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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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Personal injury can result from contact with hot hydraulic oil and from contact with hydraulic oil that is under high pressure. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. The hydraulic oil pressure must be released before any service on the hydraulic system is performed or serious personal injury could occur. Verify that all of the work tools have been completely lowered to the ground. Release the hydraulic oil pressure at the hydraulic tank through the breaker relief valve when the breaker relief valve is cool enough to touch with your bare hand. Verify that the hydraulic oil is cool before you begin to remove any hydraulic components or hydraulic lines. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids. Dispose of all fluids according to local regulations and mandates. |
| Relief Valve (Main) Pressure
High Setting |
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|---|---|---|
| Main Relief Valve Pressure (Implement) | Setting | Actual |
| 559D | |
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| 579D | |
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| Relief Valve (Main) Pressure
Low Setting |
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|---|---|---|
| Main Relief Valve Pressure (Implement) | Setting | Actual |
| 559D | |
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| 579D | |
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This procedure will test and adjust the main relief valve pressure. The main relief valve is located in the main control valve.
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Digital Indicator | |
| A2 | 1 | 198-4239 | Pressure Sensor Gp
(0 to 41,368 kPa (0 to 6,000 psi)) |
|
| A3 | 1 | 198-4236 | Adapter Cable As | |
| 1 | 22-mm wrench | |||
| 1 | 6-mm Allen wrench | |||
The following procedure will test the main relief valve for the implement circuit.
The procedure requires two people.
Note: Use the information in the reference to prepare the machine for this test. Also, use the information in the reference to relieve any hydraulic pressure that may be in the hydraulic system.
Reference: For the correct procedure to prepare the machine for this test, refer to Testing and Adjusting, "Machine Preparation for Troubleshooting" for the machine that is being serviced.
Reference: For the correct procedure to relieve any hydraulic oil pressure that may be in the hydraulic system, refer to Testing and Adjusting, "System Pressure - Release" for the machine that is being serviced.
Main Relief Valve- Test and Adjustment Procedure (High Setting)
This procedure requires connecting pilot pressure to the quick disconnect port next to the main relief location at the main valve. When pressure is added to the diagnostic nipple, the main relief will shift from
Note: The hydraulic oil temperature must be at or above
Note: Remove all personnel from the area before starting this procedure.
- Shut off the engine prior to making the pilot supply connections.
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Illustration 1 g06193483 (A) Quick disconnect port for dual main relief valve
(B) Main relief valve adjustment
(C) Pilot pressure test port at pilot shutoff valve - Use a
1524 mm (60 inch) long pilot hose with quick disconnect fittings at each end. Connect the pilot pressure test port on the pilot shutoff valve (C) to the quick disconnect port next to the main relief valve (A).Show/hide table
Illustration 2 g03321693 (FP) Pressure test port for the front pump
(RP) Pressure test port for the rear pump
(PP) Pressure test port for the pilot pump - Install Tooling onto pressure port (FP) on the front pump.
- Start the engine and run the engine at high idle with the pilot system activated.
- Operate the "Grapple Close" function until the cylinder is at the end of stroke.
- Continue holding the left joystick back and to the left, forcing oil over the relief valve at full RPM.
- Observe the pressure reading on the gage. Compare the reading to the specification. If the main relief pressure is correct, stop the engine. Remove all test equipment.
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Illustration 3 g06193505 (B) Main pressure relief valve - If the main relief pressure is not within the specifications
35163 ± 690 kPa (5100 ± 100 psi) , main pressure relief valve (B) on the main control valve must be adjusted. - Shut down the engine and remove the key.
- Use a 22-mm wrench for the locknut and a 6-mm Allen wrench for the adjusting screw. Back off the locknut. Turn the adjusting screw (CW) to increase the pressure reading, or turn the adjusting screw (CCW) to decrease the pressure reading.
Note: Use caution when adjusting the relief valve. A small amount of movement produces a great change in pressure. A 1/8 turn of the adjusting screw produces approximately a
3450 kPa (500 psi) change in pressure. - Repeat the testing procedure to ensure that the pressure setting is correct. If necessary, repeat the testing procedure until the pressure is correct.
Note: If adjustments to the main relief valve are not changing the pressure readings, the Grapple Close poet may be controlling the output pressure. Make adjustments to the Grapple Close output relief.
- Proceed to "Main Relief Valve- Test and Adjustment Procedure (Low Setting)".
Note: The pilot supply line can remain attached for the following tests:
- Grapple Close
- Grapple Open
- Stick In
- Stick Out
- Main Boom Up
- Swing Drive Right
- Swing Drive Left
- Rear Pump Minimum Displacement Flow
Main Relief Valve- Test and Adjustment Procedure (Low Setting)
This procedure requires disconnecting pilot pressure to the quick disconnect port next to the main relief location at the main valve.
Note: The hydraulic oil temperature must be at or above
Note: Remove all personnel from the area before starting this procedure.
- Shut off the engine prior to making the pilot supply connections.
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Illustration 4 g06193483 (A) Quick disconnect port for dual main relief valve
(B) Main relief valve adjustment
(C) Pilot pressure test port at pilot shutoff valve - Disconnect the pilot supply hose and connections. Reinstall rubber dust caps at the quick connect test ports
- Start the engine and run the engine at high idle with the pilot system activated.
- Operate the "Grapple Close" function until the cylinder is at the end of stroke.
- Observe the pressure reading on the gage. Compare the reading to the specification. If the main relief pressure is within
25000 ± 345 kPa (3630 ± 50 psi) , leave the main relief setting as is.Show/hide table
Illustration 5 g06193542 Dual Main Relief Adjustment
(D) Standard Pressure setting screw
(E) High-Pressure setting screw - If adjustment is needed, loosen the small locknut on the main relief valve and adjust the standard pressure internal hex adjuster screw (D).
- Verify that the pressure setting is correct to specification. Tighten the small locknut to
29 ± 2 N·m (21 ± 1 lb ft) . - When testing is complete, shutdown the machine. Remove the testing equipment.
- The pilot supply line can remain attached for the following tests:
- Grapple Close
- Grapple Open
- Stick In
- Stick Out
- Main Boom Up
- Swing Drive Right
- Swing Drive Left
- Rear Pump Minimum Displacement Flow
