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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