AP-655C and BG-2255C Asphalt Pavers Propel System Piston Pump Neutral - Test and Adjust Caterpillar


Piston Pump Neutral - Test and Adjust
`
1.1. Neutral Adjustment for the Electrical Displacement Control
2.2. Introduction
3.2. Required Tools
4.2. Caterpillar DataView Tool
5.2. Standard Tools
6.2. Test Procedure
7.2. Adjustment Procedure

Neutral Adjustment for the Electrical Displacement Control

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

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any AVSpare dealer for replacement manuals. Proper care is your responsibility.

----------------------



Illustration 1g00930412

There are two identical piston pumps (propel) on the machine. One propel pump controls the left side and the other propel pump controls the right side. The propel pumps are located on the left side of the machine in the pump compartment.

The following procedure will use the left propel pump. This procedure should be performed on both of the propel pumps. This test should be performed with low pressure gauges. A gauge that is rated for more than 485 kPa (70 psi) will show an inaccurate reading.

Introduction

The electrical displacement control has an input signal pressure that is controlled by an internal pilot control valve. The internal pilot control valve converts the electrical signal to a hydraulic signal which will operate the servo valve. The servo valve ports hydraulic pressure to either side of the servo piston. The pump servo piston will vary the angle of the swashplate. This test will ensure that the electronic displacement control is in the NEUTRAL position. This will allow the electrical signal to be proportional to the hydraulic signal. This hydraulic signal will then vary the displacement of the pump.

Required Tools

Hydraulic test procedures may be performed using either one of the following test equipment:

  • AVSpare DataView

  • Standard Pressure Gauges

AVSpare DataView Tool




Illustration 2g00920192

AVSpare DataView

AVSpare DataView is a PC based diagnostic tool. The AVSpare DataView accepts a maximum of nine standard AVSpare sensors for measurements on the machine. The signal is transmitted to a personal computer and the information is displayed.

The following table provides a list of the required tools if AVSpare DataView is used in order to perform the following test procedure. AVSpare DataView is not shown in the following test procedure.

Table 1
Required Tools    
Part Number and Description     Quantity    
131-5051 DataView Tool Gp     1    
4C-6816 Pressure Sensor
0 to 60 psi    
2    
131-5060 Auto ID Cable     1    

Standard Tools




Illustration 3g00950729

Table 2
Required Tools    
Tooling     Item     Part Number and Description     Quantity    
A     A1     8T-0862 Pressure Gauge
0 to 70 psi    
2    
A2 6V-4144 Coupler     2    
B     B1     6V-3965 Fitting As     2    
B2 3J-1907 O-Ring Seal     2    

Test Procedure

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

    Sudden movement of the machine or release of oil under pressure can cause serious injury to persons on or near the machine.

    To prevent possible injury, perform the procedure that follows before testing and adjusting the hydraulic system.

    ----------------------

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

    Hot oil and components can cause personal injury.

    Do not allow hot oil or components to contact skin.

    ----------------------

  1. Perform the following procedure before you follow the test procedure:

    • Park the machine on a level area that is clear from equipment and material.

    • Verify that the service brake system and the parking brake system are in good working condition.

    • Move the propel lever to the NEUTRAL position.

    • Apply the parking brake.

    • Make sure that the hydraulic oil is at the correct operating temperature.

  1. Assemble both 8T-0862 Pressure Gauges (A1) and both 6V-4144 Couplers (A2) .



    Illustration 4g00950731

  1. Access to the propel pumps can be obtained in the pump compartment on the left side of the machine. Access to the propel pumps may also be obtained from the top of the machine in the engine access panels.



    Illustration 5g00950745

    (1) Left propel pump

    (2) Port "M5"

    (3) Port "M4"

  1. Use a standard allen wrench in order to remove the plugs at gauge port "M5" (2) and "M4" (3) .



    Illustration 6g00950748

  1. Keep the plugs in a secure location during this procedure.



    Illustration 7g00950756

  1. Install 6V-3965 Fitting As (B1) and 3J-1907 O-Ring Seal (B2) into gauge port "M5" (2) and "M4" (3) .



    Illustration 8g00950759

  1. Install the 8T-0857 Pressure Gauges (B1) at gauge port "M5" (2) and "M4" (3) .



    Illustration 9g00930701

    (4) Connectors for the electrical displacement control (EDC)

    Note: Label the wires for the EDC before you disconnect the wires from the propel pumps. This will enable you to correctly connect the circuit after the test. This will also reduce the risk of switching the FORWARD and REVERSE coils, which may cause damage to the propel circuit.




    Illustration 10g00950765

    The location of the connectors for the EDC is next to the propel pumps on the engine mounting frame.

  1. Disconnect wires for the EDC (4) from the EDC coils.

  1. As the EDC is disconnected, a fault will appear on the AVSpare Monitoring System. Reset the system after the test and adjust procedures.

  1. Start the engine. Run the engine at normal idle.



    Illustration 11g00950770

  1. The gauges should show the same pressure. The case pressure will vary 70 to 275 kPa (10 to 40 psi). If the pressure gauges do not show the same pressure, an adjustment needs to be made.

