Operación de Sistemas

AP-200B ASPHALT PAVER VEHICLE SYSTEMS Número de medio -KENR1864-00 Fecha de

publicación -01/05/1991 Fecha de actualización -10/10/2001

Systems Operation
Introduction

Reference: For Specifications with illustrations, refer to the Specifications for the AP-200B Vehicle
Systems, Form No. KENR1863. If the Specifications in Form No. KENR1863 are not the same as
listed in the Systems Operation and the Testing And Adjusting, look at the print date on the back
cover of each book. Use the Specifications listed in the book with the latest date.

Ground Drive System

System Overview

Ver imagen

Schematic Of Ground Drive System

(1) Left ground drive pump. (2) Right ground drive pump. (3) Filter for charge pump. (4) Left drive
motor. (5) Bleed valve for cooling. (6) Oil cooler. (7) Left parking brake. (8) Valve for parking brake.
(9) Right parking brake. (10) Bleed valve for cooling. (11) Right drive motor. (12) Hydraulic tank.

The AP-200B uses two hydrostatic, closed loop ground drive systems. Each track has a separate
hydraulic system. The right ground drive pump has the only charge pump. The hydraulic oil tank
and the hydraulic oil cooler are each used for both systems.

Ver imagen

Hydraulic Tank Location

(13) Breather. (12) Hydraulic oil tank.

Hydraulic tank (12) is located at the left side of the machine. The hydraulic tank provides oil for all
of the hydraulic systems on the machine. Breather (13) prevents dirt particles from entering the
hydraulic system. The breather has a relief valve to maintain 35 kPa (5 psi) pressure in the tank.
There also is a vacuum relief valve to prevent a vacuum in the tank when the oil cools.

Ver imagen

Hydraulic oil cooler location

(6) Hydraulic oil cooler. (14) Temperature switch.

Hydraulic oil cooler (6) is located at the right side of the hydraulic oil tank. Temperature switch
(14) is installed in the inlet line to the oil cooler. An electric cooling fan draws air across the oil
cooler core. Switch (14) turns the cooling fan on when the inlet oil temperature gets to
approximately 63°C (145°F). When the oil temperature drops to approximately 54°C (130°F) the
switch turns the cooling fan off.
Ver imagen

Ground Drive Pump Location

(1) Left ground drive pump. (2) Right ground drive pump. (3) Filter.

Ground drive pumps (1) and (2) are fastened together to make one tandem pump. A tandem gear
pump for the auxiliary system is fastened to the rear of pump (1). Each pump swashplate is
controlled manually by a separate lever to give direction and speed control for each track. The
charge pump for the ground drive system is located between pumps (1) and (2). The charge pump
provides makeup oil and oil for lubrication and cooling for the ground drive system. The charge
relief and high pressure relief valves are located in the pumps. The oil for the charge pump comes
from the hydraulic tank, goes through filter (3) and then to the inlet of the pump. The pumps are
driven directly from the engine flywheel and turn at the same speed as the engine.

Ver imagen

Drive Component Location

(9) Parking brake. (11) Drive motor. (15) Planetary reduction unit.

Planetary (15), parking brake (9) and drive motor (11) are mounted as a group on the inside of the
track roller frame under the hopper. The planetary is mounted to the track roller frame. The
output shaft of the planetary turns the track drive sprocket. The planetary consists of a sun gear,
ring gear, and a planet gear carrier. The final reduction ratio is 25.43:1. Parking brake (9) is spring
applied and pressure released. Oil from the charge system is used to release the brake. The brake
has two friction discs and three steel plates. Drive motor (11) is a fixed displacement piston motor.
Bleed valves (5) and (10) for cooling are located in a high pressure loop line at the head end of the
drive motors.
Ver imagen

Parking Brake Valve Location

(8) Parking brake valve.

Parking brake valve (8) is a electric solenoid operated two position valve and is located under the
hopper. The valve can be actuated from a switch on either side of the machine.

