Specifications Systems Operation Testing and Adjusting_ CS-531D, CP-533D and CS-533D Vibratory...

CS-531D, CP-533D and CS-533D Vibratory Compactors Vibratory System AFC1-Up (Machine) AGH1 -Up (Machine) AET1-Up (Machine) 4MZ1-Up (Machine) 5CZ1-Up (Machine) 6AZ1-Up (Machine)

KENR3526 May 2000

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

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The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

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Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

WARNING

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Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

3 Table of Contents

Table of Contents

Specifications Section

Hydraulic Tank 4 Hydraulic Oil Filter 5 Manifold Valve and Mounting 6 Piston Pump 7 Support and Vibratory Drive 8 Piston Motor 9 Vibratory Support 10 Drum 12 Eccentric Weight 14

Systems Operation Section

General Information 15 Vibratory Hydraulic System 17 Piston Pump 23 Piston Motor 32 Manifold Valve 33 Drum 34

Testing and Adjusting Section

Troubleshooting Machine Preparation for Troubleshooting 37 Visual Inspection 38 Vibratory System Troubleshooting 39

Testing and Adjusting Hydraulic Oil Contamination - Test 42 Piston Pump Flow - Test 42 Relief Valve (Charge) - Test and Adjust 43 Relief Valve (Piston Pump) - Test and Adjust 45 Hydraulic Control Neutral (Piston Pump) - Test and Adjust 49

Piston Pump Servo Neutral - Test and Adjust 50 Case Drain Flow for Piston Motor - Test and Adjust 51

Vibratory Frequency - Test and Adjust 52 Variable Frequency Electrical Control - Test and Adjust (If Equipped) 56

Vibratory Tachometer - Adjust 61 Vibratory Magnetic Sensor - Test and Adjust 62

Index Section

Index 64

4 Specifications Section

Specifications Section 101193458

Hydraulic Tank SMCS Code: 5056

Part No.: 144-7266

Illustration 1 g0065i537

Capacity 80 L (21.1 US gal) (6) Torque for temperature sender 75 ± 7 N.m (55 ± 5 lb ft)

(1) Inlet screen Plastic nylon mesh screen 23.5 x 23.5

(2) Torque for breather valve 90 ± 9 N.m

(66± 6 lb ft)

(3) Torque for elbow .. 220 ± 22 N-m (162 ± 16 lb ft)

(4) Suction screen 200 x 200 stainless steel pleated wire mesh

Torque for suction screen (4) 220 ± 22 N.m (162 ± 16 lb ft)

(5) Suction screen 200 x 200 stainless steel pleated wire mesh

Torque for suction screen (5) 175 ± 17 N.m (129 ± 12 lb ft)

Hydraulic Oil Filter SMCS Code: 5068

Part No.: 133-5343

Illustration 2

(1) The oil filter bypass indicator will become red when the filter pressure differential becomes the following value 172 ± 35 kPa (25 ± 5 psi)

(2) The oil filter bypass valve will open when the filter pressure differential becomes the following value 345 ± 35 kPa (50 ± 5 psi)

(3) Torque for the hydraulic oil filter .. 44 ± 3.5 N-m (32.5 ± 2.6 lb ft)

Note: The alternative torque for the hydraulic oil filter is 3/4 turn.


101338151

Manifold Valve and Mounting SMCS Code: 3206; 5074

Part No.: 124-5185, 148-5612

Illustrations g00562380

(1) Torque for thermal bypass valve .. 48 to 54 N-m (8) Main loop (35 to 40 lb ft)

(9) Oil cooler Thermal bypass valve (1) begins to close when the temperature of the hydraulic oil reaches 65 ºC (10) Hydraulic tank (150 ºF).

(11) Oil filter bypass return port Thermal bypass valve (1) is fully closed when the temperature of the hydraulic oil reaches 71 ºC (12) Diameter of internal orifice 0.81 mm (160 °F). ' (.032 inch)

Apply 4C-5599 Anti-Seize Compound to the threads of the thermal bypass valve.

(2) Manifold return passage

(3) Axle drive pump

(4) Vibratory pump

(5) Drum motor

(6) Vibratory motor

(7) Scheduled oil sampling


Piston Pump SMCS Code: 5070; 5652

Part No.: 159-9453, 159-9454

i01346365

Illustration 4

Rotation from the drive end clockwise

(1) Type of pump variable displacement pump

Displacement 39 cc/rev (2.38 cu in/rev)

Charge pump internal 8.4 cc (.51 in3)

(2) High pressure relief valves 35000 kPa (5076 psi)

(3) Charge pressure relief valve 2950 kPa (428 psi)

Note: The charge pressure is measured at the charge filter.

(4) Drive shaft spline "SAE B-B", "15t-16/32P"

Use 6V-4876 Lubricant on splines.

(5) Solenoid for the fixed frequency pump control 21.7 ± 2.0 ohms

Solenoid for the variable frequency pump control 24.6 ± 2.0 ohms

g00403650

Note: Use SAE 10W hydraulic oil for the bench test. Oil temperature must be a minimum of 38°C (100°F).

Test At Full Speed

Output 84.9 L/min (22.1 US gpm)

Output pressure 690 kPa (100 psi)

Pump speed 2200 rpm

Engine speed 2200 rpm



Pump speed 2200 rpm


Test At Half Speed




Pump speed 1100 rpm




Pump speed 1100 rpm


i01346990

Support and Vibratory Drive SMCS Code: 6605; 6606

Part No.: 136-9744

Illustration 5

(1) Apply 9S-3263 Thread Lock Compound to the threads on the mounting bolts at assembly,

(2) The capacity for the support housing 1 L (1 qt)

(3) The oil filler plug

(4) The oil drain port

/ 9

Specifications Section

Piston Motor SMCS Code: 5058; 5651

Part No.: 136-8869

Illustration 6 g00468822

Note: Motor rotation can be clockwise or counterclockwise. Rotation depends on the direction of oil flow in the closed circuit loop line.

Type of motor piston

Fixed displacement 45 cc (2.75 in3)

Case pressure (normal) 379 kPa (55 psi)

Case pressure (maximum at cold start) .. 1000 kPa (145 psi)

(1) Torque for four bolts 69 to 84 N.m

(51 to 62 lb ft)

(2) Shaft spline 15T, 16/32P

(3) Motor charge relief valve (flushing) .... 1600 kPa

(232 psi)

Nominal distance of shim pack .. 6.5 mm (0.26 inch)

Flushing flow 5 L/min (1.3 us gpm)


Vibratory Support SMCS Code: 5656

Part No.: 159-9405

Illustration 7

Components of the Drum Support

(1) Seal. (2) Boot. (3) Bearing cone. (4) Bearing cone. (5) Washer. (6) Lockwasher tang. (7) Locknut. (8) Spindle. (9) Hub. (10) Bearing cup. (11) Bearing cup. (12) Pipe plug. (13) Spacer.

Tightening Procedure for the Spanner Nut 1. Install the seal boot (2) and the bearing cups

(10) and (11) onto the hub (9).

2. Install the bearing cone (3) into the cup (10). Position the seal spring toward the bearing cone. Install lip type seal (1). Ensure that the lip type seal is flush with the end of the hub. The seal spring must be located to the inside of the hub.


Note: The bearing should be clean and dry of all lubrication oil. The rolling torque reading will be affected if oil is on bearing assembly.

3. Rest the spindle on the flange end. Lower the hub (9) carefully onto the spindle shaft. Ensure that the bearing cone (3) contacts the shoulder of the spindle. Squeeze the small end of the bearing cone. Press the cone onto the shaft.

4. Measure the rolling torque of the assembly. This is the initial value.

5. Press the bearing cone (4) onto the spindle (8) with a slight play of the bearing. The bearing end play should measure .08 to .13 mm (0.003 to .005 inch).

6. Press the inboard cone (4) until the rolling torque increases 1.13 to 1.70 N-m (10 to 15 lb in). This torque should be higher than the torque that was measured in step (4). If the increase of the torque is greater than 1.13 to 1.70 N-m (10 to 15 lb in), then tap the back of the spindle to back off the cone.

7. Apply 4C-9507 Retaining Compound to the locknut (7). Install the washer (5), the lock washer (6), and the locknut (7).

8. Tighten locknut (7) to 375 N-m (277 lb ft). Rolling the locknut will seat the bearings. The assembly should have no end play. Check the rolling torque. The torque must increase 1.13 to 4.52 N-m (10 to 40 lb in) more than the rolling torque measurement in step (4). This will result in a bearing preload of .025 to .050 mm (0.001 to .002 inch).

9. Tap the end of the spindle and check the rolling torque again. If the rolling torque reading is different, tighten the locknut (7) again.

10. Bend the tanged washer (6) into the slot on the locknut. Check the tab on the washer. The tab must align with the locknut. Tighten the tab with the locknut in order to align.

11. Install the pipe plug (12) and apply 9S-3263 Thread Lock Compound.

12. Install the spacer (13) and the O-ring.


Drum SMCS Code: 5622; 6605

Part No.: 139-2035, 139-2036 PIN: AFC1-Up

Part No.: 147-2364 PIN: AGH1-Up

Part No.: 139-2035, 139-2036 PIN: AET1-Up

Part No.: 147-2364 PIN: 4MZ1-Up

Part No.: 139-2035, 139-2036 PIN: 5CZ1-Up

Part No.: 139-2035, 139-2036 PIN: 6AZ1-Up

Illustration 8

(1) Apply 4C-9507 Retaining Compound to the bolt threads at assembly.

(2) Apply 6V-4876 Lubricant to splines. In the cavity of the shaft, add 50 mL of 6V-4876 Lubricant. The "T" symbols must be aligned vertically for proper shaft alignment.

(3) Apply 4C-9507 Retaining Compound to the bolt threads at assembly.

(4) Notched end for housing orientation

(5) Oil fill/drain plug

(6) Oil level plug

(7) Place the drum in the above position. This position is required in order to fill the reservoir.

(8) Apply 4C-9507 Retaining Compound to threads.

(9) Plug for the drum cooling oil.. 21 L (5.5 US gal)

Torque for the plug 90 ± 15 N.m (66 ± 11 lb ft)


Eccentric Weight SMCS Code: 6606; 6645

Part No.: 140-8267

Illustration 9

(1) Apply 9S-3263 Thread Lock Compound to the bolt threads at assembly.

(2) Torque for the plug ... 100 ± 5 N-m (74 ± 4 lb ft)

(3) Apply 9S-3263 Thread Lock Compound to the bolt threads at assembly.

(4) Torque for the plug 100 ± 15 N-m

(74 ± 11 lb ft)

The weight of the shot must total 8.5 kg (18.7 lb).

(5) Torque for the two plugs 90 ± 15 N-m (66 ± 11 lb ft)

Note: In order to fill the reservoir, the position of the fill/drain plug must be located at the top of the rotation.

(6) Rotate the lobe of the weight downward. Orient the "T" upward on the splined shaft. The total shaft end play should be .50 mm (0.02 inch) to1.35 mm (0.05 inch). The assembled housing should be capable of holding 70 kPa (10 psi) static air pressure and 35 kPa (5 psi) static vacuum.

