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

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531D, CP-533D and

CS-533D Vibratory Compactors

533D Vibratory Compactors

Vibratory System

AFC1-Up (Machine) AFC1-Up (Machine) AGH1

AGH1 -Up (Machin-Up (Machin e)e) AET1-Up (Machine) AET1-Up (Machine) 4MZ1-Up (Machine) 4MZ1-Up (Machine) 5CZ1-Up (Machine) 5CZ1-Up (Machine) 6AZ1-Up (Machine) 6AZ1-Up (Machine)

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Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to 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 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 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. 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 Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have 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.

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 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.

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 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. "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING

The meaning of this safety alert symbol is as follows:

The meaning of this safety alert symbol is as follows: Attention!

Attention! BecomBecome Alert! Your Safety is Involved.e Alert! Your Safety is Involved.

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

pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

this publication. Caterpillar can

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. not anticipate every possible circumstance that might involve a potential hazard. TheThe warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, 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, 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 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 product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that 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, 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 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 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 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. current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

WARNING

When replacement parts are required for this When replacement parts are required for this product Caterpillar recommends using Caterpil product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent lar replacement parts or parts with equivalent specifications including, but not limited to, phys specifications including, but not limited to, phys ical dimensions, type, strength and material. ical dimensions, type, strength and material.

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

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hazardous situations before an accident occurs. A person must be alert to potential hazards. This 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. 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 Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have 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.

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 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.

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 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. "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING

The meaning of this safety alert symbol is as follows:

The meaning of this safety alert symbol is as follows: Attention!

Attention! BecomBecome Alert! Your Safety is Involved.e Alert! Your Safety is Involved.

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

pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

this publication. Caterpillar can

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. not anticipate every possible circumstance that might involve a potential hazard. TheThe warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, 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, 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 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 product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that 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, 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 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 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 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. current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

WARNING

When replacement parts are required for this When replacement parts are required for this product Caterpillar recommends using Caterpil product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent lar replacement parts or parts with equivalent specifications including, but not limited to, phys specifications including, but not limited to, phys ical dimensions, type, strength and material. ical dimensions, type, strength and material.

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

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Table of Contents Table of Contents

Specifications Section

Hydraulic

Hydraulic TanTank k 44

Hydraulic

Hydraulic Oil Oil Filter Filter 55

Manifold

Manifold ValValve ve and and Mounting Mounting 66 Piston

Piston Pump Pump 77

Support

Support and and Vibratory Vibratory Drive Drive 88 Piston

Piston Motor Motor 99

Vibratory

Vibratory Support Support 1010

Drum 12

Eccentric

Eccentric Weight Weight 1414

Systems Operation Section

General

General Information Information 1515

Vibratory

Vibratory HydraulHydraulic ic System System 1717 Piston

Piston Pump Pump 2323

Piston

Piston Motor Motor 3232

Manifold

Manifold Valve Valve 3333

Drum 34

Testing and Adjusting Section

Troubleshooting Troubleshooting Machine

Machine Preparation Preparation for for TroubleshooTroubleshooting ting 3737 Visual

Visual Inspection Inspection 3838

Vibratory

Vibratory System System Troubleshooting Troubleshooting 3939

Testing and Adjusting Testing and Adjusting Hydraulic

Hydraulic Oil Oil Contamination Contamination - - TesTest t 4242 Piston

Piston Pump Pump Flow Flow - - Test Test 4242 Relief

Relief Valve Valve (Charge) (Charge) - - Test Test and and AdjuAdjust st 4343 Relief

Relief Valve Valve (Piston (Piston Pump) Pump) - - Test Test and and Adjust Adjust 4545 Hydraulic Control Neutral (Piston Pump) - Test and Hydraulic Control Neutral (Piston Pump) - Test and

Adjust 49

Piston

Piston Pump Pump Servo Servo Neutral Neutral - - TesTest t and and Adjust Adjust 5050 Case Drain Flow for Piston Motor - Test and

Case Drain Flow for Piston Motor - Test and

Adjust 51

Vibrato

Vibratory ry FrequencFrequency y - - Test Test and and Adjust Adjust 5252 Variable Frequency Electrical Control - Test and Variable Frequency Electrical Control - Test and

Adjust

Adjust (If (If Equipped) Equipped) 5656 Vibratory

Vibratory Tachometer Tachometer - - Adjust Adjust 6161 Vibratory

Vibratory MagnetiMagnetic c Sensor Sensor - - TesTest t and and Adjust Adjust 6262

Index Section

Index 64

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Specifications Section

101193458

Hydraulic Tank

SMCS Code: 5056 Part No.: 144-7266 Illustration 1 g0065i537

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

(55 ± 5 lb ft) (1) Inlet screen Plastic nylon mesh screen

23.5 x 23.5

(2) Torque for breather valve 90 ± 9 N.m (66± 6 lb ft)

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

(4) Suction screen 200 x 200 stainless steel pleated wire mesh Torque for suction screen (4) 220 ± 22 N.m (162 ± 16 lb ft)

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

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

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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.