Ground Drive Pump

Ver imagen

(1) Charge pump. (2) High pressure port. (3) Valve plate. (4) Barrel assembly. (5) Swashplate. (6)
Shaft. (7) High pressure port. (8) Spring. (9) Piston.
When the engine is running, shaft (6), barrel assembly (4) and charge pump (1) rotate. Valve plate
(3) and swashplate (5) are held by the housing and do not rotate. Spring (8) keeps a force on barrel
assembly (4) to hold it against valve plate (3) to maintain a high pressure seal. When the barrel
assembly is rotating, each of the nine pistons (9) follows the angle of the swashplate. When the
angle of the swashplate is zero (neutral), the pistons do not move in and out of the barrel
assembly. The only oil flow is from the charge pump. When the angle of the swashplate is not
zero, the pistons will move in and out of the cylinder block. The length of the piston stroke is
changed when the swashplate is rotated on its axis. The amount and direction of oil flow depends
on how far and what direction the swashplate is moved from neutral.

Charge Relief Valve

Ver imagen

Charge Relief Valve

The charge relief valve is located in the right ground drive pump. When the relief valve opens, the
excess oil goes to the pump case. The relief valve is shim adjustable and is set to maintain a
pressure of 1450 kPa (210 psi).

Main Relief Valve

Ver imagen
Combination Valve
Each ground drive pump has two combination valves, one for forward direction and one for
reverse direction. Each combination valve has three functions: high pressure relief valve, charge
system check valve, and system loop bypass.

The high pressure relief valve is a direct acting valve that limits the maximum pressure in the loop
system. When the relief valve is opened, the excess oil goes to the low pressure side of the loop.
The high pressure relief valve setting is not adjustable.

The charge system check valves are built into the main relief valves and provide make-up oil for
the loop system.

The bypass function allows the machine to be moved with the engine stopped. Loosen each valve
no more than 4 turns.

Ground drive motor

Ver imagen
Ground Drive Motor
(1) Shaft. (2) Motor housing. (3) Piston race. (4) Piston. (5) Cylinder block. (6) Piston Assembly. (7)
Valve plate. (8) End cap (9) Key.

The ground drive motor is a fixed displacement piston type motor. Both the left and right drive
motors are the same. The inlet and outlet ports and the case drain are located in end cap (8).

Oil from the pump enters the motor through one of two loop ports in the end cap. The oil goes
through valve plate (7) and into piston assembly (6). The pressure oil pushes against piston (4) and
pushes the piston out of cylinder block (5). The piston is pushed out against piston race (3) and is
forced to move down the incline formed by the piston race. When the piston moves down the
incline, cylinder block (5) rotates. Cylinder block (5) is fastened to shaft (1) with key (9). This causes
the shaft to rotate with the cylinder block.

Cooling and lubrication of the internal parts of the motor is done with normal internal leakage oil.
The case drain port in the end cap is used to route case drain oil to the oil cooler and hydraulic
tank.

Planetary Group
Ver imagen
Planetary Group
(1) Output shaft. (2) Hub. (3) Internal gear. (4) Planet cluster gear. (5) Ring gear. (6) Roller bearings.
(7) Planet cluster gear shaft. (8) Cover. (9) Planet carrier assembly. (10) Sun gear. (11) Input shaft.
(12) Bolt. (13) Coupling.

The planetary gear group provides the only gear reduction between the drive motor and the track
sprocket. Hub (2) is fastened to the track roller frame and output shaft (1) is connected to the
drive sprocket. The ground drive motor is connected to the planetary group through the splined
shaft of the parking brake.
Power from the ground drive motor goes through input shaft (11) to sun gear (10). The sun gear
turns planet cluster gear (4). There are three planet cluster gears in planet carrier assembly (9).
The planet cluster gears are in mesh with ring gear (5) and internal gear (3).

The ring gear is fastened between hub (2) and cover (8) with bolts (12). The ring gear is held
stationary by the hub. Internal gear (3) is fastened to and turns output shaft (1).

