Usage:
CP-533 (3ZL028-Up, 5AL140-Up),
CS-533 (3BL120-Up, 4HL135-Up),
CP-563 (1YJ413-Up, 5AJ140-Up),
CS-563 (8XF975-Up, 7GG517-Up),
CS-573 (8PK70-Up),
CS-583 (8YJ141-Up, 1EL186-Up) Vibratory Compactors
Reference: Systems Operation, Testing and Adjusting Manual, KENR1894, CP-533, CS-533 Vibratory Compactors, Propulsion System. Systems Operation, Testing and Adjusting Manual, KENR1583-01, CP-563, CS-563 Vibratory Compactors, Propulsion System. Systems Operation, Testing and Adjusting Manual, KENR1887, CS-573, CS-583 Vibratory Compactors, Propulsion System.
Description of Change: A flushing valve has been added to the drum propel motor to improve flushing and cooling flow through the motor case. The valve is located on the drum yoke support plate, just forward of the drum propel motor.
Adaptable To: The new 110-5286 Flushing Valve Group is effective with the PIN's listed above. The new valve group is not adaptable to previous machines.
The new flushing valve group uses a spring centered shuttle spool and relief valve. Oil in the high pressure side of the hydrostatic drive loop shifts shuttle spool (3) when the machine is propelling. When spool (3) shifts, it allows oil in the return side of the loop to act against relief valve assembly (1). A portion of the return oil from the motor flows through the relief valve to the drum propel motor case. This flow combines with normal leakage flow within the motor case. The combined leakage and flushing oil flow is routed out of the motor case to the return manifold and oil cooler.
Illustration 1. Flushing Valve Assembly For Drum Propel Motor (1) Relief valve assembly. (2) Orifice. (3) Shuttle spool.
There are two different procedures for verifying correct performance of the flushing valve. The "Flushing Valve Pressure Test Procedure" is used to verify correct flushing valve operation by checking pressures. The "Flushing Valve Flow Test Procedure" is used to verify correct flushing valve operation by checking oil flow through the flushing valve. The flow measurement procedure is more accurate than the pressure measurement procedure.
The procedures for three Testing And Adjusting manuals need to be updated for the machines listed, that are equipped with the new flushing valve. The titles of the procedures are, "Front Propulsion Motor Case Leakage Test Procedure", "Vibratory/Propulsion Pump Charge Relief And Cooling Valve Pressure Verification Test", and "Adjusting Vibration/Propulsion Pump Charge Relief Valves". The new procedures listed in this article replace the existing procedures in the Service Manual Modules referenced for the above machines.
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Sudden movement of the machine or release of oil under pressure can cause injury to persons on0000near the machine. To prevent possible injury, perform the procedure on the first page of the Troubleshooting section of the Service Manual Modules referenced.
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Flushing Valve Pressure Test Procedure
NOTE: The "Flushing Valve Flow Test Procedure" yields more accurate results than the pressure test.
Illustration 2. Tooling Installation For Pressure Test (4) Propel motor. (5) Flushing valve group. (6) 8T-0846 Pressure Gauge. (7) Tee and quick disconnect. (8) Hose.
1. Stop the machine and apply the parking brake.
2. Install a tee and quick disconnect (7) between flushing valve (5) and hose (8). Hose (8) is connected to the left case drain port on drum propel motor (4).
3. Attach pressure gauge (6) to the quick disconnect.
4. Attach a 4000 kPa (580 psi) gauge to the charge filter pressure tap.
5. Start the engine and operate at high idle until the hydraulic oil temperature reaches 38°C (100°F).
6. Record the oil pressure reading on the charge filter gauge and gauge (6).
Oil pressure at the charge filter should be 3030 ± 138 kPa (440 ± 20 psi).
Oil pressure at gauge (6) should be 138 ± 34 kPa (20 ± 5 psi).
NOTE: Adjust the neutral charge pressure for the propel and vibratory pumps if required. See Service Manual Modules referenced.
7. Release the parking brake and move the propel control lever forward. Record the oil pressure reading on the two pressure gauges while the machine is moving forward.
The pressure reading at the charge filter should be 2890 ± 138 kPa (420 ± 20 psi).
The pressure reading at the flushing valve should be 138 ± 34 kPa (20 ± 5 psi) GREATER than was recorded in Step 6.
NOTE: If the pressures in Step 7 are not within the ranges specified, a problem may exist with the flushing valve. There may also be excessive motor case drain. If the pressure is too low, perform the "Flushing Valve Flow Test Procedure". If the pressure is too high, perform the "Front Propulsion Motor Case Leakage Test Procedure".
8. If the pressures measured in Step 7 are correct, stop the engine and apply the parking brake. Remove all tooling and reconnect hoses.
Flushing Valve Flow Test Procedure:
Illustration 3. Tooling Installation For Flow Test (4) Propel motor. (5) Flushing valve group. (8) Hose. (9) 4C-8689 Flowmeter. (10) Hose assembly (fabricated from hose and couplings in chart).
