Pruebas y Ajustes 924F

Final del formulario

Principio del formulario

Final del formularioPrincipio del formulario

Pruebas y Ajustes 924F WHEEL LOADER IT24F INTEGRATED TOOLCARRIER HYDRAULIC SYS Nmero de medio -SENR6732-00 Fecha de publicacin -20/09/1994 Fecha de actualizacin -12/10/2001

Testing and AdjustingFinal del formularioPrincipio del formulario

IntroductionReference: For Specifications with illustrations, make reference to SENR6731, 924F Wheel Loader and IT24F Integrated Toolcarrier, Hydraulic Systems Specifications. If the Specifications in SENR6731 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the cover of each book. Use the Specification in the book with the latest date. Hydraulic System

Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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.

1. Move the machine to a smooth horizontal location. Move away from working machines and personnel. Lower the bucket/attachment to the ground. Stop the engine.2. Permit only one operator on the machine. Keep all other personnel either away from the machine or in view of the operator.3. Engage the parking brake. Put blocks in front of and behind the wheels.4. When the bucket/attachment is raised for tests or adjustments, make sure that the bucket/attachment has correct support and that it is fully in the DUMP position. The lift circuit has high oil pressure when the lift arms raise the front of the machine.Do not stop the engine with the front of the machine off of the ground, unless a system test requires it. Lower machine to the ground and stop the engine. 5. Install the steering frame lock link so the machine can not turn.6. Move the hydraulic control levers to all positions 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.7. Carefully loosen the fill cap on the hydraulic tank to release the pressure in the tank.8. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened, tightened, removed or adjusted.9. Tighten the fill cap on the hydraulic tank.10. The pressure in the system has now been released and lines or components can be removed.During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary for correct operation. The output of the pump increases with an increase in engine speed and decreases when engine speed is decreased. Oil pressure is caused by resistance to the flow of oil. Visual Checks

Make reference to WARNING on first page of Hydraulic System Testing And Adjusting section.

