AP655D and BG655D Asphalt Pavers Propel System Relief Valve (Charge) - Test and Adjust - Left Pump (Steel Track) Caterpillar


Relief Valve (Charge) - Test and Adjust - Left Pump (Steel Track)
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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.


------ 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.


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

Personal injury can result from rotating and moving parts.

Moving fan blades and moving parts will throw or cut any object or tool that falls or is pushed into them.

Make sure no one is working on, underneath or close to an engine that is running. Make sure the area is free of personnel.



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 
B(1)  198-4236  Adapter Cable As 
C(1)  198-4237  Pressure Sensor Gp
0 to 3500 kPa (0 to 500 psi) 
D(1)  198-4238  Pressure Sensor Gp
0 to 35000 kPa (0 to 5000 psi) 
(1) Tool (A), Tool (B), Tool (C), and Tool (D) are part of the 198-4240 Digital Pressure Indicator.

Table 2
Required Tools 
Tool  Part Number  Description  Qty 
8T-0855  Pressure Gauge
0 to 4000 kPa (0 to 580 psi) 
6V-4144 Quick Connect Coupler 
177-7860  Hose As 
6V-4142 Fitting 
6V-4143 Quick Connect Coupler 

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


    Illustration 1g01390805

  2. Move propulsion lever (4) to the NEUTRAL position.

  3. Rotate speed dial (2) to the MINIMUM position.

  4. Move travel mode switch (3) to the PAVE position.


    Illustration 2g01390807

  5. Move screed lift switch (5) to the RAISE position. Completely lift the screed.


    Illustration 3g01390809

  6. Engage screed lock mechanism (6) on both sides of the machine.

  7. Move screed lift switch (5) to the FLOAT position. Allow the tow arms to rest on screed locks (6a).

    Note: The screed lift switch on the inactive operator station must also be in the FLOAT position in order to lower the screed.



    Illustration 4g01391059

  8. Move hopper switch (7) to the RAISE position. Release the switch when the hopper cylinders are completely retracted.


    Illustration 5g01391060

  9. Engage hopper lock pin (8) on both sides of the machine.


    Illustration 6g01391064

  10. Move throttle control switch (9) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

  11. After the engine reaches low idle, move engine start switch (10) to the OFF position.


    Illustration 7g01391066

  12. Open pump compartment cover (11), which is on the right side of the machine.


    Illustration 8g01391070

  13. Remove the cap from case drain tap (12) on the left propulsion pump. Connect Tool (C) to the drain tap.


    Illustration 9g01391073

  14. Remove the cap from charge pressure tap (13) on the right material feed pump. Connect Tool (D) to the pressure tap.

  15. Connect one Tool (B) to Tool (C). Connect the second Tool (B) to Tool (D). Connect each Tool (B) to Tool (A).

    Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.

  16. Move engine start switch (10) to the START position. Release the engine start switch when the engine starts.

  17. Operate the engine at low idle for a few minutes.

  18. Move throttle control switch (9) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.


    Illustration 10g01391074

  19. Monitor the hydraulic oil temperature on the operator display. Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).

  20. Move throttle control switch (9) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

  21. After the engine reaches low idle, move engine start switch (10) to the OFF position.


    Illustration 11g01391075

  22. Loosen locknut (14) on the charge relief valve on the left propulsion pump. Rotate charge relief valve adjustment screw (15) clockwise by three turns. Hold the adjustment screw and tighten the locknut to 52 N·m (39 lb ft).

    Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.

  23. Move engine start switch (10) to the START position. Release the engine start switch when the engine starts.

  24. Operate the engine at low idle for a few minutes.

  25. Move throttle control switch (9) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.

  26. Record pressure at charge pressure tap (13).

  27. Record pressure at case drain tap (12).

  28. Subtract the pressure that was recorded in Step 27 from the pressure that was recorded in Step 26. The differential pressure should be 3100 ± 170 kPa (440 ± 25 psi).

  29. Move throttle control switch (9) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

  30. After the engine reaches low idle, move engine start switch (10) to the OFF position.

  31. If the pressure is within the specified range, go to Step 34. If the pressure is not within the specified range, go to Step 32.


    Illustration 12g01391084

  32. Loosen the locknut on charge relief valve (16) on the right material feed pump. In order to increase pressure, rotate the adjustment screw clockwise. In order to decrease pressure, rotate the adjustment screw counterclockwise.

  33. Hold the adjustment screw in place, and tighten the locknut to 17 N·m (13 lb ft). Go to Step 23.

  34. Loosen the locknut on charge relief valve (16) on the right material feed pump. In order to increase pressure, rotate the adjustment screw clockwise. In order to decrease pressure, rotate the adjustment screw counterclockwise.

    Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.

  35. Move engine start switch (10) to the START position. Release the engine start switch when the engine starts.

  36. Operate the engine at low idle for a few minutes.

  37. Move throttle control switch (9) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.


    Illustration 13g01391091

  38. Monitor the hydraulic oil temperature on the operator display. Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).

  39. Record pressure at charge pressure tap (13).

  40. Record pressure at case drain tap (12).

  41. Subtract the pressure that was recorded in Step 40 from the pressure that was recorded in Step 39. The differential pressure should be 2690 ± 170 kPa (390 ± 25 psi).

  42. If the pressure is within the specified range, go to Step 47. If the pressure is not within the specified range, go to Step 43.

  43. Move throttle control switch (9) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

  44. After the engine reaches low idle, move engine start switch (10) to the OFF position.

  45. Loosen locknut (14) on the charge relief valve that is on the left propulsion pump. In order to increase pressure, rotate adjustment screw (15) clockwise. In order to decrease pressure, rotate the adjustment screw counterclockwise.

    Note: One turn of adjustment screw changes the pressure by approximately 400 kPa (58 psi).

  46. Hold the adjustment screw in place, and tighten the locknut to 52 N·m (39 lb ft). Go to Step 35.

  47. Test the flushing system with the following procedure.

    Note: The machine will move during the flushing system test.

    ------ 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.


  48. Rotate speed dial (2) to one quarter of maximum.

  49. Move parking brake switch (1) to the OFF position.

    Note: The parking brake switch on the inactive operator station must also be in the OFF position.

  50. Slowly move propulsion lever (4) to the FULL FORWARD position. Observe pressure at charge pressure tap (11). The pressure should momentarily decrease.

  51. Move propulsion lever (4) to the NEUTRAL position. Then, move the lever to the FULL REVERSE position. Observe pressure at charge pressure tap (11). The pressure should momentarily decrease.

  52. Move propulsion lever (4) to the NEUTRAL position. Move speed dial (2) to the MINIMUM position. Move parking brake switch (1) to the ON position.

  53. Move throttle control switch (9) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

  54. After the engine reaches low idle, move engine start switch (10) to the OFF position.

  55. If the flushing system operates as described in both directions, go to Step 59.

    If the flushing pressure does not drop in either direction, replace the flushing relief valve.

    If flushing pressure drops drastically in both directions, replace the flushing valve. Go to Step 56.

    If the flushing system does not operate properly after the flushing relief valve is replaced, the propulsion motor may have internal leakage.

    If the flushing system performs as described in one direction but not the other, check the flushing spool.

    Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.

  56. Move engine start switch (10) to the START position. Release the engine start switch when the engine starts.

  57. Operate the engine at low idle for a few minutes.

  58. Move throttle control switch (9) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm. Go to Step 48.

  59. Remove the tooling.

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