1. Stop the machine and apply the parking brake.
2. Disconnect hydraulic hose (8) from the left case drain port of drum propel motor (4).
3. Attach the end of hose (8) to the inlet of 4C-8689 Flowmeter (9). Connect the outlet of flowmeter (9) to the left case drain port of propel motor (4) with hose assembly (10).
4. Disconnect the electrical connector for the park brake solenoid (contains purple wire marked "777"). This will allow the machine to propel against the parking brake when the brake is released and the propel handle is moved.
5. Start the engine and operate at high idle until the hydraulic oil temperature reaches 38°C (100°F).
6. Record the reading on flowmeter (9) with the machine in neutral.
The flow should be 0 to 1.9 L/min (0 to .5 gpm).
NOTE: Hydraulic flow in excess of this specification may indicate leakage past shuttle spool (3), a stuck spool, or a propel pump on stroke. Shuttle spool (3) is identified in Illustration 1.
7. Pull the parking brake switch up. Move the propel lever to maintain 10 335 kPa (1500 psi) in the forward pressure side of the drum propel loop.
Record the reading on flowmeter (9). The hydraulic flow should be 5.8 to 9.5 L/min (1.5 to 2.5 gpm).
8. Move the propel handle in reverse to maintain 10 335 kPa (1500 psi) in the reverse pressure side of the drum propel loop.
Record the reading on flowmeter (9). The hydraulic flow should be 5.8 to 9.5 L/min (1.5 to 2.5 gpm).
NOTE: If the hydraulic flow measurement in Step 7 and/or Step 8 is less than 5.8 L/min (1.5 gpm), a problem may exist with shuttle spool (3), orifice (2), relief valve (1), or relief valve adjustment. The relief valve has a screw and locknut type adjustment (See Illustration 1).
9. If the flow values in forward and reverse are within specification:
* remove all tooling
* reconnect hoses
* reconnect the electrical connector to the park brake solenoid.
Front Propulsion Motor Case Drain Leakage Test Procedure
If abnormal leakage within the drum drive motor is suspected, this procedure may be used to test for excessive motor case drain flow.
Illustration 4. Tooling Installation For Case Drain Leakage Test. (4) Propel motor. (5) Flushing valve. (8) Hose. (9) 4C-8689 Flowmeter. (10) Hose assembly (fabricated from hose and couplings in chart). (11) Capped ports. (12) Case drain hose. (13) Graduated container.
1. Stop the machine and apply the parking brake.
2. Disconnect hose (8) from flushing valve (5). Use parts from the fittings group to cap the open adapter on flushing valve (5) and plug the exposed end of hose (8) as shown by item (11).
3. Disconnect case drain hose (12) from the right case drain port of propel motor (4). Connect one end of hose assembly (10) to the right case drain port on the propel motor. Connect the other end of hose (10) to the inlet of flowmeter (9). Install case drain hose (12) into the outlet of flowmeter (9).
NOTE: If a flowmeter is unavailable, flow from the motor case can be timed and collected in calibrated container (13). It will be necessary to plug case drain hose (12).
4. Connect two 8T-0861 Pressure Gauges [60 000 kPa (8700 psi)] to the quick disconnects for the drum propel loop (located on manifold at the drum propel pump). Place the propel speed switch in HIGH range.
5. Disconnect the electrical connector at the park brake solenoid (purple wire marked "777"). This will enable the operator to propel against the parking brake.
6. Start the engine and operate at high idle until the hydraulic oil temperature reaches 38°C (100°F).
7. Pull the parking brake switch up and move the propel lever forward until the pressure on the drum propel loop reaches 10 335 kPa (1500 psi).
8. Record the reading of flowmeter (9). [Or calculate the flow rate if using calibrated container (13).]
9. Stop the engine and push the parking brake switch down. Reconnect the parking brake solenoid connector.
10. Release the parking brake, and slowly propel the machine forward until the drum has rotated 90 degrees.
11. Repeat Steps 5 through 10 four times, until the drum has rotated 360 degrees. Be certain to record flow readings.
12. Repeat steps 5 through 11 with the drum propelled in the reverse direction.
13. Repeat steps 5 through 11 with the drum propelled in forward, in low speed range.
14. Repeat steps 5 through 11 with the drum propelled in reverse, in low speed range.
15. The maximum case drain flow allowed in any direction or speed is 5.8 L/min (1.5 gpm).
NOTE: If the case drain flow is greater than allowed, a problem may exist with the propel motor cylinder block and/or pistons, or with the port mating surfaces on the distribution valve or the cylinder block.
NOTE: The distribution valve has four different high pressure seals which may affect case drain leakage depending upon motor direction and displacement. If excessive case drain flow shows up in only one of the four different modes of testing, the high pressure seals on the distribution valve may be the cause.
16. If the case drain flows are below the maximum allowed, remove all tooling and reconnect hoses.
Vibratory/Propulsion Pump Charge Relief And Cooling Relief Valve Pressure Verification Test
Illustration 5. Vibration Pump (1) Case drain line. (2) Vibration pump.
