15/2/2021 SIS 2.

2008/03/04 Relief Valve (Line) - Test and Adjust (RENR4396)

SMCS - 5117 i02972094

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:

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.

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.

NOTICE
For all relief valve tests, the recommended method to test a
relief valve is to remove the valve from the machine and use a
test bench to test and adjust the valve.

Required Tools
Part Number Description Qty
1U-5481 Pressure Gauge Group(1) 1
1U-5482 Pressure Adapter Group 1
8S-7630(2) Stand 2
8S-7641 Tube 2
https://sis2.cat.com/#/service-detail?
8S-8048 Saddle 2
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 1/8
15/2/2021 SIS 2.0

8S-7615 Pin 2

Table 1
(1)
(2) The 198-4240 Digital Pressure Indicator is also available.
Optional tooling

Machine Preparation for Troubleshooting

1. Move the machine to a smooth horizontal location. Move away from working
machines and personnel. Lower the work tools to the ground.

2. Allow only one operator on the machine. Keep all personnel away from the machine
or in the view of the operator.

3. Engage the parking brake.

Illustration 1 g00893065

4. Place the steering frame lock in the LOCKED position.

Reference: For more information about preparing the machine for troubleshooting,
refer to the Service Manual module Testing and Adjusting, "Machine Preparation for
Troubleshooting" for the machine that is being serviced.

5. 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.

6. Lower the lift arms to the lift arm supports.

Illustration 2 g00298585
Lift Arm Supports

7. Turn the engine key start switch to the OFF position.

8. Release the hydraulic pressure. Refer to the Service Manual module Testing and
Adjusting, "System Pressure - Release" for the machine that is being serviced.

https://sis2.cat.com/#/service-detail?
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 2/8
15/2/2021 SIS 2.0

Illustration 3 g00388155
Loader Tower Access Panel
Lift arms raised for photographic purposes only.

9. Remove the loader tower access panel that is over the main control valve in order
to access the line relief valves.

Check the Main Relief Valve

Settings for the Main Relief Valve in kPa (psi)
Standard 20700 ± 340 kPa (3000 ± 50 psi)
Logging 20700 ± 340 kPa (3000 ± 50 psi)

Table 2

Illustration 4 g00819869
Main Control Valve
(1) Pressure Tap.

1. Install the proper gauge from 1U-5481 Pressure Gauge Group to pressure tap (1)
on the main control valve.
Note: The main control valve is located in the front of the loader assembly.

Illustration 5 g00893728
Remote Pressure Tap

2. If the machine is equipped with a remote pressure tap, the main system pressure
for the implements can be tested at that pressure tap. The remote pressure tap is
located on the left side of the front frame at the hitch area.

3. In order to check a line relief valve, the pressure for the main relief valve must be
set above the pressure for the line relief valve. Refer to Table 2 for the pressure of
https://sis2.cat.com/#/service-detail?
the main relief valve. Refer to Table 3 for the pressure for the line relief valves.
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 3/8
15/2/2021 SIS 2.0

Illustration 6 g00820089
Main Control Valve (Three Function)
(2) Rod end line relief valve for the tilt cylinder. (3) Head end line relief valve for the auxiliary cylinder.
(4) Head end line relief valve for the tilt cylinder. (5) Rod end line relief valve for the auxiliary cylinder.
(6) Main relief valve.

Illustration 7 g00819861
Main Control Valve (Two Function)
(2) Rod end line relief valve for the tilt cylinder. (4) Head end line relief valve for the tilt cylinder. (6)
Main relief valve.
Note: Position the work tool on the ground or position the lift arms on the lift arm
supports, before you make adjustments to the main relief valve.

4. If the main relief valve setting is below the setting for the line relief valve, it will be
necessary to temporarily increase the main relief valve setting.
Reference: For information about adjusting the main relief valve, refer to the
Service Manual module Testing and Adjusting, "Relief Valve (Main) - Test and
Adjust".

Testing Line Relief Valves (Tilt)

Machine Effectivity of Line Relief Valves
966G II 966G II 966G II
Relief
972G II 972G II 972G II
Valve
No Auxiliary Function Auxiliary Function Logging Function
Tilt 22750 ± 400 kPa 22750 ± 400 kPa 22750 ± 400 kPa
Rod End (3300 ± 60 psi) (3300 ± 60 psi) (3300 ± 60 psi)
Tilt 22750 ± 400 kPa 26000 ± 400 kPa
22750 ± 400 kPa
Head (3300 ± 60 psi) (3770 ± 60 psi)
(3300 ± 60 psi)
End
Auxiliary 20700 ± 400 kPa 22750 ± 400 kPa
Head - (3000 ± 60 psi) (3300 ± 60 psi)
End
Auxiliary 12400 ± 400 kPa 12400 ± 400 kPa
-
Rod End (1800 ± 60 psi) (1800 ± 60 psi)

Table 3
https://sis2.cat.com/#/service-detail?
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 4/8
15/2/2021 SIS 2.0

Illustration 8 g00759169
Top View of Front Frame
(7) Pressure tap for rod end of the tilt cylinder. (8) Pressure tap for head end of the tilt cylinder.

