Relief Valve (Main, Auger Conveyor and Drag Conveyor) - Test and Adjust
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Diesel engine exhaust contains products of combustion which may cause personal injury. Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside. |
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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine. |
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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. |
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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 attachments have been lowered, 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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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, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
Specifications
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| Machine Test Parameters | ||
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| Date | Product or Component SN | |
| Measurement Location | Measurement | Actual |
| Engine Test Speed | 2200 rpm | |
| Hydraulic oil temperature for test | 43 ± 6 °C (110 ± 10 °F) |
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| Illustration 1 | g03426886 |
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| Illustration 2 | g03427017 |
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| Illustration 3 | g03427299 |
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| Illustration 4 | g03427306 |
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| Illustration 5 | g03427417 |
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| Illustration 6 | g03427427 |
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| Illustration 7 | g03427518 |
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| Illustration 8 | g03427525 |
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| Test Specifications | ||
|---|---|---|
| Date | Product or Component SN | |
| Component Location | Specification | Actual |
| Right Conveyor Pump, Forward Pressure, Port "MC" (20) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Right Conveyor Pump, Reverse Pressure, Port "D" (21) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Left Conveyor Pump, Reverse Pressure, Port "MB" (25) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Left Conveyor Pump, Forward Pressure, Port "MA" (26) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Right Auger Pump, Forward Pressure, Port "MB" (37) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Right Auger Pump, Reverse Pressure, Port "A" (38) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Left Auger Pump, Forward Pressure, Port "MD" (47) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Left Auger Pump, Reverse Pressure, Port "C" (46) | 34500 ± 2100 kPa (5009 ± 305 psi) |
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| Torque Applied to Plug on Main Relief Valves | 80 N·m (59 lb ft) |
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Introduction
The pressure test for the main relief valve will determine if the main relief pressure is correct. Improper relief pressure could damage the conveyor pumps and auger pumps.
Required Tools
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| Illustration 9 | g02571852 |
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| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Digital Indicator | |
| A2 | 2 | 198-4239 | Pressure Sensor Gp (0 to 41368 kPa (0 to 6000 psi)) |
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| A3 | 2 | 198-4236 | Adapter Cable As | |
| B | 2 | 6V-9832 | Cap As | |
| C | C1 | 2 | 6V-9511 | Plugs |
| C2 | 2 | 6V-9746 | O-Ring Seals | |
- Connect one Tool (A2) to each Tool (A3) .
- Connect each Tool (A3) to Tool (A1).
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Table 4 Optional Tools (1) Tool Item Qty Part No Description D D1 2 8T-0855 Pressure Gauges D2 2 6V-4144 Quick Connect Couplers E E1 2 177-7860 Hose As E2 2 6V-4142 Fittings E3 2 6V-4143 Quick Connect Couplers Show/hide table( 1 ) The optional tools can be used to replace the digital pressure gauges in the required tool list.
- Connect one Tool (D2) to each Tool (D1) .
- Connect each Tool (E3) to each Tool (E1). Connect each Tool (E2) to each Tool (E1) .
- Connect each Tool (E3) to each Tool (D2).
Test Preparation
- Drive the machine to a smooth, horizontal surface.
- Move propel lever (4) to the NEUTRAL position.
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| Illustration 10 | g03425361 |
- Press parking brake switch (5) in order to change the status of the parking brake to "engaged". When the parking brake status is "engaged", LED (2) next to the parking brake switch will be illuminated.
- Use travel mode switch (3) to select the PAVE mode. When the travel mode switch is set to PAVE mode, an LED next to PAVE symbol (1) will be illuminated.
Note: The machine must be in PAVE mode in order to operate the screed lift systemthe hopper system, the apron system and the auger lift system.
Right and Left Conveyor Pumps
- Press the up arrow on screed raise/lower switch (6) to lift the screed. Completely raise the screed.
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| Illustration 11 | g03425717 |
- Engage screed service lock mechanism (7) on both sides of the machine.
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| Illustration 12 | g03425987 |
- Use screed float switch (9) to place the screed in the FLOAT position. When the screed is in the FLOAT position, an LED next to the screed float switch will illuminate. Allow the tow arms to rest on screed service locks (7) .
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| Illustration 13 | g03425999 |
- Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.
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| Illustration 14 | g03426016 |
- If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.
- Unhook latch (12), open access panel (13) on the right side of the machine.
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| Illustration 15 | g03426036 |
- Unhook latch (14), open access panel (15) on the right side of the machine.
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| Illustration 16 | g03427054 |
Right and Left Auger Pumps
- Press the down arrow on screed raise/lower switch (6) to lower the screed. Lower the screed all the way to the ground.
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| Illustration 17 | g03425717 |
- Use screed float switch (9) to place the screed in the FLOAT position. Allow the screed to rest on the ground. When the screed is in the FLOAT position, an LED next to the screed float switch will illuminate.
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| Illustration 18 | g03425999 |
- Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.
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| Illustration 19 | g03426016 |
- If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.
- Unhook latch (12), open access panel (13) on the right side of the machine.