Note: Flush the eccentric weight housing after assembly. A level of "ISO 19/16" or less is required.

15 Systems Operation Section

Systems Operation Section

101348848

General Information SMCS Code: 1400; 5050; 6606

Illustration 10 90 0 4 2 1 0 6 3

Vibratory System Schematic

(I) Vibratory pump. (2) Directional control valve. (3) High pressure relief valves (two valves). (4) Oil filter (vibratory charge pressure ). (5) Flushing relief valve. (6) Vibratory motor. (7) Vibratory charge pump. (8) Hydraulic servo. (9) Charge pressure relief valve. (10) Flushing valve. (11) Oil strainer. (12) Hydraulic oil tank. (13) Hydraulic oil cooler. (14) Thermal bypass valve.

The vibratory system consists of the following components: vibratory pump (1), oil filter (4), vibratory motor (6), hydraulic oil tank (12), hydraulic oil cooler (13), and bypass valve (14).

The charge oil for the vibratory system is supplied by the charge pump (7). Charge pump (7) is a gerotor type pump that is integral to the vibratory pump (1).

Two vibratory systems are available:

• The variable frequency system is an option for the machine.

The adjustment of the pump swashplate angle is the only change between the two vibratory systems.

Note: The throttle switch has two sets of contacts. The throttle switch must be in the high position for the vibration to work.

• The dual amplitude system is a standard for the machine.


Illustration 11

Right Side Of Engine

(1) Vibratory pump.

Vibratory pump (1) is a variable displacement axial piston design. The vibratory pump is mounted in-line with the two propel pumps. The three pumps are driven by the engine in a clockwise direction.

Note: The CS-531D does not have a drum propel pump.

Illustration 13 9 ° 0 6 1 4 1 9 3

Left Side Of Machine

(4) Oil filter. (16) Pressure switch.

Oil filter (4) is dedicated to the vibratory circuit. Oil from the charge pump flows through the oil filter before entering the vibratory circuit.

The pressure switch (16) will activate the alarm and the indicator light when the pressure is below 1200 kPa (174 psi). The indicator light is located on the steering console.


Right Side Area Of Drum

(6) Vibratory motor. (15) Drum support bearing housing.

Vibratory motor (6) is located on the right side of the drum, mounted to a drum support housing (15). Vibratory motor (6) is a fixed displacement axial piston motor. The flushing valve is built in the motor. A change in the direction of the oil flow to the vibratory motor changes the direction of the vibratory shaft. The change of direction in the vibratory shaft will change the vibratory amplitude.

Illustration 14 9 0 0 6 1 4 2 0 4

Right Side Of Machine

(12) Hydraulic oil tank.

Hydraulic oil tank (12) is accessible when the hood for the engine enclosure is in the raised position.


} Vibratory Hydraulic System SMCS Code: 6606

Vibratory System

OFF

)

Illustration 15 900453821

Vibratory System Circuit (Vibratory System OFF)

(1) Vibratory pump. (2) Directional control valve. (3) Charge pressure line. (4) Oil filter (vibratory charge pressure ). (5) Flushing relief valve. (6) Vibratory motor. (7) Orifices. (8) High pressure relief valve. (9) High pressure relief valve. (10) Charge pressure relief valve. (11) Charge pump. (12) Closed circuit loop line. (13) Line. (14) Pilot passage. (15) Hydraulic oil strainer. (16) Hydraulic oil tank. (17) Closed circuit loop line. (18) Flushing valve. (19) Pilot passage. (20) Lines to the return manifold (three). (21) Oil cooler. (A) Solenoid. (B) Solenoid.

>

The vibratory control switch is located on top of the propel control lever. When this switch is placed in the OFF position or the vibratory switch is placed in the OFF position, the control valve (2) is not energized. The vibratory system is not activated. The closed circuit loop lines (12) and (17) will fill with charge oil. Control valve (2) and the flushing valve (18) are in the center position.

The control valve (2) is held in the center position by the two centering springs inside the valve. Control valve (2) blocks pressurized control oil from flowing to the servo piston assembly in pump (1). The swashplate is held at zero angle (neutral position). There is no flow of oil from pump (1) to the motor (6) in this position.


Charge oil is supplied by the charge pump (11). Charge pump (11) is an internal gerotor pump, which is integral to the pump (1). Charge oil flows to charge filter (4) through line (13). Charge oil flows through charge filter (4) before entering the vibratory circuit. The filtered oil enters the vibratory circuit through the charge pressure line (3).

Charge oil fills the closed circuit loop lines (12) and (17) across the makeup function of high pressure relief valves (8) and (9). The charge pressure in both closed circuit loop lines (12) and (17) is equal when the vibratory system is off.

Charge oil flows through pilot oil passages (14) and (19). The spool is held in neutral by the springs. Oil flow is blocked to the flushing relief valve (5).

The charge pressure oil is controlled by the leakage of the closed loop and the charge relief valve (10). Charge pressure is measured after the charge filter. Charge pressure (neutral) is 3000 ± 150 kPa (435 ± 22 psi). Refer to the Testing and Adjusting module for the testing procedures.

When the vibratory system is not active, excess charge oil passes through pump (1). The return oil flows into the return manifold through the lines (20).

Return oil and normal internal leakage oil from both the propel and the vibratory circuits flow to the return manifold. The thermal bypass valve is integral to the return manifold. The thermal bypass valve directs the return oil through the oil cooler or the thermal bypass valve directs the oil to the hydraulic oil tank (16). This is dependent on oil temperature.

• The thermal bypass valve allows 13 L/min (4 us gpm) of hydraulic oil to flow through the oil cooler at temperatures that are below 65°C (149°F). The remainder of the oil flows to the hydraulic oil tank (16).

• The thermal bypass valve begins to direct some hydraulic oil to the oil cooler above to 65°C (149°F). The remainder of the oil flows to the hydraulic oil tank (16).

• The thermal bypass valve directs all of the hydraulic oil to the oil cooler at 70°C (158°F).


Vibratory System

HIGH AMPLITUDE

Illustration 16 9 ° 0 4 5 5 7 8 6

Vibratory system (HIGH AMPLITUDE)

(1) Vibratory pump. (2) Directional control valve. (3) Charge pressure line. (4) Oil filter (vibratory charge pressure ). (5) Flushing relief valve. (6) Vibratory motor. (7) Orifices. (8) High pressure relief valve. (9) High pressure relief valve. (10) Charge pressure relief valve. (11) Charge pump. (12) Closed circuit loop line. (13) Line. (14) Pilot passage. (15) Hydraulic oil strainer. (16) Hydraulic oil tank. (17) Closed circuit loop line. (18) Hushing valve. (19) Pilot passage. (20) Lines to the return manifold (three). (21) Oil cooler. (A) Solenoid. (B) Solenoid.

Charge pressure oil flows through passage (3) to the directional control valve (2) when the engine is operating.

The solenoid coil (B) on the control valve (2) receives an electrical current when the following conditions occur:

• The vibratory control switch which is located on the propel lever is in the ON position.

• HIGH AMPLITUDE has been activated. The switch for high amplitude is located on the vibratory amplitude control . The vibratory amplitude control is located on the operator control console.

• The propel speed range control is in the low speed position.

The electrical current to solenoid (B) causes the spool in the directional controi valve (2) to shift to the position in the above illustration. This allows control oil from passage (3) to be directed to the proper side of the servo in pump (1). The control oil moves the swashplate to the maximum angle for high amplitude. Orifices (7) control the oil flow to the pump servo for smooth movement of the swashplate.

• Engine speed is high.


Hydraulic oil from the pump (1) flows through the closed circuit loop line (12) to motor (6). The high pressure side and the low pressure side of the closed circuit loop lines (12) and (17) are shown in illustration 16. The oil flows to the motor and the motor becomes the high pressure side of the closed circuit. Resistance of the motor to the flow will create high pressure. The high pressure oil drives motor (6).

Low pressure oil from the motor (6) flows back to the pump (1) through line (17). Line (17) will become the low pressure side of the closed circuit.

The high pressure relief valve (9) will limit the maximum working pressure of the closed circuit loop line (12) to 35000 kPa (5076 psi) above the low pressure. When the system pressure in line (12) becomes greater than the high pressure relief valve setting, oil will dump into the closed circuit loop line (17). The closed circuit loop line (17) is the low pressure side of the closed circuit. The high pressure oil will dump into the closed circuit loop line (17). This will relieve the high pressure side of the closed circuit.

When the oil pressure in the closed circuit loop line (17) drops below pressure of the charge circuit oil, the charge circuit will replenish the closed circuit with makeup oil. The closed circuit is replenished across the makeup function of the high pressure relief valve (9). The charge circuit oil replenishes loss from both the flushing valve (18) and from the internal leakage of pump (1).

The high pressure oil from the closed circuit loop line (12) will flow through the pilot oil passage (14). This will shift the shuttle spool inside the flushing valve (18). This position is shown in illustration 16. Low pressure oil from the closed circuit loop line (17) flows through the flushing valve (18) to the flushing relief valve (5). Low pressure oil dumps over the flushing relief valve (5) to the flush motor (6). Flushing relief valve (5) is set lower than the relief pressure of the charge relief valve (10) in pump (1). This allows the motor to be flushed with the low pressure oil during vibratory system operation.

The return oil from pump (1) and motor (6) flow through line (20) to the return manifold. The thermal bypass valve is integral to the return manifold. The thermal bypass valve will direct the return oil through the oil cooler. The thermal bypass valve will also direct the return oil to the hydraulic oil tank (16). This depends on oil temperature.

• The thermal bypass valve allows 13 L/min (4 us gpm) of hydraulic oil to flow through the oil cooler at temperatures that are below 65°C (149°F). The remainder of the oil flows to the hydraulic oil tank (16).

• The thermal bypass valve begins to direct some hydraulic oil to the oil cooler at temperatures above 65°C (149°F). The remainder of the oil flows to the hydraulic oil tank (16).

• The thermal bypass valve directs all of the hydraulic oil to the oil cooler at 70 ºC (158ºF).


Vibratory System

LOW AMPLITUDE

Illustration 17 9 0 0 4 5 6 5 5 2

Vibratory system (LOW AMPLITUDE)

(1) Vibratory pump. (2) Directional control valve. (3) Charge pressure line. (4) Oil filter (vibratory charge pressure ). (5) Flushing relief valve. (6) Vibratory motor. (7) Orifices. (8) High pressure relief valve. (9) High pressure relief valve. (10) Charge pressure relief valve. (11) Charge pump. (12) Closed circuit loop line. (13) Line. (14) Pilot passage. (15) Hydraulic oil strainer. (16) Hydraulic oil tank. (17) Closed circuit loop line. (18) Flushing valve. (19) Pilot passage. (20) Lines to the return manifold (three). (21) Oil cooler. (A) Solenoid. (B) Solenoid.

Charge pressure oil flows through passage (3) to the directional control valve (2) when the engine is operating.

The solenoid coil (A) on the control valve (2) receives an electrical current when the following conditions occur:

• The vibratory control switch which is located on the propel lever is in the ON position.

• LOW AMPLITUDE has been activated. Low amplitude is located on the vibratory amplitude control. The vibratory amplitude control is located on the operator control console.