The 4C4890, 8T5320 and 6V7940 Hydraulic Test Groups, or 1U5481 Pressure Gauge Group are used to make the pressure test of the hydraulic system. Before any tests are made, visually inspect the complete hydraulic system for leakage of oil and for parts that have damage. For some of the tests, a magnet and a measuring rule (either for inches or millimeters) are usable tools. Visual checks and measurements are the first step when troubleshooting a possible problem. Then perform the Operation Checks and last the Instrument Tests. Lower the bucket/attachment to the ground and stop the engine. To remove the hydraulic tank fill cap, slowly turn the fill cap until it is loose. If oil comes out, allow the tank pressure to lower before the fill cap is removed. Make the following inspections: 1. Check the hydraulic tank oil level. Slowly turn the fill cap until it is loose. If oil comes out, allow the tank pressure to lower before the fill cap is removed.2. Look for air in the oil. Perform this immediately after the machine is stopped. Use a clear bottle or container to collect a sample of the oil. Look for air bubbles in the oil that is in the bottle.3. Remove the filter elements and look for particles removed from the oil by the filter element. A magnet will separate ferrous particles from nonferrous particles (piston rings, O-ring seals, etc.).4. Check all oil lines and connections for damage or leaks.5. Inspect control linkage for bent, broken or damaged components.Performance TestsThe tilt and lift circuits on the IT24F are connected in a interupted series arrangement. The tilt and lift circuits on the 924F are connected in a series arrangement. The hydraulic pump and relief valve for main pressure is common to the auxiliary/coupler, lift and tilt circuits. The auxiliary/coupler and tilt circuits have line relief valves in both the head and rod ends to protect the circuits should a sudden rise in pressure occur. The tilt circuit also has make-up valves on both ends of the cylinders, the lift circuit has a makeup valve only on the rod end. The relief valves in the auxiliary/coupler and tilt circuits give protection to the components from pressures in those circuits when the control valves are in the HOLD position. 1. The pressure of the oil to open the relief valves for the main system, auxiliary/coupler and tilt circuits must be to specification. Relief valve pressures that are too low will cause a decrease in the lift and the dig characteristics of the machine. Pressures that are too high will cause a decrease in the life of hoses and components. 2. Drift rates in the lift and tilt circuits: Circuit drift is caused by a leakage past cylinder pistons, O-ring seals in the control valves, check valves or makeup valves that do not seat correctly or poor adjustment or fit in the control valves. 3. Cycle times in the lift and tilt circuits: Cycle times that are longer than those shown on the charts in section Lift And Tilt Circuit Speeds are the result of leakage, pump wear and/or pump speed (rpm).If the basic tests give an indication of circuit leakage, install a Flow Meter and perform a system test. This procedure will find the source of the leakage. Problem 1: Pump makes noise, the cylinder rods do not move smoothly and there are air bubbles in the oil. Probable Cause: 1. The viscosity of the hydraulic oil is incorrect. 2. The relief valve opens at low oil pressure. 3. Loose connection of the oil line on the inlet side of the pump. 4. The pump has too much wear.Problem 2: The temperature of the oil is too hot. Probable Cause: 1. The viscosity of the hydraulic oil is incorrect. 2. The relief valve opens at low oil pressure. 3. The pump has too much wear. 4. There is a restriction in an oil passage. 5. The load of the system is too high. 6. Low oil level. 7. Air in the hydraulic oil.NOTE: If the problem is because of air in the oil, it must be corrected before the system will operate at normal temperatures. There are two things that cause air in the oil (aeration). a. Return oil to the tank flows in above the level of the oil in the tank. b. Air leaks in the oil suction line between the pump and the tank.Problem 3: The output of the pump is low. Probable Cause: 1. Low oil level. 2. The viscosity of the hydraulic oil is incorrect. 3. The pump has too much wear.Problem 4: The pressure of the oil is low. Probable Cause: 1. The relief valve opens at low oil pressure. 2. The pump has too much wear. 3. The failure of an o-ring seal in the system. 4. The main control valve and valve spool have a large amount of wear.Problem 5: Bucket/attachment moves with control lever in HOLD position. Probable Cause: 1. The control valve and valve spool have a large amount of wear. 2. A piston seal in a cylinder has a large amount of wear. 3. A leak in a connection between the pilot control valve and the main control valve. 4. A leak in a connection between the main control valve and the cylinders.Hydraulic Oil Temperature Too HighWhen the temperature of the hydraulic oil rises above 99C (210F), polyurethane seals in the system start to fail. High oil temperature causes seal failure to become more rapid. There are many reasons why the temperature of the oil will get this hot. 1. Hydraulic pump is badly worn. 2. Heavy hydraulic loads that cause the relief valve to open. 3. The setting on the relief valve is too low. 4. Too many restrictions in the system. 5. Low oil level. 6. High pressure oil leak in one or more circuits. 7. Very dirty oil. 8. Air flow through the oil cooler core is too low. 9. Oil flow through the oil cooler is too low. 10. Air in the hydraulic oil.NOTE: If the problem is because of air in the oil, it must be corrected before the system will operate at normal temperatures. There are two things that cause air in the oil (aeration). a. Return oil to the tank rises above the level of the oil in the tank. b. Air leaks in the oil suction line between the pump and the tank.Pump Efficiency CheckNOTE: For more information on the hydraulic pump, see SENR6731, Hydraulic System Specifications. For any pump test at a given rpm, the pump flow at 690 kPa (100 psi) will be larger than the pump flow at 6900 kPa (1000 psi). The difference between the pump flow of the two operating pressures is the flow loss. Method of finding flow loss:

Flow loss when expressed as a percent of pump flow is used as a measure of pump performance. Example of finding percent of flow loss:

If the percent of flow loss is more than 10%, pump performance is not good enough.

*Numbers in examples are for illustration and are not values for any specific pump or pump condition. See Specifications for pump flow of a new pump at 690 kPa (100 psi) and 6900 kPa (1000 psi). Machine TestInstall a Flow Meter. For Formula I, measure pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi) with the engine at high idle rpm.