Adjustment Procedure

  1. Leave the test equipment in place for the adjustment.



    Illustration 12g00950798

    (5) Locknut

    (6) Neutral adjustment screw

  1. Loosen locknut (5) on neutral adjustment screw (6) .

  1. Turn neutral adjustment screw (6) clockwise with a standard allen wrench. Observe the pressure on the gauges. Continue to turn neutral adjustment screw (6) until the pressure in one of the gauges increases.

    Note: Ensure that the angular position of the wrench is noted during this adjustment. This may be done by making a mark on the pump for orientation.

  1. Turn neutral adjustment screw (6) counterclockwise. Observe the pressure of the gauges. Repeat this procedure until the pressure in the other pressure gauge increases by an equal amount.

    Note: Ensure that the angular position of the wrench is noted during this adjustment. This may be done by making a mark on the pump for orientation.

  1. Rotate neutral adjustment screw (6) clockwise for half of the distance between the locations that are noted above. Observe the pressure of the gauges. The gauges should have the same pressure. This will indicate that the neutral position is set.



    Illustration 13g00950798

    (5) Locknut

    (6) Neutral adjustment screw

  1. Hold neutral adjustment screw (6) stationary. Tighten locknut (5) .

  1. Repeat Step 2 to Step 6 if neutral adjustment screw (6) turns during Step 6.

  1. Shut off the engine.



    Illustration 14g00950765

    The location of the connectors for the EDC is next to the propel pumps on the engine mounting frame.

  1. Reconnect the electrical displacement controls to the EDC coils. Clear any faults that may appear on the AVSpare Monitoring System.

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

    Hot oil and components can cause personal injury.

    Do not allow hot oil or components to contact skin.

    ----------------------

  1. Observe the machine and the operating temperature. A minimum of fifteen minutes should pass before you attempt to proceed to the next steps. This will allow the machine and the components to cool.

  1. Remove 8T-0862 Pressure Gauges (A1) and 6V-4144 Couplers (A2) .

  1. Remove 6V-3965 Fitting Assemblies (B1) and 3J-1907 O-Ring Seals (B2) from gauge port "M5" (2) and gauge port "M4" (3) .

    Note: Ensure that the plugs are free from any dirt or debris before you install the plugs.

  1. Insert the plugs back into gauge port "M5" (2) and gauge port "M4" (3) .

  1. Recalibrate the initial current setting to the electronic control module (ECM) for the left propel pump. Refer to Troubleshooting Manual, KENR5036, "Electrical and Hydraulic Systems" for the calibration procedure.

  1. Repeat the test and the adjustment procedure for the right piston pump (propel).

Information System:

3524B Engine for Caterpillar Built Machines Crankshaft Rear Seal and Wear Sleeve - Remove
797 Off-Highway Truck Power Train Transmission
RM-350B Road Reclaimer/Soil Stabilizer Machine Systems Rotor Drive Differential - Assemble
R2900 Load Haul Dump Machine Operation Information
3512 and 3516 EUI Engines for 784B, 785B, 789B and 793B Off-Highway Trucks Air Filter Restriction Lamp
3524B Engine for Caterpillar Built Machines Engine Oil Sequence Valves - Remove and Install
CP-563E, CP-573E, CS-563E, CS-573E and CS-583E Vibratory Soil Compactors Vibratory System Features
R2900 Load Haul Dump Transmission Control
TK711, TK721, TK722 and TK732 Track Feller Bunchers Hydraulic System Piston Motor (Swing Drive) Relief Valve Pressure - Test and Adjust
AP-1000D, AP-1055D, AP-655C, BG-2255C, BG-2455D and BG-260D Asphalt Pavers MID 039 - CID 0154 - FMI 08
AP-1000D, AP-1055D, AP-655C, BG-2255C, BG-2455D and BG-260D Asphalt Pavers MID 039 - CID 0153 - FMI 08
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Braking System Brake System Air - Purge
574B Forwarder Power Train Hydrostatic Drive System
AP-1000D, AP-1055D, AP-655C, BG-2255C, BG-2455D and BG-260D Asphalt Pavers MID 039 - CID 0168 - FMI 03
AP-1000D, AP-1055D, AP-655C, BG-2255C, BG-2455D and BG-260D Asphalt Pavers MID 039 - CID 0168 - FMI 04
CS-563E, CP-563E, CS-573E, CP-573E, CS-583E, CP-583E, CS-663E, CP-663E and CS-683E Vibratory Soil Compactors Drum Scrapers - Inspect/Adjust/Replace
120H and 135H Motor Graders Seat Belt
2002/11/18 Replacement Mobil-Trac System Belts Are Now Available for John Deere 8000T Series Agricultural Tractors {4198}
R2900 Load Haul Dump Stopping the Engine
CB-534D, CB-534D XW and CB-564D Paving Compactors Machine Systems Metering Pump (Steering)
14H Motor Grader Machine Systems Fuel Tank (Left Side) - Remove
14H Motor Grader Machine Systems Fuel Tank (Left Side) - Install
R2900 Load Haul Dump Lift Arm Positioner
CB-534D, CB-534D XW and CB-564D Vibratory Asphalt Compactors Vibratory System Piston Pump (Vibratory)