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Producto: TRUCK
Modelo: 793D TRUCK FDB
Configuración: 793D Off-Highway Truck FDB00001-UP (MACHINE)
POWERED BY 3516B Engine

Pruebas y Ajustes
793D Off-Highway Truck Hydraulic System
Número de medio -RENR8340-00 Fecha de publicación -01/09/2005 Fecha de actualización -03/10/2005

i02415768

Relief Valve (Hoist Dual Stage) - Test and Adjust

SMCS - 5117-036

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine or release of air pressure or oil

pressure can cause injury to persons on or near the machine.

To help prevent possible injury before testing and adjusting any air
system or hydraulic system, perform the procedure in the Testing and
Adjusting, "General Information" section.

NOTICE
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, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Table 1

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Required Tools
Part Number Description Qty
198-4240 Digital Pressure Indicator 1

Note: Before you perform any tests, visually inspect the entire hydraulic system for oil leaks and for
damaged components.

The 198-4240 Digital Pressure Indicator may be used to test the pressure at the pressure taps.

Illustration 1 g01208015

Location of pressure taps on the hoist pump for the relief valve.

The hoist dual stage relief valve is part of the hoist control valve. The hoist control valve is located
under the truck. The relief pressure for the RAISE position is different from the relief pressure for the
LOWER position.

Relief Valve Test (High Pressure)

1. Lower the dump body completely. Stop the engine.

2. Relieve any system pressure that may be present. Move the hoist control to the RAISE and
LOWER positions. Place the hoist control in the FLOAT position.

3. Use 198-4240 Digital Pressure Indicator. Connect the appropriate sensors and cables to the correct
hydraulic tap on the hoist pump and to the digital pressure gauge. Make sure that the hoses for the
digital pressure gauge are long enough to be extended into the cab.

4. Start the engine. Operate the dump body repeatedly until the temperature of the hydraulic oil is
above 38 °C (100.0 °F).

5. Run the engine at LOW IDLE. Move the hoist control to the RAISE position until the cylinders

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are fully extended. Attach the safety cable for the dump body.

6. Slowly accelerate the engine to the HIGH IDLE position. Hold the hoist control in the RAISE
position. The pressure range for the 785C and 789C machines is 17225 to 17925 kPa (2500 to
2600 psi). The pressure range for the 793C, 793D machines is 20370 to 21070 kPa (2955 to 3057
psi). Record the highest pressure that is read on the gauge. If the pressure exceeds this range,
investigate the cause of the higher pressure.

7. If the pressure setting is incorrect, adjust the relief valve on the hoist diverter valve. Refer to
"Relief Valve Adjustment" within the original Service Module for the correct procedure.

8. Raise the dump body completely. Remove the safety cable.

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Illustration 2 g00283734
High pressure relief valve

(1) 5J-2721 Shim

(2) 5J-2722 Shim

9. As needed, adjust the number of shims in order to achieve the correct relief valve pressure setting.

Table 2

Shims for Adjusting the Relief Valve Pressure Setting

Part Number Thickness Pressure Change

5J-2721
0.13 mm (0.005 inch) 65 kPa (9 psi)

5J-2722
1.22 mm (0.048 inch) 610 kPa (88 psi)

Relief Valve Test (Low Pressure)

1. Lower the dump body. Stop the engine.

2. Use 198-4240 Digital Pressure Indicator. Connect the appropriate sensors and cables to the correct
hydraulic tap on the hoist pump and to the digital pressure gauge. Make sure that the hoses for the
digital pressure gauge are long enough to be extended into the cab.

3. Start the engine. Operate the dump body repeatedly until the temperature of the hydraulic oil is
above 38°C (100°F).

4. Run the engine at high idle and move the hoist control to the LOWER position.

5. After the dump body is fully lowered, look at the gauge and hold the hoist control in the LOWER
position. The high pressure gauge reading is the relief valve pressure setting. The correct pressure
setting is 3450 to 3800 kPa (500 to 550 psi).

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Illustration 3 g00283735
Low pressure relief valve

(3) 5J-2721 Shim

(4) 5J-2722 Shim

6. As needed, adjust the number of shims in order to achieve the correct relief valve pressure setting.

Table 3

Shims for Adjusting the Relief Valve Pressure Setting

Part Number Thickness Pressure Change

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5J-2721
0.13 mm (0.005 inch) 13 kPa (2 psi)

5J-2722
1.22 mm (0.048 inch) 125 kPa (18 psi)

Copyright 1993 - 2009 Caterpillar Inc. Sat Mar 21 09:15:56 UTC-0400 2009
Todos los derechos reservados.
Red privada para licenciados del SIS.

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