Specifications Systems Operation Testing and Adjusting_ CS-531D, CP-533D and CS-533D Vibratory Compactors Vibratory System (1)

KENR3526 May 2000

CS-531D, CP-533D and CS533D Vibratory Compactors Vibratory System AFC1-Up (Machine) AGH1 -Up (Machin e) AET1-Up (Machine) 4MZ1-Up (Machine) 5CZ1-Up (Machine) 6AZ1-Up (Machine)

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.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. 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 Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot 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 When replacement parts are required for this product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent specifications including, but not limited to, phys ical dimensions, type, strength and material. Failure to heed this warning can lead to prema ture failures, product damage, personal injury or death.

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.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. 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 Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot 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 When replacement parts are required for this product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent specifications including, but not limited to, phys ical dimensions, type, strength and material. Failure to heed this warning can lead to prema ture failures, product damage, personal injury or death.

3 Table of Contents

Table of Contents Specifications Section Hydraulic Tank Tank Hydraulic Oil Filter Manifold Valve Valve and Mounting Piston Pump Support and Vibratory Drive Piston Motor Vibratory Support Drum Eccentric Weight

4 5 6 7 8 9 10 12 14

Systems Operation Section General Information Vibratory Hydraulic Hydraulic System Piston Pump Piston Motor Manifold Valve Drum

15 17 23 32 33 34

Testing and Adjusting Section Troubleshooting Machine Preparation for Troubleshooting Troubleshooting Visual Inspection Vibratory System Troubleshooting

37 38 39

Testing and Adjusting Hydraulic Oil Contamination - Test Test 42 Piston Pump Flow - Test 42 Relief Valve (Charge) - Test and Adjust Adju st 43 Relief Valve (Piston Pump) - Test and Adjust 45 Hydraulic Control Neutral (Piston Pump) - Test and Adjust 49 Piston Pump Servo Neutral - Test Test and Adjust 50 Case Drain Flow for Piston Motor - Test and Adjust 51 Vibratory Vibrato ry Frequency Frequency - Test and Adjust 52 Variable Frequency Electrical Control - Test and Adjust (If Equipped) 56 Vibratory Tachometer - Adjust 61 Vibratory Magnetic Magnetic Sensor - Test 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 (1) Inlet screen

80 L (21.1 US gal) 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)

(6) Torque for temperature sender

75 ± 7 N.m (55 ± 5 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.

6 Specifications Section

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 (35 to 40 lb ft)

(8) Main loop (9) Oil cooler

Thermal bypass valve (1) begins to close when the temperature of the hydraulic oil reaches 65 (150 ºF).

ºC

(10) Hydraulic tank (11) Oil filter bypass return port

Thermal bypass valve (1) is fully closed when the temperature of the hydraulic oil reaches 71 ºC (160 °F). ' 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

(12) Diameter of internal orifice

0.81 mm (.032 inch)

7 Specifications Section

i01346365

Piston Pump SMCS Code:  5070; 5652 Part No.:  159-9453, 159-9454

g00403650

Illustration 4

Rotation from the drive end (1) Type of pump

clockwise

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 (3) Charge pressure relief valve

35000 kPa (5076 psi) 2950 kPa (428 psi)

Note: The charge pressure is measured at the charge filter. (4) Drive shaft spline

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

"SAE B-B", "15t-16/32P"

Test At Full Speed Output Output pressure

84.9 L/min (22.1 US gpm) 690 kPa (100 psi)

Pump speed

2200 rpm

Engine speed

2200 rpm

Output Output pressure

84.1 L/min (21.9 US gpm) 6900 kPa (1000 psi)

Pump speed

2200 rpm

Use 6V-4876 Lubricant on splines.

