060616
Figure #7c
Procedure E
(Location: R.H. Front Steer Cylinder)
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Procedure I
Center front Stabilizer
Relief valve
GP9
Figure #8
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Procedure A Procedure H
Piston Pump P max Setting Piston Pump Δ P Setting
Figure #9
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REVISION RECORD
REV ECO/ER DESCRIPTION BY DATE APPR’D BY

# 117248 FIRST RELEASE MLD 26AUG08 SDS

TMS800E Hyd Press Set Proc

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Copy Printed 11/26/2008. To confirm status of revision check the Engineering Design Standards – Lotus Notes database.

Printed Copy is Uncontrolled

TMS800E07 PRESSURE SETTING PROCEDURES

Procedure Title Page

Pressure Setting Table 3

B. To Check/Set the Outrigger/swing Circuit Pressure 5-6

C. To Check/Set the Oil Cooler and Air Conditioner Motor Pressure 6

D. To check/Set the Charge Air Cooler Pressure 6

E. To Check/Set the Front Steer Pressure 6-7

F. To Check/Set the Swing Brake Release Pressure 7

G. To Check/Set the Pilot Supply Pressure 7

H. To Check/Set the Piston Pump ΔP Pressure 7

I. To Check/Set the Center Front Stabilizer Pressure 8

J. Procedure for setting Threshold on Electronic Controllers 8-9

K. Procedure for setting Threshold and Max on Swing brake pedal 9

Valve Pressure Setting Table

VALVE TO BE SET PRESSURE TOLERANCE GAUGE PORT (GPX) &

To set hoist(s) & boom lift;

To set the telescope extend and retract;

To set the cab tilt and the counterweight removal pressure;

B. Procedure for checking/setting the outrigger/swing pressures.

3. Stop engine. Remove the diagnostic coupler.

4. Stop engine. Remove diagnostic couplers and re-connect plumbing.

D. Procedure for checking/setting the engine charge air cooler pressure.

5. Stop engine. Remove diagnostic couplers and re-connect plumbing.

E. Procedure for checking/setting the front steer pressure.

2. Disconnect and plug steer hose as shown (see figure #7c).

4. Stop engine. Remove diagnostic couplers.

F. Procedure for checking/setting the swing brake release pressure.

4. Stop engine. Remove diagnostic couplers.

G. Procedure for checking/setting the pilot supply pressure.

3. Stop engine. Remove diagnostic couplers.

H. Procedures for checking/setting the piston pump ΔP.

3. Stop engine. Remove diagnostic couplers.

I. Procedure for checking/setting the Center Front Stabilizer Pressure.

3. Stop engine. Remove diagnostic couplers.

J. Procedure for setting Threshold on Electronic controllers.

K. Procedure for setting Threshold and Max on Swing brake pedal

GPA GPB GPC GPD

REV ECO/ER DESCRIPTION BY DATE APPR’D BY

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