Specifications Systems Operation Testing and Adjusting - CS-531D, CP-533D and CS-533D Vibratory Compactors Vibratory System

KENR3526
May 2000
CS-531D, CP-533D and CS533D Vibratory Compactors

Vibratory System
AFC1-Up (Machine)
AGH1 -Up (Machine)
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 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 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 Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents
Specifications Section
Hydraulic Tank
Hydraulic Oil Filter
Manifold 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 System
Piston Pump
Piston Motor
Manifold Valve
Drum
15
17
23
32
33
34
Testing and Adjusting Section

Troubleshooting
Machine Preparation for Troubleshooting
Visual Inspection
Vibratory System Troubleshooting
37
38
39
Testing and Adjusting

Hydraulic Oil Contamination - Test
42
Piston Pump Flow - Test
42
Relief Valve (Charge) - Test and Adjust
43
Relief Valve (Piston Pump) - Test and Adjust
45
Hydraulic Control Neutral (Piston Pump) - Test and
Adjust
49
Piston Pump Servo Neutral - Test and Adjust
50
Case Drain Flow for Piston Motor - Test and
Adjust
51
Vibratory Frequency - Test and Adjust
52
Variable Frequency Electrical Control - Test and
Adjust (If Equipped)
56
Vibratory Tachometer - Adjust
61
Vibratory Magnetic Sensor - Test and Adjust
62
Index Section
Index
64
4
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)

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
101338151

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 F).
(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
C
(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
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 38C (100F).
"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
Pump speed
1100 rpm
Engine speed
1100 rpm
Output
Output pressure
42.0 L/min (11.0 US gpm)

6900 kPa (1000 psi)
Pump speed
1100 rpm
Engine speed
1100 rpm
i01346990

SMCS Code: 6605; 6606
Part No.: 136-9744
Illustration 5
(1) Apply 9S-3263 Thread Lock Compound to the

threads on the mounting bolts at assembly,
(2) The capacity for the support housing 1 L (1 qt)
(3) The oil filler plug
(4) The oil drain port
/
9
Piston Motor
SMCS Code: 5058; 5651
Part No.: 136-8869
Illustration 6
g00468822
Note: Motor rotation can be clockwise or

counterclockwise. Rotation depends on the direction
of oil flow in the closed circuit loop line.
Type of motor
Fixed displacement
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
15T, 16/32P
(3) Motor charge relief valve (flushing) .... 1600 kPa

(232 psi)
Nominal distance of shim pack .. 6.5 mm (0.26 inch)
Flushing flow
5 L/min (1.3 us gpm)
10
Vibratory Support
SMCS Code: 5656
Part No.: 159-9405
Illustration 7
Components of the Drum Support
(1) Seal. (2) Boot. (3) Bearing cone. (4) Bearing cone. (5) Washer. (6) Lockwasher tang. (7) Locknut. (8) Spindle. (9) Hub. (10) Bearing
cup. (11) Bearing cup. (12) Pipe plug. (13) Spacer.
Tightening Procedure for the

Spanner Nut
1. Install the seal boot (2) and the bearing cups
(10) and (11) onto the hub (9).
2. Install the bearing cone (3) into the cup (10).

Position the seal spring toward the bearing cone.
Install lip type seal (1). Ensure that the lip type
seal is flush with the end of the hub. The seal
spring must be located to the inside of the hub.
11
Note: The bearing should be clean and dry of all