1. Disconnect case drain line (1) at vibration pump (2). Install a tee, a quick disconnect, and 8T-0855 Pressure Gauge [0 to 4000 kPa (0 to 580 psi)] from the fittings group. On the vibration pump adapter that the case drain line was disconnected, connect the case drain line to the tee. This pressure gauge will measure the vibration pump case drain pressure.
Illustration 6. Location At Rear Of Seat (3) Charge pressure test port.
2. Install a 8T-0855 Pressure Gauge [0 to 4000 kPa (0 to 580 psi)] at the quick disconnect after the charge filter.
Illustration 7. View Underneath Operators Platform On Right Side Of Machine (4) Test port on vibratory cooling valve. (5) Remove line and install plug in hose and a cap on adapter.
3. Install a 8T-0855 Pressure Gauge [0 to 4000 kPa (0 to 580 psi)] at test port (4), located on the vibratory cooling valve on the right side of the machine.
4. Start the engine. Run the engine at high idle (2350 ± 50 rpm) until the hydraulic oil temperature reaches 38°C (100°F). You may turn the steering wheel to go against the steering pivot stops to increase the temperature.
NOTE: If difficulty is experienced in getting the system temperature up to 38°C (100°F), it may be necessary to operate the machine. Another method of increasing the system temperature is to disconnect the oil line at port (5) from the vibration cooling valve and install a plug in the hose and a cap in the adapter.
5. Once the system reaches 38°C (100°F), remove the plug and cap from the vibratory cooling valve (if previously installed).
6. Activate the vibratory system momentarily. This shifts the shuttle valve spool in the vibratory cooling relief valve.
7. Record three pressure readings: vibratory pump case, cooling relief valve, and charge system. Use the chart below as a reference.
NOTE: If the pressure values recorded for the cooling relief and charge system are below specifications, perform the procedure, "Adjusting Vibration/Propulsion Pump Charge Relief Valves", in this article.
Adjusting Vibration/Propulsion Pump Charge Relief Valves
Illustration 8. Left Side Of Pump Compartment (1) Vibration cooling valve. (2) Oil line.
1. Disconnect oil line (2) from vibratory cooling valve (1). Install a plug in the oil line and cap the ports of the vibratory cooling valve.
Illustration 9. Vibration Pump (3) Case drain line. (4) Vibration pump.
2. Install an 8T-0854 Pressure Gauge [0 to 1000 kPa (0 to 145 psi)] from the fittings group to the quick disconnect at case drain line (3). This will measure vibratory pump case pressure.
3. Install a 8T-0855 Pressure Gauge [0 to 4000 kPa (0 to 580 psi)] from the fittings group to the charge pressure tap located after the charge filter.
4. Install a tachometer on the engine to measure engine speed.
5. Engage the parking brake and put the propulsion lever in the STOP position. Start the engine. Run the engine at high idle (2350 ± 50 rpm) until the hydraulic oil tank temperature reaches 38°C (100°F).
6. Stop the engine. Turn both adjustable charge relief valves for the axle and drum propel pumps fully clockwise. This will allow the charge relief valve in the vibratory pump, which is shim adjustable, to determine the system charge pressure.
7. Start the engine again and run engine at low idle (800 rpm) with the hydraulic oil temperature at 38°C (100°F). Record the pressure at the charge filter and vibratory case pressure and determine the difference.
8. Add shims (to increase pressure) or remove shims (to decrease pressure) to the vibration pump charge relief valve to set the differential pressure to 2894 ± 138 kPa (420 ± 20 psi). Record the final pressure at the charge pressure port and use this pressure as a reference pressure to set the two propulsion pump charge relief valves. Stop the engine.
NOTE: A shim stack height of 11.2 mm (.44 in) from 077-3775 Shim may be used as a reference point. It should be not be necessary to install a total shim stack of more than 12.2 mm (.48 in).
9. Slowly open the charge relief valve on the axle propel pump approximately three turns. Start the engine and increase the engine speed to 1575 rpm. With the hydraulic oil temperature at 38°C (100°F), turn the adjustable relief valve until the charge filter pressure is the same as the reference pressure that was recorded in Step 6. Tighten the locknut to a torque of 46 to 55 N·m (34 to 41 lb ft). Stop the engine.
10. Slowly open the charge relief valve on the drum propel pump for approximately three turns. Start the engine and increase the engine speed to 2350 rpm (high idle). With the hydraulic oil temperature at 38°C (100°F), adjust the drum propel charge relief valve until the charge pressure is the same as the reference pressure that was recorded in step 6. Turn the charge relief valve for the drum propel pump clockwise an additional 1 1/2turns. Tighten the locknut to a torque of 46 to 55 N·m (34 to 41 lb ft).
11. Stop the engine and reconnect the oil line from the vibration cooling valve to the hydraulic return manifold.
12. Finish by performing the procedure, "Vibratory/Propulsion Pump Charge Relief And Cooling Relief Valve Pressure Verification Test", in this article. When finished, remove all test equipment and reconnect hoses.