Service Training MALAGA

Challenger 35 & 45

IV. IMPLEMENT SYSTEM

1. Components 2. Pump Operation and Control Valves 3. Testing & Adjusting
Sara MAY 1997

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HITCH VALVE

IMPLEMENT HYDRAULIC SYSTEM

TO STEERING PUMP CHARGE CIRCUIT HITCH RELIEF VALVE IMPLEMENT VALVES FILTER AND BYPASS VALVE TO PTO BEARING LUBE TANDEM CHARGE PUMP

IV III II I
ORIFICE

TO TRANSMISSION CHARGE CIRCUIT

CHAPTER : Implement System

CHALLENGER 35 & 45

INLET MANIFOLD

LOAD CHECK VALVES

QUICK COUPLERS = CYL. EXTEND = CYL. RETRACT

IMPLEMENT PUMP

DRIVE GEAR

STEERING PUMP

REGULATOR VALVE

SUCTION SCREEN

HITCH CYLINDERS COMMON SUMP

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IMPLEMENT VALVE BANK SIGNAL NETWORK

HOLD
HITCH PRIMARY RESOLVER SECONDARY RESOLVER

PRIMARY RESOLVER SECONDARY RESOLVER

IV

HITCH VALVE

FLOW CONTROL SPOOL SPRING CHAMBER III

CHAPTER : Implement System

IV
CHECK BALL IMPLEMENT VALVES

CHALLENGER 35 & 45

III

II

II
MAIN CONTROL VALVE SPOOL CHAMBER

I I
ORIFICE

SIGNAL TO PUMP COMPENSATOR VALVE RETURN OIL INLET OIL FROM PUMP

CHALLENGER 35 & 45
CHAPTER : Implement System

Resolver Network

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IV-3

II

III

IV

Hitch

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PUMP COMPENSATOR VALVE

SIGNAL FROM IMPLEMENT VALVE BANK FLOW COMPENSATOR (MARGIN) SPOOL

PRESSURE COMPENSATOR (CUTOFF) SPOOL

CHAPTER : Implement System

CHALLENGER 35 & 45

PUMP OUTPUT PRESSURE

ORIFICE CASE DRAIN

SIGNAL TO ACTUATOR PISTON

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NO SIGNAL

FLOW COMPENSATOR (MARGIN) SPOOL

PUMP OPERATION
MARGIN SPRING

ENGINE OFF

ACTUATOR PISTON

BIAS SPRING

CHAPTER : Implement System

CHALLENGER 35 & 45

PUMP OUTPUT DRIVE SHAFT PUMP INLET SWASHPLATE

PISTON AND BARREL ASSEMBLY

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IMPLEMENT CONTROL VALVE I

HOLD
SECONDARY RESOLVER PRIMARY RESOLVER DETENT PRESSURE LIMITER VALVE ORIFICE FLOW CONTROL SPOOL FLOW CONTROL METERING SLEEVE SIGNAL TO PUMP COMPENSATOR SIGNAL FROM PREVIOUS VALVE FROM PUMP

IV-6
DETENTS LOAD CHECK VALVE QUICK COUPLERS

TO VALVES ADJUSTABLE FLOW CONTROL ASSEMBLY

CHAPTER : Implement System

CHALLENGER 35 & 45

MAIN CONTROL VALVE SPOOL

"+" PORT

"-" PORT

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DETENT KICKOUT

IV-7

ADJUSTMENT SCREW ORIFICE DETENT PRESSURE LIMITER VALVE BALLS

CHAPTER : Implement System

CHALLENGER 35 & 45

MAIN CONTROL VALVE SPOOL PISTON DETENTS CENTERING SPRING

CHALLENGER 35 & 45
CHAPTER : Implement System

Machine Preparation
Two pressure taps are used when testing the implement hydraulic system. On the left side of the implement valve bank, remove the plug for power beyond from the inlet manifold (2). Install the 3K0360 Seal and 5P6944 Adapter, and the 3J1907 Seal and 6V3965 Quick Coupler (1) into the inlet manifold port.

1. Supply Pressure Tap 2. Inlet Manifold 3. Signal Pressure Tap

1 3

On the right side of the implement valve bank inlet manifold, a quick disconnect fitting (3) for signal pressure is provided in the signal line to the compensator valve. When testing the margin pressure and detent kickout pressures, the FT2220 Hose Assembly must be installed to provide a complete circuit. Install the hose assembly in the quick coupler RAISE (+) and LOWER () ports of the implement circuit to be tested.