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| Illustration 20 | g03426036 |
Test Procedure
Right Conveyor Pump
- Disconnect hose assembly (17) and hose assembly (19) from the right conveyor motor. Cap port (16) with Tool (B). Cap port (18) with other Tool (B). Plug fitting on hose assembly (17) with Tool (C). Plug fitting on hose assembly (19) with other Tool (C) .
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| Illustration 21 | g03426833 |
- Connect Tool (A2) to the forward pressure tap in port "MC" (20) .
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| Illustration 22 | g03426886 |
- Connect second Tool (A2) to the reverse pressure tap in port "D" (21) on the right material feed pump.
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| Illustration 23 | g03427017 |
- Move machine power switch (11) to the ON position.
- Press push to start switch (8) for 2 seconds in order to start the engine. An LED next to the push to start switch will flash when the engine is in start mode. When the engine has started, the LED will remain illuminated.
Note: Only one attempt to start the engine is allowed per key cycle. A new key cycle will need to be done in order to restart the process.
- Operate the engine at low idle for a few minutes.
- Press the up arrow on throttle control switch (10) in order to place the engine in high idle. The engine speed should increase to 2200 rpm.
- Monitor the hydraulic oil temperature on operator display (22). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
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| Illustration 24 | g03660971 |
- Press and hold right conveyor manual switch (24) .
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| Illustration 25 | g03426960 |
- Record the pressure at the forward pressure tap in port "MC" (20). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release right conveyor manual switch (24) .
- Press and hold right conveyor manual switch (24). At the same time, press and hold right conveyor reverse switch (23).
Note: Right conveyor manual switch (24) and right conveyor reverse switch (23) must be pressed simultaneously.
- Record the pressure at the reverse pressure tap in port "D" (21). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release right conveyor reverse switch (23) .
- Move right conveyor manual switch (24) to the OFF position.
- Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.
- If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.
- If the forward pressure and the reverse pressure are both within the specified range, the system is operating within design parameters. Go to Step 20. If either the forward pressure or the reverse pressure is outside the specified range, go to "Adjustment Procedure", "Right Conveyor Pump".
- Remove the tooling. Reconnect the hose assembly (17) and hose assembly (19) on right conveyor motor.
- Close access panel (13), secure latch (12) .
- Close access panel (15), secure latch (14) .
Left Conveyor Pump
- Connect Tool (A2) to the reverse pressure tap in port "MB" (25) .
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| Illustration 26 | g03427299 |
- Connect Tool (A2) to the forward pressure tap in port "MA" (26) .
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| Illustration 27 | g03427306 |
Top of right, upper pump | |
- Disconnect hose assembly (27) and hose assembly (28) from the left conveyor motor. Cap port (29) with Tool (B). Cap port (30) with Tool (B). Plug fitting on hose assembly (27) with Tool (C). Plug fitting on hose assembly (28) with Tool (C) .
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| Illustration 28 | g03427338 |
- Move machine power switch (12) to the ON position.
- Press push to start switch (8) for 2 seconds in order to start the engine. An LED next to the push to start switch will flash when the engine is in start mode. When the engine has started, the LED will remain illuminated.
Note: Only one attempt to start the engine is allowed per key cycle. A new key cycle will need to be done in order to restart the process.
- Operate the engine at low idle for a few minutes.
- Press the up arrow on throttle control switch (10) in order to place the engine in high idle. The engine speed should increase to 2200 rpm.
- Monitor the hydraulic oil temperature on operator display (22). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
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| Illustration 29 | g03660971 |
- Press and hold left conveyor manual switch (32) .
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| Illustration 30 | g03427359 |
- Record the pressure at the forward pressure tap in port "MA" (26). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release left conveyor manual switch (32) .
- Press and hold left conveyor manual switch (32). At the same time, press and hold left conveyor reverse switch (31).
Note: Left conveyor manual switch (32) and left conveyor reverse switch (31) must be pressed simultaneously.
- Record the pressure at the reverse pressure tap in port "MB" (25). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release left conveyor reverse switch (31) .
- Move left conveyor manual switch (32) to the OFF position.
- Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.
- If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.
- If the forward pressure and the reverse pressure are both within the specified range, the system is operating within design parameters. Go to Step 2. If either the forward pressure or the reverse pressure is outside the specified range, go to "Adjustment Procedure", "Left Conveyor Pump".
- Remove the tooling. Reconnect the hose assembly (17) and hose assembly (19) on left conveyor motor.
- Close access panel (13), secure latch (12) .
- Close access panel (15), secure latch (14) .
Right Auger Pump
- Disconnect hose assembly (33) and hose assembly (34) from the right auger motor. Cap port (35) with Tool (B). Cap port (36) with Tool (B). Plug fitting on hose assembly (33) with Tool (C). Plug fitting on hose assembly (34) with Tool (C) .
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| Illustration 31 | g03427403 |
- Connect Tool (A2) to the forward pressure tap in port "MB" (37) .
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| Illustration 32 | g03427417 |
- Connect Tool (A2) to the reverse pressure tap (39) in port "A" (38) on the right material feed pump.
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| Illustration 33 | g03427427 |
- Move machine power switch (11) to the ON position.
