CP56, CS56, CP64, CS64, CP74 and CS74 Vibratory Compactors Propel System Relief Valve (Main, Drum Propel Pump) - Test and Adjust Caterpillar


Relief Valve (Main, Drum Propel Pump) - Test and Adjust
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------ WARNING! ------

Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts.

Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified.

The machine must be parked on a level surface and the engine stopped.

Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine.


------ WARNING! ------

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine can cause injury to persons on or near the machine.

To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.


------ WARNING! ------

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, 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.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in AVSpare machines.

Dispose of all fluids according to local regulations and mandates.


Table 1
Required Tools 
Tool  Part
Number 
Description  Qty 
A(1)  198-4234  Pressure Gauge Tool Gp 
198-4236 Adapter Cable As 
251-9600  Pressure Sensor
0 to 69000 kPa (0 to 10000 psi) 
6V-9828  Cap As 
6V-9507  Plug 
4J-5477 O-Ring Seal 
6V-9829  Cap As 
6V-9508  Plug 
6V-8397 O-Ring Seal 
4C-6500  Digital Thermometer 
(1) Tool (A) is part of 198-4240 Digital Pressure Indicator.

  1. Drive the machine to a smooth, horizontal surface.


    Illustration 1g01412481

  2. Move propulsion lever (1) to the NEUTRAL position.


    Illustration 2g01412483

  3. Move parking brake switch (2) to the ON position.


    Illustration 3g01412484

  4. Move throttle switch (3) to the LOW IDLE position.


    Illustration 4g01412486

  5. Move engine start switch (4) to the OFF position.

  6. Block the wheels. Block the drum.

  7. Assemble Tool (A). Connect Tool (A) to Tool (B).


    Illustration 5g01412676

  8. Remove bolts (5) and remove right cover plate (6).


    Illustration 6g01412677

  9. Remove bolts (7) and remove left cover plate (8).


    Illustration 7g01412798

  10. Disconnect brake supply line (9) from the drum. Use Tool (C) to cap the port. Use Tool (D) to plug the hose.

  11. Raise the cab. Refer to Disassembly and Assembly, KENR6004, "Cab - Tilt".


    Illustration 8g01413630
    The Drum Pump is Shown From Left Side.

  12. Disconnect balance line (10) and balance line (11) from drum pump. Use Tool (E) to cap ports. Use Tool (F) to plug the hoses.


    Illustration 9g01413633
    The Axle Pump is Shown From Left Side.

  13. Disconnect electrical connector (12) for the axle interlock from the axle pump.


    Illustration 10g01413639
    The Drum Pump is Shown From Left Side.

  14. Connect one Tool (B) to each of the following pressure taps:

    • Reverse pressure tap (13) on the drum pump

    • Forward pressure tap (14) on the drum pump


    Illustration 11g01413642
    The Drum Pump is Shown From Left Side.

  15. Remove the cap from the POR valve. Loosen the locknut and rotate adjustment screw (15) for two turns in the clockwise direction. Hold the adjustment screw and tighten the locknut.

  16. Lower the cab but do not install cover plates (6) and (8). Refer to Disassembly and Assembly, KENR6004, "Cab - Tilt".

  17. Move engine start switch (4) to the START position. Release the switch when the engine starts.

  18. Operate the engine at low idle for few minutes. Move throttle switch (3) to the HIGH IDLE position.

  19. Monitor hydraulic oil temperature with Tool (G). Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).


    Illustration 12g01413645

  20. Move shift switch (16) to the HIGH SPEED position. Move parking brake switch (2) to the RELEASE position.

  21. Modulate propulsion lever (1) forward until the peak pressure is registered at forward pressure tap (14) (approximately one-half of the total travel). Read pressure on Tool (A). The pressure should be 46500 ± 1000 kPa (6750 ± 145 psi).

  22. Modulate propulsion lever (1) to the rear until the peak pressure is registered at reverse pressure tap (13) (approximately one-half of the total travel). Read pressure on Tool (A). The pressure should be 46500 ± 1000 kPa (6750 ± 145 psi).

  23. Move the propulsion lever to the NEUTRAL position.

  24. Move throttle control switch (3) to the LOW IDLE position.

  25. Move parking brake switch (2) to the ON position.

  26. Move engine start switch (4) to the OFF position.

  27. If either pressure reading is outside the specified range, go to Step 28. If both pressure readings are inside the specified range, go to Step 32.

  28. Raise the cab. Refer to Disassembly and Assembly, KENR6004, "Cab - Tilt".


    Illustration 13g01413648
    Reverse Main Relief Valve on Left Side of Drum Pump


    Illustration 14g01413650
    Forward Main Relief Valve on Right Side of Drum Pump

  29. Use the following procedure in order to adjust the main relief valves:

    1. Remove cap (17) or remove cap (18) from the relief valve that needs to be adjusted.

    2. Remove the spring and the relief valve cartridge from drum pump. Reinstall cap (17) or reinstall cap (18) on the pump in order to prevent oil from leaking out of the port.


      Illustration 15g01413653
      Arrows Indicate the Clamping Position.

    3. Clamp the relief valve cartridge in a soft vise jaw. See Illustration 15. Loosen locking setscrew (20) with a 3 mm Allen wrench.

    4. Use a 5 mm wrench to turn spindle (21). Turn the spindle clockwise in order to increase pressure. Turn the spindle counterclockwise in order to decrease pressure.

      Note: One full revolution of spindle (21) changes the pressure setting by approximately 4400 kPa (638 psi).

    5. Tighten locking setscrew (20).

    6. Remove the relief valve cartridge from the vise.

    7. Remove cap (17) or (18). Install spring (19) and the relief valve cartridge in the cap. Reinstall the cap in the drum pump.

  30. Go to Step 16.

  31. Raise the cab. Refer to Disassembly and Assembly, KENR6004, "Cab - Tilt".

  32. Loosen the locknut and reset the POR valve setting by rotating adjustment screw (15) by two turns in the counterclockwise direction. Hold the adjustment screw and tighten the locknut.

  33. Remove Tool (E) and Tool (F) from balance line (10) and balance line (11). Reconnect both of the balance lines.

  34. Reconnect electrical connector (12) for the axle interlock.

  35. Remove Tool (B) from pressure tap (13) and from pressure taps (14).

  36. Remove Tool (C) and Tool (D). Reconnect brake supply line (9) to the drum motor.

  37. Lower the cab. Refer to Disassembly and Assembly, KENR6004, "Cab - Tilt".

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