"Relief Valve (Line) - Test and Adjust" | ||||
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Machine Settings | Main Relief Pressure(1) | |||
Standard | |
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Heavy lift | |
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Cylinder | Cylinder Position | Engine Speed | Relief Pressure Setting | Actual |
Boom | Extended | Speed Dial "10"
AEC switch OFF |
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Retracted | |
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Stick | Extended | Speed Dial "10"
AEC switch OFF |
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Retracted | |
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Bucket | Extended | Speed Dial "10"
AEC switch OFF |
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Retracted | ||||
VA Boom | Extended | Speed Dial "10"
AEC switch OFF |
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Retracted | |
(1) | System pressure setting before temporary setting adjustment |
The line relief valves are located between each cylinder and the respective control valve. The line relief valve limits the overload pressures that can be created in the implement cylinders. The line relief valves are located on the left side and right side of the main control valve. The line relief valves are accessible from above the main control valve and below the machine after removal of the access plate.
Illustration 1 | g02571852 |
Tooling group "A" 198-4240 Digital Pressure Indicator Gp |
Tool | Item | Part Number | Description | Qty |
---|---|---|---|---|
A | 198-4240 | Digital Pressure Indicator Gp | ||
A1 | 198-4234 | Indicator | 1 | |
A2 | 198-4239 | Pressure Sensor |
2 | |
A3 | 198-4236 | Extension Cable | 2 | |
311-1362 | Vacuum Transducer | 1 |
- Position the machine on level ground and stop the engine.
- Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".
Show/hide table
Illustration 2 g06234630 Pump compartment
(1) Pressure tap (delivery pressure for drive pump)
(2) Pressure tap (delivery pressure for idler pump) - Attach both
41,368 kPa (6,000 psi) pressure sensors to pressure tap (1) and pressure tap (2).
Note: A temporary setting of the main relief valve is required before any line relief valves can be adjusted. Refer to Table 3 for temporary main relief setting for the function being tested.
Function | Temporary Main Relief Setting |
Boom Cylinder Rod End | |
Stick Cylinder Head End | |
Bucket Cylinder Head End | |
Bucket Cylinder Rod End | |
VA Boom Cylinder Head End | |
Boom Cylinder Head End | |
Stick Cylinder Rod End | |
VA Boom Cylinder Rod End |
Relief Valve | Pressure Change With One Turn Of Adjustment Screw |
Main relief valve | |
Line relief valves | |
Note: Pressure values in Table 4 are approximate values. Use a pressure gauge for adjustment.
Bucket Cylinder Head End, Stick Cylinder Head End, and Bucket Cylinder Rod End
Note: A continuous relief of the valve for more than 10 seconds is not allowed.
Illustration 3 | g03688041 |
Main control valve (3) Main relief valve (4) Line relief valve for the boom cylinder rod end (5) Line relief valve for the stick cylinder head end (6) Line relief valve for the bucket cylinder rod end (7) Line relief valve for the bucket cylinder head end |
- Start the engine.
- Place the hydraulic activation control lever in the UNLOCKED position.
- Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Move the joystick for the stick until the stick is at the full STICK OUT position (full retraction of the stick cylinder).
- Check the main relief valve pressure setting at pressure tap (1) or pressure tap (2). The main relief valve pressure setting should be
35000 + 500 - 1000 kPa (5076 + 73 - 145 psi) .Show/hide tableIllustration 4 g02102305 Main relief valve (standard)
(A) Adjustment screw
(L) LocknutShow/hide tableIllustration 5 g02102306 Main relief valve (heavy lift)
(A) Adjustment screw
(L) Locknut - Loosen the locknut. Set the main relief pressure to
37000 ± 500 kPa (5366 ± 73 psi) . Tighten the locknut.Note: Turn the adjustment screw clockwise in order to increase the pressure. Turn the adjustment screw counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
- Verify the temporary main relief pressure setting with a second function. Move the joystick for the boom until the boom is at full BOOM RAISE position (full extension of the boom cylinder). The main relief pressure should be
37000 ± 500 kPa (5366 ± 73 psi) . - Mark the original position of the line relief for the bucket cylinder head end (7).
- Move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full extension of bucket cylinder).
- Check the pressure setting of the line relief for the bucket cylinder head end (7).
- Loosen the locknut of the bucket line relief valve. Turn adjustment screw of the bucket line relief valve until the pressure reading at pressure tap (1) is
35000 kPa (5076 psi) . - Move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full extension of bucket cylinder).
- Check the pressure setting of the line relief for the bucket cylinder head end (7).
- Turn the adjustment screw of the bucket line relief valve until the pressure reading at pressure tap (1) is
37000 ± 500 kPa (5366 ± 73 psi) .Note: Always make final pressure adjustments on the pressure rise.
Note: In order to prevent over setting, the adjustment should be stopped immediately after the pressure becomes within specification.
- Repeat Step 9 to Step 13 for the following line relief valves:
- Line relief valve for stick cylinder head end
- Line relief valve for bucket cylinder rod end
Note: This procedure can be used to adjust the boom rod line relief (4) when the boom cannot be retracted fully. This procedure will use the BUCKET OPEN circuit to adjust the line relief to proper specification.