Bench TestIf the test bench can be run at 6900 kPa (1000 psi) and at full pump rpm, find the percent of flow loss using Formula I. If the test bench cannot be run at 6900 kPa (1000 psi) and at full pump rpm, run the pump shaft at 1000 rpm. Measure the pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Use these values in the top part of Formula II. For the bottom part of the formula, run the pump shaft at 2000 rpm. Measure the pump flow at 690 kPa (100 psi).

Operation Checks


The operation checks can be used to find leakage in the system. They can also be used to find a bad valve or pump. The speed of rod movement when the cylinders move can be used to check the condition of the cylinders and the pump. Raise, lower, dump and tilt back the bucket/attachment several times. 1. Watch the cylinders as they are extended and retracted. Movement must be smooth and regular.2. Listen for noise from the pump.3. Listen for the sound of the relief valves. They must not open except when the cylinders are fully extended or retracted, when the bucket/attachment is empty.4. Watch the operation of the bucket/attachment positioner and lift kickouts.The lift pilot control lever has detents in the RAISE and FLOAT positions. The tilt pilot control lever has a detent in the TILT BACK position (only when the bucket/attachment is between full dump and the work angle). Test Procedures


Lift And Tilt Cylinder Drift TestsThe drift rates will change with different conditions of the hydraulic components as well as with the operation, the type of bucket/attachment (empty or loaded), hydraulic oil temperature, etc. The values shown are for an empty bucket/attachment. Before measuring drift on the cylinder rod, the cylinders must be extended at least five times. Check the oil temperature. To check the lift circuit, lift the bucket to maximum height and move the control lever to the HOLD position. Measure the distance (and check the time) that the cylinders retract, with the chart. NOTE: The drift distances in the charts are for new machines

To check the tilt circuit, lift the bucket/attachment to maximum height, and move the lift control lever to the HOLD position. Activate the tilt circuit until the bucket/attachment is at the angle to dig/load (almost level) and move the tilt control lever to the HOLD position. Measure the distance and check the time that the cylinder retracts, with the chart.

If the cylinder drift is too much: 1. Check the makeup valves in the lift and tilt control valve.2. Check the condition of the valve spools in the lift and tilt control valve.3. Check the piston seals in the cylinders.Lift And Tilt Circuit SpeedsThe oil in the system must be SAE 10 and at a recommended temperature of 65 3C (150 5F) to get accurate tests results. All speed tests are made with the engine at high idle. The speeds in the charts that follow are those of a machine equipped with a general purpose bucket. System speeds that are similar to those given in the charts give an indication that the circuits under test are operating normally. Separate tests must be made for the relief valve to be sure that they are working at their correct rating.

Pilot System Pressure TestPressure Reducing Valve

Make reference to WARNING on first page of Loader Hydraulic System Testing And Adjusting section.

Pilot Pressure Tap Location (1) Pressure tap. (2) Pressure reducing valve. 1. Attach the correct hose and pressure gauge to pressure tap (1).2. Start and run the engine at high idle rpm. The pressure reading, with the oil at normal temperature, must be 3100 400 kPa (450 60 psi).

Pressure Reducing Valve (1) Pressure tap. (2) Pressure reducing valve. (3) Check valve. (4) Pressure reducing valve cartridge. (5) Locknut. (6) Adjusting screw. 3. If the pressure reading is not correct, stop the engine.4. Move the control valves to all positions to release any pressure in the pilot circuits.5. Carefully loosen the hydraulic tank fill cap to release any pressure in the tank. Tighten the cap.6. Loosen locknut (5). Turn adjusting screw (6) clockwise to increase pressure reading, or counterclockwise to decrease the pressure reading. Tighten locknut (5).7. Start the engine. Repeat step 2.8. If pressure reading is correct, stop the engine. Remove the test equipment from pressure tap (1).9. If pressure reading is not correct, stop the engine. Repeat steps 4, 5, 6 and 7.Relief Valves - 924F


1. Lower the bucket/attachment so it is on the ground and can not be tilted.2. Increase the temperature of the oil up to normal operating temperature.Tilt Circuit Rod End Relief Valve


Relief Valve - Typical Example (1) Locknut. (2) Cover nut. (3) Adjusting screw.

