HYDRAULIC SYSTEM TMS800E SERVICE MANUAL
2-34
Published 01-29-2014, Control # 496-00
DIRECTIONAL CONTROL VALVES
Description
The directional control valves direct and control hydraulic oil
flow from the pumps to the boom lift and telescope cylinders,
each hoist motor, the swing motor, and the counterweight
removal/cab tilt cylinders. The swing directional control valve
and the boom lift/telescope/hoist directional control valve are
located on the outside of the right superstructure side plate.
Each valve bank is removed and installed as an assembly.
The boom lift/telescope/hoist directional control valve (see
Figure 2-23) is a sectional, three position four way, pressure
compensated, closed center directional valves. The inlet
section contains a load sense relief valve set at 275.8 bar
(4000 psi) protecting the main and auxiliary hoist and boom
lift sections. The boom lift retract has a thermal port relief set
at 296.5 bar (4300 psi). The telescope section has port
relief’s set at 238.6 bar (3460 psi) for retract and 179.3 bar
(2600 psi) for extend. All working sections have a two
position two way solenoid RCL lockout valve in each pilot
end cap.
The counterweight removal/cab tilt directional control valve
(see Figure 2-24) is a sectional, three position four way,
pressure compensated, closed center directional valve. It is
plumbed in parallel with the boom lift/telescope/hoist
directional control valve. The inlet section contains a load
sense relief valve set at 172.4 bar (2500 psi) protecting all
three working sections.
Maintenance
Hoist/Lift/Telescope Valve Bank Removal
1. Tag and disconnect the hydraulic lines from the valves.
Cap or plug the lines and ports.
2. Tag and disconnect electrical connectors from the valve.
3. Remove the capscrews and washers securing the valve
bank and remove the valve bank.
Hoist/Lift/Telescope Valve Bank Installation
1. Place the valve bank on the turntable upright and fasten
it with the capscrews and washers. Torque capscrews
refer to Fasteners and Torque Values, page 1-13.
2. Connect the electrical connectors to the valve as tagged
during removal.
3. Connect the hydraulic lines to the valves as tagged
during removal.
Counterweight Removal/Cab Tilt Valve Bank Removal
1. Tag and disconnect the hydraulic lines from the valves.
Cap or plug the lines and ports.
2. Remove the cotter pins, clevis pins, and washers
securing the control levers to the clevis on each valve.
3. Remove the locknut, bolt, and bushings securing each
set of control levers to the bracket and remove the
control levers.
4. Remove the capscrews, washers and nuts securing the
valve bank to the mounting bracket and remove the
valve bank.
Counterweight Removal/Cab Tilt Valve Bank
Installation
1. Position the valve bank on the mounting bracket and
secure with the capscrews, washers and nuts. Torque
the capscrews refer to Fasteners and Torque Values,
page 1-13.
2. Attach the control levers to the bracket using the
bushings, bolts, and locknuts.
3. Attach the control levers to the clevis on each valve with
two washers, a clevis pin, and a cotter pin.
4. Connect the hydraulic lines to the valves as tagged
during removal.
Functional Check (All Valve Banks)
1. Start the engine and run it at normal speed.
2. Operate the control levers of the valve bank(s). Check
for smooth operation of cylinders and motors.
3. Check the valve bank(s) and lines for leakage. Make
repairs as needed.
Functional Check (RCL Lockout Valves)
1. Remove fuse F12 from the circuit breaker panel in the
superstructure cab. This cuts off power to the RCL.
2. Start the engine.
3. Try to extend the boom out, lower the boom, hoist up the
main hoist, and hoist the auxiliary hoist up (if installed).
Verify none of these functions work.
4. Shut down the engine. Reinstall fuse F12.
5. Extend the boom, lower the boom, hoist up the main
hoist, and hoist the auxiliary hoist up (if installed). Verify
all of these functions work.
6. Check for leaks. Make repairs as needed.
CAUTION
The approximate weight of the directional control valve is
81 kg (217 lb).
Reference Only
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