Note: A continuous relief of the valve for more than 10 seconds is not allowed.
Illustration 6 | g03712283 |
Main control valve (3) Main relief valve (4) Line relief for the boom cylinder rod end (6) Line relief for the bucket cylinder rod end |
- Stop the engine.
- Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".
- Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply onto the assembly. Apply
276 - 414 kPa (40 - 60 psi) . This procedure will pull a vacuum on the hydraulic system. - Remove the line relief valves for boom cylinder rod end (4) and bucket cylinder rod end (6) in order to exchange the valve locations.
- Install the line relief for the bucket cylinder rod end (6) into the BOOM DOWN circuit.
- Install the line relief for the boom cylinder rod end (4) into the BUCKET OPEN circuit.
- Start the engine.
- Place the hydraulic activation control lever in the UNLOCKED position.
- Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Move the joystick for the bucket until the bucket is at the full BUCKET OPEN position (full retraction of bucket cylinder).
- Check the pressure setting of the line relief for the bucket cylinder rod end (6).
- Loosen the locknut of the bucket line relief valve. Turn adjustment screw of the bucket line relief valve until the pressure reading at pressure tap (1) is
35000 kPa (5076 psi) . - Move the joystick for the bucket until the bucket is at the full BUCKET OPEN position (full retraction of bucket cylinder).
- Check the pressure setting of the line relief for the bucket cylinder rod end (6).
- Turn the adjustment screw of the bucket line relief valve until the pressure reading at pressure tap (1) is
37000 ± 500 kPa (5366 ± 73 psi) .Note: Always make final pressure adjustments on the pressure rise.
Note: In order to prevent over setting, the adjustment should be stopped immediately after the pressure becomes within specification.
- Tighten the locknut on the line relief valve.
- Stop the engine.
- Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".
- Return the line relief valves to the original line relief locations.
- Reset main relief valve pressure setting to the normal operating condition after the completion of the line relief test and adjust. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Boom Cylinder Head End and Stick Cylinder Rod End
Note: A continuous relief of the valve for more than 10 seconds is not allowed.
Illustration 7 | g03700449 |
Main control valve (3) Main relief valve (8) Line relief valve for the boom cylinder head end (9) Line relief valve for the stick cylinder rod end |
- Mark the original position of the line relief valve for the stick cylinder rod end (9).
- Loosen the locknut for line relief valve (9). Turn the adjustment screw clockwise by one quarter turn. Tighten the locknut.
- Start the engine.
- Place the hydraulic activation control lever in the UNLOCKED position.
- Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Move the joystick for the stick until the stick is at the full STICK OUT position (full retraction of stick cylinder).
- Check the main relief valve pressure setting at pressure tap (1) or pressure tap (2). The main relief pressure setting should be
35000 + 500 - 1000 kPa (5076 + 73 - 145 psi) .Show/hide tableIllustration 8 g02102305 Main relief valve (standard)
(A) Adjustment screw
(L) LocknutShow/hide tableIllustration 9 g02102306 Main relief valve (heavy lift)
(A) Adjustment screw
(L) Locknut - Loosen the locknut. Set the main relief pressure to
40000 ± 500 kPa (5802 ± 73 psi) . Tighten the locknut.Note: Turn the adjustment screw clockwise in order to increase the pressure. Turn the adjustment screw counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
- Mark the original position of the line relief valve for the boom cylinder head end (8).
- Move the joystick for the boom until the boom is at the full BOOM RAISE position (full extension of boom cylinders).
- Check the pressure setting of the line relief valve for the boom cylinder head end (8).
- Loosen the locknut of the boom line relief valve. Turn adjustment screw of the boom line relief valve until the pressure reading at pressure tap (1) is
38000 kPa (5512 psi) . - Move the joystick for the boom until the boom is at the full BOOM RAISE position (full extension of boom cylinders).
- Check the pressure setting of the line relief valve for the boom cylinder head end (8).
- Turn the adjustment screw of the boom line relief valve until the pressure reading at pressure tap (1) is
40000 ± 500 kPa (5802 ± 73 psi) .Note: Always make final pressure adjustments on the pressure rise.
Note: In order to prevent over setting, the adjustment should be stopped immediately after the pressure becomes within specification.
- Move the joystick for the stick until the stick is at the full STICK OUT position (full retraction of stick cylinder).
- Check the pressure setting of the line relief for the stick cylinder rod end (9).
- Loosen the locknut for the stick line relief valve (9). Turn adjustment screw of the stick line relief valve counterclockwise until the pressure reading at pressure tap (1) is
38000 kPa (5512 psi) . - Move the joystick for the stick until the stick is at the full STICK OUT position (full retraction of stick cylinder).
- Check the pressure setting of the line relief for the stick cylinder rod end (9).
- Turn the adjustment screw of the stick line relief valve until the pressure reading at pressure tap (1) is
40000 ± 500 kPa (5802 ± 73 psi) .Note: Always make final pressure adjustments on the pressure rise.