• The propel high/low switch is in low range. The machine will not vibrate in high speed.

The electrical current to solenoid (A) causes the spool in the directional control valve (2) to shift to the position in illustration 17. This allows control oil from passage (3) to be directed to the proper side of the servo in pump (1). The control oil moves the swashplate to the maximum angle for high amplitude. Orifices (7) control the oil flow to the pump servo for smooth movement of the swashplate.

• Engine speed is high enough to close the vibratory lockout switch.


Hydraulic oil from the pump (1) flows through the closed circuit loop line (17) to motor (6). The high pressure side and the low pressure side of the closed circuit loop lines (12) and (17) are shown in illustration 17. The oil flows to the motor and the motor becomes the high pressure side of the closed circuit. Resistance of the motor to the flow will create high pressure. The high pressure oil drives motor (6).

Low pressure oil from the motor (6) flows back to the pump (1) through line (12). Line (12) will become the low pressure side of the closed circuit.

The high pressure relief valve (8) will limit the maximum working pressure of the closed circuit loop line (17) to 35000 kPa (5076 psi) above the low pressure. When the system pressure in line (17) becomes greater than the high pressure relief valve setting, oil will dump into the closed circuit loop line (12). The closed circuit loop line (12) is the low pressure side of the closed circuit. The high pressure oil will dump into the closed circuit loop line (12). This will relieve the high pressure side of the closed circuit.

The high pressure oil from the closed circuit loop line (17) will flow through the pilot oil passage (19). This will shift the shuttle spool inside the flushing valve (18). This position is shown in illustration 17. Low pressure oil from the closed circuit loop line (17) flows through the flushing valve (18) to the flushing relief valve (5). Low pressure oil dumps over the flushing relief valve (5) to the flush motor (6). Flushing relief valve (5) is set lower than the relief pressure of the charge relief valve (10) in pump (1). This allows the motor to be flushed with the low pressure oil during vibratory system operation.

The return oil from pump (1) and motor (6) flow to the return manifold through lines (20). The thermal bypass valve is integral to the return manifold. The thermal bypass valve will direct the return oil through the oil cooler. The thermal bypass valve will also direct the return oil to the hydraulic oil tank (16). This depends on oil temperature,

• The thermal bypass valve allows 13 L/min (4 us gpm) of hydraulic oil to flow through the oil cooler at temperatures that are below 65ºC (149ºF). The remainder of the oil flows to the hydraulic oil tank (16).

• The thermal bypass valve begins to direct some hydraulic oil to the oil cooler at temperatures above 65°C (149°F). The remainder of the oil flows to the hydraulic oil tank (16).

When the oil pressure in the closed circuit loop line (17) drops below pressure of the charge circuit oil, the charge circuit will replenish the closed circuit with makeup oil. The closed circuit is replenished across the makeup function of the high pressure relief valve (9). The charge circuit oil replenishes loss from both the flushing valve (18) and from the internal leakage of pump (1).

• The thermal bypass valve directs all of the hydraulic oil to the oil cooler at 70°C (158ºF).


Piston Pump SMCS Code: 5070; 5652

Part No.: 159-9453, 159-9454

Illustration 18 9 ° 0 4 6 0 4 0 9

Vibratory Pump

(1) Shaft. (2) Servo housing. (3) Servo piston. (4) Barrel. (5) Housing. (6) Control valve. (7) Port plate. (8) Swashplate. (9) Spring assembly. (10) Piston (one of nine). (11) Main passage. (12) Main passage. (13) Passage for charge oil. (14) Vibratory charge pump (Internal gear pump). (15) Head. (16) Charge relief valve (one of two).


When the engine is running, the shaft (1) and the barrel (4) are rotating. There are nine pistons (10) in barrel (4). The port plate (7) and the swashplate (8) are held by the housing (5). The port plate (7) and the swashplate (8) do not rotate. The spring assembly (9) keeps a force on the barrel (4) in order to make a high pressure seal between the barrel (4) and the port plate (7). When barrel (4) is rotating, each piston (10) follows the angle of the swashplate. If the swashplate angle is at zero, the pistons do not move in and out of the barrel and there will be no flow. The charge oil from the internal charge pump (14) maintains oil pressure in the pump in order to keep the barrel full of oil. The charge oil lubricates the pump components. The charge oil compensates for the normal internal loss of oil due to leakage.

The position of the swashplate (8) is controlled by the control valve (6) and the servo piston (3). The control valve (6) receives an electrical signal from the vibratory on/off control and this causes the servo piston (3) to move. The control valve (6) routes the control oil in order to move the servo piston (3). The servo piston (3) controls the angle of the swashplate (8).

Note: If the machine is equipped with the variable frequency system, the control valve receives the electrical signal by way of-the variable vibration control knob. Refer to Variable Frequency Electrical Control for more information.

Oil flows from the pump to the vibratory motor and back to the main passage (12). The position of the swashplate (8) determines the direction of flow of the two main passages (11) and (12).

Illustration 19

Swashplate and Barrel Assembly

(1) Shaft. (4) Cylinder barrel. (7) Port plate. (8) Swashplate. (9) Spring. (10) Piston

The maximum position of the swashplate (8) is shown in illustration 19. As the pistons (10) follow the swashplate the pistons move in and out of the barrel (4). As the pistons (10) move out of the cylinder, oil is supplied behind the pistons. This oil is supplied under pressure from the charge circuit through passage (13). Oil is pushed ahead of the pistons (10) and this oil goes through the outlet passages of the port plate (7). Oil will exit the pump through the main loop (11). The surfaces of the port plate (7) and the barrel (4) are spherical in shape. The inlet oil and the outlet oil are sealed from each Other by a metal-to-metal seal. The seal is located between the spherical faces of the port plate (7) and the cylinder barrel (4).


Main Relief Valve


Spring Assembly

(4) Cylinder barrel. (9) Spring. (17) Cup. (18) Shim.

Spring (9) and shims (18) are held in place on the swashplate (8) by the cup (17). Spring force holds the face of the barrel (4) against the port plate (7) and the head (15).

The length of the stroke of pistons (10) is changed when the swashplate (8) is rotated about the axis. In a neutral position, the piston stroke is ±15° and the oil delivery is zero. When the piston is at a maximum inclination, the stroke is at the maximum.

The main relief valve (1) is a cartridge type valve The main relief valve provides two functions for the vibratory circuit.

• The main relief valve limits the pressure.

• The main relief valve acts as a makeup valve for the main loop circuit.

The maximum pressure of each loop line of the closed circuit is limited by the main relief valves to 35000 kPa (5076 psi). The pressure is above the low pressure side of the main loop circuit.

Main Relief Function

Illustration 21

Relief Valve Cross Section

(1) Main relief valve. (2) Locking cap. (3) Conical spring. (4) Collar. (5) Spindle. (6) Spring. (7) Collar.


Oil from the vibratory pump flows through the relief valve (1) at the passages (A). High pressure oil enters passage (A) and the oil acts on the collars (4) and (7). The force of spring (6) keeps the valve closed until the oil pressure in the high pressure side of the main loop circuit reaches relief pressure. After the relief pressure is reached, the pressure moves the spindle (5) downward while the pressure compresses the spring (6). The relief oil flows from the high pressure side to the low pressure side of the main loop. The oil flows through the gap between the spindle (5) and the collar (7). The arrows show this flow in illustration 21. High pressure oil enters the low pressure side of the main loop circuit until the force of the spring (6) seats the spindle (5) and the collar (7).

Make Up Function


Relief Valve Cross Section

(2) Locking cap. (3) Conical spring. (4) Collar. (5) Spindle. (6) Spring. (7) Collar.

Oil from the vibratory pump flows through the relief valve (1) at the passages (A). The force of the spring (3) and the oil pressure in passage (A) keep the collar (7) closed. Charge pressure acts on the bottom of collar (7) and the spindle (5). When the oil pressure in passage (A) drops below the charge pressure, collar (7) and the spindle (5) move upward compressing the spring (3).

The charge oil flows through the gap. The closed loop circuit will be replenished with the makeup oil. The arrows show this flow in illustration 22. Charge oil continues to replenish the low pressure side of the circuit with the make up oil until the pressure in passage (A) becomes greater than the charge pressure.


Solenoid Valve

Illustration 23 9 ° 0 4 6 0 0 1

Servo

(1) Springs. (2) Solenoid. (3) Valve spool. (4) Solenoid.

The control valve is attached to the vibratory pump. The valve is a three-position solenoid. The valve is a four-way directional control valve. The solenoid control valve directs oil to the servo circuit of the vibratory pump.

When current is supplied to either solenoid (2) or (4), the solenoid moves the valve spool (3). The controlled oil passes across the valve spool (3). The oil exits the passage to the hydraulic servo.

When the vibratory circuit is not activated, current flow to the solenoid (2) or (4) is interrupted. The force of the springs (1) moves the valve spool (3) to the center position. The force of each spring (1) is identical. The springs (1) balance each other. The springs also maintain the center position of the valve spool (3).


Servo Piston Assembly

Illustration 24 9 0 0 5 6 5 4 2 2

Section View Of The Vibratory Pump

(1) Shaft. (2) Bearing. (3) Pump housing. (4) Swashplate. (5) Joint pin. (6) Servo housing. (7) Servo piston. (8) Barrel. (9) Solenoid valve.

Illustration 25 9 ° 0 5 6 5 4 4 6

Section View Of The Servo Piston

(6) Servo housing. (7) Servo piston. (10) Springs (centering). (11) Piston rod. (12) Stroke limiter screw. (13) Locknut.

The servo control assembly controls the swashplate angle (4) of the vibratory pump. The servo housing (6) is an integral part of the vibratory pump. The servo housing (6) contains the servo piston (7).

The charge circuit supplies control oil to the control valve (9) on the vibratory pump. The control valve (9) regulates the servo piston (7) by directing the oil flow which enters the servo housing (6). The control valve (9) also acts on the servo piston (7). Linear movement of the servo piston (7) mechanically controls the rotational movement of the swashplate (4) with the joint pin (5). When the servo piston (7) moves, the angle of the swashplate (4) changes in the pump.

The flow of the pump output is zero when the swashplate angle is zero. The swashplate angle is zero when the servo piston (7) is in the center position. The servo piston (7) will return to the center position when the control valve (9) is not energized. The servo piston (7) is mechanically centered by the springs (10). The center position of the servo piston (7) can be adjusted by loosening the locknut (13) and turning the piston rod (11).

The pump flow is controlled by the servo piston (7). The maximum pump output is determined when the swashplate (4) is at the maximum angle. The maximum swashplate angle is controlled by limiting the travel of the servo piston (7). Adjust the stroke limiter screw (12) in order to control the travel of the servo piston. There are two stroke limiter screws. The screws determine the direction of travel for the servo piston (7). The stroke limiter screws (12) are located on each end of the servo housing (6). The stroke limiter screws (12) are used when you set the VPM in high amplitude and in low amplitude.

Variable Frequency Electrical Control (If Equipped)


Control Console

(1) Vibratory ON/OFF control. (2) Vibratory amplitude control. (3) Variable vibration control knob.