Tests and adjustments for the implement hydraulic system include: Margin pressure test Low pressure standby test High pressure stall test Detent kickout pressure test

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CHALLENGER 35 & 45
CHAPTER : Implement System

TESTING & ADJUSTING

Margin Pressure Test

1. Install the FT2220 Hose Assembly in the raise and lower ports of one of the implement control valves. 2. Position the flow control adjustment for that valve at approximately half of the full flow position. 3. Connect the 1U5796 Differential Pressure Gauge across the two pressure taps. The system pressure tap is connected to the left (high pressure) side of the differential gauge and the signal pressure tap is connected to the right (low pressure) side of the differential gauge. Also connect a 0 to 40000 kPa (0 to 5800 psi) gauge to the tee on the left (high pressure) side of the differential pressure gauge. 4. Start and run the engine at high idle. Warm the oil to a minimum temperature of 60C (140F). 5. Pull the implement control lever (for the control valve with the FT2220 Hose Assembly) into the RAISE detent position. 6. Adjust the needle valve in the hose assembly until a pressure of 6900 to 10300 kPa (1000 to 1500 psi) is read on the gauge for system pressure. The reading on the differential pressure gauge should be approximately 1830 kPa (265 psi).

Check Low Pressure Standby before adjusting Margin Pressure

7. If the margin pressure is not correct, check low pressure standby.

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CHALLENGER 35 & 45
CHAPTER : Implement System

TESTING & ADJUSTING

Low Pressure Standby Test

1. Connect the 1U5796 Differential Pressure Gauge across the two pressure taps. The system pressure tap is connected to the left (high pressure) side of the differential gauge and the signal pressure tap is connected to the right (low pressure) side of the differential gauge. Also connect a 0 to 4000 kPa (0 to 580 psi) gauge to the tee on the left (high pressure) side of the differential pressure gauge. 2. Start and run the engine at high idle. Warm the oil to a minimum temperature of 60C (140F). 3. With all the control levers in the HOLD position, the differential pressure gauge should read approximately 2070 kPa (300 psi). Low pressure standby depends on margin pressure. Low pressure standby is approximately 240 kPa (35 psi) higher than margin pressure. This test can be used as a quick, approximate check of margin pressure if the FT2220 Hose Assembly is not available.

Low Pressure Standby Adjustment

4. If the low pressure standby is not correct, remove the protecting nut from the flow compensator (1). Loosen the locknut, and adjust the setscrew for the flow compensator spool. Turn the screw clockwise to increase low pressure standby and counterclockwise to decrease low pressure standby. Tighten the locknut. 5. If an adjustment is made, repeat the test to verify the new setting and check margin pressure too.

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CHALLENGER 35 & 45
CHAPTER : Implement System

TESTING & ADJUSTING

High Pressure Stall Test

1. Connect the 1U5796 Differential Pressure Gauge as for the margin pressure test or connect a 0 to 40000 kPa (0 to 5800 psi) gauge to the pressure tap for system pressure. 2. Start and run the engine at high idle. Warm the oil to a minimum temperature of 60C (140F). 3. Pull the implement control lever (for a control valve without the FT2220 Hose Assembly) into the RAISE detent position. Hold the lever in this position so the automatic kickout does not move the lever to the HOLD position. The reading on the system pressure gauge should be approximately 18950 345 kPa (2750 50 psi).

Pressure Compensator Adjustment

4. If the pressure at high pressure stall is not correct, remove the protecting nut from the pressure compensator (2). Loosen the locknut, and adjust the setscrew for the pressure compensator spool. Turn the screw clockwise to increase pressure and counterclockwise to decrease pressure. Tighten the locknut. 5. If an adjustment is made, repeat the test from Step 2 to verify the new setting.

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CHALLENGER 35 & 45
CHAPTER : Implement System

TESTING & ADJUSTING

Detent Kickout Pressure Test

Each control valve must be checked separately for the correct kickout pressure. Before testing the control valve kickout pressures, rotate each flow control counterclockwise to the full flow position. 1. Install the FT2220 Hose Assembly in the quick couplers for implement control valve I. Fully open the needle valve. 2. Install a 0 to 40000 kPa (0 to 5800 psi) gauge on the pressure tap for signal pressure (see slide No. 41). 3. Start and run the engine at high idle. Warm the oil to a minimum temperature of 60C (140F). 4. Pull the implement control lever I (the circuit with the FT2220 Hose Assembly) into the RAISE detent position. Slowly close the needle valve on the FT2220 Hose Assembly while watching the pressure gauge. As the needle valve is closed, the pressure on the gauge will increase. At approximately 15500 kPa (2250 psi), the pressure should drop immediately to zero as the control lever kicks out of the RAISE detent and returns to the HOLD position. 5. Repeat the procedure for each implement circuit.

Detent Pressure Limiter Valve Adjustment

6. If the detent kickout pressure for a circuit is not correct, loosen the locknut, and turn the adjustment screw for the detent pressure limiter valve. Turn the screw clockwise to increase the pressure and counterclockwise to decrease the pressure. Tighten the locknut. 7. If an adjustment is made, repeat the test from Step 3 to verify the new setting.

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