Engine speed

2200 rpm

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

Test At Half Speed

Solenoid for the variable frequency pump control 24.6 ± 2.0 ohms

Output Output pressure

42.5 L/min (11.1 US gpm) 690 kPa (100 psi)

8 Specifications Section

Pump Pump speed

1100 rpm

Engine Engine spee d

1100 rpm

Output Output pressure

42.0 L/min L/min (11.0 US gpm) 6900 kPa (1000 psi)

Pump spee d

1100 rpm

Engine speed spee d

1100 rpm i01346990

Support and Vibratory Drive SMCS Code:  Code:  6605; 6606 Part No.:  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:  Code:  5058; 5651 Part No.:  No.:  136-8869

Illustration Illustrati on 6

g00468 g00468822 822

Note: Motor rotation can be clockwise or counterclockwise. Rotation depends on the direction of oil flow in the closed circuit loop line. Type Type of motor Fixed displacement displac ement Case pressure (normal)

piston 45 cc (2.75 in3) 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 spli ne

15T, 15T, 16/32P

(3) Motor charge relief relief valve (flushing) .... 1600 kPa kPa (232 psi) Nominal distance of shim pack .. 6.5 mm (0.26 inch) Flushing flow

5 L/min L/min (1.3 us gpm)

10 Specifications Section

Vibratory Support SMCS Code: 5656 Code: 5656 Part No.: 159-9405 15 9-9405

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) (2) and the bearing cups c ups (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.

11

Specifications Section

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 en d. 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.

12 Specifications Section

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 oi l. . 21 L (5.5 US gal) Torque for the plug

90 ± 15 N.m (66 ± 11 lb ft)

14

Specifications Section

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.

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

(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)

(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

9

00421063

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 dual amplitude system is a standard for the machine.

• The variable frequen cy 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.

16

Systems Operation Section

0614193

Illustration 11

Illustration 13

Right Side Of Engine

Left Side Of Machine

(1) Vibratory pump.

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

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.

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

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

Illustration 12

9°

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.

g00447568

Right Side Area Of Drum

Illustration 14

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

Right Side Of Machine

9

00614204

(12) Hydraulic oil tank.

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.

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

17 Systems Operation Section

} 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.

18

Systems Operation Section

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).

19 Systems Operation Section

Vibratory System HIGH AMPLITUDE

Illustration 16

9

°

0455 786

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 activate d. The switch for high amplitude is located on the vibratory amplitude control . The vibratory amplitude control is located on the operator control console. • Engine speed is high.

• 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.

20 Systems Operation Section

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. 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).

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).

21 Systems Operation Section

Vibratory System LOW AMPLITUDE

Illustration 17

9

00456552

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

• 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.

22 Systems Operation Section

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

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).

23 Systems Operation Section

Piston Pump SMCS Code:  5070; 5652 Part No.:  159-9453, 159-9454

Illustration 18

9

0460 409

°

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).

24 Systems Operation Section

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).

26 Systems Operation Section

Main Relief Valve 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 20

900461598

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.

Illustration 21 Relief Valve Cross Section (1) Main relief valve. (2) Locking cap. (3) Conical spring. (4) Collar. (5) Spindle. (6) Spring. (7) Collar.

27 Systems Operation Section

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

Illustration 22

g00459758

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.

28 Systems Operation Section

Solenoid Valve

Illustration 23

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).

9

046 001

°

29 Systems Operation Section

Servo Piston Assembly

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).

 

Illustration 24

900565422

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.

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)

Illustration 25

9

056 544 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). Illustration 26

g006i0238

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

30 Systems Operation Section

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 Illustration 29

(4) Variable frequency controller.

g00565350

Variable Frequency Controller Potentiometers (4) Variable frequency controller. (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. Illustration 28

g00565350

"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.

32 Systems Operation Section

i01158199

Piston Motor SMCS Code:  5058; 5651 Part No.: 136-8869

Illustration 30

900461787

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).

33 Systems Operation Section

Case Flushing

• 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.:  148-5612 PIN: AGH1-Up Part No.:  124-5185 PIN: AET1-Up Part No.:  148-5612 PIN: 4MZ1-Up Part No.:  124-5185 PIN: 5CZ1-Up

Illustration 31

9 °0 4 6 2 1 1 9

Part No.:  124-5185 PIN: 6AZ1-Up

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:

Illustration 32

900563134

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.

34 Systems Operation Section

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

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).

Thermal Bypass Valve 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 33

g00563202

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 is below 65ºC (149°F) the thermal bypass valve directs ch arge flow to the tank.

35 Systems Operation Section

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.

36 Systems Operation Section

Illustration 36

g0045i066

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.