The variable vibratory system is an option. The functions of the vibratory ON/OFF control (1) and the vibratory amplitude control (2) are identical to the dual amplitude system.

Illustration 27

Control Console

(4) Variable frequency controller.



Variable Frequency Controller Potentiometers


(5) Ramp time potentiometer.

(6)" P5" Low amplitude-minimum frequency potentiometer.

(7) Ramp time potentiometer.

(8)" P6" High amplitude-minimum frequency potentiometer.

(9)" P3" Low amplitude-maximum frequency potentiometer.

(10)" P4" High amplitude-maximum frequency potentiometer.

The main differences between the variable frequency system and the dual amplitude system are the variable frequency controller (4) and the rheostat.

Variable vibration control knob (3) is connected to the rheostat. The rheostat controls the hydraulic system for the drum vibration. The rheostat will vary the amperage to the control valve on the vibratory pump.

"P1" and "P2" ramp time potentiometers (5) and (7) control the amount of time so that the pump control can receive the correct amount of amperage. The ramp time potentiometers allow the amperage to increase from zero to the maximum amperage in two seconds.

Place the vibratory amplitude control (2) in the LOW AMPLITUDE position and turn the variable vibration control knob (3) to a full counterclockwise position. The position enables the "P5" potentiometer (6) to control the amperage to the pump control. The position enables the "P5" potentiometer (6) to maintain the lower limit of vibration per minute (VPM) at 1400 ± 50 VPM.

The nominal amperage for the P5' low amplitude-minimum frequency potentiometer (6) is 450 mA.

Place the vibratory amplitude control (2) in the HIGH AMPLITUDE position and turn the variable vibration control knob (3) to a full counterclockwise position. The position enables the "P6" potentiometer (8) to control the amperage to the pump control. The position enables the "P6" potentiometer (8) to maintain the lower limit of vibration per minute (VPM) at 1400 ± 50 VPM.

The nominal amperage for the "P6" high amplitude-minimum frequency potentiometer (8) is 450 mA.

Place the vibratory amplitude control (2) in the LOW AMPLITUDE position and turn the variable vibration control knob (3) to a full clockwise position. The position enables the 'V3'" potentiometer (9) to control the amperage to the pump control. The position enables the "P3" potentiometer (9) to maintain the upper limit of vibration per minute (VPM) at 1965 ± 50 VPM.

The nominal amperage for the "P3" low amplitude-maximum frequency potentiometer (9) is 520 mA.

Place the vibratory amplitude control (2) in the HIGH AMPLITUDE position and turn the variable vibration control knob (3) to a full clockwise position. The position enables the "P4" potentiometer (10) to control the amperage to the pump control. The position enables the ":P4" potentiometer (10) to maintain the upper limit of vibration per minute (VPM) at 1965 ± 50 VPM.

The nominal amperage for the "P4" high amplitude-maximum frequency potentiometer (10) is 520 mA.


i01158199

Piston Motor SMCS Code: 5058; 5651

Part No.: 136-8869


Vibratory Motor Components

(1) End Cap. (2) Port plate. (3) Cylinder block. (4) Piston. (5) Shaft. (6) Flushing shuttle spool. (7) Shim. (8) Flushing relief valve. (9) Fixed swashplate. (10) Housing.

The vibratory motor is a fixed displacement hydraulic motor. Oil flows to the motor and from the motor through hoses attached to the end cap (1).

High pressure oil from the pump enters the motor through the end cap (1). The oil will pass through the port plate (2) and the oil will act on the piston (4). Piston (4) is one of seven pistons in the assembly of the cylinder block (3).

As the pistons react to the high pressure oil, the cylinder block (3) and the pistons (4) rotate as an assembly. The cylinder block (3) is splined to the shaft (5). Rotating torque is transferred to the shaft (5). The displacement of the motor is controlled by the angle of the fixed swashplate (9). The nonadjustable swashplate angle is machined into the motor housing (10).


Case Flushing

Illustration 31 9 ° 0 4 6 2 1 1 9

Hydraulic Schematic For The Motor

(8) Flushing relief valve. (10) Motor housing. (11) Flushing shuttle valve. (12) Line (drain to return manifold). (13) Pilot passages. (14) Loop lines.

Lubrication for the internal moving parts is done with the normal internal leakage oil. The case flushing and the cooling of the pump and the motor is accomplished by the flushing circuit.

The flushing circuit oil is supplied by the charge circuit. The flushing of the vibratory pump is continuous. Case flushing of the motor occurs during the pump stroke.

Oil enters the motor and oil exits the motor (10) through the loop lines (14). The pilot oil from the loop lines (14) flows to both ends of the shuttle spool (6). The flow is through the pilot oil passages (13). The high pressure side of the circuit shifts the shuttle spool (6). The shift of the shuttle spool allows the low pressure oil of the loop lines (14) to flow through the flushing relief valve (8). The oil flushes the motor housing (10) and flows to the return manifold through line (12). The thermal bypass valve directs the oil through the oil cooler or to the hydraulic tank. The temperature of the oil will determine the direction of the oil.

The charge pump supplies approximately 20 L/min (5.3 US gpm). The charge pump replenishes normal leakage oil. The remaining charge oil will dump in one of two places:

• The relief valve

• Flow through the flushing valve

In order to flush the motor housing, the flow rate of the oil in the flushing relief valve (8) must be 4.9 L/min (1.3 US gpm).

Manifold Valve SMCS Code: 5074; 5264

Part No.: 124-5185 PIN: AFC1-Up


Part No.: 124-5185 PIN: AET1-Up


Part No.: 124-5185 PIN: 5CZ1-Up

Part No.: 124-5185 PIN: 6AZ1-Up


Return Valve

(1) Thermal Bypass Valve. (2) Return Manifold.

Thermal bypass valve (1) is integral to return manifold (2). The return valve directs the case drain oil and the return oil to either the tank or the hydraulic oil cooler.


Return Manifold Returning oil from the propel system, the vibratory system, and the steering system flows to the return manifold (2).

Thermal Bypass Valve


Thermal Bypass Valve

(3) Cap. (4) Piston. (5) Actuator spring. (6) Pressure relief spring. (7) Valve.

Thermal bypass valve (1) is a cartridge type valve. The thermal bypass valve controls the amount of return oil through the oil cooler. Oil flow through the oil cooler is dependent on oil temperature.

When the hydraulic oil temperature reaches 65ºC (149°F), additional oil is directed through the oil cooler. As the temperature of the oil rises, the bypass valve closes farther. Total oil flow to the cooler is approximately 50 L/min (13 US gpm) when the temperature of the oil reaches 71°C (160°F).

Drum SMCS Code: 5622; 6605

Part No.: 139-2035, 139-2036 PIN: AFC1-Up


Part No.: 139-2035, 139-2036 PIN: AET1-Up


Part No.: 139-2035, 139-2036 PIN: 5CZ1-Up

Part No.: 139-2035, 139-2036 PIN: 6AZ1-Up

When the hydraulic oil temperature is below 65ºC (149°F) the thermal bypass valve directs charge flow to the tank.


Illustration 35

Vibratory Drum Assembly

(1) Eccentric weight. (2) Eccentric weight. (3) Drive Shaft. (4) Vibratory motor. (5) Coupling shaft. (6) Vibratory Support.

Vibratory action for the machine occurs at the drum assembly. Drive shaft (3) is connected to the vibratory motor (4). Eccentric weights (1) and (2) are connected by the coupling shaft (5).

The vibratory motor will cause the drive shaft (3), eccentric weight (2), coupling shaft (5), and eccentric weight (1) to rotate when the operator has moved the vibratory system to the ON position. The rotation of the eccentric weights creates the desired vibratory action of the drum assembly.



Eccentric Weight Cross Section (High Amplitude)

(7) Steel shot.

Eccentric weights (1) and (2) are partially filled with steel shot (7). When the vibratory switch is placed in the HIGH AMPLITUDE mode, the eccentric weights rotate in one direction. The steel shot is captured in one area of the weight compartment, as shown above.

The weight of the steel shot in this position increase the fixed eccentricity of the weights. The drum assembly will then vibrate in the HIGH AMPLITUDE mode.


Eccentric Weight Cross Section (Low Amplitude)

(7) Steel shot.

When the vibratory switch is placed in the LOW AMPLITUDE mode, the eccentric weights rotate in the opposite direction. This causes the steel shot (7) to be captured in the opposite area of the weight compartment, as shown above.

The weight of the steel shot in this position offsets the fixed eccentricity of the weights. This causes the drum assembly to vibrate in the LOW AMPLITUDE mode.

37 Testing and Adjusting Section


Troubleshooting

Machine Preparation for Troubleshooting SMCS Code: 6606-035

Refer to the following warnings for all inspections and tests of the vibratory system. If the source of the problem is not determined, perform the inspections and tests. Perform the inspections and tests in sequential order. For all tests, the vibratory system oil must be at normal operating temperature.

WARNING

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows before testing and adjusting the vibratory system.

WARNING

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, 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.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Move the machine to a smooth, horizontal location that is away from operating machines and away from personnel.

Note: Permit only one operator on the machine. Keep all other personnel away from the machine or in the operator's sight.

2. Engage the parking brake. Place blocks around the wheels and around the drum.

3. Lower the leveling blade to the ground.

4. Stop the engine.

5. Make sure that all of the hydraulic pressure is released before any of the hydraulic components are altered.

During a diagnosis of the hydraulic system, remember that correct oil flow and pressure are necessary for correct operation. The output of the pump (oil flow) increases with an increase in engine speed (rpm) and decreases when engine speed (rpm) is decreased. Oil pressure is caused by resistance to the flow of oil.

The 4C-4892 ORFS Fittings Group can be used to make pressure tests on the vibratory system. Before any tests are made, visually inspect the complete hydraulic system for leakage of oil and for parts that are damaged. For some of the tests, a magnet and a measuring rule are usable tools.

When any test is made of the vibratory system, the hydraulic oil must be at the normal temperature for operation.

Troubleshooting can be complex. A list of some of the possible problems and corrections are on the following pages.


This list of possible problems and possible corrections will only provide an indication of the location of a problem and the repairs that are required. Remember that a problem is not necessarily caused by one part, but by the relation of one part with other parts. This list can not provide all possible problems and corrections. Service personnel must find the problem and the source of the problem. Then, complete the necessary repairs.

Perform a visual inspection first. If the visual checks are completed but the problem has not been identified, perform operational checks. If the problem is not understood, perform instrument tests. This procedure will help to identify vibratory system problems.

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.


100913403

Visual Inspection SMCS Code: 6606-035; 6606-040

WARNING

Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

WARNING




Perform visual checks first when you are troubleshooting a problem. Before you make these checks, stop the engine and apply the parking brake. Shift the propel control lever to the NEUTRAL position. During these checks, use a magnet to separate ferrous particles (iron) from nonferrous particles (O-ring seals, aluminum, bronze, etc), if necessary.

1. Check the oil level of the hydraulic oil tank.

2. Look for air bubbles in the oil or water in the oil immediately after the machine is stopped. Use a clear bottle or a container in order to get a sample of the oil. Refer to Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities" for the recommended oil grade and the recommended oil viscosity.

a. Air bubbles may be caused by a fitting that is loose or damaged. A loose fitting or damaged fitting allows air to enter the suction side of the system and oil is also allowed to leak.