The sun gear rotates the planet carrier around the ring gear and causes the internal gear and
output shaft to rotate. The final drive ratio is 25.43:1.

Brake
Ver imagen
Parking Brake
(1) Splined shaft. (2) Cover. (3) Primary disc. (4) Rotor disc. (5) Stator disc. (6) Assembly bolt. (7)
Spring plate. (8) Piston. (9) Pressure plate. (10) Pressure oil cavity. (11) Spring. (12) Tension bolt.

The parking brake is spring applied and is released by charge pressure.

Splined shaft (1) connects the ground drive motor to the planetary group. Rotor discs (4) are
fastened to the splined shaft. Primary disc (3) and stator disc (5) are fastened to piston (8) by four
tension bolts (12). There are six springs (11) that apply the brake.

When the brake is applied, the charge oil to pressure oil cavity (10) is blocked at the brake
solenoid valve and the pressure oil cavity is open to the hydraulic tank. Springs (11) push on piston
(8). Tension bolts (12) compress primary disc, rotor discs, and stator disc against spring plate (7).
With the discs compressed together, the splined shaft is locked to the brake housing and the shaft
will not turn.

When the brake is released, the passage to the hydraulic tank is closed and charge oil is routed to
pressure cavity (10) by the brake solenoid valve. The oil enters pressure oil cavity (10) and acts
against piston (8). The charge oil pressure overcomes the force of springs (11) and moves the
piston to the left and releases the parking brake.

Brake Valve
Ver imagen
Components Of Valve

(1) Solenoid assembly. (2) Manual actuator. (3) Coil. (4) Plunger. (5) Wire connector. (6) Valve
assembly. (7) Spool. (8) Bolt hole. (9) Port A. (10) Return passageway. (11) Supply passageway. (12)
Spring. (13) Piston port.

The brake valve consists of two major components: solenoid assembly (1) and valve assembly (6).
The solenoid assembly is made up of coil (3), plunger (4), and wire connector (5). The major
components of the valve assembly consists of spool (7) and spring (12). Spool (7) is attached to
plunger (4).

When the parking brake switch is in the ON position no current flows to coil (3) in the brake valve.
Spring (12) forces spool (7) and plunger (4) up. Charge oil in passageway (11) is routed to port A
(9). Port A of the brake valve is plugged.

Port B (not shown) is connected to the port on the parking brake by a hydraulic hose. When the
plunger is in the up position brake piston port (13) is open to return passageway (10). The springs
behind the parking brake piston force the oil back through the solenoid valve to tank.
When the parking brake switch is positioned in the OFF position current flows to coil (3). The
current flowing through coil (3) forces plunger (4) and spool (7) to overcome the tension of spring
(12) and move down. When the plunger is in this position parking brake piston port (13) is open to
supply passageway (11) and charge oil is routed to the parking brake piston.

Ground Drive System Operation

Ver imagen

Ground Drive System Schematic

(1) Closed loop line. (2) Left ground drive pump. (3) Combination valve. (4) Combination valve. (5)
Charge pump relief valve. (6) Charge pump. (7) Closed loop line. (8) Right ground drive pump. (9)
Filter. (10) Closed loop line. (11) Left ground drive motor. (12) Bleed valve. (13) Combination valve.
(14) Oil cooler. (15) Left parking brake. (16) Parking brake valve. (17) Right parking brake. (18)
Hose. (19) Combination valve. (20) Bleed valve. (21) Right ground drive motor. (22) Closed loop
line. (23) Hydraulic tank.

When the engine is running, ground drive pumps (2) and (8) are rotating. Charge pump (6) in the
right ground drive pump provides charge oil for the propulsion system. Oil is pulled from hydraulic
tank (23) through filter (9) to the charge pump. Charge oil pressure is maintained at 1450 kPa (210
psi) by charge relief valve (5) in the right ground drive pump.

