CP54 and CS54 Vibratory Soil Compactors Machine Systems Relief Valve (Charge) - Test and Adjust Caterpillar


Relief Valve (Charge) - 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.

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------ 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.

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------ 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.

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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    
(1)     198-4234     Pressure Gauge Tool Gp     2    
198-4236 Adapter Cable As     3    
(1)     198-4239     Pressure Sensors
0 to 69000 kPa (0 to 10000 psi)    
2    
C     198-4238     Pressure Sensors

0 to 35000 kPa (0 to 5000 psi)    
1    
D     6V-9828     Cap As     1    
E     6V-9507     Plug     1    
4J-5477 O-Ring Seals     1    
F     6V-9829     Cap As     2    
G     6V-9508     Plug     2    
6V-8397 O-Ring Seal     2    
H     6V-9511     Plug     1    
6V-9746 O-Ring Seal     1    
J     124-2121     Couplings     2    
122-6872 Hydraulic Hose     1    
6V-8733 Union     1    
6V-9746 O-Ring Seals     3    
K     4C-8688     Flow meter

.4 ± 7.5 L/min (-.1 ± 2 US gpm)    
1    
8C-6874 Connectors     2    
L     122-6872     Hydraulic Hose     1    
124-2121 Coupling     1    
124-2153 Coupling     1    
6V-9746 O-Ring Seal     1    
M     124-2117     Coupling     1    
122-6870 Hydraulic Hose     1    
124-2147 Coupling     1    
6V-8398 O-Ring Seals     2    
N     4C-8689     Flow Meter     1    
8B-2664 Reducer Bushing     2    
8C-6872 Connectors     2    
P     124-2117     Couplings     2    
122-6870 Hydraulic Hose     1    
6V-8731 Union     1    
6V-8398 O-Ring Seals     3    
R     6V-7788     Flow Meter     1    
8C-6874 Connectors     2    
S     124-2153     Couplings     2    
122-6872 Hydraulic Hoses     2    
124-2121 Couplings     2    
6V-9746 O-Ring Seals     4    
T     4C-6500     Digital Thermometer     1    
( 1 ) Tool (A) is part of 198-4240 Digital Pressure Indicator .

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



    Illustration 1g01415204

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



    Illustration 2g01415246

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



    Illustration 3g01415249

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



    Illustration 4g01415252

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



    Illustration 5g01415466

  1. Assemble Tool (J) to the outlet port of Tool (K) . Assemble Tool (L) to the inlet port of Tool (K) , as shown.



    Illustration 6g01415644

  1. Assemble Tool (M) to the inlet port of Tool (N) , as shown. Assemble Tool (P) to the outlet port of Tool (N) , as shown.



    Illustration 7g01415649

  1. Assemble Tool (S) to the inlet port of Tool (R) , as shown. Assemble second Tool (S) to the outlet port of Tool (R) , as shown.



    Illustration 8g01415658

  1. Disconnect the brake supply line (5) from the drum. Use Tool (C) to cap the port. Use Tool (D) to plug the hose.

  1. Raise the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".



    Illustration 9g01415663

    The Pump for the Drum is Shown From the Left Side.

  1. Disconnect upper balance line (6) and lower balance line (7) from the pump for the drum. Use Tool (E) to cap ports. Use Tool (F) to plug the hoses.



    Illustration 10g01415668

    The Vibratory Pump is Shown From the Left Side.

  1. Disconnect hose (8) from port "T2" on the vibratory pump.

  1. Connect Tool (M) (inlet side of the flow meter) to port "T2".

  1. Connect Tool (P) (outlet side of flow meter) to hose (8) .



    Illustration 11g01415673

  1. Disconnect hose (9) from port "T1" on the pump for the axle.

  1. Connect Tool (L) (inlet side of the flow meter) to port "T1".

  1. Connect Tool (J) (outlet side of flow meter) to hose (9) .



    Illustration 12g01415687

  1. Remove four bolts (10) and washers. Remove plate (11) .

  1. Clean the area around cap (12) . Remove the cap from the hydraulic tank.



    Illustration 13g01415690

  1. Disconnect hose (13) from port "T1" on the pump for the drum. Use Tool (H) to plug the hose.

  1. Attach Tool (S) on the inlet side of flow meter to port "T1" on the pump for the drum.



    Illustration 14g01415694

  1. Make sure that Tool (S) is clean. Place Tool (S) on the outlet side of the flow meter into the hydraulic tank. Cover the opening of the hydraulic tank.