3. Check all oil lines, all hoses, and all connections for damage and for leaks. Look for oil on the ground under the machine.

Note: If oil can leak out of a fitting or out of a connection, air can leak into the system. Air in the system is as harmful as having too little oil.


Vibratory System Troubleshooting SMCS Code: 6606-035

WARNING

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.

WARNING







Operational Checks

Note: Operate the machine in each direction and in all speeds. Note the noises that are not normal and find the sources of the noises. If the machine is not operating correctly, refer to the list of problems and probable causes below.

Probable Causes of Vibratory System Problems

Problem

The vibration system does not work in high amplitude or low amplitude.

Probable causes

• The speed range switch is in the HIGH range.

Note: Some machines may be wired in order to disable the vibratory system when the speed range switch is in the HIGH range.

• Fuse failure.

Note: On machines that are equipped with the variable frequency system, an additional 4 amp fuse is located on the control card which is located in the control console.

• The vibratory on/off control on the propel control lever has failed.

• The amplitude selector on the control console has failed.

• The electrical circuit has a fault.

• The alternator has failed.

• Low charge oil pressure.

• The solenoid valve on the vibratory pump has failed.

• The optional variable frequency dial has failed.

• Mechanical failure of the vibrator mechanism

Problem

Low charge oil pressure.

Probable Cause

• There is a low oil level in the hydraulic tank.

• The hydraulic filter element is restricted.

• There is excessive case leakage in the pump and/or the motor.

• The gerotor charge pump has failed.

• The relief valve adjustment on the charge pump is not correct.

Problem


There is periodic loss of vibration in HIGH range or LOW range.

Probable Cause

• There is a loose connection in the electric circuit wiring.

• The control card for the variable frequency is faulty.

• The vibratory on/off control is faulty.

• The vibratory amplitude selector is faulty.

Problem

The engagement of vibration system is harsh.

Probable Cause

• The diameter of the flow control orifice is too large.

• The relief valve for the charge circuit is set too high.

Problem

Slow stopping of the vibratory frequency.

Probable Cause

• The swashplate and/or the servo piston is sticking.

• The diameter of the flow control orifice is too small or the orifice is plugged.

• The main relief valve does not close completely on the return side circuit.

Problem

The compactor will not reach maximum vibration frequency.

Probable Cause

• The frequency gauge is not correctly adjusted or the gauge is faulty.

• Engine high idle is not correctly adjusted.

• The adjustment of the stop in the pump servo is not correct.

• The oil level in the eccentric weight housing is too high.

• The high pressure relief valves are set too low.

• Low charge pressure.

• The high pressure relief valve is worn or the valve has not seated properly.

• The shuttle valve in the vibratory motor is sticking.

• The O-rings in the servo piston assembly have failed.

Problem

The vibratory mechanism is noisy.

Probable Cause

• The lubrication oil in the vibrator housing is low.

• Loose retaining bolts for the piston motor.

• The vibrator shaft bearings have failed.

Problem

The hydraulic oil in the circuit overheats.

Probable Cause

• The hydraulic cooler and/or the radiator is restricted.

• Low charge pressure.

• The thermal bypass valve is faulty.

• The main relief valve is open.

• An incorrect type of oil is used in the hydraulic system.

Vibratory Electrical Circuit

The vibratory system is engaged by pressing the ON/OFF control switch (button) on the propel control lever. The vibratory system does not operate unless the control switch for the throttle is in the HIGH position and the speed range switch is in the LOW position.

Problem

The Vibratory system does not engage.

Probable Cause

• The vibratory fuse is open.

• Vibratory ON/OFF control has failed in the open position.

• The speed range switch has failed.

• The switch for the throttle control has failed.

• The switch for the vibratory amplitude control has failed.

• The vibratory control solenoid has failed.

• An open circuit exists in the harness for the vibratory system.

• The pump servo piston is not stroking.


Testing and Adjusting

100913678

Hydraulic Oil Contamination -Test SMCS Code: 5050-008

WARNING

Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

WARNING




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.


Use the following procedure in order to determine the contamination of the oil in the hydraulic systerr

1. Check the hydraulic filter element for foreign materials.

a. Bronze colored particles give an indication c" pump or motor port plate failure.

b. Shiny steel particles give an indication of pump or motor piston failure.

c. Rubber particles indicate a seal failure or a hose failure.

d. Aluminum particles give an indication of steering and/or charge pump failure.

Note: If any of these particles are found in the hydraulic filter element, all components of the hydraulic oil system must be cleaned. Do not use any damaged parts. Any damaged parts must be removed and new parts must be installed.

101079"-::;

Piston Pump Flow - Test SMCS Code: 5652-032-ON; 5652-032-TB

This test is designed to determine whether a pumc is operating within design parameters.

For any pump test, the pump flow at 690 kPa (100 psi) will be larger than the pump flow at 6900 kPa (1000 psi) if the pump is operating at the same rpm. The pump flow is measured in L/min (US gpm).

The difference between the pump flow of two operating pressures is the flow loss.

Table 1

Method of determining flow loss:

Pump flow at 690 kPa (100 psi)

- Pump flow at 6900 kPa (1000 psi)

Flow loss

If the oil becomes contaminated, premature component failure could result. Contaminated oil can also contribute to overheating.


Table 2

Example of determining flow loss:

217.6 L/min (57.5 US gpm)

- 196.8 L/min (52.0 US gpm)

20.8 L/min (5.5 US gpm)

Flow loss that is expressed as a percentage of pump flow is used as a measure of pump performance.

Table 3

If the percent of flow loss is greater than 10%, the pump performance is inadequate.

Note: The values in the examples are not set values for any specific pump or for any specific pump condition. See the Specification for your machine for the pump flow of a new pump at 690 kPa (100 psi) and at 6900 kPa (1000 psi).

Machine Test Install a flow meter. Run the engine at high idle. Measure the pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Use these values in the following formula.

Table 5

Relief Valve (Charge) - Test and Adjust SMCS Code: 5117-025-PX; 5117-081 -PX

Table 7

Required Tools

Part Number

4C-6500

4C-4892

9U-7400

Description

Digital Thermometer

ORFS Fittings Group

Multitach

Qty

1

1

1

WARNING




If the bench test can be performed at 6900 kPa (1000 psi) and at full pump rpm, determine the percent of flow loss by using the above formula.

Method of determining perct

Flow loss (L/min or US gpm)

Pump flow at 690 kPa (100 psi)

snt of flow loss

x 100 = Percent of flow loss

Table 4

If the bench test cannot be performed at 6900 kPa (1000 psi) or at full pump rpm, run the pump shaft at 1000 rpm. Measure the pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Use these values in the top portion of the following formula. For the bottom part of the formula, run the pump shaft at 2000 rpm. Measure the pump flow at 690 kPa (100 psi).

Table 6




Dispose of ail fluids according to local regulations and mandates.

NOTICE To avoid damage to the vibratory system during testing, always perform the testing with the vibratory drum on top of tires or on loose dirt. Tires will simulate a non-compacted soil condition.

Never operate the vibratory system when the machine is on concrete.

NOTICE If a testing time longer than three (3) minutes is required, rotate the drum periodically in order to lubricate the eccentric weight shaft bearings.

Note: The hydraulic oil temperature should be at least 38°C (100ºF).

Note: Two separate charge pressures are measured during this test. The following procedure measures the charge pressure after the charge filter, when the propel control lever is in the STOP position and when the vibratory system is OFF. The second pressure measures the charge pressure after the charge filter, when the propel control lever is in the STOP position and when the vibratory system is ON.

Vibratory System OFF

1. Stop the machine and apply the parking brake.

Illustration 38 9 0 0 4 6 0 6 8 7

Left Side of Machine

(1) Charge pressure test port. (2) Charge filter.

2. Install a 4134 kPa (600 psi) pressure gauge at the charge pressure test port (1) which is located after vibratory charge filter (2).

3. Install the multitach in order to measure the engine rpm.

4. lnstall-4C-6500 Digital Thermometer into the hydraulic oil tank.

5. Start the machine and run the machine at high idle (2350 ± 50 RPM) until the hydraulic oil temperature reaches 38°C (100ºF).

6. Read the charge pressure at pressure test port (1). Charge pressure (NEUTRAL) should be 2950 ± 150 kPa (428 ± 22 psi).

Illustration 39 9 ° 0 4 6 0 7 3 4

Vibratory Pump

(3) Screw For The Adjustment Of The Charge Pressure.

7. To increase the charge pressure in NEUTRAL, add shims to the relief valve. Remove shims from the relief valve in order to decrease the charge pressure.


Note: Determine the condition of the charge filter before any adjustments are made. This affects the charge pressure. Nominal stack height of the shims for the charge relief valve is 3.04 mm (.120 inch).

8. Once Step 7 is complete, tighten the locknut to a torque of 50 ± 5 N.m (37 ± 4 lb ft).

9. Recheck the charge pressure. Once the vibratory charge pressure is correct, proceed to "Vibratory System ON.

Vibratory System ON

Illustration 40 • Q00610458

Control Console

(4) Amplitude selector.

1. Place the amplitude selector (4) in the LOW AMPLITUDE position.

2. With the engine at high idle (2350 ± 50 RPM), activate the vibratory system. Observe the vibratory charge pressure at pressure test port (1). The vibratory charge pressure should be 130 ± 70 kPa (19 ± 10 psi) lower than the normal operating pressure that was measured in "Vibratory System OFF".

3. Place the amplitude selector (4) in the HIGH AMPLITUDE position. Repeat Step 2 again. The charge pressure should have the same value. This step verifies the movement of the spool in the flushing valve.

Note: The vibratory charge pressure is controlled by the flushing valve which is located in the motor. If the charge pressure at test port (1) does not decrease from the pressure that was recorded in "Vibratory System OFF", a problem may exist with the flushing valve and/or the adjustment of the charge relief valve. The vibratory charge pressure should be 130 ± 70 kPa (19 + 10 psi) lower than the pressure that was recorded in "Vibratory System OFF". If the pressure decreases too much, excessive case leakage may exist or the flushing valve may be improperly shimmed. The nominal stack height of the shims should be 6.5 mm (0.26 inch). The Testing and Adjusting Vibratory Motor Case Drain Flow -Test and Adjust should be performed if the charge pressure is too low.

4. Stop the vibratory system and stop the engine. Remove all tooling.

Relief Valve (Piston Pump) -Test and Adjust SMCS Code: 3203-025-PV; 3203-081-PV;

5070-025-PV; 5070-081-PV

Table 8

Part Number

4C-6500

4C-4892

9U-7400

Required Tools

Description

Digital Thermometer

ORFS Fittings Group

Multitach

WARNING

Qty

1

1

1











Note: The hydraulic oil temperature should be at least 38ºC (10ºF).

>• ' ,y*. A&*SS»V^

2. Connect a 60000 kPa (8700 psi) pressure gauge to relief valve test port (1).

Illustration 42

Control Console

(2) Vibratory amplitude control. (3) Vibratory ON/OFF control.