System Pressure Relief Valves And Test Location (4) Auxiliary rod end relief valve. (5) Tilt head end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Auxiliary head end relief valve. (9) Tilt rod end relief valve.

1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.NOTE: The tilt rod relief valve has a higher pressure setting than the main relief valve. In order to set properly, the relief valve must be removed and placed in a test bench, or a remote pump must be installed. 3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Remove the hose from the rod end of the main control valve and plug it.5. Assemble fittings and attach 3S6224 pump.NOTE: 3S6224 pump reservoir only contains 7.58 L (2 gal U.S.) of oil. Ensure the pump does not run out of oil. 6. Start the pump and slowly increase pump pressure.7. Move the tilt control lever to the DUMP position.8. The pressure setting of tilt rod end relief valve (9) should be 25 850 1000 kPa (3750 145 psi).NOTE: Do not keep the control lever in the DUMP position, at the relief valve setting, more than 5 seconds. 9. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.10. Stop the pump.11. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.12. After screw (3) is turned for an adjustment, tighten locknut (1).13. Tighten cover nut (2).14. Start the pump. Repeat steps 6, 7 and 8.15. If pressure is correct, stop the pump.16. If pressure is not correct, repeat steps 11, 12, 13 and 14.17. When pressure setting is correct, stop the pump. Remove the test equipment.Tilt Circuit Head End Relief Valve



System Pressure Relief Valves And Test Location (4) Auxiliary rod end relief valve. (5) Tilt head end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Auxiliary head end relief valve. (9) Tilt rod end relief valve.

1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.NOTE: The tilt head relief valve has a higher pressure setting than the main relief valve. In order to set properly, the relief valve must be removed and placed in a test bench, or a remote pump must be installed. 3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Remove the hose from the head end of the main control valve and plug it.5. Assemble fittings and attach 3S6224 pump.NOTE: 3S6224 pump reservoir only contains 7.58 L (2 gal U.S.) of oil. Ensure the pump does not run out of oil. 6. Start the pump and slowly increase pump pressure.7. Move the tilt control lever to the TILT BACK position.8. The pressure setting of tilt head end relief valve (5) should be 25 850 1000 kPa (3750 145 psi).NOTE: Do not keep the control lever in the TILT BACK position, at the relief valve setting, more than 5 seconds. 9. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.10. Stop the pump.11. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.12. After screw (3) is turned for an adjustment, tighten locknut (1).13. Tighten cover nut (2).14. Start the pump. Repeat steps 6, 7 and 8.15. If pressure is correct, stop the pump.16. If pressure is not correct, repeat steps 11, 12, 13 and 14.17. When pressure setting is correct, stop the pump. Remove the test equipment.Auxiliary Cylinder Head End Relief Valve (Optional)



System Pressure Relief Valves And Test Location (4) Auxiliary rod end relief valve. (5) Tilt head end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Auxiliary head end relief valve. (9) Tilt rod end relief valve. 1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.3. Install necessary fittings, connector, hose and pressure gauge in head end line.4. Start the engine.5. With the bucket on the ground. Move the control lever to the OPEN position until the auxiliary cylinder rods are fully extended.6. Increase engine rpm to high idle, look at the test gauge and move the auxiliary control lever to the OPEN position.7. The pressure setting of auxiliary head end relief valve (8) should be 22 100 350 kPa (3210 50 psi).NOTE: Do not keep the control lever in the OPEN position, at the relief valve setting, more than 5 seconds. 8. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.9. Stop the engine.10. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.11. After screw (3) is turned for an adjustment, tighten locknut (1).12. Tighten cover nut (2).13. Start the engine. Repeat steps 7, 8 and 9.14. If pressure is correct, stop the engine.15. If pressure is not correct, repeat steps 10, 11, 12 and 13.16. When pressure setting is correct, stop the engine. Remove the test equipment.Auxiliary Cylinder Rod End Relief Valve (Optional)



