587R Pipelayer Hydraulic System Caterpillar

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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

Introduction

This story includes the following tests:

• "Test Procedure (Winch Loop Pressures)"

• "Test Procedure (Pressures for Crossover Relief and Makeup Valves)"

This story includes the following adjustment procedures:

• "Adjustment Procedure (POR Valve)"

• "Adjustment Procedure (Crossover Relief and Makeup Valves)"

Required Tools

Illustration 1	g01105965
Tooling (A)

Illustration 2	g01089425
Tooling (B) ( 6V-7830 Pressure Gauge (Tetragauge))

Note: Two sets of tooling (A) or two sets of tooling (B) are required to perform the following tests.

Illustration 3	g01254619
Tooling (C)

Test Procedure (Winch Loop Pressures)

1. Move the machine to a smooth horizontal location.

2. Fully retract the counterweight.

3. Stop the engine.

4. Remove the covers from the winch motors on the right hand side of the operator's seat.

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Illustration 4	g01347843

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Illustration 5	g01255033
(1) Pressure Tap ("HMR") (2) Pressure Tap ("BMR") (3) Pressure Tap ("BML") (4) Pressure Tap ("HML")

5. Attach one set of tooling (A2 or B) to pressure tap (1) ("HMR") of the hook winch.

6. Attach one set of tooling (A2 or B) to pressure tap (4) ("HML") of the hook winch.

7. Start the engine. Warm the hydraulic oil to a minimum temperature of 65 °C (150 °F).

8. Operate the engine at HIGH IDLE.

9. Verify that the pressure at tooling (A2) is not more than 4000 kPa (580 psi). If the pressure at tooling (A2) is less than 4000 kPa (580 psi), replace tooling (A2) with tooling (A1) .

10. Measure the pressures at pressure tap (1) and (4) . The pressure at pressure tap (1) should be 100 kPa (15 psi) lower than main pressure. The pressure at pressure tap (4) should be 150 kPa (22 psi) lower than main pressure. Main pressure is 3470 ± 100 kPa (503 ± 15 psi).

11. Attach one set of tooling (A2 or B) to pressure tap (2) ("BMR") of the boom winch.

12. Attach one set of tooling (A2 or B) to pressure tap (3) ("BML") of the boom winch.

13. Verify that the pressure at tooling (A2) is not more than 4000 kPa (580 psi). If the pressure at tooling (A2) is less than 4000 kPa (580 psi), replace tooling (A2) with tooling (A1) .

14. Measure the pressures at pressure tap (2) and (3) . The pressure at pressure tap (2) should be 100 kPa (15 psi) lower than main pressure. The pressure at pressure tap (3) should be 150 kPa (22 psi) lower than main pressure. Main pressure is 3470 ± 100 kPa (503 ± 15 psi).

15. If the pressure at pressure tap (1, 2, 3, or 4) is higher than 3470 ± 100 kPa (503 ± 15 psi), then the main pressure relief valve is improperly adjusted or failed. High pressures could also be caused by low oil temperature.

    If the pressures are too low, then check for a problem in the implement pilot system.

    Check these possible causes:

    • The POR valve could be stuck open.

    • The main pressure relief valve is improperly adjusted or failed.

    • The implement pilot circuit is leaking excessively.

    • The winch motor is worn.

    • The flushing valve is worn or the flushing valve is stuck open.

    • The oil level is low.

    • The winch pump is worn.

    • The cold oil relief valve is set improperly or the cold oil relief valve is stuck open.

    Note: In order to check the cutoff pressures for the implement pumps, perform Step 16 through Step 30.

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Illustration 6	g01255177

16. Attach one set of tooling (A2 or B) to pressure tap (1) ("HMR") of the hook winch.

17. Disconnect hose (6) from the hook winch motor.

18. Install tooling (C) in order to block hose (6) .

    Note: Make sure that you use the four 8T-4835 Bolts . This is a high pressure joint.

19. Start the engine. Warm the hydraulic oil to a minimum temperature of 65 °C (150 °F).

20. Operate the engine at HIGH IDLE.

21. Move the hand control for the hook to the RAISE position. The implement pump for the hook will be in a RAISE STALL CONDITION.

    Note: Do not hold the pump in a RAISE STALL CONDITION for more than 20 seconds at a time.

22. With the machine in a RAISE STALL CONDITION, record the pressure at pressure tap (1) ("HMR") of the hook winch. The pressure at pressure tap (1) should be 41715 ± 1205 kPa (6050 ± 175 psi).

23. Stop the engine.

24. Attach one set of tooling (A2 or B) to pressure tap (2) ("BMR") of the boom winch.

25. Disconnect hose (5) from the boom winch motor.

26. Install tooling (C) in order to block hose (5) .

    Note: Make sure that you use the four 8T-4835 Bolts . This is a high pressure joint.

27. Start the engine. Warm the hydraulic oil to a minimum temperature of 65 °C (150 °F).

28. Operate the engine at HIGH IDLE.

29. Move the hand control for the boom to the RAISE position. The implement pump for the boom will be in a RAISE STALL CONDITION.

    Note: Do not hold the pump in a RAISE STALL CONDITION for more than 20 seconds at a time.

30. With the machine in a RAISE STALL CONDITION, record the pressure at pressure tap (2) ("BMR") of the boom winch. The pressure at pressure tap (2) should be 41715 ± 1205 kPa (6050 ± 175 psi).