- Press push to start switch (8) for 2 seconds in order to start the engine. An LED next to the push to start switch will flash when the engine is in start mode. When the engine has started, the LED will remain illuminated.
Note: Only one attempt to start the engine is allowed per key cycle. A new key cycle will need to be done in order to restart the process.
- Operate the engine at low idle for a few minutes.
- Press the up arrow on throttle control switch (10) in order to place the engine in high idle. The engine speed should increase to 2200 rpm.
- Monitor the hydraulic oil temperature on operator display (22). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
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| Illustration 34 | g03660971 |
- Press and hold right auger manual switch (40) .
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| Illustration 35 | g03427449 |
- Record the pressure at the forward pressure tap in port "MB" (37). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release right auger manual switch (40) .
- Press and hold right auger manual switch (40). At the same time, press and hold right auger reverse switch (41).
Note: Right auger manual switch (40) and right auger reverse switch (41) must be pressed simultaneously.
- Record the pressure at the reverse pressure tap in port "A" (38). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release right auger reverse switch (41) .
- Release right auger manual switch (40) .
- Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.
- If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.
- If the forward pressure and the reverse pressure are both within the specified range, the system is operating within design parameters. Go to Step 1. If either the forward pressure or the reverse pressure is outside the specified range, go to "Adjustment Procedure", "Right Auger Motor".
- Remove the tooling. Reconnect the hose assembly (17) and hose assembly (19) on right auger motor.
- Close access panel (13), secure latch (12) .
- Close access panel (15), secure latch (14) .
Left Auger Pump
- Disconnect hose assembly (42) and hose assembly (43) from the left auger motor. Cap port (44) with Tool (B). Cap port (45) with Tool (B). Plug fitting on hose assembly (42) with Tool (C). Plug fitting on hose assembly (43) with Tool (C) .
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| Illustration 36 | g03427511 |
- Connect Tool (A2) to the forward pressure tap in port "MD" (46) .
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| Illustration 37 | g03427518 |
Top right pump, front side of pump | |
- Connect Tool (B) to the reverse pressure tap in port "C" (47) .
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| Illustration 38 | g03427525 |
Tap located in tee in top, right pump | |
- Move machine power switch (11) to the ON position.
- Press push to start switch (8) for 2 seconds in order to start the engine. An LED next to the push to start switch will flash when the engine is in start mode. When the engine has started, the LED will remain illuminated.
Note: Only one attempt to start the engine is allowed per key cycle. A new key cycle will need to be done in order to restart the process.
- Operate the engine at low idle for a few minutes.
- Press the up arrow on throttle control switch (10) in order to place the engine in high idle. The engine speed should increase to 2200 rpm.
- Monitor the hydraulic oil temperature on operator display (22). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
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| Illustration 39 | g03660971 |
- Press and hold left auger manual switch (48) .
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| Illustration 40 | g03427534 |
- Record the pressure at the forward pressure tap in port "MD" (46). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release left auger manual switch (48) .
- Press and hold left auger manual switch (48). At the same time, press and hold left auger reverse switch (49).
Note: Left auger manual switch (48) and left auger reverse switch (49) must be pressed simultaneously.
- Record the pressure at the reverse pressure tap in port "C" (47). The pressure should be 34500 ± 2100 kPa (5009 ± 305 psi).
- Release left auger reverse switch (49) .
- Release left auger manual switch (48) .
- Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.
- If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.
- If the forward pressure and the reverse pressure are both within the specified range, the system is operating within design parameters. Go to Step 22. If either the forward pressure or the reverse pressure is outside the specified range, go to "Adjustment Procedure", "Left Auger Pump".
- Remove the tooling. Reconnect the hose assembly (17) and hose assembly (19) on left auger motor.
- Close access panel (13), secure latch (12) .
- Close access panel (15), secure latch (14) .
Adjustment Procedure
Right Conveyor Pump
- If the forward pressure is outside the specified range, replace faulty forward relief valve (50). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Right Conveyor Pump", Step 4.
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| Illustration 41 | g03427578 |
- If the reverse pressure is outside the specified range, replace faulty reverse relief valve (51). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Right Conveyor Pump", Step 4.
Left Conveyor Pump
- If the forward pressure is outside the specified range, replace faulty forward relief valve (53). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Left Conveyor Pump", Step 4.
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| Illustration 42 | g03427632 |
- If the reverse pressure is outside the specified range, replace faulty reverse relief valve (52). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Left Conveyor Pump", Step 4.
Right Auger Pump
- If the forward pressure is outside the specified range, replace faulty forward relief valve (54). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Right Auger Pump", Step 4.
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| Illustration 43 | g03427583 |
- If the reverse pressure is outside the specified range, replace faulty reverse relief valve (55). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Right Auger Pump", Step 4.
Left Auger Pump
- If the forward pressure is outside the specified range, replace faulty forward relief valve (56). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Left Auger Pump", Step 4.
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| Illustration 44 | g03427641 |
- If the reverse pressure is outside the specified range, replace faulty reverse relief valve (57). Tighten the plug to a torque of 80 N·m (59 lb ft). Go to "Test Procedure", "Left Auger Pump", Step 4.
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