Charge oil is used as make-up oil for pump and motor leakage, cooling for the pumps and motors,
and to release the parking brakes. Charge oil goes through the check valves in left side
combination valves (3) and (13), and right side combination valves (4) and (19) to closed loop lines
(1), (7), (10), and (22). The charge pump is a fixed displacement pump. Excess oil flow not needed
to make up for leakage must flow through charge relief valve (5). From the charge relief valve the
oil flows through pump and motor case drain circuits and oil cooler (14) to the hydraulic tank.

With the parking brake switch in the ON position, parking brake valve (16) is not energized and
charge oil is blocked. The springs in parking brakes (15) and (17) apply the parking brake.

When the parking brake switch is in the OFF position, parking brake valve (16) is energized and
charge oil goes to the parking brake. The oil pressure pushes on the piston in the parking brake
and compresses the springs. The parking brake is released.

The direction of the swashplate angle of ground drive pumps (2) and (8) determines whether the
systems is in FORWARD or REVERSE. The two drive pumps are controlled separately by manual
control levers. These control levers are connected to the pump swashplate levers with mechanical
linkage. When the system is in FORWARD direction, drive pumps (2) and (8) route high pressure oil
to combination valves (3) and (4), loop lines (1) and (7), and to drive motors (11) and (21). The high
pressure oil acts against the pistons inside the ground drive motors causing the output shafts to
rotate.

Oil from the charge pump enters low pressure loop lines (10) and (22) through the check valve in
combination valves (13) and (19).

Low pressure return oil from drive motors (11) and (21) flows back to drive pumps (2) and (8)
through loop lines (10) and (22) completing the closed circuit. Bleed valves (12) and (20) allow a
metered amount of oil to flow from the closed loop system to the case drain circuit for cooling
purposes.

When the system is in REVERSE direction, drive pumps (2) and (8) route high pressure oil to
combination valves (13) and (20), loop lines (10) and (22), and to drive motors (11) and (21). The
high pressure oil acts against the pistons inside the ground drive motors causing the output shafts
to rotate.

Oil from the charge pump enters low pressure loop lines (1) and (7) through the check valve in
combination valves (3) and (4).

Low pressure return oil from drive motors (11) and (21) flows back to drive pumps (2) and (8)
through loop lines (1) and (7) completing the closed circuit. Bleed valves (12) and (20) allow a
metered amount of oil to flow from the closed loop system to the case drain circuit for cooling
purposes.
Combination valves (3), (4), (13), and (19) each contain a relief valve, and charge check valve. The
relief valves limit maximum system pressure to 23 000 kPa (3350 psi). The combination valves are
identical. In each drive pump, one combination valve controls the system while the machine is in
FORWARD operation and the other combination valve controls the system while the machine is in
REVERSE operation.

Auxiliary System
System Overview

Ver imagen

Auxiliary System Schematic

(1) Left auger motor. (2) Right auger motor. (3) Hopper cylinder. (4) Screed lift cylinder. (5) Left
wing cylinder. (6) Right wing cylinder. (7) Left material door cylinder. (8) Right material door
cylinder. (9) Control valve bank. (10) Valve for left auger. (11) Valve for right auger. (12) Auger
relief valve. (13) Valve for hopper lift. (14) Valve for screed lift. (15) Valve for left wing extend. (16)
Valve for right wing extend. (17) Valve for left material door. (18) Valve for right material door.
(19) Cylinder relief valve. (20) Vibration motor. (21) Vibration selector valve. (22) Auxiliary tandem
gear pump. (23) Pump for vibration motor and cylinders. (24) Hydraulic tank. (25) Pump for auger
motors.

The auxiliary system is an open circuit hydraulic system. The main components of the auxiliary
system are hydraulic tank (24), auxiliary tandem pump (22), control valve bank (9), auger motors
(1) and (2), vibration motor (20), and cylinders (3 through 8).

Ver imagen

--------------------------------------------------------------------------------

Copyright 1993 - 2021 Caterpillar Inc.

Todos los derechos reservados.

Red privada para licenciados del SIS.

Fri Apr 23 09:12:24 EST 2021