Altec DL Series User manual

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749-50092
This instruction explains the procedure to adjust and calibrate the controls on the
DL/DM,DLB/DMB,D2000A,D3000A,D4000A,D2000B,D3000B,D4000B,andDT80
Seriesderricks.Theprocedurerequiresthefollowingitemsinadditiontonormal
mechanics tools:
• Quick disconnect installed in the return line of the control valve
(Alteckitp/n 970457959,ifrequired)
•ElectronicLowpressuregauge(0-600psior0-1000psirange)
•CADI
•Infrared(IR)thermometer
Therearethreesections to the procedure:Section1:Differential Pilot Pressure Testing
andAdjustmentProcedure,Section2:ThresholdCalibrationProcedure,andSection
3:MaxOut andLow Speed Calibration. Read and understand all steps of the instruc-
tionsbeforebeginningtheprocedure.
1. Position the unit on a level surface. Apply the parking brake and chock the wheels.
Engage the unit’s hydraulic system. Properly set the outriggers. Disengage the
hydraulic system and shut off the engine.
Section 1: Differential Pilot Pressure Testing and Adjustment Procedure
2. Removetheturntablecoverfromtherightsideoftheturntable(asviewedfromthe
boomtiplookingtoward theturntable).
3. Attach the pressure gauge to the tank pressure quick disconnect. Depending on
the design of the valve, this quick disconnect will be located either on the large tee
inthe returnline locatedto theleft of the lower control valve (refer to Figure 1) or on
the small tee in the external pilot drain port located in the upper left corner of the
lowercontrol valve (refer to Figure 2). Turnthe gauge on, and zero it ifit isnot
showingzero.
Figure 1 — Gauge On Return Quick Disconnect
Instructions
Derrick Controls
Adjustment Procedure
Introduction
Tools
Sections of
Procedure
Section 1
Testing
Gauge
Return
Line

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Section 1
Testing
(Continued)
Figure 2 — Gauge On Pilot Drain Quick Disconnect
4. Start the engine. With the engine running at idle, energize the pilot system as
described in Step 4a or 4b.
a. Iftheunitisequippedwithatwospeeddigger,movethediggershiftswitchtothe
Highposition.
b. If the unit is not equipped with a two speed digger, fully shift and hold the
intermediateorupper boom hand controlinthe Retract position.
5. Recordthetank pressure shown onthegauge.
6. Turn off the engine. Leaving the pressure gauge turned on, remove it from the tank
pressurequickdisconnectandattachittothepilotpressurequickdisconnect,located
onthelowerrightcornerofthelowercontrolvalve(refertoFigure3).Do not rezero
the pressure gauge when relocating it. The same pressure gauge must be
used for both readings.
Figure3—GaugeOnPilotPressureQuickDisconnect
7. Add160 psi to the tank pressure recordedin Step5 to obtain the upper value ofthe
pilotpressurerange.Add155psitothetankpressurevaluetoobtainthelowervalue
of the pilot pressure range. (Example: upper value=160+tank pressure; lower
value=155+tankpressure.)
DrainPort
Test Quick
Disconnect
PilotPressure
Port

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8. Starttheengine.With theenginerunningatidle,energizethepilotsystemusingthe
samefunctionasinStep4aor4b.Thepressuregaugeshouldindicatewithintherange
calculated in Step 7. If the pilot pressure is above or below this range, adjust the
pressure as described in Adjustment at the end of this Section.
9. Disengagetheunit’shydraulicsystemandturnofftheengine.Disconnectthepressure
gaugeand replace the turntable cover. Proceed to Section2: Threshold Calibration
Procedure
Adjustment
1. Removethecapandloosenthejamnutonthepilotpressurereducingcartridgeonthe
lowercontrolvalve(refertoFigure4).Turntheadjustingscrewclockwisetoincrease
thepressureorcounterclockwisetodecreasethepressure.Holdtheadjustingscrew
to keep it from turning, and tighten the jam nut
Figure4-PilotPressureReducingCartridge
2. Test the pressure at the pilot pressure quick disconnect.
3. RepeattheadjustmentuntilthegaugeindicatesthewithintherangecalculatedinStep
7underTesting.
4. Replacethecaponthepilotpressurereducingcartridge.DisengagethePTOandturn
offtheengine.Disconnectthepressuregaugeandreplacetheturntablecover.
5. ProceedtoSection2:ThresholdCalibrationProcedure
Section 2: Threshold Calibration Procedure
1. Operate the unit to warm the hydraulic oil to 120 to 130 degrees Fahrenheit.This
temperaturerangeisimportant.Iftheoilisnotwarmedtothistemperaturerange,
the CADI settings resulting from the calibration procedures will not be
accurate, and poor meterability will result. One way to verify the oil temperature
istouseaninfrared(IR)thermometertoreadthetemperatureofthehydraulicreservoir
onorneartheendoppositefromthereturnlinefilter,atapointabout1/3ofthewayabove
the bottom of the reservoir (refer to Figure 5). The oil can be warmed quickly as
described in Step 1a or 1b.
PilotPressure
ReducingCartridge
Section 1
Testing
(Continued)
Section 1
Adjustment
Section 2

