1 Test 924G, Relief Valve (Line)

Pruebas y Ajustes 924G and 924GZ Wheel Loaders Hydraulic System

Pilot System Pressure - Test SMCS - 5050-032-PS

Cerrar SIS

Pantalla anteriorProducto: WHEEL LOADER Modelo: 924G WHEEL LOADER 3PZ Configuracin: 924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE) POWERED BY 3056 Engine

Nmero de medio -RENR3511-03 Fecha de publicacin -01/03/2007 Fecha de actualizacin -09/03/2007

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Table 1Required Tools

Quantity Part Number Description 2 8T-0856 6000 kPa (870 psi) Pressure Gauge 2 177-7860 Hose Assembly 4 6V-4143 Coupler Assembly 2 6V-3989 Nipple

NOTICECare 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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Pgina 1 de 3924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE) POWERED BY 3056 Eng...

09/09/2011https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

1. Remove the access panel on the right side of the machine.

1. Install a 8T-0856 Pressure Gauge on a 177-7860 Hose Assembly . Install the other end of the hose to the test port (2) for the steering pressure in the pressure reducing valve. Note: Prior to testing the pilot system pressure, make sure that the standby pressure of the steering pump is within the specification. The maximum standby pressure of the steering pump is 4300 170 kPa (625 25 psi).

2. Install a 8T-0856 Pressure Gauge on a 177-7860 Hose Assembly . 3. Install the other end of the hose assembly on the test port for the pilot pressure (1) .

Illustration 1 g00623972

Illustration 2 g00623709Pressure reducing valve

(1) Test port for the pilot oil pressure in the pressure reducing valve. (2) Test port for the steering pressure in the pressure reducing valve. (3) Relief valve.



4. Start the engine and run the engine at high idle. With the oil at normal operating temperature, the pressure reading must be 2600 170 kPa (375.0 25.0 psi).

5. If the pressure reading is correct, stop the engine and remove the test equipment from pressure tap (1) . If the pressure reading is not correct, stop the engine. Perform the following procedure:

a. Loosen the locknut on the relief valve (3) . Turn the stem on the relief valve clockwise in order to increase the pressure. Turn the stem on the relief valve counterclockwise in order to decrease the pressure.

6. If the pressure reading is correct, stop the engine and remove the test equipment from the pressure tap (1) .

Copyright 1993 - 2011 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.

Fri Sep 9 21:56:24 EST 2011




Hydraulic System Pressure - Release SMCS - 4250-553-PX ; 4300-553-PX ; 5050-553-PX

1. Lower the work tool to the ground. 2. Stop the engine. Engage the parking brake.

Cerrar SIS



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Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.






3. Move the control levers through the full range of travel. Repeat the movement of the levers several times in order to discharge the accumulator for the pilot system. This will relieve any pressure that may be present in the work tool hydraulic system.

4. Depress the brake pedal repeatedly. This will relieve any pressure that may be present in the brake hydraulic system.


Fri Sep 9 22:12:31 EST 2011




General Testing and Adjusting Information SMCS - 5050-025; 5050-081

Note: Permit only one operator on the machine. Keep other personnel away from the machine or in the operator's sight.

1. Park the machine on a smooth, level surface. Move away from other operating machines and away from personnel.

2. Lower the work tools to the ground. Stop the engine.

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows before testing and adjusting the hydraulic system.






3. Engage the parking brake. Place blocks in front of the wheels and behind the wheels. 4. When the work tool is raised for testing or for adjusting, make sure that the work tool is

supported correctly. Also, make sure that the work tool is fully in the DUMP position. The lift circuit has high oil pressure when the lift arms raise the front of the machine. Note: When you stop the machine, make sure that the front of the machine is not off the ground. Unless raising the machine off the ground is required for a test, lower the machine to the ground and stop the engine.

5. Install the steering frame lock so that the machine cannot articulate. 6. Turn the key to the ON position without starting the engine. Cycle the hydraulic control levers

through all positions in order to release the pressure in the hydraulic system. Place the tilt control lever in the FLOAT position. Place the lift control lever in the HOLD position.