System Pressure Relief Valves And Test Location (4) Auxiliary rod end relief valve. (5) Tilt head end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Auxiliary head end relief valve. (9) Tilt rod end relief valve. 1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.3. Install necessary fittings, connector, hose and pressure gauge in rod end line.4. Start the engine.5. With the bucket on the ground. Close the bucket until the auxiliary cylinder rods are fully retracted.6. Increase engine rpm to high idle, look at the test gauge and move the auxiliary control lever to the CLOSE position.7. The pressure setting of auxiliary rod end relief valve (4) should be 22 100 350 kPa (3210 50 psi).NOTE: Do not keep the control lever in the CLOSE position, at the relief valve setting, more than 5 seconds. 8. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.9. Stop the engine.10. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.11. After screw (3) is turned for an adjustment, tighten locknut (1).12. Tighten cover nut (2).13. Start the engine. Repeat steps 7, 8 and 9.14. If pressure is correct, stop the engine.15. If pressure is not correct, repeat steps 10, 11, 12 and 13.16. When pressure setting is correct, stop the engine. Remove the test equipment.Main Relief Valve



System Pressure Relief Valves And Test Location (4) Auxiliary rod end relief valve. (5) Tilt head end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Auxiliary head end relief valve. (9) Tilt rod end relief valve. 1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Start the engine.5. Raise the bucket off the ground. Tilt back the bucket until the tilt cylinder rods are fully extended.6. Increase engine rpm to high idle, look at the test gauge and move the tilt control lever to the TILT BACK position.7. The pressure setting of main relief valve (6) should be 24 800 700 kPa (3600 100 psi).NOTE: Do not keep the control lever in the TILT BACK position, at the relief valve setting, more than 5 seconds. 8. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.9. Stop the engine.10. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.11. After screw (3) is turned for an adjustment, tighten locknut (1). Tighten cover nut (2).12. Start the engine. Repeat steps 5, 6 and 7.13. If pressure is correct, lower the bucket to the ground and stop the engine.14. If pressure is not correct, repeat steps 10, 11, 12 and 13.15. When pressure setting is correct, stop the engine. Remove the test equipment.Relief Valves - IT24F


1. Lower the bucket/attachment so it is on the ground and can not be tilted.2. Increase the temperature of the oil up to normal operating temperature.Tilt Circuit Rod End Relief Valve



System Pressure Relief Valves And Test Location (4) Coupler rod end relief valve. (5) Tilt rod end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Coupler head end relief valve. (9) Tilt head end relief valve.

1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.NOTE: The tilt rod relief valve has a higher pressure setting than the main relief valve. In order to set properly, the relief valve must be removed and placed in a test bench, or a remote pump must be installed. 3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Remove the hose from the rod end of the main control valve and plug it.5. Assemble fittings and attach 3S6224 pump.NOTE: 3S6224 pump reservoir only contains 7.58 L (2 gal U.S.) of oil. Ensure the pump does not run out of oil. 6. Start the pump and slowly increase pump pressure.7. Move the tilt control lever to the DUMP position.8. The pressure setting of tilt rod end relief valve (5) should be 19 300 350 kPa (2800 50 psi).NOTE: Do not keep the control lever in the DUMP position, at the relief valve setting, more than 5 seconds. 9. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.10. Stop the pump.11. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.12. After screw (3) is turned for an adjustment, tighten locknut (1).13. Tighten cover nut (2).14. Start the pump. Repeat steps 6, 7 and 8.15. If pressure is correct, stop the pump.16. If pressure is not correct, repeat steps 11, 12, 13 and 14.17. When pressure setting is correct, stop the pump. Remove the test equipment.Tilt Circuit Head End Relief Valve



System Pressure Relief Valves And Test Location (4) Coupler rod end relief valve. (5) Tilt rod end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Coupler head end relief valve. (9) Tilt head end relief valve.