Illustration 37

900451068

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

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.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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.

To prevent possible injury, perform the procedure that follows before testing and adjusting the vibra tory sys tem.

WARNING Personal injury can result from hydraulic oil pres sure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Seri ous injury can be caused if this pressure is not re leased before any service is done on the hydraulic system. Make sure all of the attachments have been low ered, oil is cool before removing any components or lines. Remove the oil filler cap only when the en gine is stopped, and the filler cap is cool enough to touch with your bare hand.

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.

38 Testing and Adjusting Section

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. 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 doc tor 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, test ing, 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 sup plies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. 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.

Personal injury can result from hydraulic oil pres sure and hot oil.

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.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Seri ous injury can be caused if this pressure is not re leased before any service is done on the hydraulic system.

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

Make sure all of the attachments have been low ered, oil is cool before removing any components or lines. Remove the oil filler cap only when the en gine is stopped, and the filler cap is cool enough to touch with your bare hand.

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.

39 Testing and Adjusting Section

Vibratory System Troubleshooting SMCS Code: 6606-035

WARNING

Probable Causes of Vibratory System Problems Problem The vibration system does not work in high amplitude or low amplitude. Probable causes

Personal injury or death can result from sudden machine movement.

• The speed range switch is in the HIGH range.

Sudden movement of the machine can cause in jury to persons on or near the machine.

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

To prevent injury or death, make s ure that the area around the machine is clear of personnel and ob structions before operating the machine.

• Fuse failure.

WARNING Personal injury can result from hydraulic oil pres sure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Seri ous injury can be caused if this pressure is not re leased before any service is done on the hydraulic system. Make sure all of the attachments have been low ered, oil is cool before removing any components or lines. Remove the oil filler cap only when the en gine 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, test ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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.

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.

Dispose of all fluids according to local regulations and mandates.

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.

• 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

40 Testing and Adjusting Section

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.

• 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 on/off control is faulty. The vibratory mechanism is noisy. • The vibratory amplitude selector is faulty. Probable Cause Problem • The lubrication oil in the vibrator housing is low. The engagement of vibration system is harsh. • Loose retaining bolts for the piston motor. Probable Cause • The vibrator shaft bearings have failed. • The diameter of the flow control orifice is too large. • The relief valve for the charge circuit is set too high.

Problem The hydraulic oil in the circuit overheats. Probable Cause

Problem Slow stopping of the vibratory frequency.

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

Probable Cause

• Low charge pressure.

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

• The thermal bypass valve is faulty.

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

• The main relief valve is open.

• 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.

• 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

• Engine high idle is not correctly adjusted.

The Vibratory system does not engage.

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

Probable Cause

• The oil level in the eccentric weight housing is too high. • The high pressure relief valves are set too low.

• 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.

42 Testing and Adjusting Section

Testing and Adjusting

Use the following procedure in order to determine the contamination of the oil in the hydraulic systerr 100913678

Hydraulic Oil Contamination Test

1. Check the hydraulic filter element for foreign materials. a. Bronze colored particles give an indication c" pump or motor port plate failure.

SMCS Code:  5050-008

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

WARNING

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

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 doc tor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

WARNING Personal injury can result from hydraulic oil pres sure and hot oil.

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

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Seri ous injury can be caused if this pressure is not re leased before any service is done on t he hydraulic system.

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

Make sure all of the attachments have been low ered, oil is cool before removing any components or lines. Remove the oil filler cap only when the en gine is stopped, and the filler cap is cool enough to touch with your bare hand.

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).

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, 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 sup plies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. If the oil becomes contaminated, premature component failure could result. Contaminated oil can also contribute to overheating.

SMCS Code:  5652-032-ON; 5652-032-TB

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

43 Testing and Adjusting Section

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 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 6

Table 3

Method of determining perct snt of flow loss Flow loss (L/min or US gpm) Pump flow at 690 kPa (100 psi)

x

100

=

Percent of flow loss

Table 4

Relief Valve (Charge) - Test and Adjust SMCS Code:  5117-0 25-PX; 5117 -081 -PX 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).

