Procedure to Install EP Control Plate on the Paving Compactors{5455} Caterpillar

Paving Compactor:

CB-434D (S/N: CNH1-UP)

CB-534D (S/N: C2B1-UP; C4B1-UP; EAA1-UP; FEA1-UP; FGH1-UP; GCA1-UP)

CB-634D (S/N: CDF1-UP)

Introduction

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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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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 work tools have been lowered to the ground, 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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Use an appropriate lifting device that is rated for the specific load. Failure to do so can result in serious injury or death.

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Personal injury or death can result from improper lifting or blocking. When a jack is used to lift the machine, stand clear of the area. Use a jack that is rated for the correct capacity to lift the machine. Install blocks or stands before performing any work on the machine.

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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 product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

This Special Instruction provides the necessary information in order to replace the EP control plate with a control plate that contains a 300 Micron screen on the following Paving Compactors:

• CB-434D

• CB-534D

• CB-634D

The table below lists the required parts for the installation.

Table 1

Required Parts
Part Number	Description
6J-3134	O-Ring Seal
196-4253	Gasket
236-5153	Cover As

Read the following thoroughly before performing the procedure.

Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned.

Reference: See Testing and Adjusting, "Pump Control (Electronic Displacement Control) Neutral - Test and Adjust" for adjustment procedures.

Disassembly for the CB-434D

1. Wash the area and dry the area that surrounds the propel pump.

2. Remove the access panel.

3. Raise the rear of the machine about eight inches and support on jack stands.

4. Chock the front drum.

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Illustration 1	g01157684

5. Rotate (1) coil 90° counterclockwise.

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Illustration 2	g01157685

6. Remove the line (2) from the "T2" port. Cap the line and the "T2" port.

7. Place a drain pan under the pump area.

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Illustration 3	g01148344

8. Remove the five bolts (3) that secure the EP control plate (4) .

9. Remove EP control plate (4). Do not remove the control unit (6) or dislodge the control unit. The pump control neutral must be tested if the control unit (6) should become dislodged. Refer to the Test and Adjust reference in the introduction.

10. Make sure that the gasket (5) is removed from the EP control plate (4) or the control unit (6) .

    Note: The gasket is transparent.

Installation for the CB-434D

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Illustration 4	g01148378

1. Install new O-ring seal (9) onto the new plate assembly (8). Use 1U-6396 O-Ring Assembly Compound .

2. Install the new gasket (7) with the raised blue sealant toward the new plate assembly (8) .

3. Insert all five bolts (3) into the new plate assembly (8) .

4. The new plate assembly (8) is secured in two directions. Hand tighten all the bolts (3). Start with the bolt that fastens the plate to the pump case. Torque the bolts (3) to 10.4 N·m (8 lb ft). Start with the bolt that fastens the plate to the pump case.

   Note: Torque the five bolts twice. Use the same tightening sequence.

5. Reconnect the "T2" port line.

6. Once the assembly procedure is complete, go to the Test procedure.

Disassembly for the CB-534D

1. Wash the area and dry the area that surrounds the propel pump.

2. Raise the rear of the machine about eight inches and support on jack stands.

3. Chock the front drum.

4. Place a drain pan under the pump area.

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Illustration 5	g01152845

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Illustration 6	g01152842

5. Rotate (10) coil 90° counterclockwise.

6. Remove the line (13) from the "T2" port. Cap the line and the "T2" port.

7. Remove hose (11) and cap the bottom hose from the rear distribution block (12) .

8. Remove the rear distribution block (12) .

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Illustration 7	g01157813

9. Remove the five bolts (3) that hold the EP control plate.

10. Remove the EP control plate (4). Do not remove the control unit (6) or dislodge the control unit. The pump control neutral must be tested if the control unit (6) should become dislodged. Refer to the Test and Adjust reference in the introduction.

11. Remove gasket (5) from the EP control (4) or control unit (6) .

    Note: The gasket is transparent.