lubrication oil. The rolling torque reading will be
affected if oil is on bearing assembly.
3. Rest the spindle on the flange end. Lower the
hub (9) carefully onto the spindle shaft. Ensure
that the bearing cone (3) contacts the shoulder
of the spindle. Squeeze the small end of the
bearing cone. Press the cone onto the shaft.
4. Measure the rolling torque of the assembly. This
is the initial value.
5. Press the bearing cone (4) onto the spindle
(8) with a slight play of the bearing. The
bearing end play should measure .08 to .13 mm
(0.003 to .005 inch).
6. Press the inboard cone (4) until the rolling torque
increases 1.13 to 1.70 N-m (10 to 15 lb in).
This torque should be higher than the torque
that was measured in step (4). If the increase
of the torque is greater than 1.13 to 1.70 N-m
(10 to 15 lb in), then tap the back of the spindle
to back off the cone.
7. Apply 4C-9507 Retaining Compound to the
locknut (7). Install the washer (5), the lock
washer (6), and the locknut (7).
8. Tighten locknut (7) to 375 N-m (277 lb ft).
Rolling the locknut will seat the bearings. The
assembly should have no end play. Check
the rolling torque. The torque must increase
1.13 to 4.52 N-m (10 to 40 lb in) more than the
rolling torque measurement in step (4). This will
result in a bearing preload of .025 to .050 mm
(0.001 to .002 inch).
9. Tap the end of the spindle and check the rolling
torque again. If the rolling torque reading is
different, tighten the locknut (7) again.
10. Bend the tanged washer (6) into the slot on the
locknut. Check the tab on the washer. The tab
must align with the locknut. Tighten the tab with
the locknut in order to align.
11. Install the pipe plug (12) and apply 9S-3263
Thread Lock Compound.
12. Install the spacer (13) and the O-ring.
12
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
(4) Notched end for housing orientation
(5) Oil fill/drain plug
(6) Oil level plug
(7) Place the drum in the above position. This
position is required in order to fill the reservoir.
(8) Apply 4C-9507 Retaining Compound to
threads.
(9) Plug for the drum cooling oil.. 21 L (5.5 US gal)
Torque for the plug
90 15 N.m (66 11 lb ft)
14
Eccentric Weight
SMCS Code: 6606; 6645
Part No.: 140-8267
Illustration 9

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)
(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

101348848
General Information
SMCS Code: 1400; 5050; 6606
Illustration 10
900421063
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 frequency system is an option for

the machine.
The adjustment of the pump swashplate angle is
the only change between the two vibratory systems.
Note: The throttle switch has two sets of contacts.
The throttle switch must be in the high position for
the vibration to work.
16
90614193
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
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
900614204
(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
} 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
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 65C
(149F). 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 65C
The thermal bypass valve directs all of the
hydraulic oil to the oil cooler at 70C (158F).
19
Vibratory System
HIGH AMPLITUDE
Illustration 16
0455786
Vibratory system (HIGH AMPLITUDE)

Hushing valve. (19) Pilot passage. (20) Lines to the return manifold (three). (21) Oil cooler. (A) Solenoid. (B) Solenoid.
Charge pressure oil flows through passage (3) to

the directional control valve (2) when the engine
is operating.
The solenoid coil (B) on the control valve (2)
receives an electrical current when the following
conditions occur:
The vibratory control switch which is located on
the propel lever is in the ON position.
HIGH AMPLITUDE has been activated. The switch
for high amplitude is located on the vibratory
amplitude control . The vibratory amplitude
control is located on the operator control console.
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
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.
hydraulic oil to the oil cooler at temperatures
above 65C (149F). The remainder of the oil
flows to the hydraulic oil tank (16).
hydraulic oil to the oil cooler at 70 C (158F).
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
Vibratory System
LOW AMPLITUDE
Illustration 17
900456552
Vibratory system (LOW AMPLITUDE)

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
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,
hydraulic oil to the oil cooler at temperatures
above 65C (149F). The remainder of the oil
flows to the hydraulic oil tank (16).
hydraulic oil to the oil cooler at 70C (158F).
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
Piston Pump
SMCS Code: 5070; 5652
Part No.: 159-9453, 159-9454
Illustration 18
0460409
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
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
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
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
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).
046001
29
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).
900565422
Illustration 24
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
0565446
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
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

(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
control knob (3) to a full counterclockwise position.
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
control knob (3) to a full clockwise position. The
position enables the 'V3'" 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
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
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
0462119
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
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 65C

(149F), 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 71C (160F).
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

(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 65C

(149F) the thermal bypass valve directs charge
flow to the tank.
35
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
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

