Hydraulic Pressure Settings

Number: A80001819
ENGINEERING Revision Number: #

SPECIFICATION Revision Date: (26-SEP-07)
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OBSOLETES A6-829-103589
TITLE
RT600E2 HYDRAULIC PRESSURE SETTING PROCEDURES
OBJECTIVE
To assist personnel in properly checking, adjusting and setting the hydraulic system pressures.
EQUIPMENT
Required; Pressure gauge (1) three dial gauge 0-5000 PSI (0-34.5 MPa).
Accumulator charging and gauging assembly for 3000 PSI (20.7 MPa).
PROCEDURE INDEX PAGE
A. To Check Main Directional Control Valve Reliefs ……………………………………………. 2-3
B. To Check Main Directional Control Valve Pilot Supply Pressure…………………………….. 3
C. To Check Swing Brake Pilot Supply Pressure .……………………………………………….. 4
D. To Check Service Brake & A/C Circuit Relief Valve Pressure ……..………………………….. 4
E. To Check Service Brake Dual Accumulator Charge Valve Pressure Limits ….…….…………. 5
F. To Check Accumulator Pre-Charge Pressure …….…..………………………………………… 6
G. To Set Accumulator Pre-Charge Pressure …….…..…….……………………………………… 6-7
H. To Check Front Steer Relief Valve Pressure ….…………………………………………...….. 8
I. To Check Swing/Steer Directional Control Valve Work Port Reliefs Pressure …....……….… 8
J. To Check Outrigger/Rear Steer Relief Valve Pressure …..……………………………………... 9
Revision Record ………………………………………………………………………….….…. 10

Notes:
• When checking the directional control valve relief settings, start with the engine at idle RPM and move the
controller to it’s 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 and activate and hold the
extend switch. Then slowly accelerate the engine to the specified RPM. Read gauge and make adjustment
as required.
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.
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Number: A80001819
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Valve Pressure Setting Table