Installation for the CB-534D

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Illustration 8	g01157815

1. Install the new O-ring seal (9) onto the new plate assembly (8). Use 1U-6396 O-Ring Assembly Compound .

2. Install the new gasket (7) with the raised blue sealant toward the new plate assembly (8) .

3. Insert all five bolts (3) into the new plate assembly (8) .

4. The new plate assembly (8) is secured in two directions. Hand tighten all the bolts (3). Start with the bolt that fastens the plate to the pump case. Torque the bolts (3) to 10.4 N·m (8 lb ft). Start with the bolt that fastens the new plate assembly to the pump case.

   Note: Torque the five bolts twice. Use the same tightening sequence.

5. Reinstall the distribution block.

6. Reconnect the line to the distribution block.

7. Reconnect the "T2" port line.

8. Once the assembly procedure is complete, go to the Test procedure.

Disassembly for the CB-634D

1. Wash the area and dry the area that surrounds the propel pump.

2. Raise the rear of the machine about eight inches and support on jack stands.

3. Chock the front drum.

4. Place a drain pan under the pump area.

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Illustration 9	g01152843

5. Turn the left coil (14) so the wiring points upward.

6. Remove the hose and cap the "G" port line (16) on the pump.

7. Remove the lines and cap all of the lines from the distribution block (15) .

8. Remove the top distribution block (15) .

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Illustration 10	g01157816

9. Remove the five bolts (3) that hold the EP control plate (4) .

10. Remove the EP control plate. Do not remove the control unit (6) or dislodge the control unit. The pump control neutral must be tested if the control unit should become dislodged. Refer to the Test and Adjust reference in the introduction.

11. Make sure that the gasket (5) is removed from the EP control (4) or control unit (6) .

    Note: The gasket is transparent.

Installation for the CB-634D

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Illustration 11	g01157818

1. Install the new O-ring (9) onto the new plate assembly (8). Use 1U-6396 O-Ring Assembly Compound .

2. Install the new gasket (7) with the raised blue sealant toward the new plate assembly (8) .

3. Insert all five bolts (3) into the new plate assembly (8) .

4. The new plate assembly (8) is secured in two directions. Hand tighten all the bolts (3). Start with the bolt that fastens the plate to the pump case. Torque the bolts (3) to 10.4 N·m (8 lb ft). Start with the bolt that fastens the plate to the pump case.

   Note: Torque the five bolts twice. Use the same tightening sequence.

5. Reinstall the distribution block.

6. Reconnect all of the lines to the distribution block.

7. Reconnect the "G" port line.

8. Once the assembly procedure is complete, go to the Test procedure.

Test Procedure

1. Do not remove the machine from the jack stands for the test procedure. Top off the hydraulic oil reservoir. Make sure that the parking brake is applied. Start the machine. Set the engine in low idle.

   Note: Verify that the rear drum is not touching the ground.

2. Set the propel speed range control in the low position.

3. Set the variable speed control to the maximum setting.

4. Release the parking brake.

5. Verify that the drum is not rotating in the neutral position.

6. Place the propel lever in the full forward position and allow the drum to rotate for 15 seconds.

7. Place the propel lever in the neutral position. The drum should not rotate in neutral.

8. Place the propel lever in the reverse direction, and allow the drum to rotate for 15 seconds.

9. Place the propel lever in the neutral position. The drum should not rotate in neutral.

10. Repeat steps 6 through 9 for 15 minutes.

11. If the drum rotates continuously with the control lever in the neutral position or if the control unit was dislodged during the disassembly or the assembly procedure, adjust the pump control neutral according to the Test and Adjust reference in the introduction.

    1. Raise the front of the machine six inches off the ground and support on jack stands before performing the adjustment procedure.

       Note: Verify that neither drum is touching the ground.

    2. Remove the lines and cap the brake supply line. The front brakes and rear brakes must remain applied during the adjustment procedure.

12. Raise the machine and remove the jack stands.

13. Check for proper operation.