When any test is performed on the hydraulic system, the hydraulic oil must be at the normal operating temperature. During a diagnosis of the hydraulic system, remember that correct oil flow and correct pressure are necessary for correct machine operation. The pump output increases as the engine speed increases and vice versa.


Fri Sep 9 22:19:43 EST 2011



Operacin de Sistemas 924G and 924GZ Wheel Loaders Hydraulic System

General Information SMCS - 5050 S/N - 9SW1-2026 S/N - AAN1-UP S/N - 3PZ1-1342

Cerrar SIS



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Schematic for the Work Tool System for the 924G Wheel Loader with the VersaLink front end



(1) Coupler

(2) Accumulator for the ride control

(3) Solenoid for the ride control

(4) Combination valve

(5) Tilt cylinder

(6) Lift cylinder

(7) Lines to the third function

(8) Lines to the fourth function

(9) Bank valves

(10) Pilot valves

(11) Connector with an orifice

(12) Accumulator for the pilot valves

(13) Pressure reducing valve

(14) Screen

(15) Shutoff for the pilot valve

(16) Back pressure valve

(17 ) Manifold

(18) Piston pump

(19) Hydraulic tank

(20) Coupler control valve

(A) Test port for the signal pressure of the piston pump for the work tool

(B) Test port for the signal pressure of the piston pump for the steering system

(C) Test port for the piston pump for the work tools

(D) Test port for the steering system

(E) Test port at the pressure reducing valve

(F) Line to the pressure switch for the secondary steering

(G) Lines to the steering system

(H) Lines from the relief valve in the steering system

(J) Line from the coupler to the load sensing pressure for the steering system

(K) Test port for the pressure for float detent

(L) Rackback position

(M) Dump



The 924G Wheel Loader hydraulic system is made up of three systems: Work Tool Hydraulic System, Brake And Fan Drive System and Steering System. All three systems share a common hydraulic tank. The hydraulic tank is vented.

The location for the hydraulic tank is behind the cab.

The location for the sight glass for the hydraulic oil is on the left side of the machine.

Work Tool Hydraulic System The work tool hydraulic system is composed of the following components: (1) Coupler cylinder, (2) Accumulator for the ride control, (3) Ride control solenoid valve, (4) Combination valve, (5) Tilt cylinder, (6) Lift cylinders, (9) Bank valve, (10) Pilot valve, (12) Accumulator for pilot oil, (13) Pressure reducing valve, (14) Screen, (15) Shutoff valve for the pilot control valves, (16) Back pressure valve, (17) Manifold, (18)

(N) Raise

(P) Lower

(Q) Auxiliary

(R) Auxiliary

(S) Auxiliary

(T) Auxiliary





Piston pump, (19) Hydraulic tank and (20) Coupler control valve.

Access to the piston pump (18) is achieved by removing panels under the platform. The lift cylinders (6) are mounted under the box boom in the front frame. The ride control solenoid valve (3) is mounted on the left side of the machine.

Access to the pilot accumulator (12) is achieved by opening the door to the engine compartment. Access to the bank valves (9) is achieved by removing an access panel. Access to the pressure reducing valve (13) and access to the combination valve (4) is achieved by removing the access panels under the platform. The manifold (17) is mounted in the center of the machine on the piston pump.

Illustration 4 g00652406Left side of the machine

(1) Coupler. (2) Accumulator for the ride control. (3) Ride control solenoid valve. (5) Tilt cylinder. (6) Lift cylinders. (18) Piston pump. (19) Hydraulic tank. (20) Coupler control valve.

Illustration 5 g00652411Right side view of the machine

(4) Combination valve. (9) Bank valves. (10) Pilot valves. (12) Accumulator for the pilot valves. (13) Pressure reducing valve. (14) Screen. (15) Shutoff for the pilot valves. (16) Back pressure valve. (17) Manifold.