Reservoir oil temperature to be 140° - 160° F
VALVE TO BE SET PRESSURE TOLERANCE ADJUSTMENT LOCATION
SETTING PSI (MPa)
PSI (MPa)
Load Sense Relief * 3500 (24.0 ) ± 50 (0.4 ) Main Control Valve Inlet Gauge Port
Tele Retract Relief 3000 (20.7 ) ± 50 (0.4 ) Main Control Valve Tele Retract
Port
Tele Extend Relief 3000 (20.7 ) ± 50 (0.4 ) Main Control Valve Tele Extend Port
Pilot Pressure Supply 325 to 450 (2.2 to 3.1) See Range Main Control Valve Inlet
Swing Brake Pilot Supply 250 (1.7 ) +50/-0 (+.4/-0) Pressure Reducing Valve
Fr. Steer Priority Flow Divider 2500 (17.2 ) ± 50 (0.4 ) Swing/Steer Control Valve
Swing “Left” Relief 1750 (12.1) ± 50 (0.4 ) Swing/Steer Control Valve
Swing “Right” Relief 1750 (12.1) ± 50 (0.4 ) Swing/Steer Control Valve
Outrigger/Rear Steer Relief 2500 (17.2 ) ± 50 (0.4 ) Outrigger/Rear Steer Valve Inlet
Service Brake & A/C Relief 2800-3000 (19.3-20.7) See Range Service Brake & A/C Pump
Service Brake High Charge Limit 2750 (19 ) +50/-0 (+.4/-0) Dual Accumulator Charge Valve
Service Brake Low Charge Limit 2200-2350 (15.2-16.2) See Range Dual Accumulator Charge Valve
Accumulator Pre-charge 1200 (8.3 ) +50/-0 (+.4/-0) Accumulator
* This setting is for Boom Lift and Hoist circuits.
A. Procedure for checking Main Control Valve Reliefs (see Figures 1 & 2 ).
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ the Main
Directional
Control Valve Inlet Gauge Port (Fig 2).
2. Disconnect the Hoist Brake Release line at the Main Hoist (see Figure 1). Cap fitting & plug hose.
3. With the Boost Switch ON, attempt to Hoist Down with the Engine running @ Full RPM, adjust the Load Sense
Relief to 3500 ± 50 PSI (24.0 ± .4 MPa).
4. Remove pressure gauge.
5. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ the Main
Directional Control Valve Load Sense relief Test Port (Fig2).
Disconnect
hoist brake
release line
Figure 1: MAIN HOIST (Right Side View)
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Number: A80001819
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Inlet Gauge
Port
PILOT SUPPLY
PRESSURE REDUCING CARTRIDGE
Figure 2: MAIN DIRECTIONAL CONTROL VALVE
6. With the Boost Switch ON and Engine running @ Full RPM, completely retract the Tele Cylinder, & adjust the Tele
Retract Relief to 3000 ± 50 PSI (20.7 ± .4 MPa).
7. With the Boost Switch ON and Engine running @ Full RPM, completely extend the Tele Cylinder, & adjust the Tele
Extend Relief to 3000 ± 50 PSI (20.7 ± .4 MPa).
8. Remove pressure gauge from the Load Sense Test Port.
9. Reconnect the Hoist Brake Release line on the Hoist.
B. Procedure for checking Directional Control Valve Pilot Supply Pressure (see Figure 1 & 2).
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ on Pilot Supply
Test
Port (see Figure 2).
2. Disconnect the Hoist Brake Release line at the Main Hoist (see Figure 1). Cap fitting & plug hose.
3. While attempting to Hoist Down with the Engine running @ Full RPM, check the Pilot Supply Pressure.
4. Adjust the pressure reducing cartridge located in the inlet of the Hoist/Lift/Telescope directional control valve to 325-
450 PSI. Turn adjustment CW to increase or CCW to decrease the pressure setting.
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Number: A80001819
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5. Remove pressure gauge from the Pilot Supply Test Port.
6. Reconnect the Hoist Brake Release line on the Hoist.
C. Procedure for checking Swing Brake Pilot Supply Pressure (see Figure 3).
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ on Swing Brake
Pilot Supply Valve Test Port.
2. Adjust Pressure Reducing Valve Cartridge to 250 +50/-0 PSI (1.7 +.4/-0 MPa ). At idle, pressure should read a
minimum of 250 PSI (1.7 MPa) to ensure brake is released for swing operation @ idle.
3. Remove pressure gauge from the Test Port.
Figure 3: Swing Brake Pressure Reducing Valve
D. Procedure for checking Service Brake & Air Conditioning Circuit Relief Valve Pressure (see Figure 4).
1. Disconnect pressure hose at the Dual Accumulator Charge Valve “P” port (see Figure 5) and attach a pressure gauge.
2. Run the engine @ idle (950 RPM) for a short period of time (5-10 seconds), Check the pressure. Adjust the Service
Brake & Air Conditioning Relief Valve in the pump (see Figure 4) from 2800 to 3000 PSI (19.3 to 20.7 MPa). If this
step needs to be repeated make sure pump is Not Hot to touch. If it is leave cool before proceeding.
3. Remove pressure gauge and reconnect the pressure line.
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Number: A80001819
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S U C T IO N R E L IE F
PO RT VALVE
Figure 4: Service Brake & Air Conditioning Pump