1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Start the engine.5. Raise the bucket/attachment off the ground. Tilt back the bucket/attachment until the tilt cylinders rods are fully retracted.6. Increase engine rpm to high idle, look at the test gauge and move the tilt control lever to the TILT BACK position.7. The pressure setting of tilt head end relief valve (9) should be 9300 350 kPa (1350 50 psi).NOTE: Do not keep the control lever in the TILT BACK position, at the relief valve setting, more than 5 seconds. 8. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.9. Stop the engine.10. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.11. After screw (3) is turned for an adjustment, tighten locknut (1). Tighten cover nut (2).12. Start the engine. Repeat steps 6, 7 and 8.13. If pressure is correct, lower the bucket/attachment to the ground and stop the engine.14. If pressure is not correct, repeat steps 10, 11, 12 and 13.15. When pressure setting is correct, stop the engine. Remove the test equipment.Coupler Cylinder Head End Relief Valve



System Pressure Relief Valves And Test Location (4) Coupler rod end relief valve. (5) Tilt rod end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Coupler head end relief valve. (9) Tilt head end relief valve. 1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.NOTE: The coupler head relief valve has a higher pressure setting than the main relief valve. In order to set properly, the relief valve must be removed and placed in a test bench, or a remote pump must be installed. 3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Remove the hose from the head end of the main control valve and plug it.5. Assemble fittings and attach 3S6224 pump.NOTE: 3S6224 pump reservoir only contains 7.58 L (2 gal U.S.) of oil. Ensure the pump does not run out of oil. 6. Start the pump and slowly increase pump pressure.7. Move the coupler control lever to the OPEN position.8. The pressure setting of coupler head end relief valve (8) should be 19 300 350 kPa (2800 50 psi).NOTE: Do not keep the control lever in the OPEN position, at the relief valve setting, more than 5 seconds. 9. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.10. Stop the pump.11. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.12. After screw (3) is turned for an adjustment, tighten locknut (1).13. Tighten cover nut (2).14. Start the pump. Repeat steps 6, 7 and 8.15. If pressure is correct, stop the pump.16. If pressure is not correct, repeat steps 11, 12, 13 and 14.17. When pressure setting is correct, stop the pump. Remove the test equipment.Coupler Cylinder Rod End Relief Valve



System Pressure Relief Valves And Test Location (4) Coupler rod end relief valve. (5) Tilt rod end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Coupler head end relief valve. (9) Tilt head end relief valve. 1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.NOTE: The coupler head relief valve has a higher pressure setting than the main relief valve. In order to set properly, the relief valve must be removed and placed in a test bench, or a remote pump must be installed. 3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Remove the hose from the rod end of the main control valve and plug it.5. Assemble fittings and attach 3S6224 pump.NOTE: 3S6224 pump reservoir only contains 7.58 L (2 gal U.S.) of oil. Ensure the pump does not run out of oil. 6. Start the pump and slowly increase pump pressure.7. Move the coupler control lever to the CLOSE position.8. The pressure setting of coupler rod end relief valve (4) should be 19 300 350 kPa (2800 50 psi).NOTE: Do not keep the control lever in the CLOSE position, at the relief valve setting, more than 5 seconds. 9. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.10. Stop the pump.11. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.12. After screw (3) is turned for an adjustment, tighten locknut (1).13. Tighten cover nut (2).14. Start the pump. Repeat steps 6, 7 and 8.15. If pressure is correct, stop the pump.16. If pressure is not correct, repeat steps 11, 12, 13 and 14.17. When pressure setting is correct, stop the pump. Remove the test equipment.Main Relief Valve