3. Move amplitude selector (2) to the HIGH AMPLITUDE position.

4. Install the Multitach in order to measure engine rpm. Install 4C-6500 Digital Thermometer into the hydraulic oil tank. Start the machine and run the machine at high idle (2350 ± 50 RPM) until the hydraulic oil temperature reaches 38°C (TOOT).

5. Look at the gauge and depress vibratory control switch (3) to the ON position in order to start the vibratory system.

Note: The force that is needed to overcome the inertia of the weights causes the pressure in the vibration system to momentarily reach the high amplitude relief valve setting. Look at the gauge and turn on the vibration system. The highest reading on the gauge is the high amplitude relief valve setting.

6. The high amplitude relief valve setting should be 35000 ± 3000 kPa (5076 ± 435 psi).

Illustration 41

Vibratory Pump

(1) Test port.

High Amplitude 1. Make sure that the parking brake is applied.

Ensure that the propel control lever is in the STOP position.



Vibratory Pump

(4) High amplitude relief valve.

7. If the high amplitude relief valve setting is not correct, high amplitude relief valve (4) must be adjusted.

f. Use a 5 mm wrench and adjust the pressure by turning spindle (5). Turn the spindle clockwise in order to increase the pressure. Turn the spindle counterclockwise in order to decrease the pressure. One full rotation of spindle (5) equals 4400 kPa (638 psi).

g. Tighten lock screw(7).

h. Remove the high pressure relief valve from the vise.

i. Reinstall the high pressure relief valve cartridge. Install the cap of high pressure relief valve (4) and torque to specifications.

9. Repeat Step 5.

10. Stop the engine.

Note: After five minutes of operation, when the drum is on tires, the vibratory operating pressure should decrease to a maximum of 10340 kPa (1500 psi). If continued high pressure is observed, a problem may exist with the vibratory drive mechanism.

Low Amplitude


Relief Valve Cartridge

(5) Spindle. (6) Collar. (7) Lock screw.

8. Adjust high amplitude relief valve (4) in the following steps:

a. Stop the engine.

b. Remove the cap of high amplitude relief valve (4).

c. Remove the high pressure relief valve cartridge. Install the cap of high pressure relief valve (4). This will ensure that the oil does not leak while adjustments are made to the cartridge and the spring.

d. Hold the high pressure relief valve cartridge in a bench vise. Secure the high pressure relief valve cartridge by clamping on collar (6).

e. Loosen lock screw (7) with a 3 mm Allen wrench.

Illustration 45

Vibratory Pump

(8) Test port.

1. Make sure that the parking brake is applied. Ensure that the propel control lever is in the STOP position.

2. Connect a 60000 kPa (8700 psi) pressure gauge to relief valve test port (8).


7. If the low amplitude relief valve setting is not correct, low amplitude relief valve (9) must be adjusted.


Control Console

(2) Vibratory amplitude control. (3) Vibratory ON/OFF control.

3. Move vibratory amplitude control (2) to the LOW AMPLITUDE position.

4. Install the Multitach in order to measure the engine rpm. Install 4C-6500 Digital Thermometer into the hydraulic oil tank. Start the machine and run the machine at high idle (2350 ± 50 RPM) until the hydraulic oil temperature reaches 38°C (100°F).

5. Look at the gauge and depress vibratory on/off control (3) to the ON position in order to start the vibratory system.

Note: The force that is needed to overcome the inertia of the weights causes the pressure in the vibration system to momentarily reach the low amplitude relief valve setting. Look at the gauge and turn on the vibration system. The highest reading on the gauge is the low amplitude relief valve setting.

6. The low amplitude relief valve setting should be 35000 ± 3000 kPa (5076 ± 435 psi).

Illustration 48 9 ° 0 4 6 1 6 5 5

Relief Valve Cartridge

(5) Spindle. (6) Collar. (7) Lock screw.

8. Adjust low amplitude relief valve (9) in the following steps:

a. Stop the engine.

b. Remove the cap of high amplitude relief valve (4).

c. Remove the high pressure relief valve cartridge. Install the cap of high pressure relief valve (4). This will prevent oil leakage while adjustments are made to the cartridge and the spring.

d. Hold the high pressure relief valve cartridge in a bench vise. Secure the high pressure relief valve cartridge by clamping on collar (6).

e. Loosen lock screw (7) with a 3 mm Allen wrench.

'"•«'-:J•iKjt^',

* I

Illustration 47

Vibratory Pump

(9) Low amplitude relief valve.

f. Use a 5 mm wrench and adjust the pressure by turning spindle (5). Turn the spindle clockwise in order to increase the pressure. Turn the spindle counterclockwise in order to decrease the pressure. One full rotation of spindle (5) equals 4400 kPa (638 psi).

g. Tighten lock screw (7).

h. Remove the high pressure relief valve from the vise.

i. Reinstall the high pressure relief valve cartridge. Install the cap of high pressure relief valve (4) and torque to specifications.

9. Repeat Step 5.


10. Stop the engine.

Note: After five minutes of operation, when the drum is on tires, the vibratory operating pressure should decrease to a maximum of 10340 kPa (1500 psi). If continued high pressure is observed, a problem may exist with the vibratory drive mechanism.

i01349669

Hydraulic Control Neutral (Piston Pump) - Test and Adjust SMCS Code: 5050-081: 5051-025; 5070-025-V4;

5070-081-V4

Variable Frequency Table 9

1. Make sure that the parking brake is applied. Make sure that the propel control lever is in neutral.

Required Tools

Part Number Description

8T-0855(1) Pressure Gauge

(1) Part of 4C-4892 ORFS Fittings Group

WARNING

Qty

2







Illustration 49

Vibratory Pump

(1) Servo ports. (2) Adjustment screw. (3) Pump control.

2. Remove the plugs from servo ports (1).

3. Assemble the two 8T-0855 Pressure Gauges. Install the proper fittings from 4C-4892 ORFS Fittings Group. Install the two pressure gauges at servo ports (1).

4. Start the engine and run the engine at 1200 rpm.

5. Read the pressure on the two pressure gauges. If the pressures are not identical, the pump control must be adjusted.

Note: Adjustment screw (2) is an eccentric adjuster. One half of a revolution of the adjustment screw gives all the adjustment that is possible. A small amount of movement of the adjustment screw (2) makes a large pressure change.

6. To adjust the pump control, loosen the locknut and turn adjustment screw (2) in either direction in order to attain equal pressures on the two pressure gauges. When the pressures are equal, hold the adjustment screw and tighten the locknut.

7. Stop the engine. Remove the two pressure gauges from servo ports (1), and install the two plugs.

Note: Perform the Pump Servo Neutral - Adjust before doing this test. The position of the servo piston will affect the pressure readings that are obtained from the adjustment of the eccentric screw.


Piston Pump Servo Neutral Test and Adjust SMCS Code: 5070-025-SJ; 5070-081-SJ

Fixed Frequency and Variable Frequency Table 10

Required Tools

Part Number

6V-7830

6V-8628

4J-5477

3J-7354

9X2348

9X-3757

Description

Tetragauge

Elbow

O-Ring Seal

O-Ring Seal

Hose

Coupling

Qty

2

2

2

2

36 inches

2

WARNING Personal injury or death can result from sudden machine movement.






Note: Perform the Charge Relief Valve - Test and Adjust and the Main Relief Valve - Test and Adjust before conducting the Piston Pump Servo Neutral - Test and Adjust.

Illustration 50

Vibratory Pump

(1) Servo. (2) Servo Ports. (3) Locknut. (4) Servo valve neutral adjustment screw. (5) Main relief valve test ports.

1. Make sure that the parking brake is applied. Make sure that the propel control lever is in neutral.

2. Disconnect the electrical connection for the vibratory pump control.

3. Remove the plugs from servo ports (2). Install the 3J-7354 O-Ring Seals on the 6V-8628 Elbows. Install the elbows in servo ports (2), and install the 4J-5477 O-Ring Seals in the elbows.

4. Fabricate a hose assembly by using the 9X-2348 Hose and 9X-3757 Coupling . Connect the hose assembly between the elbows that were installed in the servo ports.

5. Install the two 6V-7830 Tetragauges on the main relief valve test ports (5).

6. Start and run the engine at high idle.

7. Read pressure readings on the two 6V-7830 Tetragauges. The pressure readings should be identical.

8. If the pressure readings are not identical, loosen locknut (3) so that the neutral position of the servo piston may be adjusted. Use an alien wrench in order to turn servo valve neutral adjustment screw (4). Turn the screw clockwise or counterclockwise in order to adjust the mechanical center of the servo valve. The pressures on the two 6V-7830 Tetragauges should change. Turn servo valve neutral adjustment screw (4) until the pressure readings on main relief valve test ports are identical. Tighten locknut (3).

9. Stop the engine. Remove the two 6V-7830 Tetragauges.


10. Remove the hose assembly and the elbows that connect servo ports (2), and install the two plugs.

Case Drain Flow for Piston Motor - Test and Adjust SMCS Code: 5058-025-FW; 5058-081-FW

Table 11

Part Number

4C-8689

8C-6874

6V-8942

6V-8556

7X-1449

7X-1447

9X-2350

4C-6500

Required Tools

Description

Flow Meter

Adapter

Adapter

Nut

Orifice Coupling

Orifice Coupling

Hose

Digital Thermometer

WARNING

Qty

1

2

2

2

1

1

36 Inches

1










Note: The hydraulic oil temperature should be at least 38°C (100ºF).

1. Make sure that the parking brake is applied. Make sure that the propel control lever is in neutral. Make sure that the vibratory on/off control on the propel control lever is in the OFF position.

Illustration 51 9 0 0 4 6 2 7 7 2

End of Drum

(1) Vibratory motor. (2) Drain line. (3) Flushing valve.

2. Disconnect drain line (2) from vibratory motor (1).

3. Install 90 cm (36 inch)of 9X-2350 Hose and 4C-8689 Flow Meter (5) Between vibratory motor (1) and drain line (2).

4. Install 4C-6500 Digital Thermometer into the hydraulic oil tank.

5. Move the vibratory amplitude control to the LOW AMPLITUDE position.

6. Start the engine and run the machine at high idle until the hydraulic oil temperature reaches 38°C (100°F). Engine speed should be 2350 ± 50 rpm.

7. When the vibratory system is off and when the machine is at high idle, read the amount of oil flow that passes through the flow meter. The flow should be less than 3.8 L/min (1 US gpm).


8. Depress the vibratory on/off control to the ON position in order to start the vibratory system. The flow should be at a minimum of 5.0 L/min (1.3 US gpm) to a maximum 8.8 L/min (2.3 US gpm).

9. Depress the vibratory on/off control to the OFF position in order to stop the vibration system. Stop the engine.

10. Move the vibratory amplitude control to the HIGH AMPLITUDE position.

11. Repeat Steps 7 through 9.

12. If the flow is not within 5.0 L/min (1.3 US gpm) to a maximum8.8 L/min (2.3 US gpm), the size of the orifice in the flushing valve may need to be changed. The diameter of the orifice should be 1.9 mm (0.075 inch). If the flow from the vibratory motor cannot be adjusted correctly, the vibratory motor should be repaired or replaced.