Table 7

Required Tools Part Number

Description

Qty

4C-6500

Digital Thermometer

1

4C-4892

ORFS Fittings Group

1

9U-7400

Multitach

1

Machine Test WARNING

Install a flow meter. Run the en gin e at hig h idle . Measure the pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Use these values in the following formula.

Personal injury or death can result from sudden machine movement.

Table 5

Sudden movement of the machine can cause in jury to persons on or near the machine. To prevent injury or death, ma ke sure that the area around the machine is clear of personnel and ob structions before operating the machine.

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.

44 Testing and Adjusting Section

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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 ail fluids according to local regulations and mandates. NOTICE To avoid damage to the vibratory system during test ing, 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 re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings. Note:  The hydraulic oil temperature should be at least 38°C  (100ºF).

Illustration 38

9

00460687

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 charg e pressure at pressure test port (1). Charge pressure (NEUTRAL) should be 2950 ± 150 kPa (428 ± 22 psi).

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 39

9

°

0460 734

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.

45 Testing and Adjusting Section

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

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 Illustration 40

•

Q00610458

Table 8

Control Console

Required Tools

(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.

Part Number

Description

Qty

4C-6500

Digital Thermometer

1

4C-4892

ORFS Fittings Group

1

9U-7400

Multitach

1

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine.

46 Testing and Adjusting Section

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids.

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

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. Illustration 42

NOTICE To avoid damage to the vibratory system during test ing, 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 re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings. Note:  The hydraulic oil temperature should be at least 38ºC (10ºF). >• ' 

,y*. A&*SS»V^

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.

47 Testing and Adjusting Section

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.

Illustration 43

900461659

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.

Vibratory Pump (4) High amplitude relief valve.

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

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

Illustration 44

900461655

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 cartridg e 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).

48 Testing and Adjusting Section

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

Illustration 46

900610475

Control Console (2) Vibratory amplitude control. (3) Vibratory ON/OFF control. Illustration 48

9

04616 55

°

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

Relief Valve Cartridge

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).

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

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). '"•«'- :J•iKjt^' ,

* I

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

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 cart ridge 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. 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.

Illustration 47

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

Vibratory Pump (9) Low amplitude relief valve.

9. Repeat Step 5.

49 Testing and Adjusting Section

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.

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

i01349669

Hydraulic Control Neutral (Piston Pump) - Test and Adjust SMCS Code: 5050-081: 5051-025; 5070-025-V4; 5070-081-V4 Illustration 49

Variable Frequency

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

Table 9

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

Required Tools Part Number

Description

Qty

8T-0855(1)

Pressure Gauge

2

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

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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. 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.

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.

50 Testing and Adjusting Section

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

Description

Qty

6V-7830

Tetragauge

2

6V-8628

Elbow

2

4J-5477

O-Ring Seal

2

3J-7354

O-Ring Seal

2

9X2348

Hose

36 inches

9X-3757

Coupling

2

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, adjusting and repair of the produ ct. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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. 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- 78 30 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.

51 Testing and Adjusting Section

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

Required Tools Part Number

Description

Qty

4C-8689

Flow Meter

1

8C-6874

Adapter

2

6V-8942

Adapter

2

6V-8556

Nut

2

7X-1449

Orifice Coupling

1

7X-1447

Orifice Coupling

1

9X-2350

Hose

36 Inches

4C-6500

Digital Thermometer

1

NOTICE To avoid damage to the vibratory system during test ing, 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 re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings. 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.

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine.

Illustration 51

90 0 4 6 2 7 7 2

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

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent 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.

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).

52 Testing and Adjusting Section

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).

NOTICE To avoid damage to the vibratory system during test ing, 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 wh en the machine is on concrete. NOTICE If a testing time longer than three (3) minutes is re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings.

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

Vibratory Frequency - Test and Adjust SMCS Code:  6606-025; 6606-081 Table 12

Required Tools Part Number

Description

Qty

133-9905

Frequency Meter

1

Illustration 52

133-0963

Drum Vibration Tachometer

1

Control Console

4C-6500

Digital Thermometer

1

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine.

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

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

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 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 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.

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.

54 Testing and Adjusting Section

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 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.