System Pressure Relief Valves And Test Location (4) Coupler rod end relief valve. (5) Tilt rod end relief valve. (6) Main relief valve. (7) Pressure tap. (8) Coupler head end relief valve. (9) Tilt head end relief valve. 1. Release hydraulic system pressure.2. Carefully loosen the tank fill cap to release any pressure in the tank. Tighten the cap.3. Install a connector, hose and pressure gauge at inline pressure tap (7).4. Start the engine.5. Raise the bucket/attachment off the ground. Tilt back the bucket/attachment until the tilt cylinder rods are fully retracted.6. Increase engine rpm to high idle, look at the test gauge and move the tilt control lever to the TILT BACK position.7. The pressure setting of main relief valve (6) should be 17 300 300 kPa (2510 45 psi).NOTE: Do not keep the control lever in the TILT BACK position, at the relief valve setting, more than 5 seconds. 8. If the opening pressure of the relief valve is not to specification it will be necessary to adjust the valve.9. Stop the engine.10. Remove cover nut (2). Loosen locknut (1) and turn screw (3) clockwise for an increase or counterclockwise for a decrease in the pressure setting of the relief valve.11. After screw (3) is turned for an adjustment, tighten locknut (1). Tighten cover nut (2).12. Start the engine. Repeat steps 5, 6 and 7.13. If pressure is correct, lower the bucket/attachment to the ground and stop the engine.14. If pressure is not correct, repeat steps 10, 11, 12 and 13.15. When pressure setting is correct, stop the engine. Remove the test equipment.Ride Control Accumulator Recharging Procedure924F


Ride Control Accumulator (1) Charging valve. (2) Accumulator. 1. Move the machine to level ground. Turn the machine to the left to allow better access to accumulator (2). Stop the engine.2. Move transmission control lever to NEUTRAL. Move the transmission neutral lock into the LOCKED position.3. Engage the parking brake.4. Lower the bucket/attachment to the ground and place the lift control lever in the FLOAT position.5. Depress the spring loaded stem in charging valve (1) until pressure is relieved.6. Using the proper sized socket wrench, remove the charging valve assembly.7. Start the engine. Raise the bucket/attachment to release the rest of the air from the gas side of the accumulator.8. Stop the engine. Lower the bucket/attachment to the ground and place the lift control lever in the FLOAT position.9. Reinstall the charging valve and tighten it with the wrench.10. Remove the small cap on the charging valve assembly. Attach chuck assembly 1S8938 and extension 1U5551 to the valve.11. Attach nitrogen bottle to extension and open valve to gauge on bottle. Open gas valve and charge the accumulator to 2280 kPa (330 psi).12. Charge time should be 10-20 seconds.13. If gauge instantly goes to 2280 kPa (330 psi), air has not been properly purged from the gas chamber. Repeat steps 4 through 12.14. When properly charged, close gas valve, but leave gauge valve open.NOTE: Leaving the gauge valve open ensures the accumulator piston is at the bottom of its stroke and the chamber is full of nitrogen gas. 15. Remove the gas bottle, extension and chuck. Replace the charging valve cap.IT24F


Ride Control Accumulator (1) Charging valve. (2) Accumulator. 1. Move the machine to level ground. Turn the machine to the left to allow better access to accumulator (2). Stop the engine.2. Move transmission control lever to NEUTRAL. Move the transmission neutral lock into the LOCKED position.3. Engage the parking brake.4. Lower the bucket/attachment to the ground and place the lift control lever in the FLOAT position.5. Depress the spring loaded stem in charging valve (1) until pressure is relieved.6. Using the proper sized socket wrench, remove the charging valve assembly.7. Start the engine. Raise the bucket/attachment to release the rest of the air from the gas side of the accumulator.8. Stop the engine. Lower the bucket/attachment to the ground and place the lift control lever in the FLOAT position.9. Reinstall the charging valve and tighten it with the wrench.10. Remove the small cap on the charging valve assembly. Attach chuck assembly 1S8938 and extension 1U5551 to the valve.11. Attach nitrogen bottle to extension and open valve to gauge on bottle. Open gas valve and charge the accumulator to 1720 kPa (250 psi).12. Charge time should be 10-20 seconds.13. If gauge instantly goes to 1720 kPa (250 psi), air has not been properly purged from the gas chamber. Repeat steps 4 through 12.14. When properly charged, close gas valve, but leave gauge valve open.NOTE: Leaving the gauge valve open ensures the accumulator piston is at the bottom of its stroke and the chamber is full of nitrogen gas. 15. Remove the gas bottle, extension and chuck. Replace the charging valve cap.

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Pruebas y Ajustes 924F

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