( Viewed from rear of pump)
E. Procedure for checking the Service Brake Dual Accumulator Charge Valve Pressure Limits (see Figure 5).
1. With the engine off, discharge all oil stored in the accumulators by pushing the service brake pedal.
2. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ the Brake Dual
Accumulator Charge Valve “A1” Pressure Test Port (see Figure 5).
3. Start the engine, the valve will start to charge the accumulators. Watch the pressure gauge. The High Charge Limit
should be 2750 +50/-0 PSI (19 +.4/-0 MPa) when the valve stops charging. If the High Charge Limit pressure is less
than 2750 PSI (19 MPa), then do step 5 next.
4. With the engine running, bleed off the hydraulic pressure stored in the accumulators by pushing the service brake pedal
until the gauge reads about 2400 PSI (16.5 MPa). Listen to hear when the Dual Accumulator Charge Valve starts to
recharge. Push the service brake pedal once more, the valve should start to recharge. Watch the pressure gauge, the
Low Charge Limit should not be less than 2200 PSI (15.2 MPa) when the valve starts to recharge. If the Low Charge
Limit is 2200-2350 PSI (15.2 - 16.2 MPa), then go to step 8.
5. Turn the engine off, remove all of the fittings in the Tank port on the Dual Accumulator Charge Valve and plug the
tee.
6. Using a wrench, turn the socket head screw inside the Tank port clockwise to raise the Charge Limits or counter-
clockwise to lower. Turning the screw a full turn will change both limits by approximately 250 PSI (1.7 MPa).
7. Adjust the pressure until the High Charge Limit is 2750 +50 PSI (19 +.4 MPa) and the Low Charge Limit is within
2200-2350 PSI (15.2-16.2 MPa) as stated in step 4.
8. Remove the pressure gauge from the Tank port on the Dual Accumulator Charge Valve.
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Number: A80001819
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Figure 5: Service Brake Dual Accumulator Charge Valve
F. Procedure for checking Accumulator Pre-Charge Pressure (see Figure 6).
1. With the engine off, discharge all oil stored in the accumulators by pushing the service brake pedal several times.
Remove the gas valve guard and gas valve cap on the accumulator (see Figure 6).
2. Before attaching charging assembly (see Figure 7) to the accumulator gas valve, back the gas chuck “T” handle all the
way out (counter-clockwise).
3. Close the charging assembly bleed valve. Attach the swivel nut to the gas valve and tighten (10-15 in. lb).
4. Turn the gas chuck “T” handle all the way down (clockwise) which will depress the core in the gas valve.
5. Check the pre-charge pressure. The pre-charge pressure should be 1200 +50/-0 PSI (8.3 +.4-/0 MPa).
6. If the pressure is 1200 +50/-0 PSI (8.3 +.4/-0 MPa), then remove charging assembly by turning “T” handle all the way
out on gas chuck and then open bleed valve (see Figure 7).
7. Hold gas valve from turning, loosen swivel nut, and remove charging assembly. Replace gas valve cap and guard.
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Number: A80001819
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GAUGE
GAS
CHUCK
BLEED VALVE
Figure 6: ACCUMULATOR Figure 7: CHARGING ASSEMBLY
G. Procedure for Pre-Charging Accumulator (see Figure 6).

