AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems Caterpillar

Relief Valve (Main) - Test - Drag Conveyor and Auger Conveyor

Usage:

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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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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, "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.

Drag Conveyor

Note: This machine is equipped with two identical material feed pumps. One pump provides the flow which operates the material feed system on the right side of the machine. The second pump provides the flow which operates the material feed system on the left side of the machine. Each material feed pump contains two rotating groups. The rotating group that is closest to the input shaft provides the flow which operates the drag conveyor. The second rotating group provides the flow which operates the auger. The following procedure tests the main relief pressure for the rotating group which provides flow to the left conveyor motor. The procedure which tests the main relief pressure for the rotating group that provides flow to the right conveyor motor is similar.

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Table 1
Required Tools
Tool	Part Number	Description	Qty
A ⁽¹⁾	198-4234	Pressure Gauge Tool Gp	1
B ⁽¹⁾	198-4236	Adapter Cable As	1
C ⁽¹⁾	198-4239	Pressure Sensor Gp 0 to 69000 kPa (0 to 100,000 psi)	1
D	6V-9832	Cap As	1
E	6V-9511	Plug	1
F	6V-9746	O-Ring Seal	1
G	4C-6500	Digital Thermometer	1

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^( 1 )

The 198-4234 Pressure Gauge Tool Gp , 198-4236 Adapter Cable As , and the 198-4239 Pressure Sensor Gp are part of the 198-4240 Digital Pressure Indicator .

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Table 2
Optional Tools ⁽¹⁾
Tool	Part Number	Description	Qty
H	8T-0861	Pressure Gauge 0 to 60000 kPa (0 to 8700 psi)	1
J	6V-3989	Fitting	1
K	6V-4143	Quick Connect Coupler	2
L	177-7860	Hose As	1

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^( 1 )

The optional tools can be used in place of the digital pressure measurement tools which are specified in the required tool list.

Perform the procedure in Specifications, Systems Operation/Testing and Adjusting, KENR5045, "Relief Valve (Charge) - Test and Adjust" in this module.

Open the access doors on the left side of the machine.

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Illustration 1	g01163455

Disconnect the inlet line to the conveyor motor. Cap port (2) with Tool (D) . Plug fitting (1) on the inlet line with Tool (E) and Tool (F) .
Note: Port "B" is the inlet line on the left motor. Port "A" is the inlet line on the right motor.

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Illustration 2	g01163456

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Illustration 3	g01163458

Connect Tool (C) to the pressure tap in port "M2" (3) .
Note: Illustration 3 shows port "M2" on the left pump. The location of port "M2" on the right pump is similar.

Use Tool (B) in order to connect Tool (C) to Tool (A) .

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Illustration 4	g01163463

Move ignition switch (4) to the ON position.

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Illustration 5	g01163467

Move engine start switch (5) to the START position. Release the engine start switch after the engine starts.

Move throttle control switch (6) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2310 rpm.

Monitor the hydraulic oil temperature with Tool (G) . Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).

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Illustration 6	g01163469

Move left conveyor ratio dial (7) to the MAXIMUM position.

Move switch (8) for the left conveyor to the MANUAL position. Hold the switch in this position.

Record the pressure at port "M2" (3) as "forward pressure". The pressure should be 36000 ± 2070 kPa (5220 ± 300 psi).

Release switch (8) for the left conveyor.

Move ratio dial (7) for the left conveyor to the MINIMUM position.

Move throttle control switch (6) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

After the engine reaches low idle, move engine start switch (5) to the OFF position.

Move ignition switch (4) to the OFF position.

Remove Tool (C) from the pressure tap in port "M2" (3) .

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Illustration 7	g01163475

Disconnect plug (11) from connector (10) for the forward EDC. Connect plug (11) to connector (9) for the reverse EDC.

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Illustration 8	g01163476

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Illustration 9	g01163478

Connect Tool (C) to the pressure tap in port "M1" (12) .
Note: Illustration 9 shows port "M1" on the left pump. The location of port "M1" on the right pump is similar.

Start the engine. Operate the engine at high idle.

Monitor the hydraulic oil temperature with Tool (G) . Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).

Move ratio dial (7) for the left conveyor to the MAXIMUM position.

Move switch (8) for the left conveyor to the MANUAL position. Hold the switch in this position.

Record the pressure at port "M1" (12) as "reverse pressure". The pressure should be 36000 ± 2070 kPa (5220 ± 300 psi).

Release switch (7) for the left conveyor.

Move ratio dial (7) for the left conveyor to the MINIMUM position.

Stop the engine. Refer to Step 15 through Step 17.

Disconnect plug (11) from connector (9) for the reverse EDC. Connect plug (11) to connector (10) for the forward EDC.

