AP-655C and BG-2255C Asphalt Pavers Propel System Relief Valve (Charge) - Test and Adjust Caterpillar


Relief Valve (Charge) - Test and Adjust
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AP-655C and BG-2255C Asphalt Pavers Propel System [KENR5026]
HYDRAULIC SYSTEM
VALVE GP-RELIEF
AP-655C and BG-2255C Asphalt Pavers Propel System Relief Valve (Charge) - Test and Adjust
AP-655C and BG-2255C Asphalt Pavers Propel System Pressure Limiter Valve - Test and Adjust
1.1. Testing and Adjusting the System Charge Pressure
2.2. Introduction
3.2. Required Tools
4.2. Caterpillar DataView Tool
5.2. Standard Tools
6.2. Test Procedure
7.2. Adjustment Procedure
8.2. Flushing Valve Test

Testing and Adjusting the System Charge Pressure

------ 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.

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Illustration 1g00930412

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

The following procedure will illustrate the right propel pump. This procedure should be performed on both of the propel pumps.

Introduction

Charge pressure maintains a positive pressure in the main hydraulic system and accounts for any internal leakage. The charge pressure must remain at the specified pressure for all conditions in machine travel and in braking. This test will measure the charge pressure. This test will ensure that the charge relief valve is within an acceptable limit. The charge pressure should be tested before you attempt to perform any other test or any maintenance procedure. This will ensure that the other tests and adjustments are accurate. Repeat this procedure after any calibration or maintenance on the propel pumps. Ensure that the new settings are recalibrated with the machine controller or ECM.

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    
131-5062 Adapter Cable As     1    
4C-6818 Pressure Sensor     1    

Standard Tools




Illustration 3g01207549

Pressure Gauge and Coupler

Table 2
Required Tools    
Tool     Item     Part Number     Description     Qty    
A     A1     8T-0855  (1)     Pressure Gauge     1    
A2 6V-4144     Quick Connect Coupler     1    
B     B1     8T-0854     Pressure Gauge     1    
B2 6V-4144     Quick Connect Coupler     1    
( 1 ) 8T-0855 Pressure Gauge is part of 6V-4157 Hydraulic Test Fitting Gp .

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.

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

  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 the 8T-0855 Pressure Gauge (A1) and 6V-4144 Coupler (A2) .



    Illustration 4g00931475

    The charge filters are located on the left side of the machine in the pump compartment.

    (1) Right propel charge filter

    (2) Right test port (charge)

    (3) Left propel charge filter

    (4) Left test port (charge)




    Illustration 5g00976491

    Left Side of the Machine

    (1) Right propel charge filter

    (2) Right test port (Charge)

  1. Assemble Tooling (A) to test port (2) . Test port (2) is located on right propel charge filter (1) .

  1. Assemble the 8T-0854 Pressure Gauge (B1) and 6V-4144 Coupler (B2) .



    Illustration 6g01207535

  1. Attach a pressure gauge onto the case drain return port (5) of the left propel.

  1. Ensure that the propel lever is in the NEUTRAL position.

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

  1. Observe the gauge reading (5) for the case drain pressure and record the gauge reading for future use.

  1. Observe the gauge reading at test port (2) . The gauge reading is not the correct pressure for the pump charge relief valve. The pressure for the charge relief valve is the gauge reading (2) minus the case drain pressure (5) that was recorded previously. The corrected pressure for the pump charge relief valve should be 2700 ± 103 kPa (385 ± 15 psi).

  1. If the pressure is not within this limit, an adjustment needs to be made.

Adjustment Procedure




    Illustration 7g01207539

    Right Propel Pump

    (6) Right propel pump

    (7) Adjustment locknut

    (8) Adjustment screw




    Illustration 8g01207540

    Top View of the Right Propel Pump

    (6) Right propel pump

    (7) Adjustment locknut

    (8) Adjustment screw

  1. Locate adjustment locknut (7) on right propel pump (6) .

  1. Loosen adjustment locknut (7) . Adjust adjustment screw (8) until the charge pressure reaches 2700 ± 103 kPa (385 ± 15 psi).

    Note: The adjustment screw (8) must not turn as adjustment locknut (7) is tightened. If the adjustment screw turns, then you must repeat Step 2. Ensure that the charge pressure remains at a pressure of 2700 ± 103 kPa (385 ± 15 psi).

  1. Tighten adjustment locknut (7) .

  1. Stop the engine. Ensure that the test equipment is left in place.

  1. If the charge pressure of 2700 ± 103 kPa (385 ± 15 psi) can not be obtained, refer to Troubleshooting Manual, KENR5036-00, "Electrical and Hydraulic Systems" for a possible solution.

    Note: Do not proceed with the flushing valve test unless the charge pressure is within the limits of 2700 ± 103 kPa (385 ± 15 psi)..

Flushing Valve Test

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

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

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

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

To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area.

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

  1. Ensure that the machine is still in an area that is clear from any equipment and personnel.

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

    Injury to personnel can result if they are not in the operator's view. Allow only essential personnel near the machine, and make sure the personnel are in the operator's view when testing, to prevent injury. Make sure checks are done in an open area.

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



    Illustration 9g00929385

  1. An assistant is needed for this portion of the test. The assistant should be approximately 1.25 m (4 ft) away from the machine during this test. The assistant will need to read the pressure gauge during this test.

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



    Illustration 10g00931606

    (1) Speed control switch

    (2) "PAVE" mode

    (3) Propel lever

    (4) Throttle control switch

    (5) High idle position

    (6) Propel speed potentiometer

  1. Ensure that speed control switch (1) is in "PAVE" mode (2) .

  1. Turn propel speed potentiometer (6) clockwise to the 1/4 position. This will ensure that the machine will not move forward in a rapid motion.

    Note: Ensure that the pressure gauge is still in clear view of the assistant.

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

    To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area.

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

  1. Move propel lever (3) slowly to the full FORWARD position.



    Illustration 11g00931642

    The charge filter is located on the left side of the machine in the pump compartment.

    (7) Right propel charge filter

    (8) Right test port (charge)

    (9) Left propel charge filter

    (10) Left test port (charge)

  1. The pressure at test port (8) should drop a minimum of 34 ± 105 kPa (5 ± 15 psi) lower than the charge pressure of 2700 ± 103 kPa (385 ± 15 psi). The pressure reading should be 2520 ± 103 kPa (365 ± 15 psi).

    Note: Basically, observe the charge pressure. Ensure that there is a momentary drop in pressure at pressure port (8) . This will ensure that the flushing valve is operational.

  1. Move propel lever (3) to the NEUTRAL position.

  1. Move propel lever (3) slowly to the full REVERSE position.

  1. The pressure at test port (8) should drop a minimum of 34 ± 105 kPa (5 ± 15 psi) lower than the charge pressure of 2700 ± 103 kPa (385 ± 15 psi). The pressure reading should be 2520 ± 103 kPa (365 ± 15 psi).

    Note: Basically, observe the charge pressure. Ensure that there is a momentary drop in pressure at pressure port (8) . This will ensure that the flushing valve is operational.

  1. Move propel lever (3) to the NEUTRAL position.

  1. If the pressure does not drop, a problem exists in the flushing valve. Refer to Troubleshooting Manual, KENR5036-00, "Electrical and Hydraulic Systems" for a possible solution.

  1. Shut off the engine.

  1. Return the controls to the normal operational settings.

  1. Remove tooling (A) from the machine.

  1. Repeat the same procedures for the left propel pump. Repeat "Test Procedure" and "Flushing Valve Test" for the left propel pump.

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