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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Move the machine to a smooth, horizontal
location that is away from operating machines
and away from personnel.
Note: Permit only one operator on the machine.
Keep all other personnel away from the machine
or in the operator's sight.
2. Engage the parking brake. Place blocks around
the wheels and around the drum.
3. Lower the leveling blade to the ground.
To prevent possible injury, perform the procedure

that follows before testing and adjusting the vibratory system.
WARNING
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic
system.
Make sure all of the attachments have been lowered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough
to touch with your bare hand.
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
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 doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.
WARNING
NOTICE
during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any
component containing fluids.
Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar
machines.
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.
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.

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.
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
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 injury 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 sure that the area

around the machine is clear of personnel and obstructions before operating the machine.
Fuse failure.
WARNING
system.
NOTICE
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.

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
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
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 doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.
WARNING
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"-::;

system.
This test is designed to determine whether a pumc

is operating within design parameters.
For any pump test, the pump flow at 690 kPa

(100 psi) will be larger than the pump flow at
6900 kPa (1000 psi) if the pump is operating at the
same rpm. The pump flow is measured in L/min
(US gpm).
NOTICE
during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any
component containing fluids.
Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar
machines.
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
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 perctsnt of flow loss

Flow loss (L/min or US gpm)
Pump flow at 690 kPa
(100 psi)
100
Percent
of flow
loss
Table 4
Relief Valve (Charge) - Test

and Adjust
SMCS Code: 5117-025-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
4C-4892
ORFS Fittings Group
9U-7400
Multitach
Machine Test
WARNING
Install a flow meter. Run the engine at high idle.

Measure the pump flow at 690 kPa (100 psi) and
at 6900 kPa (1000 psi). Use these values in the
following formula.

machine movement.
Table 5
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
NOTICE
products.
Dispose of ail fluids according to local regulations and
mandates.
NOTICE
To avoid damage to the vibratory system during testing, always perform the testing with the vibratory drum
on top of tires or on loose dirt. Tires will simulate a
non-compacted soil condition.
Never operate the vibratory system when the machine
is on concrete.
NOTICE
If a testing time longer than three (3) minutes is required, rotate the drum periodically in order to lubricate the eccentric weight shaft bearings.
Note: The hydraulic oil temperature should be at
least 38C (100F).
900460687
Illustration 38
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 38C (100F).
6. Read the charge 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
0460734
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
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
4C-4892
ORFS Fittings Group
9U-7400
Multitach
WARNING
machine movement.
46
NOTICE
2. Connect a 60000 kPa (8700 psi) pressure gauge

to relief valve test port (1).

products.
mandates.
Illustration 42
NOTICE
is on concrete.
NOTICE
least 38C (10F).
> '
,y*. A&*SSV^
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 38C
(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
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
relief valve (4). This will ensure that the oil
does not leak while adjustments are made to
the cartridge and the spring.
d. Hold the high pressure relief valve cartridge in
a bench vise. Secure the high pressure relief
valve cartridge by clamping on collar (6).
e. Loosen lock screw (7) with a 3 mm Allen
wrench.
Illustration 45
Vibratory Pump
(8) Test port.

STOP position.
2. Connect a 60000 kPa (8700 psi) pressure gauge
to relief valve test port (8).
48
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
0461655
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)
(100F).
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).
'"'-:JiKjt^',
* 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
relief valve (4). This will prevent oil leakage
while adjustments are made to the cartridge
and the spring.
d. Hold the high pressure relief valve cartridge in
a bench vise. Secure the high pressure relief
valve cartridge by clamping on collar (6).
e. Loosen lock screw (7) with a 3 mm Allen
wrench.
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

relief valve (4) and torque to specifications.
Vibratory Pump
(9) Low amplitude relief valve.
9. Repeat Step 5.
49
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.