31. If the pressures at "HMR" and "BMR" are too high, the setting of the POR valve is too high.

32. If the pressures at "HMR" and "BMR" are lower than the specified limit, check the following possible causes:
    • The POR valve is misadjusted or the POR valve has failed.

    • The motor flushing valve is stuck or the valve is not functioning properly.

    • The winch motor is worn or leaking.

    • The implement pump is worn or leaking.

    • The crossover relief and makeup valve is leaking or set too low.

    Note: If the engine speed drops more than 30 rpm from HIGH IDLE in the RAISE STALL CONDITION, the corresponding crossover relief and makeup valve may be leaking or set too low.

33. If the pressure is not within the specified limit, perform the procedure in "Adjustment Procedure (POR Valve)".

Adjustment Procedure (POR Valve)

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Illustration 7	g01255301
Location of the POR valve for the 583T Pipelayer (7) POR Valve for the Boom Pump (8) POR Valve for the Hook Pump

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Illustration 8	g01343104
Location of the POR valve for the 587R and the 587T Pipelayers (7) POR Valve for the Boom Pump (8) POR Valve for the Hook Pump

1. Locate the POR valve on the pump.

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Illustration 9	g01255302
(9) Adjustment Screw (10) Locknut

2. Loosen locknut (10) while you hold adjustment screw (9) in place.

3. Turn adjustment screw (9) in the clockwise direction in order to increase the pressure setting. Turn adjustment screw (9) counterclockwise in order to decrease the pressure setting.

4. Perform the Steps in "Test Procedure (Winch Loop Pressures)" in order to check the pressure setting.

5. When the pressure is within the specified limit, the adjustment procedure is complete.

Test Procedure (Pressures for Crossover Relief and Makeup Valves)

1. Move the machine to a smooth horizontal location.

2. Fully retract the counterweight.

3. Stop the engine.

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Illustration 10	g01255033
(1) Pressure Tap ("HMR") (2) Pressure Tap ("BMR") (3) Pressure Tap ("BML") (4) Pressure Tap ("HML")

4. Attach one set of tooling (A2 or B) to pressure tap (4) ("HML") of the hook winch.

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Illustration 11	g01255541

5. Disconnect hose (8) from the hook winch motor.

6. Install tooling (C) in order to block hose (8) .

   Note: Make sure that you use the four 8T-4835 Bolts . This is a high pressure joint.

7. Start the engine. Warm the hydraulic oil to a minimum temperature of 65 °C (150 °F).

8. Operate the engine at HIGH IDLE.

9. Move the hand control for the hook to the LOWER position. The hook pump will be in a LOWER STALL CONDITION.

   Note: Do not hold the pump in a LOWER STALL CONDITION for more than 20 seconds at a time.

10. With the machine in a LOWER STALL CONDITION, record the pressure at pressure tap (4) ("HML") of the hook winch. The pressure at pressure tap (4) should be 16000 ± 1000 kPa (2320 ± 145 psi).

11. Stop the engine.

12. Attach one set of tooling (A2 or B) to pressure tap (3) ("BML") of the boom winch.

13. Disconnect hose (7) from the boom winch motor.

14. Install tooling (C) in order to block hose (7) .

    Note: Make sure that you use the four 8T-4835 Bolts . This is a high pressure joint.

15. Start the engine. Warm the hydraulic oil to a minimum temperature of 65 °C (150 °F).

16. Operate the engine at HIGH IDLE.

17. Move the hand control for the boom to the LOWER position. The boom pump will be in a LOWER STALL CONDITION.

    Note: Do not hold the pump in a LOWER STALL CONDITION for more than 20 seconds at a time.

18. With the machine in a LOWER STALL CONDITION, record the pressure at pressure tap (3) ("BML") of the boom winch. The pressure at pressure tap (3) should be 16000 ± 1000 kPa (2320 ± 145 psi).

19. Perform the procedure in "Adjustment Procedure (Crossover Relief and Makeup Valve)".

Adjustment Procedure (Crossover Relief and Makeup Valves)

Note: The crossover relief and makeup valve can not be adjusted on the machine. Use the following procedure to adjust these valves.

Bench Test

The crossover relief and makeup valve has a setting that is higher than the main relief valve for the steering. The valve cannot be adjusted on the machine.

Note: Make sure that you use 8T-0861 Pressure Gauge (A2) for the higher pressure that is going to be felt at tooling (A2) .

The two implement pump crossover relief and makeup valves have different settings for RAISE and LOWER. Use the 9U-5785 Manifold to test the crossover relief and makeup valves on the test bench. The setting for the valves in the winch pumps during RAISE is 46000 ± 500 kPa (6672 ± 72.5 psi). The setting for the valves in the winch pumps during LOWER is 16000 ± 1000 kPa (2320 ± 145 psi) under the following conditions:

• SAE 10W hydraulic oil

• 65°C (150°F)

• Flow rate between 20 to 100 L/min (5 to 26 gpm)

The two winch motor crossover relief and makeup valves have the same settings for RAISE and LOWER. Use the 9U-5785 Manifold to test the crossover relief and makeup valves on the test bench. The setting for the valves in the winch motors during RAISE or LOWER is 44000 ± 500 kPa (6382 ± 72.5 psi) under the following conditions:

• SAE 10W hydraulic oil

• 65°C (150°F)

• Flow rate between 20 to 100 L/min (5 to 26 gpm)

If the crossover relief and makeup valves are not within the specifications, use the adjustment screw to change the pressure setting until the specifications are met.