1. Install the proper gauge from 1U-5481 Pressure Gauge Group to pressure tap (8).

2. Hold the tilt control lever in the full TILT BACK position.
Note: Do not hold the tilt control lever in the full TILT BACK position for more than 5
seconds.

3. Record the pressure reading from the test gauge that is connected to pressure tap
(8).
If the pressure reading does not agree with the value in Table 3, proceed to Section
"Adjusting the Line Relief Valve".

If the pressure reading agrees with the value in Table 3, proceed to Step 4.

4. Remove the 1U-5481 Pressure Gauge Group from pressure tap (8) and install the
proper gauge from 1U-5481 Pressure Gauge Group to pressure tap (7). Pressure
tap (7) is the pressure for the rod end of the tilt cylinder.

5. Hold the tilt control lever in the full DUMP position.

Note: Do not hold the tilt control lever in the full DUMP position for more than 5
seconds.

6. Record the pressure reading from the test gauge that is connected to pressure tap
(7).
If the pressure reading does not agree with the value in Table 3, proceed to Section
"Adjusting the Line Relief Valve".

If the machine is not equipped with a auxiliary function and the pressure reading
agrees with the value in Table 3, proceed to Section "Remove Test Equipment".

7. If the machine is equipped with an auxiliary function, proceed to Section "Testing

Line Relief Valves (Auxiliary)".

Testing Line Relief Valves (Auxiliary)

https://sis2.cat.com/#/service-detail?
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 5/8
15/2/2021 SIS 2.0

Illustration 9 g00759170
Top View of Front Frame
(9) Pressure tap for the head end. (10) Pressure tap for the rod end.

1. Install the proper gauge from 1U-5481 Pressure Gauge Group to pressure tap (10).

2. Run the engine at high idle.

3. Hold the auxiliary control lever in the full FORWARD position.

Note: Do not hold the auxiliary control lever in the full FORWARD position for more
than 5 seconds.

4. Record the pressure reading from the test gauge that is connected topressure tap
(10).
If the pressure reading does not agree with the value in Table 3, proceed to Section
"Adjusting the Line Relief Valve".

If the pressure reading agrees with the value in Table 3, proceed to Step 5.

5. Remove the 1U-5481 Pressure Gauge Group from pressure tap (10). Install the
proper gauge from 1U-5481 Pressure Gauge Group to pressure tap (9).

6. Hold the auxiliary control lever in the full REARWARD position.

Note: Do not hold the auxiliary control lever in the full REARWARD position for
more than 5 seconds.

7. Record the pressure reading from the test gauge that is connected topressure tap
(9).
If the pressure reading does not agree with the value in Table 3, proceed to Section
"Adjusting the Line Relief Valve".

If the pressure reading agrees with the value in Table 3, proceed to Section
"Remove Test Equipment".

Adjusting the Line Relief Valve

Note: Position the work tool on the ground or position the lift arms on the stands,
before you make adjustments to the line relief valve.

1. Proceed with the following steps in order to adjust the line relief valve.

a. Refer to Illustration 6 and Illustration 7 for the location of the line relief valves.

https://sis2.cat.com/#/service-detail?
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 6/8
15/2/2021 SIS 2.0

Illustration 10 g00821357

b. Loosen locknut (11). Turn adjusting screw (12) clockwise in order to increase
the relief valve setting.

c. Turn adjusting screw (12) counterclockwise in order to decrease the relief

valve setting.

d. After adjusting screw (12) is turned for an adjustment, tighten locknut (11) to
the following torque 50 ± 7 N·m (37 ± 5 lb ft).

2. Verify that the hydraulic oil pressure is correct. If the pressure does not agree with
the values in Table 3, repeat Step 1a through 1d until the pressure is set correctly.

Remove Test Equipment

Note: Position the work tool on the ground or position the lift arms on the stands, before
you adjust the hydraulic oil pressure for the main relief valve.

1. Install the proper gauge from 1U-5481 Pressure Gauge Group to pressure tap (1)
on the main control valve.

2. Adjust the hydraulic oil pressure for the main relief valve to the pressure that is in
Table 2.
Reference: For information on adjusting hydraulic oil pressure for the main relief
valve, refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".

3. When the hydraulic oil pressure for the main relief valve is correctly adjusted, lower
the work tool to the ground or lower the lift arms to the lift arm supports. Turn the
engine key start switch to the OFF position.

4. Remove the test equipment and install the loader tower access panel.

5. If the lift arms are in the lift arm supports then start the engine and remove the lift
arms from the lift arm supports. Ensure that the work tool is on the ground. Turn the
engine start switch to the OFF position.

Illustration 11 g00893707

6. Place the steering frame lock in the STORE position.

ANZ1-UP, AWP1-UP, AXJ1-UP, AXL1-UP, AXN1-UP, AXP1-UP

https://sis2.cat.com/#/service-detail?
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 7/8
15/2/2021 SIS 2.0

PIP-10346044
2021/02/16
01:09:31-03:00
i01552117
© 2021 Caterpillar Inc.
Caterpillar:
Confidential Green

https://sis2.cat.com/#/service-detail?
serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false
https://sis2.cat.com/#/service-detail?serialNumber=awp00270&ieSystemControlNumber=i01552117&mediaNumber=RENR4396&infoType=-1&hideDocumentStructure=false 8/8