Illustration 56 Control Console (8) Variable frequency controller.

g00457488

:

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 frequ ency 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 Testing and Adjusting Section

High Ampl itud e (Maximum Frequency)

Low Amplitu de (Minimum Frequency)

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

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

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

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

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.

Illustration 58

g00457569

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.

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.

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.

Illustration 59 Vibratory Pump (14) Servo valve neutral adjustment screw.

56 Testing and Adjusting Section

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.

NOTICE If a testing time longer than three (3) minutes is re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings. Table 13

Required Tools

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.

6V-7070 Digital Multimeter (or equivalent)

1

Fabricated Wiring Harness

1

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.

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

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine. NOTICE To avoid damage to the vibratory system during test ing, always perform the testing with the vibratory drum on top of tires or on loose dirt. Tires will simulate a non-compacted soil condi tion. Never operate the vibratory system when the machine is on concrete.

Illustration 60 Control Console (1) Variable frequency controller. (5) Fuse.

57 Testing and Adjusting Section

Illustration 61 Variable Frequency Controller (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.

58 Testing and Adjusting Section

Controller

200A

Illustration 62 Fabricated Wiring Harness Table 14

Termination

Circuit ldent

Ga

Length Ref

Color ldent

Item No.

Circuit ldent

Termination

Main Harness

200A

16

150 mm (6 in)

BK

3

200B

Main Harness

Main Harness

200C

16

365 mm (14 in)

BK

3

200D

Main Harness

Multimeter

920A

16

365 mm (14 in)

YL

1

920B

Main Harness

Multimeter

920C

16

365 mm (14 in)

YL

1

920D

Main Harness

Multimeter

921A

16

365 mm (14 in)

BK

2

921B

Main Harness

Multimeter

921C

16

365 mm (14 in)

BK

2

921D

Main Harness

59 Testing and Adjusting Section

Table 15

Required Parts

Part No.

Description

Quantity

5P-0659

Electrical Wire

0.8 m (2.6 ft)

5P-5623

Electrical Wire

1.1 m (3.6 ft)

102-8804

Receptacle Kit

1

8T-8729

Connector Pins

8

102-8809

Plug Kit

1

8T-8730

Connector Socket

4

102-8802

Receptacle Kit

2 Illustration 63

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.

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.

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

Illustration 64 Variable Frequency Controller (4) Variable frequency controller.

60 Testing and Adjusting Section

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

Illustration 65

g00474697

Variable Frequency Controller (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). 13. Depress vibratory on/off control switch (2) in order to supply current to the vibratory system. 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. 16. Place vibratory amplitude control (3) in the LOW AMPLITUDE position.

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

61 Testing and Adjusting Section

101151012

Vibratory Tachometer - Adjust SMCS Code: 7462-025 Table 16

Required Tools Part Number

Description

Qty

133-9905

Frequency Meter

1

133-0963

Drum Vibration Tachometer

1

NOTICE To avoid damage to the vibratory system during test ing, always perform the testing with the vibra tory 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.

Illustration 67

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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).

NOTICE If a testing time longer than three (3) minutes is re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings.

Illustration 68

900458216

End of Drum (4) Drum vibration tachometer.

Illustration 66

9

00610701

Control Console

5. Read the VPM from 13 3- 09 63 Drum Vibration Tachometer (4) or the 133-9905 Frequency Meter. Compare these values with the reading from the optional VPM gauge (3).

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

Note: The hydraulic oil temperature should be at least 38ºC (100ºF). 1. Make sure that the parking brake is applied. Ensure that the propel control lever is in the STOP position. 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.

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

62 Testing and Adjusting Section

NOTICE If a testing time longer than three (3) minutes is re quired, rotate the drum periodically in order to lubri cate the eccentric weight shaft bearings. Table 17

Tools Needed 6V-7070 Digital Multimeter (or equivalent)

1

Note: The hydraulic oil temperature should be at least 38°C (100°F). Illustration 69 (5) Dial. (6) Small calibration screw.

•

i )

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.

Illustration 70 Right Side Of Drum As Viewed From Operator Seat (1) Guard. (2) Magnetic sensor.

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

WARNING Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause in jury 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 ob structions before operating the machine. NOTICE To avoid damage to the vibratory system during test ing, 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.

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 obtaine d, 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.