The work tool hydraulic system features control valves that are pilot operated. The control valves are closed center valves. The system is load sensing with a variable displacement pump. The work tool hydraulic system is load sensing and the system has pressure compensation. The control valves are parallel to each other. The system only consumes horsepower for the engine as the system requirements are needed. The 924G uses a box boom construction. Because of the box boom design, the orientation of the tilt cylinder is different from the 924Gz machine.

Brake And Fan Drive System The brake and fan drive system circulates the oil to the cooler in order to cool the oil in the hydraulic system. Also, the brake and fan drive system provides supply oil to the brake system. For more information about the specifications for the brake and fan drive system, refer to Service Manual module, RENR3510, "Hydraulic System Specifications". For more information about the brake and fan drive system, refer to Service Manual module, RENR3509, "Brake and Fan Drive System, Systems Operation Testing and Adjusting".

Steering System The steering system steers the machine by changing the angle of the articulation of the machine. For more information about the specifications for the steering systems, refer to Service Manual module, RENR3510, "Hydraulic System Specifications". For more information about the steering system, refer to Service Manual module, RENR3508, "Steering System, Systems Operation Testing and Adjusting".

Illustration 6 g00611051Control levers

(15) Shutoff for the pilot valve. (21) Lift lever and tilt lever. (22) Auxiliary lever for the third function control. (23) Auxiliary lever for the fourth function control.


Fri Sep 9 22:23:48 EST 2011




Relief Valve (Line) - Test and Adjust SMCS - 5117-025-L9 ; 5117-081-L9 S/N - 3DZ1-892 S/N - AAB1-UP S/N - 9SW1-2026 S/N - 6YW1-863 S/N - AAN1-UP S/N - 3PZ1-1342

Cerrar SIS



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Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine.

To prevent personal injury or death, perform the following:



Pump Cutoff Pressure

Park the machine on a smooth, level surface.

Lower the work tool to the ground and engage the parking brake.

Stop the engine and remove the key.

Block the wheels and install the steering frame lock.




Table 1Required Tools

Quantity Part Number Description

1 8T-0855 4000 kPa (580 psi) Pressure Gauge

2 8T-0860 40000 kPa (5800 psi) Pressure Gauge 2 177-7860 Hose Assembly 4 6V-4143 Coupler Assembly 2 6V-3989 Nipple 1 6H-4746 Adapter 1 8T-3613 Valved Nipple Assembly



1. Remove the access panel that is over the bank valve in order to access the line relief valves.


Illustration 2 g00621281Bank valve

(1) Test port for the pressure of the piston pump for the work tools. (2) Line relief valve for the rod end of the tilt cylinder. (3) Line relief valve (auxiliary cylinder rod end). (4) Line relief valve (auxiliary cylinder rod end). (5) Test port for the pressure for the float detent.



2. Turn the start switch to the ON position. 3. Start the engine. Run the engine at HIGH idle. Operate the control levers and move all the

cylinders in order to increase the temperature of the hydraulic oil to normal operating temperature.

4. Stop the engine. Turn the start switch to the ON position. 5. Move the control levers through the full range of travel several times. This will relieve any

pressure that may be present in the pilot hydraulic system. 6. Install an 8T-0855 Pressure Gauge (4000 kPa (580 psi)) on a 177-7860 Hose Assembly . 7. Install the other end of the hose assembly on the test port for the pressure of the piston pump

(1). Note: Do not move any work tool controls in order to check the standby pressure for the pump.

8. Run the engine at HIGH idle. Observe the pressure on the test port for the pressure of the piston pump. The standby pressure for the pump is 2000 200 kPa (290 30 psi).

9. Remove the 8T-0855 Pressure Gauge (4000 kPa (580 psi)). 10. Install an 8T-0860 Pressure Gauge (40000 kPa (5800 psi)) on a 177-7860 Hose Assembly. 11. Install the other end of the hose assembly on the test port for the pressure of the piston pump

(1) . 12. Raise the lift arms to the full height. Hold the lift control in the RAISE position against the


(6) Bypass valve for lowering the loader arms. (7) Line relief valve (auxiliary cylinder head end). (8) Line relief valve (auxiliary cylinder head end).



stops. Observe the pressure of the pump cutoff pressure. The pump cutoff pressure is 25850 345 kPa (3750 50 psi).