13. Remove all test tooling and reconnect line (2) to motor (1).

Vibratory Frequency - Test and Adjust SMCS Code: 6606-025; 6606-081

Table 12

Required Tools

Part Number

133-9905

133-0963

4C-6500

Description

Frequency Meter

Drum Vibration Tachometer

Digital Thermometer

Qty

1

1

1

WARNING







Fixed Frequency

High Amplitude

Note: The hydraulic oil temperature should be at least 38ºC (100°F).

Illustration 52

Control Console

(1) Vibratory on/off control switch. (2) Vibratory amplitude control. (3) Variable vibration control knob.


2. Move vibratory amplitude control (2) to the HIGH AMPLITUDE position.

3. Start the engine and run the engine at high idle. Engine speed should be 2350 ± 50 rpm.

\ 53


4. Depress vibratory on/off control switch (1) to the ON position in order to start the vibratory system. Record the vibrations per minute (VPM) from the optional gauge on the steering console. The vibrations per minute may be read from 133-0963 Vibration Tachometeror the 133-9905 Frequency Meter. The maximum VPM setting for high amplitude for the CS-533D and the CP-533D should be 1965 ± 50 VPM. The maximum VPM setting for high amplitude for the CS-531D should be 1965 ± 50 VPM.

Note: Verify the accuracy of the optional gauge on the control panel. Refer to Testing and Adjusting, "Vibratory Tachometer - Adjust".

5. Depress the vibratory on/off control to the OFF position in order to stop the vibratory system.

Illustration 53 Q00457313

Frequency Adjustment

(4) High amplitude adjustment screw. (5) Vibratory pump.

6. If the frequency is not correct, adjust high amplitude adjustment screw (4) on pump (5). Loosen the locknut on the adjustment screw (4). Turn high amplitude adjustment screw counterclockwise in order to increase maximum VPM. Turn the adjustment screw clockwise in order to decrease maximum VPM.

Low Amplitude

1. Move vibratory amplitude control (2) to the LOW AMPLITUDE position.

2. Depress vibratory on/off control switch (1) to the ON position in order to start the vibratory system. Read the vibrations per minute (VPM) from optional VPM gauge or read the VPM from the 133-0963 Vibration Tachometer or the 133-9905 Frequency Meter. The maximum VPM for low amplitude is 1965 ± 50 VPM.

Illustration 54 Q00457394

Frequency Adjustment

(6) Vibratory pump. (7) Low amplitude adjustment screw.

3. If the frequency is not correct, adjust low amplitude adjustment screw (7). Loosen the locknut on the adjustment screw (7). Turn adjustment screw counterclockwise in order to increase maximum VPM. Turn adjustment screw clockwise in order to decrease maximum VPM.

4. Depress vibratory on/off control switch (1) to the OFF position in order to stop the vibratory system.

Variable Frequency

High Amplitude (Minimum Frequency)

1. Use the 4C-6500 Digital Thermometer in order to verify that the hydraulic oil temperature is at least 38°C (100ºF).

2. Position the drum on tires.

3. Apply the parking brake and place the propel control lever in the STOP position.

4. Run the engine at high idle. The engine rpm should be 2350 ± 50 rpm.

5. Place the vibratory amplitude control (2) in the HIGH AMPLITUDE position.


Illustration 55

Control Console

(1) Vibratory on/off control switch . (2) Vibratory amplitude control. (3) Variable vibration control knob.

6. Turn variable vibration control knob (3) to the full counterclockwise position.

7. Depress vibratory on/off control switch (1) in order to start the vibratory system. Read the vibrations per minute (VPM) from optional VPM gauge or read the VPM from the 133-0963 Vibration Tachometer or the 133-9905 Frequency Meter. The minimum frequency for high amplitude should be 1400 ± 50 VPM.

Illustration 56

Control Console


g00457488

Illustration 57

Variable Frequency Controller

(8) Variable frequency controller. (9)"P5" Low amplitude-minimum frequency potentiometer. (10) "P6" High amplitude-minimum frequency potentiometer. (11) "P3" Low amplitude-maximum frequency potentiometer. (12) "P4" High amplitude-maximum frequency potentiometer.

8. Depress the vibratory on/off control switch in order to shut off the vibratory system.

Note: Refer to Testing and Adjusting, "Vibratory Tachometer - Adjust" if the vibration tachometer is installed and the minimum frequency for high amplitude appears incorrect. This adjustment procedure should be followed before making any :

machine adjustments.

Note: Adjustment of the vibratory frequency is done through the adjustment of potentiometers which are found by removing the panel on the side of the control console. The potentiometers are located on the variable frequency controller. The adjustment of the potentiometers is done with a small screwdriver.

Note: Turning the potentiometers clockwise will increase the frequency.

Note: If the frequency has not shown any variation after rotating the potentiometers for two full turns, refer to the Troubleshooting section.

9. If the minimum frequency for high amplitude is not at 1400 ± 50 VPM, "P6" high amplitude-minimum frequency potentiometer (10) must be adjusted. After adjusting "P6" high amplitude-minimum frequency potentiometer (10), verify that the minimum frequency for high amplitude is correct.

) 55


High Amplitude (Maximum Frequency) Low Amplitude (Minimum Frequency)

1. Turn variable vibration control knob (3) to the full clockwise position.

2. Depress vibratory on/off control switch (1) in order to start the vibratory system. Read the vibrations per minute (VPM) from optional VPM gauge or read the VPM from the 133-0963 Vibration Tachometer or the 133-9905 Frequency Meter. The maximum frequency for high amplitude should be 1965 ± 50 VPM.

3. If the maximum frequency for high amplitude is not at 1965 ± 50 VPM, "P4" high amplitude-minimum frequency potentiometer (10) must be adjusted.


Vibratory Pump

(13) Servo valve neutral adjustment screw.

4.. The maximum frequency should be controlled by the electrical signal from the variable frequency controller. If the correct maximum frequency cannot be obtained by adjusting "P4" high amplitude-maximum frequency potentiometer (12), turn servo valve neutral adjustment screw (13) counterclockwise. This will ensure that the movement of the servo piston is not limited.

5. Remove the plastic cover from servo valve neutral adjustment screw (13). Loosen the jam nut arrangement and turn the servo valve neutral adjustment screw counterclockwise for approximately two turns.

6. Repeat Steps 2 through 3. When the correct frequency for high amplitude has been obtained, servo valve neutral adjustment screw (13) should be turned clockwise until the frequency is slightly decreased. Then, servo valve neutral adjustment screw (13) should be rotated counterclockwise for one half turn.

7. Hold the screw and tighten the jam nut arrangement. Install the plastic cover.

1. Place vibratory amplitude control (2) in the LOW AMPLITUDE position.

2. Turn the variable vibration control knob (3) to the full counterclockwise position.

3. Depress vibratory on/off control switch (1) in order to start the vibratory system. Read the vibrations per minute (VPM) from optional VPM gauge or read the VPM from the 133-0963 Vibration Tachometer or the 133-9905 Frequency Meter. The minimum frequency for low amplitude should be 1400 ± 50 VPM.

4. If the minimum frequency for low amplitude is not at 1400 ± 50 VPM, "P5" low amplitude-minimum frequency potentiometer (9) must be adjusted. After adjusting "P5" low amplitude-minimum frequency potentiometer (9), verify that the minimum frequency for low amplitude is correct.

Low Amplitude (Maximum Frequency)

1. Turn variable vibration control knob (3) to the full clockwise position.

2. Depress vibratory on/off control switch (1) in order to start the vibratory system. Read the vibrations per minute (VPM) from optional VPM gauge or read the VPM from the 133-0963 Vibration Tachometer or the 133-9905 Frequency Meter. Depress the vibratory on/off control switch in order to shut off the vibratory system. The maximum frequency for low amplitude should be 1965 ± 50 VPM.

3. If the maximum frequency for low amplitude is not at 1965 ± 50 VPM, "P3" low amplitude-maximum frequency potentiometer (11) must be adjusted.

Illustration 59

Vibratory Pump

(14) Servo valve neutral adjustment screw.


4. The maximum frequency should be controlled by the electrical signal from the variable frequency controller. If the correct maximum frequency cannot be obtained by adjusting "P3" low amplitude-maximum frequency potentiometer (11), turn servo valve neutral adjustment screw (14) counterclockwise. This will ensure that the movement of the servo piston is not limited.

5. Remove the plastic cover from servo valve neutral adjustment screw (14). Loosen the jam nut arrangement and turn the servo valve neutral adjustment screw counterclockwise for approximately two turns.

6. Repeat Steps 2 through 3. When the correct maximum frequency for low amplitude has been obtained, servo valve neutral adjustment screw (14) should be turned clockwise until the frequency is slightly decreased. Then, servo valve neutral adjustment screw (14) should be rotated counterclockwise for one half turn.

7. Hold the screw and tighten the jam nut arrangement. Install the plastic cover.

8. When the frequency is correct, stop the engine and remove all tooling.

Variable Frequency Electrical Control - Test and Adjust (If Equipped) SMCS Code: 6606-025-EL; 6606-081-EL


Table 13

Voltage Regulator Test Note: Before you perform this test, the condition of fuse (5), which is located on the variable frequency controller (1) should be verified.

Illustration 60

Control Console

(1) Variable frequency controller. (5) Fuse.

WARNING






Required Tools

6V-7070 Digital Multimeter (or equivalent)

Fabricated Wiring Harness

1

1


Illustration 61


(2) Wire terminal 1. (3) Wire terminal 7. (4) Wire terminal 8. (6) Frame ground wire terminal 2.

1. Apply the parking brake. Place the propel control lever in the STOP position. Put the vibratory control switch on the propel control lever in the OFF position.

2. Remove the cover from the operator console in order to access variable frequency controller (1).

3. Turn the key start switch to the ON position. Do not start the engine.

4. Use 6V-7070 Digital Multimeter in order to check the input voltage between wire terminal 1 (2) and frame ground wire terminal 2 (6). The input voltage should be a minimum of 24 DCV.

5. Use the multimeter to check the reference voltage between wire terminal 7 (3) and frame ground wire terminal 2 (6) on the variable frequency controller. The voltage should be 5.1 DCV.

6. Use the multimeter to check the reference voltage between wire terminal 8 (4) and frame ground wire terminal 2 (6) on the variable frequency controller. The voltage should be 2.55 DCV.

7. If the reference voltage that is measured at wire terminal 7 (3) and 8 (4) is not correct, and there is a minimum of 24 DCV at wire terminal 1 (2), then a problem exists with the voltage regulator for the variable frequency controller.

If the reference voltages that are measured at wire terminals 7 (3) and 8 (4) are correct, and there is a minimum of 24 DCV at wire terminal 1 (2), then perform Testing and Adjusting Controller in the section that follows.


Controller

200A

Illustration 62

Fabricated Wiring Harness

Table 14

Termination

Main Harness

Main Harness

Multimeter

Multimeter

Multimeter

Multimeter

Circuit ldent

200A

200C

920A

920C

921A

921C

Ga

16

16

16

16

16

16

Length Ref

150 mm (6 in)

365 mm (14 in)

365 mm (14 in)

365 mm (14 in)

365 mm (14 in)

365 mm (14 in)

Color ldent

BK

BK

YL

YL

BK

BK

Item No.