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101338151

Manifold Valve and Mounting

SMCS Code: 3206; 5074

Part No.: 124-5185, 148-5612

Illustrations g00562380

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

(9) Oil cooler Thermal bypass valve (1) begins to close when

the temperature of the hydraulic oil reaches 65 ºC (10) Hydraulic tank (150 ºF).

(11) Oil filter bypass return port Thermal bypass valve (1) is fully closed when the

temperature of the hydraulic oil reaches 71 ºC (12) Diameter of internal orifice 0.81 mm

(160 °F). ' (.032 inch)

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

(2) Manifold return passage

(3) Axle drive pump

(4) Vibratory pump

(5) Drum motor

(6) Vibratory motor

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Specifications Section

Piston Pump

SMCS Code: 5070; 5652 Part No.: 159-9453, 159-9454 i01346365 Illustration 4

Rotation from the drive end clockwise

(1) Type of pump variable displacement pump

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

Charge pump internal 8.4 cc (.51 in3)

(2) High pressure relief valves 35000 kPa (5076 psi) (3) Charge pressure relief valve 2950 kPa

(428 psi)

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

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

Use 6V-4876 Lubricant on splines.

(5) Solenoid for the fixed frequency pump

control 21.7 ± 2.0 ohms

Solenoid for the variable frequency pump

control 24.6 ± 2.0 ohms

g00403650

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

Test At Full Speed

Output 84.9 L/min (22.1 US gpm)

Output pressure 690 kPa (100 psi)

Pump speed 2200 rpm

Engine speed 2200 rpm

Output pressure 6900 kPa (1000 psi)

Pump speed 2200 rpm

Engine speed 2200 rpm

Test At Half Speed

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Pum

Pump p speed speed 1100 1100 rpmrpm

Engin

Engine e speespee d d 1100 1100 rpmrpm

Output

Output 42.0 42.0 L/miL/min n (11.0 (11.0 US US gpm)gpm)

Output

Output pressure pressure 6900 6900 kPa kPa (1000 (1000 psi)psi)

Pump

Pump speespee d d 1100 1100 rpmrpm

Engine

Engine speespeed d 1100 1100 rpmrpm

i01346990 i01346990

Support and Vibratory Drive

SMCS Code: SMCS Code: 6605; 6606 6605; 6606 Part No.: Part No.: 136-9744 136-9744 Illustration 5 Illustration 5

(1) Apply 9S-3263 Thread Lock Compound to the (1) Apply 9S-3263 Thread Lock Compound to the

threads on the mounting bolts at assembly, threads on the mounting bolts at assembly,

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

(3) The oil filler plug (3) The oil filler plug

(4) The oil drain port (4) The oil drain port

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9 9 Specifications Section Specifications Section

Piston Motor

SMCS Code: SMCS Code: 5058; 5651 5058; 5651 Part No.: Part No.: 136-8869 136-8869 Illustrati Illustration on 6 6 g00g00468468822822

Note: Motor rotation can be clockwise or Note: Motor rotation can be clockwise or

counterclockwise. Rotation depends on the direction counterclockwise. Rotation depends on the direction of oil flow in the closed circuit loop line.

of oil flow in the closed circuit loop line.

Typ

Type e of of motor motor pistonpiston

Fixed

Fixed displacdisplacement ement 45 45 cc cc (2.75 (2.75 inin33))

Case

Case pressure pressure (normal) (normal) 379 379 kPa kPa (55 (55 psi)psi)

Case pressure (maximum at cold start) .. 1000 kPa Case pressure (maximum at cold start) .. 1000 kPa (145 psi) (145 psi) (1)

(1) Torque Torque for for four four bolts bolts 69 69 to to 84 84 N.mN.m (51 to 62 lb ft) (51 to 62 lb ft)

(2)

(2) Shaft Shaft splispline ne 1515T, T, 16/32P16/32P

(3) Motor charge

(3) Motor charge relirelief valve (flushing) .... ef valve (flushing) .... 1600 kP1600 kPaa

(232 psi) (232 psi)

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

Flushing

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Vibratory Support

SMCS Code: SMCS Code: 5656 5656 Part No.: 15 Part No.: 159-94059-9405 Illustration 7 Illustration 7

Components of the Drum Support 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 (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.

cup. (11) Bearing cup. (12) Pipe plug. (13) Spacer.

Tightening Procedure for the

Spanner Nut

1.

1. Install the Install the seal boot (seal boot (2) and 2) and the bearing cthe bearing cupsups (10) and (11) onto the hub (9).

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

2.

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

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

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

5. Press the bearing cone (4) onto the spindle (8) with a slight play of the bearing. The

bearing end play should measure .08 to .13 mm (0.003 to .005 inch).