13. Use Table 2 in order to determine the line relief specification for the cylinder that is being serviced.

Tilt Cylinder for the 924G Line Relief Valve for the Head End of the Tilt Cylinder

Table 2Settings for Line Relief Valves

Cylinder Head End Rod End

Tilt (924G)

12300 170 kPa (1785 25 psi)

27579 345 kPa (4000 50 psi)

Tilt (924Gz)

27579 kPa (4000 psi)

18616 345 kPa (2700 50 psi)

Auxiliary for the third function hydraulic arrangement

27579 kPa (4000 psi)

27579 kPa (4000 psi)

Auxiliary for the fourth function hydraulic arrangement

27579 kPa (4000 psi)

27579 kPa (4000 psi)




1. Remove the access panel for access to the combination valve.

Bank valve




Illustration 6 g00634215Remove the access panel.



2. Observe the pressures at the pressure test port (15) . 3. Install an 8T-0860 Pressure Gauge (40000 kPa (5801 psi)) on a 177-7860 Hose Assembly. 4. Install the other end of the hose assembly on the test port for the head end of the tilt cylinder

(15) . 5. Start the engine. Run the engine at HIGH idle. Operate the control levers and move all the


6. Raise the arm to half of the height and dump the bucket. Dump the bucket until the cylinder rods are fully extended. Slowly raise the lift arm. Observe the pressure at port (15) for the head end of the tilt cylinder. As the lift arms raise, the linkage pushes the rod into the cylinders.

7. Observe the gauge at port (15) for the relief valve setting and record the pressure. 8. If the line relief valve is not set to the correct specifications, stop the engine. Adjust the line

relief valve.

Illustration 7 g00643897Combination valve

(12) Nut

(13) Adjuster for the relief valve

(14) Test port for the rod end of the tilt cylinder

(15) Test port for the head end of the tilt cylinder



9. Loosen locknut (12). Turn adjusting screw (13) clockwise in order to increase the relief valve setting. Turn adjusting screw (13) counterclockwise in order to decrease the relief valve setting. a. After adjusting screw (13) is turned for an adjustment, tighten locknut (12) to a torque of

4 1 Nm (3 1 lb ft). b. Start the engine. c. Observe the pressure gauge and record the pressure gauge.

10. When the pressure settings for the relief valve are correct, stop the engine and remove the test equipment.

Line Relief Valve for the Rod End of the Tilt Cylinder



Bank valve



1. Remove the access panel for access to the combination valve.




Illustration 11 g00634215Remove the access panel.



2. Observe the pressures at the pressure test ports (14) . 3. Install an 8T-0860 Pressure Gauge (40000 kPa (5801 psi)) on a 177-7860 Hose Assembly. 4. Install the other end of the hose assembly on the test port for the rod end of the tilt cylinder

(14) . 5. Start the engine. Run the engine at HIGH idle. Operate the control levers and move all the


6. Raise the arm to a level position. Tilt back the bucket until the cylinder rods are fully retracted. Lower the arm until the stops for the tilt back position are engaged. Slowly lower the lift arm. Observe the pressure at port (14) for the rod end of the tilt cylinder. As the lift arms lower, the linkage pulls the rod from the cylinders. The linkage pulls the rod from the cylinder and the pressure increases.

7. Observe the gauge at port (14) for the relief valve setting and record the pressure. 8. If the line relief valve is not set to the correct specifications, stop the engine. Adjust the line

relief valve.

Illustration 12 g00643897Combination valve

(12) Nut

(13) Adjuster for the relief valve

(14) Test port for the rod end of the tilt cylinder

(15) Test port for the head end of the tilt cylinder

Pgina 10 de 21924G 924Gz Wheel Loader 3PZ00001-UP (MACHINE) POWERED BY 3056 E...