3

3

1

1

2

2

Circuit ldent

200B

200D

920B

920D

921B

921D

Termination

Main Harness

Main Harness

Main Harness

Main Harness

Main Harness

Main Harness


Table 15

Part No.

5P-0659

5P-5623

102-8804

8T-8729

102-8809

8T-8730

102-8802

Required Parts

Description

Electrical Wire

Electrical Wire

Receptacle Kit

Connector Pins

Plug Kit

Connector Socket

Receptacle Kit

Quantity

0.8 m (2.6 ft)

1.1 m (3.6 ft)

1

8

1

4

2

Note: Use this procedure during the installation of a new variable frequency controller or during an operational test of the variable frequency controller.

1. Apply the parking brake and place the propel control lever in the STOP position. Stop the engine. Turn the key start switch to the ON position. Put the throttle switch in the HIGH position. Put the propel range switch in the LOW position.

Note: This procedure should be performed with the key start switch in the ON position, but the engine stopped.

2. if necessary, tilt the platform in order to gain access to the vibratory pump.

Illustration 63

Control Console

(1) Vibratory control dial. (2) Vibratory on/off control switch. (3) Vibratory amplitude control.

6. Place the vibratory amplitude control (3) in the HIGH AMPLITUDE position.

7. Turn vibratory control dial (1) to the full counterclockwise position (minimum frequency).

8. Depress vibratory on/off control switch (2) in order to supply current to the vibratory system.

9. The nominal amperage that is measured for high amplitude-minimum frequency is 450 mA.

3. Disconnect the main wiring harness from the electrical connectors for the vibratory pump.

. Assemble the fabricated wiring harness. Refer to the illustration and the charts that are provided for specific details. Install the fabricated wiring harness in the main harness.

Note: The amperage reading which is given during the procedure may be used to predetermine the vibration frequency values for the Variable Frequency - Test.

Note: In order to obtain the correct readings, the nominal amperage values for the minimum frequency settings should be checked and adjusted before doing the maximum frequency settings.

Illustration 64



4. Connect the 6V-7070 Digital Multimeter to item 2 on the fabricated wiring harness so that the amperage reading and the high amplitude solenoid may be measured.

5. Select the correct amperage range on the multimeter. The range of milliamperes which may be measured is 400 to 1200 mA.




(4) Variable frequency controller. (5) "P5" Low amplitude-minimum frequency potentiometer. (6) "P6" High amplitude-minimum frequency potentiometer. (7) "P3" Low amplitude-maximum frequency potentiometer. (8) "P4" High amplitude-maximum frequency potentiometer.

10. If the nominal amperage that is measured for high amplitude-minimum frequency is not 450 mA, potentiometer (6) must be adjusted. Depress the vibratory on/off control switch (2) in order to stop current flow to the vibratory system.

11. Keep vibratory amplitude control (3) in the HIGH AMPLITUDE position.

12. Turn vibratory control dial (1) to the full clockwise position (maximum frequency).


14. The nominal amperage that is measured for high amplitude-maximum frequency is 520 mA.

15. If the nominal amperage that is measured for high amplitude-maximum frequency is not 520 mA, adjust potentiometer (8). Depress the vibratory on/off control switch (2) in order to stop current flow to the vibratory system.

Note: After the nominal amperage for the high amplitude-maximum frequency has been adjusted, repeat Steps 6 through 10 in order to verify that the nominal amperage for the high amplitude-minimum frequency has not changed.

17. Connect the 6V-7070 Digital Multimeter to item 1 on the fabricated wiring harness so that the amperage to the low amplitude solenoid may be measured.

18. Turn vibratory control dial (1) to the full counterclockwise position (minimum frequency).


20. The nominal amperage that is measured for low amplitude-minimum frequency is 450 mA.

21. If the nominal amperage that is measured for low amplitude-minimum frequency is not 450 mA, adjust potentiometer (5). Depress the vibratory on/off control switch (2) in order to stop current flow to the vibratory system.

22. Keep the vibratory amplitude control (3) in the LOW AMPLITUDE position.

23. Turn vibratory control dial (1) to the full clockwise position (maximum frequency).


25. The nominal amperage that is measured for low amplitude-maximum frequency is 520 mA.

26. If the nominal amperage that is measured for low amplitude-maximum frequency is not 520 mA, adjust potentiometer (7). Depress the vibratory ON/OFF control switch (2) in order to stop current flow to the vibratory system.

Note: After the nominal amperage for the low amplitude-maximum frequency has been adjusted, repeat Steps 16 through 21 in order to verify that the nominal amperage for the low amplitude-minimum frequency has not changed.

Note: After the nominal amperages for the low amplitude maximum frequency and low amplitude minimum frequency have been adjusted, repeat Steps 6 through 15 in order to verify that the nominal amperages for the high amplitude-maximum frequency and high amplitude-minimum frequency have not changed.

Note: After you perform this procedure, perform the Variable Frequency - Test procedure in order to make sure that the vibratory frequencies are correct.

16. Place vibratory amplitude control (3) in the LOW AMPLITUDE position.


101151012

Vibratory Tachometer - Adjust SMCS Code: 7462-025

Table 16

Part Number

133-9905

133-0963

Required Tools

Description

Frequency Meter

Drum Vibration Tachometer

Qty

1

1



Illustration 67 g004582l4

Steering Console

(3) Vibratory tachometer.

4. Depress the vibratory on/off control (1) on the control console to the ON position. Read the vibrations per minute (VPM) from optional VPM gauge (3).


Illustration 66 90 0 6 1 0 7 0 1

Control Console

(1) Vibratory on/off control. (2) Vibratory amplitude control.

Note: The hydraulic oil temperature should be at least 38ºC (100ºF).


2. Move the vibratory amplitude control (2) to the HIGH AMPLITUDE position.

3. Start the engine. Run the engine at high idle. Engine speed should be 2350 ± 50 rpm.


End of Drum

(4) Drum vibration tachometer.

5. Read the VPM from 133-0963 Drum Vibration Tachometer (4) or the 133-9905 Frequency Meter. Compare these values with the reading from the optional VPM gauge (3).

6. VPM gauge (3) must be calibrated if the values are not equal.


Illustration 69

(5) Dial. (6) Small calibration screw.

7. Set large dial (5) on 8.

8. Use small calibration screw (6) in order to calibrate the gauge. Use a 2.0 mm (5/64 inch) alien wrench in order to adjust the small calibration screw.

Note: If the reading from VPM gauge (3) is significantly different from the reading for 133-0963 Drum Vibration Tachometer (4) or the 133-9905 Frequency Meter, the magnetic sensor output should be verified before tachometer (3) is calibrated.

Vibratory Magnetic Sensor Test and Adjust SMCS Code: 6606-025-NS; 6606-081-NS

WARNING






Table 17

Tools Needed

6V-7070 Digital Multimeter (or equivalent) 1

Note: The hydraulic oil temperature should be at least 38°C (100°F).

• i )

Illustration 70

Right Side Of Drum As Viewed From Operator Seat

(1) Guard. (2) Magnetic sensor.

Illustration 71

Vibratory Magnetic Sensor Location

(2) Magnetic sensor. (3) Wires. (4) Case.

1. Remove guard (1) from top of magnetic sensor (2).

2. Remove rubber boot. Disconnect two wires (3) from magnetic sensor (2).


3. Select the resistance scale on the multimeter. Attach the multimeter leads to magnetic sensor terminals. Resistance should be 265 ± 30 ohms. If the resistance is correct go to Step 4 If the resistance is not correct, replace the magnetic sensor. After you have replaced magnetic sensor (2) go to Step 11 and adjust the air gap.

4. Set the multimeter on the highest resistance scale. Attach one lead of the multimeter to one of magnetic sensor terminals. Touch the other lead to case (4) of magnetic sensor (2).

5. Electrical resistance should be infinite. If the multimeter gives any reading, the magnetic sensor should be replaced. After your have replaced magnetic sensor (2) go to Step 11 and adjust the air gap.

6. Select the AC voltage mode on the multimeter. Attach two leads from multimeter to the magnetic sensor terminals.

7. Start the engine and run at high idle.

8. Place the vibratory amplitude control switch in LOW AMPLITUDE position.

9. Depress the vibratory control switch on the propel lever to the ON position to start the vibratory system. The multimeter should indicate approximately 2 ACV.

10. If no reading is obtained, magnetic sensor (2) may need to be adjusted and/or replaced. Depress the vibratory control switch on the propel lever to the OFF position to stop the vibratory system. Stop the engine.

11. To adjust gap, loosen locknut and turn magnetic sensor clockwise until it touches gear. Rotate magnetic sensor (2) counterclockwise one full turn. The gap between the end of the sensor and the gear tooth should be 1.57 mm (0.062 inch). Tighten the locknut.

12. Once the correct reading is obtained, remove tooling and reinstall hardware.

Index

Printed in U.S.A.

c

Case Drain Flow for Piston Motor - Test and Adjust 51

D

Drum 12, 34

E

Eccentric Weight 14

G

General Information 15

H

Hydraulic Control Neutral (Piston Pump) - Test and Adjust 49 Variable Frequency 49

Hydraulic Oil Contamination - Test 42 Hydraulic Oil Filter 5 Hydraulic Tank 4

I

Important Safety Information 2

M

Machine Preparation for Troubleshooting 37 Manifold Valve 33

Return Manifold 34 Thermal Bypass Valve 34

Manifold Valve and Mounting 6

P

Piston Motor 9, 32 Case Flushing 33

Piston Pump 7, 23 Main Relief Valve 26 Servo Piston Assembly 29 Solenoid Valve 28 Test At Full Speed 7 Variable Frequency Electrical Control (If Equipped) 29

©2000 Caterpillar All Rights Reserved

Piston Pump Flow - Test 42 Bench Test 43 Machine Test 43

Piston Pump Servo Neutral - Test and Adjust 50 Fixed Frequency and Variable Frequency 50

R

Relief Valve (Charge) - Test and Adjust 43 Vibratory System OFF 44 Vibratory System ON 45

Relief Valve (Piston Pump) - Test and Adjust 45 High Amplitude 46 Low Amplitude 47

S

Specifications Section 4 Support and Vibratory Drive 8 Systems Operation Section 15

T

Table of Contents 3 Testing and Adjusting 42 Testing and Adjusting Section 37 Troubleshooting. 37

V

Variable Frequency Electrical Control - Test and Adjust (If Equipped) 56 Controller 58 Voltage Regulator Test 56

Vibratory Frequency - Test and Adjust 52 Fixed Frequency 52 Variable Frequency 53

Vibratory Hydraulic System 17 Vibratory System 17, 19,21

Vibratory Magnetic Sensor - Test and Adjust 62 Vibratory Support 10

Tightening Procedure for the Spanner Nut 10 Vibratory System Troubleshooting 39

Operational Checks 39 Probable Causes of Vibratory System Problems 39

Vibratory Electrical Circuit 40 Vibratory Tachometer - Adjust 61 Visual Inspection 38

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