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

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.

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

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

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Illustration 1	g02037476

3. Disconnect the inlet line to the conveyor motor. Cap port (2) with Tool (D). Plug hose assembly (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	g02037548
Port "MB" (3) on the left conveyor pump.

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Illustration 3	g02037599
Port "MB" (3) on the right conveyor pump.

4. Connect Tool (C) to the pressure tap in port "MB" (3) .

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

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Illustration 4	g02037573

6. Move key start switch (4) to the ON position.

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Illustration 5	g02037574

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

8. 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.

9. 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	g02037577

10. Move throttle control switch (6) to the LOW IDLE position. Lower the engine rpm to 1200 rpm. Hold the switch in this position until the engine reaches the desired rpm.

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

12. Move left conveyor mode switch (8) to the MANUAL position. Hold the switch in this position for a short period of time.

13. Record the pressure at port "MB" (3) as "forward pressure". The pressure should be 35165 to 39300 kPa (5100 to 5700 psi).

14. Release left conveyor mode switch (8) .

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

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

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

18. Move key start switch (4) to the OFF position.

19. Analyze the test results by using the following procedure:
    • If the forward pressure is within the specified range, the system is operating within design parameters. Go to Step 20.

    • If the forward pressure is outside the specified range, replace the faulty valve. Retest the pressure.

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

21. Reconnect the inlet hose to the conveyor motor. Close the access doors.

Auger Conveyor

1. 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 7	g02078873

2. Disconnect hose assemblies (1) and (2) from the auger motor. Install Tooling (D), Tool (E), and Tool (F) to the hose assemblies and the auger motor.

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

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Illustration 8	g02037636
Port "MD" (3) on the left auger pump.

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Illustration 9	g02037654
Port "MD" (3) on the right auger pump.

4. Connect Tool (C) to the forward pressure tap in port "MD" (3) on the left auger pump.

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

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Illustration 10	g02038842
The Reverse pressure tap in port "MC" (4) on the left auger pump

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Illustration 11	g02038844
The Reverse pressure tap in port "MC" (4) on the right auger pump

6. Connect Tool (C) to the reverse pressure tap in port "MC" (4) .

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

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Illustration 12	g02038853

8. Move key start switch (5) to the ON position.

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Illustration 13	g02038854

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

10. 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.

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

12. Move throttle control switch (7) to the LOW IDLE position. Lower engine rpm to 1200 rpm. Hold the switch in this position until the engine reaches the desired rpm.

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Illustration 14	g02038857

13. Move left auger mode switch (8) to the MANUAL position. Hold the switch in this position for a short time.

14. Record the pressure at port "MC" (4) as "forward pressure". The pressure should be 35165 to 39302 kPa (5100 to 5700 psi).

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

16. Record the pressure at port "MD" (3) as reverse pressure. The pressure should be 35165 to 39302 kPa (5100 to 5700 psi).

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

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

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

20. Move key start switch (5) to the OFF position.

21. 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 22.

    • 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, the case drain flow through the pump may be excessive. Troubleshoot the pump. Retest the pressure.

22. Remove the Tooling. Connect the hose assemblies to the auger motor. Close the access doors.