Note: In order to prevent over setting, the adjustment should be stopped immediately after the pressure becomes within specification.
- Reset main relief valve pressure setting to the normal operating condition after the completion of the line relief test and adjust. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Note: A continuous relief of the valve for more than 10 seconds is not allowed.
Illustration 10 | g03328024 |
Main control valve (3) Main relief valve (10) Line relief valve for the va boom cylinder head end |
- Mark the original position of the line relief valve for the va boom cylinder head end (10).
- Loosen the locknut for line relief valve (10). Turn the adjustment screw clockwise by one quarter turn. Tighten the locknut.
- Start the engine.
- Place the hydraulic activation control lever in the UNLOCKED position.
- Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Move the foot pedal for the va boom until the va boom is at the full VA BOOM UP position (full extension of va boom cylinder).
- Check the main relief valve pressure setting at pressure tap (1) or pressure tap (2). The main relief pressure setting should be
35000 ± 500 kPa (5076 ± 73 psi) .Show/hide tableIllustration 11 g02102305 Main relief valve (standard)
(A) Adjustment screw
(L) LocknutShow/hide tableIllustration 12 g02102306 Main relief valve (heavy lift)
(A) Adjustment screw
(L) Locknut - Loosen the locknut. Set the main relief pressure to
37000 ± 500 kPa (5366 ± 73 psi) . Tighten the locknut.Note: Turn the adjustment screw clockwise in order to increase the pressure. Turn the adjustment screw counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
- Move the foot pedal for the va boom until the va boom is at the full VA BOOM RAISE position (full extension of the va boom cylinder).
- Check the pressure setting of the line relief valve for the va boom cylinder head end (10).
- Loosen the locknut of the va boom line relief valve. Turn adjustment screw of the boom line relief valve until the pressure reading at pressure tap (1) is
35000 kPa (5076 psi) . - Move the foot pedal for the va boom until the va boom is at the full VA BOOM RAISE position (full extension of va boom cylinder).
- Check the pressure setting of the line relief valve for the va boom cylinder head end (10).
- Turn the adjustment screw of the boom line relief valve until the pressure reading at pressure tap (1) is
37000 ± 500 kPa (5366 ± 73 psi) .Note: Always make final pressure adjustments on the pressure rise.
Note: In order to prevent over setting, the adjustment should be stopped immediately after the pressure becomes within specification.
- Reset main relief valve pressure setting to the normal operating condition after the completion of the line relief test and adjust. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Note: A continuous relief of the valve for more than 10 seconds is not allowed.
Illustration 13 | g03400855 |
- Mark the original position of the line relief valve for the va boom cylinder rod end (11).
- Loosen the locknut for line relief valve (11). Turn the adjustment screw clockwise by one quarter turn. Tighten the locknut.
- Start the engine.
- Place the hydraulic activation control lever in the UNLOCKED position.
- Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Move the foot pedal for the va boom until the va boom is at the full VA BOOM DOWN position (full retraction of va boom cylinder).
- Check the main relief valve pressure setting at pressure tap (1) or pressure tap (2). The main relief pressure setting should be
35000 ± 500 kPa (5076 ± 73 psi) .Show/hide tableIllustration 14 g02102305 Main relief valve (standard)
(A) Adjustment screw
(L) LocknutShow/hide tableIllustration 15 g02102306 Main relief valve (heavy lift)
(A) Adjustment screw
(L) Locknut - Loosen the locknut. Set the main relief pressure to
40000 ± 500 kPa (5802 ± 73 psi) . Tighten the locknut.Note: Turn the adjustment screw clockwise in order to increase the pressure. Turn the adjustment screw counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
- Move the foot pedal for the va boom until the va boom is at the full VA BOOM DOWN position (full retraction of the va boom cylinder).
- Check the pressure setting of the line relief valve for the va boom cylinder rod end (10).
- Loosen the locknut of the va boom line relief valve. Turn adjustment screw of the boom line relief valve until the pressure reading at pressure tap (1) is
38000 kPa (5511 psi) . - Move the foot pedal for the va boom until the va boom is at the full VA BOOM DOWN position (full retraction of va boom cylinder).
- Check the pressure setting of the line relief valve for the va boom cylinder rod end (10).
- Turn the adjustment screw of the boom line relief valve until the pressure reading at pressure tap (1) is
40000 ± 500 kPa (5802 ± 73 psi) .Note: Always make final pressure adjustments on the pressure rise.
Note: In order to prevent over setting, the adjustment should be stopped immediately after the pressure becomes within specification.
- Reset main relief valve pressure setting to the normal operating condition after the completion of the line relief test and adjust. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Illustration 16 | g02068598 |
Line relief valve (typical example) (L) Locknut (A) Adjustment screw |
- Loosen locknut and turn adjustment screw in order to increase or decrease pressure.
Note: Turn the adjustment screw clockwise in order to increase pressure. Turn adjustment screw counterclockwise in order to decrease pressure.
Note: Always make final pressure adjustments on the pressure rise.
- Tighten the locknut to specification once adjustments are complete.