9. Loosen the locknut on relief valve (2). Turn the adjusting screw clockwise in order to increase the relief valve setting. Turn the adjusting screw counterclockwise in order to decrease the relief valve setting. a. After the adjusting screw is turned for an adjustment, tighten the locknut to a torque of 4

1 Nm (3 1 lb ft). b. Start the engine. c. Observe the pressure gauge and record the pressure gauge.

10. When the pressure settings for the relief valve are correct, stop the engine and remove the test equipment.

Tilt Cylinder for the 924Gz Line Relief Valve For The Head End Of The Tilt Cylinder





1. Install an 8T-0860 Pressure Gauge on the test port for the pressure of the piston pump (1) . Note: You must increase the high pressure cutoff of the pump in order to raise the pressure above the setting for the relief valve for the head end of the tilt cylinder.

2. Loosen nut (7). Turn the adjusting screw (8) clockwise in order to increase the pressure. Turn the adjusting screw (8) counterclockwise in order to decrease the pressure. Increase the high pressure cutoff of the pump to 30000 kPa (4351 psi).

3. Start the engine and run the engine at HIGH idle.


(1) Test port for the pressure of the piston pump for the work tools. (2) Line relief valve for the head end of the tilt cylinder. (3) Line relief valve (auxiliary cylinder rod end). (4) Line relief valve (auxiliary cylinder rod end). (5) Test port for the pilot pressure for the float detent.

Illustration 15 g00643873Location of the test port (6) for the signal pressure of the piston pump, nut (7), and screw (8) for adjusting the high pressure cutoff of the pump.



4. Raise the bucket and tilt back the bucket. 5. Continue to hold the lever for the pilot control valve in the TILT BACK position. This will

cause the pressure to rise to the relief valve setting. 6. Observe the gauge at the relief valve setting for the head end of the tilt cylinder and record the

pressure.

7. If the line relief valve is not set to the correct specifications, stop the engine. Adjust the line relief valve. a. Loosen locknut (12). Turn adjusting screw (13) clockwise in order to increase the relief

valve setting. Turn adjusting screw (13) counterclockwise in order to decrease the relief valve setting.

b. After adjusting screw (13) is turned for an adjustment, tighten locknut (12) to a torque of 4 1 Nm (3 1 lb ft).

c. Observe the pressure gauge. 8. Return the setting for the high pressure cutoff of the pump at 25850 350 kPa (3750 50 psi).

Line Relief Valve For The Rod End Of The Tilt Cylinder 1. You must install a fitting into the line between the tilt cylinder and the bank valve in order to

check the relief pressure for the rod end of the tilt cylinder.

Illustration 16 g00621586Line relief valve

(9) Seat. (10) Poppet valve. (11) Spring. (12) Nut. (13) Adjuster.



2. Remove the plug. Install the 6H-4746 Adapter and install 8T-3613 Valved Nipple Assembly . 3. Install an 8T-0860 Pressure Gauge on the 8T-3613 Valved Nipple Assembly . 4. Raise the arms to half of the height. Dump the work tool fully against the stops. Slowly raise

the lift arms. As the lift arms raise, the linkage pulls the rod from the cylinders and the pressure rises.

5. Observe the gauge at the relief valve setting and record the pressure.



(14) Adjusting screw

(15) Nut

(16) Spring






c. Observe the pressure gauge. 7. When the pressure settings for the relief valves are correct, stop the engine and remove the test

equipment.

Auxiliary Line Relief Valves for the Third Function Hydraulic Arrangement 1. Install an 8T-0860 Pressure Gauge (40000 kPa (5800 psi)) on a 177-7860 Hose Assembly.

2. Install the other end of the hose assembly on the test port for the pressure of the piston pump (1) .

(17) Poppet





3. Loosen nut (7). Turn the adjusting screw (8) clockwise in order to increase the pressure. Turn the adjusting screw (8) counterclockwise in order to decrease the pressure. Increase the high pressure cutoff adjustment of the pump to 30000 kPa (4350 psi).