    Illustration 15g01415701

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

    • Reverse pressure tap (14) on the pump for the drum

    • Forward pressure tap (15) on the pump for the drum

  1. Connect Tool (C) to charge pressure tap (16) on the propulsion pump for the drum.

  1. Connect one Tool (A) to each Tool (B) . Connect remaining Tool (A) to Tool (C) .

  1. Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

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

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

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

  1. Read charge pressure on Tool (A) . The pressure should be 2600 ± 250 kPa (377 ± 36 psi).

  1. Read the flow of the pump for the drum on Tool (R) . The flow should be 37.9 ± 5 L (10 ± 1.3 US gal).

  1. Read the flow of the pump for the axle on Tool (K) . The flow should be 4.9 ± 1.1 L (1.3 ± 0.3 US gal).

  1. Read vibratory pump flow on Tool (N) . The flow should be 7.6 ± 1.9 L (2 ± .5 US gal).

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

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

  1. If the pressure and the flow rates are inside the specified range, go to Step 60. If the pressure is outside the specified range, go to Step 37.

  1. Raise the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

  1. Analyze the test results according to Table 2.

    Table 2
    Test Parameters     Actions    
    Charge Pressure     Drum Flow     Axle Flow     Vibratory Flow    
    Low     -     -     -     Shim the charge relief valve for the drum.
    Go to Step 39    
    High     Low     High     High     Remove shims from the relief valve for the drum.
    Go to Step 39    
    OK     Low     OK     OK     Check the flow of the steering pump flow.
    Check the case drain for the motor.
    Refer to Testing and Adjusting, "Gear Pump Flow (Steering) - Test"    
    OK     High     Low     OK     Check the orifice in the charge relief valve for the axle. Step 61    
    OK     High     OK     Low     Check the orifice in the vibratory charge relief valve.
    Go to Step 53    



    Illustration 16g01415754

    The Pump for the Drum

  1. Remove charge relief valve (17) from the pump for the drum.



    Illustration 17g01415766

  1. Remove the following components from the housing for the pump for the drum:

    • Spool (18)

    • Poppet (19)

    • Shims (20)

    • Spring (21)

  1. Add shims (20) in order to increase pressure. Remove shims in order to decrease pressure.

    Note: A change of 1 mm (0.0394 inch) shim thickness results in a pressure change of 390 kPa (57 psi).

  1. Install the following components in the pump housing:

    • Spring (21)

    • Shims (20)

    • Poppet (19)

    • Spool (18)

  1. Install charge relief valve (17) .

  1. Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

  1. Go to Step 27.



    Illustration 18g01415789

    Vibratory Pump

  1. Remove charge relief valve (22) on the pump for the axle.



    Illustration 19g01415800

  1. Remove the following components from the housing for the pump for the axle:

    • Spool (23)

    • Poppet (24)

    • Shims (25)

    • Spring (26)

  1. Check each orifice in charge relief valve (22) for debris. If necessary, clean the valve body.

  1. Install the following components in the pump housing:

    • Spring (26)

    • Shims (25)

    • Poppet (24)

    • Spool (23)

  1. Install charge relief valve (22) .

  1. Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

  1. Go to Step 27.



    Illustration 20g01415808

    Vibratory Pump

  1. Remove charge relief valve (27) on the vibratory pump.



    Illustration 21g01415826

  1. Remove the following components from the vibratory pump housing:

    • Spool (28)

    • Poppet (29)

    • Shims (30)

    • Spring (31)

  1. Check each orifice in charge relief valve (27) for debris. If necessary, clean the valve body.

    Note: A change of 1 mm (.04 inch) in shim thickness results in a pressure change of 390 kPa (57 psi).

  1. Install the following components in the vibratory pump housing:

    • Spring (31)

    • Shims (30)

    • Poppet (29)

    • Spool (28)

  1. Install vibratory charge relief valve (27) .

  1. Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

  1. Go to Step 27.

  1. Raise the cab, if necessary. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

  1. Remove Tool (C) from charge pressure tap (16) on the propulsion pump for the drum.

  1. Remove each Tool (B) from forward and reverse pressure taps (15) and (14) on the propulsion pump for the drum.

  1. Remove each Tool (S) and Tool (R) from the propulsion pump for the drum and the hydraulic tank.

  1. Reconnect hose (13) to port "T1" on the pump for the drum.

  1. Clean the area around cap (12) . Replace the cap on the hydraulic tank.

  1. Replace plate (11) , washers, and four bolts (10) .

  1. Remove Tool (J) , Tool (K) , and Tool (L) from the propulsion pump for the axle.

  1. Reconnect hose (9) to port "T1" on the pump for the axle.

  1. Remove Tool (M) , Tool (N) , and Tool (P) from the vibratory pump.

  1. Reconnect hose (8) to port "T2" on the vibratory pump.

  1. Remove Tool (E) and Tool (F) from balance line (6) and balance line (7) . Reconnect both of the balance lines.

  1. Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".

  1. Remove Tool (C) and Tool (D) . Reconnect brake supply line (5) to the drum motor.

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