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
(1) Part of 4C-4892 ORFS Fittings Group
WARNING
machine movement.
NOTICE
products.
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
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
6V-8628
Elbow
4J-5477
O-Ring Seal
3J-7354
O-Ring Seal
9X2348
Hose
36 inches
9X-3757
Coupling
Illustration 50
Vibratory Pump
(1) Servo. (2) Servo Ports. (3) Locknut. (4) Servo valve neutral
adjustment screw. (5) Main relief valve test ports.

neutral.
2. Disconnect the electrical connection for the
vibratory pump control.
WARNING
machine movement.
NOTICE
products.
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.
3. Remove the plugs from servo ports (2). Install the

3J-7354 O-Ring Seals on the 6V-8628 Elbows.
Install the elbows in servo ports (2), and install
the 4J-5477 O-Ring Seals in the elbows.
4. Fabricate a hose assembly by using the
9X-2348 Hose and 9X-3757 Coupling .
Connect the hose assembly between the elbows
that were installed in the servo ports.
5. Install the two 6V-7830 Tetragauges on the main
relief valve test ports (5).
6. Start and run the engine at high idle.
7. Read pressure readings on the two 6V-7830
Tetragauges. The pressure readings should be
identical.
8. If the pressure readings are not identical,
loosen locknut (3) so that the neutral position
of the servo piston may be adjusted. Use
an alien wrench in order to turn servo valve
neutral adjustment screw (4). Turn the screw
clockwise or counterclockwise in order to adjust
the mechanical center of the servo valve. The
pressures on the two 6V-7830 Tetragauges
should change. Turn servo valve neutral
adjustment screw (4) until the pressure readings
on main relief valve test ports are identical.
Tighten locknut (3).
9. Stop the engine. Remove the two 6V-7830
Tetragauges.
51
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
8C-6874
Adapter
6V-8942
Adapter
6V-8556
Nut
7X-1449
Orifice Coupling
7X-1447
Orifice Coupling
9X-2350
Hose
36 Inches
4C-6500
Digital
Thermometer
NOTICE
is on concrete.
NOTICE
least 38C (100F).
neutral. Make sure that the vibratory on/off control
on the propel control lever is in the OFF position.
WARNING
machine movement.
Illustration 51
900462772
End of Drum
(1) Vibratory motor. (2) Drain line. (3) Flushing valve.
NOTICE
products.
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
(100F). 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
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
is on concrete.
NOTICE
Fixed Frequency
High Amplitude
least 38C (100F).
Vibratory Frequency - Test and

Adjust
SMCS Code: 6606-025; 6606-081
Table 12
Required Tools
Part Number
Description
Qty
133-9905
Frequency Meter
Illustration 52
133-0963
Drum Vibration Tachometer
Control Console
4C-6500
Digital Thermometer
WARNING
machine movement.
(1) Vibratory on/off control switch. (2) Vibratory amplitude control.

(3) Variable vibration control knob.

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
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.
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.
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 38C (100F).
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
54
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
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 frequency for high amplitude is not
at 1400 50 VPM, "P6" high amplitude-minimum
frequency potentiometer (10) must be adjusted.
After adjusting "P6" high amplitude-minimum
frequency potentiometer (10), verify that the
minimum frequency for high amplitude is correct.
)
55
High Amplitude (Maximum Frequency)
Low Amplitude (Minimum Frequency)

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.

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
After adjusting "P5" low amplitude-minimum
frequency potentiometer (9), verify that the
minimum frequency for low amplitude is correct.
Low Amplitude (Maximum Frequency)

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.

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
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
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
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)
Fabricated Wiring Harness
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
machine movement.
NOTICE
is on concrete.
Illustration 60
Control Console
(1) Variable frequency controller. (5) Fuse.
57
Illustration 61
(2) Wire terminal 1. (3) Wire terminal 7. (4) Wire terminal 8. (6)
Frame ground wire terminal 2.
1. Apply the parking brake. Place the propel control