1. With the engine off, discharge all oil stored in the accumulators by pushing the service brake pedal several times.
Remove the gas valve guard and gas valve cap on the accumulator (see Figure 6).
2. Check that the nitrogen supply bottle valve is shut off, then attach charging assembly hose to nitrogen bottle.
3. Before attaching charging assembly (see Figure 7) to the accumulator gas valve, back the gas chuck “T” handle all the
way out (counter-clockwise).
4. Close the charging assembly bleed valve. Without looping or twisting the hose, attach the swivel nut to the
accumulator gas valve and tighten (10-15 in. lb).
5. Turn the gas chuck “T” handle all the way down (clockwise) which will depress the core in the gas valve.
6. Crack open the nitrogen bottle valve and slowly fill the accumulator. Shut off the valve when the pre-charge pressure
is 1200 +50 PSI/-0 (8.3 +.4/-0 MPa).
8. If the pre-charge pressure is higher than 1200 +50/-0 PSI (8.3 +.4/-0 MPa), then close the nitrogen bottle valve and
slowly open the bleed valve on the charging assembly (see Figure 7) until the pre-charge pressure is correct.
9. Remove charging assembly by turning “T” handle all the way out (counter-clockwise) on gas chuck and then open
bleed valve.
10. Hold gas valve from turning, loosen swivel nut, and remove charging assembly. Replace gas valve cap and guard.
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Number: A80001819
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H. Procedure for checking Front Steer Relief Pressure (see Figure 8).
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ Swing/Steer Valve
Load Sense Test Port.
2. With the Engine running @ 1000 RPM, turn the steering wheel to LOCK position & adjust pressure at the Steer
Priority Flow Divider Section Relief to 2500 ± 50 PSI (17.2 ± .4 MPa).
3. Remove pressure gauge from the Load Sense Test Port.
I. Procedure for checking Swing Valve Work Port Reliefs Pressure (see Figure 8).
1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ Swing Valve Test
Port.
2. With the Swing Brake ON and the Engine running @ FULL RPM swing LEFT & adjust “A” port swing Relief to
1750 ± 50 PSI (12.1 ± .4 MPa).
3. With the Swing Brake ON and the Engine running @ FULL RPM swing RIGHT & adjust “B” port swing Relief to
1750 ± 50 PSI (12.1 ± .4 MPa).
4. Remove pressure gauge from the Swing Test.
Figure 8: Swing Steer Directional Control Valve
J. Procedure for checking Outrigger Rear Steer Valve Relief (see Figure 9).
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Number: A80001819
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1. Install pressure check diagnostic quick disconnect (Parker PD240) with gauge onto test nipple @ Outrigger Rear
Steer Valve Pressure Check Port.
2. With the Boost Switch OFF and the Engine running @ FULL RPM, press the Extend Switch & adjust the Outrigger
Rear Steer Relief Valve to 2500 ± 50 PSI (17.2 ± .4 MPa).
3. Remove pressure gauge from the Pressure Check Port.
Outrigger & Rear Steer

Adjustable Relief:
Remove cap, loosen jam nut
& turn stem in “CW” to
increase or out “CCW” to
decrease pressure.
Right Hand End View Top View
Figure 9: OUTRIGGER REAR STEER VALVE
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Number: A80001819
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Revision Record
REV ECO/ER DESCRIPTION BY DATE APPR’D BY
# 115072 NEW RELEASE DGC 27SEP07 TFE
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Number: A80001819

ENGINEERING Revision Number: #

PROCEDURE INDEX PAGE

A. To Check Main Directional Control Valve Reliefs ……………………………………………. 2-3

B. To Check Main Directional Control Valve Pilot Supply Pressure…………………………….. 3

C. To Check Swing Brake Pilot Supply Pressure .……………………………………………….. 4

F. To Check Accumulator Pre-Charge Pressure …….…..………………………………………… 6

G. To Set Accumulator Pre-Charge Pressure …….…..…….……………………………………… 6-7

H. To Check Front Steer Relief Valve Pressure ….…………………………………………...….. 8

J. To Check Outrigger/Rear Steer Relief Valve Pressure …..……………………………………... 9

Revision Record ………………………………………………………………………….….…. 10

Valve Pressure Setting Table

Figure 1: MAIN HOIST (Right Side View)

Figure 2: MAIN DIRECTIONAL CONTROL VALVE

8. Remove pressure gauge from the Load Sense Test Port.

9. Reconnect the Hoist Brake Release line on the Hoist.

5. Remove pressure gauge from the Pilot Supply Test Port.

6. Reconnect the Hoist Brake Release line on the Hoist.

3. Remove pressure gauge from the Test Port.

Figure 3: Swing Brake Pressure Reducing Valve

3. Remove pressure gauge and reconnect the pressure line.

Figure 4: Service Brake & Air Conditioning Pump

Figure 5: Service Brake Dual Accumulator Charge Valve

F. Procedure for checking Accumulator Pre-Charge Pressure (see Figure 6).

Figure 6: ACCUMULATOR Figure 7: CHARGING ASSEMBLY

G. Procedure for Pre-Charging Accumulator (see Figure 6).

3. Remove pressure gauge from the Load Sense Test Port.

4. Remove pressure gauge from the Swing Test.

Figure 8: Swing Steer Directional Control Valve

3. Remove pressure gauge from the Pressure Check Port.

Outrigger & Rear Steer

Right Hand End View Top View

Figure 9: OUTRIGGER REAR STEER VALVE

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