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a. Iftheunitisequippedwithadigger,unstowthedigger.Makesuretheboomsare
fullyretracted.WiththeengineatfullRPM,operateDiggerDigatfullspeedwhile
holdingtheintermediateboomcontrolfullyshiftedintheRetractpositionorholding
thepoleguideopen/closeswitchintheCloseposition.Whentheoilhasreached
120to 130 degrees Fahrenheit, stowthe digger and proceed to Step 2.
b. Iftheunitisnotequippedwithadigger,makesuretheboomsarefullyretracted.
WiththeengineatfullRPM,operateWinchRaise/WinchLowerrepeatedlyatfull
speedwhile holding the intermediate boomcontrol fullyshifted inthe Retract
positionorholdingthepoleguideopen/closeswitchintheCloseposition.Donot
allowthe load hook to contact the boom tip whenoperating WinchRaise. When
the oil has reached 120 to 130 degrees Fahrenheit, proceed to Step 2.
Figure5-ReservoirTemperatureMeasurement
LocationUsingIRThermometer
2. Connect the cable from the CADI to the CADI connection socket (refer to Figure 6).
Figure 6 - CADI Attached to Connection Socket
3. Positiontheboomatananglefrom10to30degreesabovehorizontal(refertoFigure
7), and rotate it to a position where all the functions can be operated for calibration.
Measure
temperature
hereon side or
end
ReturnLineFilter
Control
Console
Connection
Socket
CADI
Section 2
(Continued)

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Figure 7 - Boom Angle Indicator
4. Set the low speed/standard switch to Standard on the control panel being used.
Operate with the engine at full RPM.
5. RecordtheMXsettingforthefunctiontobecalibrated(BoomUp/Down,RotationCW/
CCW, Intermediate Boom Extend/Retract, Upper Boom Extend/Retract, Winch In/
Out,orDiggerDig/Clean).ThenchangetheTHandMXsettingsforthisfunctionto00.
ThevaluebuttonontheCADIcanbehelddowncontinuouslyuntilthesettingreaches
00.
6. Operate the hand control and adjust the MX and TH values for the function being
calibrated as described in Steps 6a through 6g.
a. Fully shift and hold the hand control, and increase the MX value slowly until the
functionstartsmoving.
b. Releasethehand control, anddecrease the MXvalue by3 points.
c. Fullyshift and hold the hand control, and checkfor function movement. If the
functionisfullystopped,continuetostepd.Ifthefunctionisnotfullystopped,go
back to step b.
d. IncreasetheMXvalueby1pointevery5secondsuntilthefunctionbeginstocreep,
meaningtooperateat theslowestmovementnoticeable.ForBoomUp/Down,
watchtheliftcylinderrodformovement.Forotherfunctions,comparethemoving
component to a stationary object.
e. Releasethehandcontrol.Subtract15pointsfromtheMXvaluedeterminedinthe
previousstepto obtain therequiredTH setting. Thenadjust the THvalueto this
number.Forexample,ifthefunctionbeginstocreepatMX=42,subtract42-15=27,
and adjust the TH setting to 27.
f. RecordthefinalTHsettingontheCADIValuesSheetortheFieldCADISettings
Guide.
g. Return the MX setting to the value it had before it was changed to 00.
7. RepeatSteps5-6for each directionofeach boom, winch,anddigger function.
8. Proceed to Section 3:Max Out andLow Speed Calibration.
Indicating10-30
Degrees
Section 2
(Continued)

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Section 3:Max Out and Low Speed Calibration
TheMaxOut(MX) andLowSpeed(LMX)settingsfortheboom,winch,and digger
functionsmustbeproperlyadjustedtoachievethecorrectvalvespooltravelandcycle
timesatfullcontrolhandletravel.BecausetheMXandLMXcalibrationproceduresvary
fordifferentmodels,refertothelatestCADIQuickReferenceGuide(p/n749-30200)or
theappropriatemaintenancemanualfortheproperprocedures.
1. Afterall testing and adjustments are completed, engagethe unit’s hydraulic system
andoperatetheunitinallfunctionslookingforleaksandproperoperation.Makeany
correctionsnecessary.
2. Stowtheunit.Retract theoutriggers.Disengagethehydraulicsystemandreturnthe
unittoservice.
8-23-13
Section 3
Testing and
Completion