4. Start the engine and run the engine at LOW idle. Note: In the following steps, do not keep the auxiliary control lever in the ENGAGED position for more than five seconds while the pressure is at the line relief valve setting. This may cause rapid heating of the hydraulic oil.

5. Observe the pressure gauge and move the control lever to the ENGAGED position. The position of the control lever will depend on the line relief valve that is being tested.








c. Start the engine. d. Observe the pressure gauge, and move the control lever to the ENGAGED position.

7. When all pressure settings are correct, return the high pressure cutoff adjustment of the implement pump to 25850 350 kPa (3750 50 psi).

Auxiliary Line Relief Valves for the Fourth Function Hydraulic Arrangement 1. Install an 8T-0860 Pressure Gauge (40000 kPa (5800 psi)) on a 177-7860 Hose Assembly.

2. Install the other end of the hose assembly on the test port for the pressure of the piston pump






(1) .

3. Loosen nut (7). Turn the adjusting screw (8) clockwise in order to increase the pressure. Turn the adjusting screw (8) counterclockwise in order to decrease the pressure. Increase the high pressure cutoff adjustment of the pump to 30000 kPa (4350 psi).

4. Start the engine and run the engine at LOW idle. Note: In the following steps, do not keep the auxiliary control lever in the ENGAGED position for more than five seconds while the pressure is at the line relief valve setting. This may cause rapid heating of the hydraulic oil.

5. Observe the pressure gauge and move the control lever to the ENGAGED position. The position of the control lever will depend on the line relief valve that is being tested.







c. Start the engine. d. Observe the pressure gauge, and move the control lever to the ENGAGED position.

7. When all pressure settings are correct, return the high pressure cutoff adjustment of the implement pump to 25850 350 kPa (3750 50 psi).

Resolvers

1. Remove the access panels to the pump.






2. Install an 8T-0860 Pressure Gauge (40000 kPa (5800 psi)) on a 177-7860 Hose Assembly. Install the other end of the hose assembly on the test port for the piston pump (16).

3. Start the engine. Run the engine at high idle. Operate the control levers and move all the cylinders in order to increase the temperature of the hydraulic oil to normal operating temperature.

4. Observe the pressure at the test port (16) for the signal pressure of the pump. 5. Install an 8T-0860 Pressure Gauge (40000 kPa (5800 psi)) on a 177-7860 Hose Assembly .

Illustration 26 g00632996Test port (16) for the signal pressure for the piston pump.


(1) Test port for the pressure of the piston pump for the work tools. (2) Line relief valve for the rod end of the tilt cylinder. (3) Line relief valve (auxiliary cylinder rod end). (4) Line relief valve (auxiliary cylinder rod end). (5) Test port for the pilot pressure for the float detent.



6. Install the other end of the hose assembly on the test port for the pressure of the piston pump (1). Observe the gauge at the test port (1). The high pressure cutoff of the pump is set at 25850 350 kPa (3750 50 psi). Note: You must increase the high pressure cutoff of the pump in order to raise the pressure above the setting for the relief valve for the tilt cylinder.

7. Loosen nut (17). Turn the adjusting screw (18) clockwise in order to increase the pressure. Turn the adjusting screw (18) counterclockwise in order to decrease the pressure. Increase the high pressure cutoff of the pump to 30000 kPa (4350 psi).

8. Move the work tool controls in the following order. 9. Move the work tool controls to the DUMP position. Observe the pressures. 10. Move the tilt control to the TILT BACK position. Observe the pressures. 11. Move the lift control to the RAISE position. Observe the pressures. 12. Move the lift control to the LOWER position. Observe the pressures. 13. Move the control for the third function hydraulic arrangement. Observe the pressures. 14. Move the control for the fourth function hydraulic arrangement. Observe the pressures. 15. Identify the pressure setting for the relief valve that is correct. 16. Return the setting for the high pressure cutoff of the pump at 25850 350 kPa (3750 50 psi).



Fri Sep 9 22:27:15 EST 2011



1 Test 924G, Relief Valve (Line)

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