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

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

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

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

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

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

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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.

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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)

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Eccentric Weight

SMCS Code: 6606; 6645 Part No.: 140-8267

Illustration 9

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

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

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

(4) Torque for the plug 100 ± 15 N-m

(74 ± 11 lb ft)

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

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

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

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

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

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Systems Operation Section

101348848

General Information

SMCS Code: 1400; 5050; 6606

Illustration 10 90 0 4 2 1 0 6 3

Vibratory System Schematic

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

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

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

Two vibratory systems are available:

• The variable 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.

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

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Illustration 11

Right Side Of Engine (1) Vibratory pump.

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

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

Illustration 13 9 °0 6 1 4 1 9 3

Left Side Of Machine

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

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

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

Illustration 12 g00447568 Right Side Area Of Drum

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

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

Illustration 14 90 0 6 1 4 2 0 4 Right Side Of Machine

(12) Hydraulic oil tank.

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

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} 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.

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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).

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Vibratory System

HIGH AMPLITUDE

Illustration 16 9°0 4 5 5 7 8 6

Vibratory system (HIGH AMPLITUDE)

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

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

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

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

• HIGH AMPLITUDE has been 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.

• 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.

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

Low pressure oil from the motor (6) flows back to the pump (1) through line (17). Line (17) will

become the low pressure side of the closed circuit.

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

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

The high pressure oil from the closed circuit loop line (12) will flow through the pilot oil passage (14). This will shift the shuttle spool inside the flushing valve (18). This position is shown in illustration 16.

Low pressure oil from the closed circuit loop line (17) flows through the flushing valve (18) to the flushing relief valve (5). Low pressure oil dumps over the flushing relief valve (5) to the flush motor (6). Flushing relief valve (5) is set lower than the relief pressure of the charge relief valve (10) in pump (1). This allows the motor to be flushed with the low pressure oil during vibratory system operation.

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

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

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

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

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Vibratory System

LOW AMPLITUDE

Illustration 17 90 0 4 5 6 5 5 2

Vibratory system (LOW AMPLITUDE)

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

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

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

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

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

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

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

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

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

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

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

The high pressure oil from the closed circuit loop line (17) will flow through the pilot oil passage (19). This will shift the shuttle spool inside the flushing valve (18). This position is shown in illustration 17.

Low pressure oil from the closed circuit loop line (17) flows through the flushing valve (18) to the flushing relief valve (5). Low pressure oil dumps over the flushing relief valve (5) to the flush motor (6). Flushing relief valve (5) is set lower than the relief pressure of the charge relief valve (10) in pump (1). This allows the motor to be flushed with the low

pressure oil during vibratory system operation.

The return oil from pump (1) and motor (6) flow to the return manifold through lines (20). The thermal

bypass valve is integral to the return manifold. The thermal bypass valve will direct the return oil through the oil cooler. The thermal bypass valve will also direct the return oil to the hydraulic oil tank (16). This depends on oil temperature,

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

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

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

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

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Piston Pump

SMCS Code: 5070; 5652 Part No.: 159-9453, 159-9454 Illustration 18 9°0 4 6 0 4 0 9 Vibratory Pump

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

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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).

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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).

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Main Relief Valve

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.

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

• The main relief valve limits the pressure.

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

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

Main Relief Function

Illustration 21

Relief Valve Cross Section

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

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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.

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Solenoid Valve

Illustration 23 9°0 4 6 0 0 1

Servo

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

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

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

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

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Servo Piston Assembly

Illustration 24 9 0 0 5 6 5 4 2 2 Section View Of The Vibratory Pump

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

Illustration 25 9°0 5 6 5 4 4 6

Section View Of The Servo Piston

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

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

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

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

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

Variable Frequency Electrical

Control (If Equipped)

Illustration 26 g006i0238 Control Console

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

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

Illustration 27 Control Console

(4) Variable frequency controller.

Illustration 28 g00565350

Illustration 29 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.

"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.

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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.

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i01158199

Piston Motor

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

Vibratory Motor Components

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

The vibratory motor is a fixed displacement

hydraulic motor. Oil flows to the motor and from the motor through hoses attached to the end cap (1).

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

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

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Case Flushing

Illustration 31 9 °0 4 6 2 1 1 9

Hydraulic Schematic For The Motor

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

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

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

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

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

• The relief valve

• Flow through the flushing valve

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

Manifold Valve

SMCS Code: 5074; 5264 Part No.: 124-5185 PIN: AFC1-Up Part No.: 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 Part No.: 124-5185 PIN: 6AZ1-Up 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.

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Return Manifold

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

Thermal Bypass Valve

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

Drum

SMCS Code: 5622; 6605 Part No.: 139-2035, 139-2036 PIN: AFC1-Up Part No.: 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

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

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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.

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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.

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.

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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.

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.

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.

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.

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

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

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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.

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

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.

Perform visual checks first when you are

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

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

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

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

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

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