Analyze the test results by using the following procedure:
- If the forward pressure and the reverse pressure are both within the specified range, the system is operating within design parameters. Go to Step 31.
- If either the forward pressure or the reverse pressure is outside the specified range, replace the faulty valve. Retest the pressure.
- If the forward pressure and the reverse pressure are both outside the specified range, case drain flow through the pump may be excessive. Troubleshoot the pump. Retest the pressure.

Remove the tooling. Reconnect the inlet hose to the conveyor motor. Close the access doors.

Auger Conveyor

This machine is equipped with two identical material feed pumps. One pump provides the flow which operates the material feed system on the right side of the machine. The second pump provides the flow which operates the material feed system on the left side of the machine. Each material feed pump contains two rotating groups. The rotating group that is closest to the input shaft provides the flow which operates the drag conveyor. The second rotating group provides the flow which operates the auger. The following procedure tests the main relief pressure for the rotating group which provides flow to the left auger motor. The procedure which tests the main relief pressure for the rotating group that provides flow to the right auger motor is similar.

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Table 3
Required Tools
Tool	Part Number	Description	Qty
A ⁽¹⁾	198-4234	Pressure Gauge Tool Gp	1
B ⁽¹⁾	198-4236	Adapter Cable As	2
C ⁽¹⁾	198-4239	Pressure Sensor Gp 0 to 69000 kPa (0 to 10000 psi)	2
D	6V-9832	Cap As	1
E	6V-9511	Plug	1
F	6V-9746	O-Ring Seal	1
G	4C-6500	Digital Thermometer	1

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^( 1 )

The 198-4234 Pressure Gauge Tool Gp , 198-4236 Adapter Cable As , and the 198-4239 Pressure Sensor Gp are part of the 198-4240 Digital Pressure Indicator .

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Table 4
Optional Tools ⁽¹⁾
Tool	Part Number	Description	Qty
H	8T-0861	Pressure Gauge 0 to 60000 kPa (0 to 8700 psi)	1
J	6V-3989	Fitting	1
K	6V-4143	Quick Connect Coupler	2
L	177-7860	Hose As	1

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^( 1 )

The optional tools can be used in place of the digital pressure measurement tools which are specified in the required tool list.

Perform the procedure in Specifications, Systems Operation/Testing and Adjusting, KENR5045, "Relief Valve (Charge) - Test and Adjust" in this module.

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Illustration 10	g01163482

Disconnect the inlet line to the auger motor. Cap port (1) with Tool (D) . Plug fitting (2) on the inlet line with Tool (E) and Tool (F) .
Note: Port "B" is the inlet line on the left motor. Port "A" is the inlet line on the right motor.

Open the access doors on the left side of the machine.

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Illustration 11	g01163484
Upper Pump Stacks

Connect Tool (C) to the pressure tap in port "M2" (3) on the left conveyor and the auger pump.
Note: Illustration 11 shows port "M2" on the left pump. The location of port "M2" on the right pump is similar.

Use Tool (B) in order to connect Tool (C) to Tool (A) .

Connect Tool (C) to the pressure tap in port "M1" (4) .
Note: Illustration 11 shows port "M1" on the left pump. The location of port "M1" on the right pump is similar.

Use Tool (B) in order to connect Tool (C) to Tool (A) .

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Illustration 12	g01163491

Move ignition switch (5) to the ON position.

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Illustration 13	g01163492

Move engine start switch (6) to the START position. Release the engine start switch after the engine starts.

Move throttle control switch (7) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2310 rpm.

Monitor the hydraulic oil temperature with Tool (G) . Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).

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Illustration 14	g01163497

Move left auger switch (8) to the MANUAL position. Hold the switch in this position.

Record the pressure at port "M1" (4) as "forward pressure". The pressure should be 36000 ± 2070 kPa (5220 ± 300 psi).

Hold left auger switch (8) in the MANUAL position. Then, move auger reverse switch (9) to the LEFT AUGER REVERSE position.

Record the pressure at port "M2" (3) as reverse pressure. The pressure should be 36000 ± 2070 kPa (5220 ± 300 psi).

Release auger reverse switch (9) . Release left auger switch (8) .

Move throttle control switch (7) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

After the engine reaches low idle, move engine start switch (6) to the OFF position.

Move ignition switch (5) to the OFF position.

Analyze the test results by using the following procedure:
- If the forward pressure and the reverse pressure are both within the specified range, the system is operating within design parameters. Go to Step 21.
- If either the forward pressure or the reverse pressure is outside the specified range, replace the faulty valve. Retest the pressure.
- If the forward pressure and the reverse pressure are both outside the specified range, case drain flow through the pump may be excessive. Troubleshoot the pump. Retest the pressure.