lever in the STOP position. Put the vibratory
control switch on the propel control lever in the
OFF position.
2. Remove the cover from the operator console in
order to access variable frequency controller (1).
3. Turn the key start switch to the ON position. Do
not start the engine.
4. Use 6V-7070 Digital Multimeter in order to
check the input voltage between wire terminal 1
(2) and frame ground wire terminal 2 (6). The
input voltage should be a minimum of 24 DCV.
5. Use the multimeter to check the reference voltage
between wire terminal 7 (3) and frame ground
wire terminal 2 (6) on the variable frequency
controller. The voltage should be 5.1 DCV.
6. Use the multimeter to check the reference voltage
between wire terminal 8 (4) and frame ground
wire terminal 2 (6) on the variable frequency
controller. The voltage should be 2.55 DCV.
7. If the reference voltage that is measured at wire
terminal 7 (3) and 8 (4) is not correct, and there
is a minimum of 24 DCV at wire terminal 1 (2),
then a problem exists with the voltage regulator
for the variable frequency controller.
If the reference voltages that are measured at wire
terminals 7 (3) and 8 (4) are correct, and there is
a minimum of 24 DCV at wire terminal 1 (2), then
perform Testing and Adjusting Controller in the
section that follows.
58
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
200B
Main Harness
Main Harness
200C
16
365 mm (14 in)
BK
200D
Main Harness
Multimeter
920A
16
365 mm (14 in)
YL
920B
Main Harness
Multimeter
920C
16
365 mm (14 in)
YL
920D
Main Harness
Multimeter
921A
16
365 mm (14 in)
BK
921B
Main Harness
Multimeter
921C
16
365 mm (14 in)
BK
921D
Main Harness
59
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
8T-8729
Connector Pins
102-8809
Plug Kit
8T-8730
Connector Socket
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

7. Turn vibratory control dial (1) to the full
counterclockwise position (minimum frequency).
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
60
17. Connect the 6V-7070 Digital Multimeter to item

1 on the fabricated wiring harness so that the
amperage to the low amplitude solenoid may
be measured.
18. Turn vibratory control dial (1) to the full
counterclockwise position (minimum frequency).
20. The nominal amperage that is measured for low
amplitude-minimum frequency is 450 mA.
21. If the nominal amperage that is measured for
low amplitude-minimum frequency is not 450 mA,
adjust potentiometer (5). Depress the vibratory
on/off control switch (2) in order to stop current
flow to the vibratory system.
Illustration 65
g00474697

(4) Variable frequency controller. (5) "P5" Low amplitude-minimum
frequency potentiometer. (6) "P6" High amplitude-minimum
frequency potentiometer. (7) "P3" Low amplitude-maximum
frequency potentiometer. (8) "P4" High amplitude-maximum
frequency potentiometer.
10. If the nominal amperage that is measured for

high amplitude-minimum frequency is not 450
mA, potentiometer (6) must be adjusted. Depress
the vibratory on/off control switch (2) in order to
stop current flow to the vibratory system.
11. Keep vibratory amplitude control (3) in the HIGH
AMPLITUDE position.
12. Turn vibratory control dial (1) to the full clockwise
position (maximum frequency).
14. The nominal amperage that is measured for high
amplitude-maximum frequency is 520 mA.
15. If the nominal amperage that is measured
for high amplitude-maximum frequency is not
520 mA, adjust potentiometer (8). Depress the
vibratory on/off control switch (2) in order to stop
current flow to the vibratory system.
Note: After the nominal amperage for the high
amplitude-maximum frequency has been adjusted,
repeat Steps 6 through 10 in order to verify that the
nominal amperage for the high amplitude-minimum
frequency has not changed.
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).
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
101151012

SMCS Code: 7462-025
Table 16
Required Tools
Part Number
Description
Qty
133-9905
Frequency Meter
133-0963
Drum Vibration
Tachometer
NOTICE
is on concrete.
Illustration 67
g004582l4
Steering Console
(3) Vibratory tachometer.
4. Depress the vibratory on/off control (1) on the

control console to the ON position. Read the
vibrations per minute (VPM) from optional VPM
gauge (3).
NOTICE
Illustration 68
900458216
End of Drum
(4) Drum vibration tachometer.
Illustration 66
900610701
Control Console
5. Read the VPM from 133-0963 Drum Vibration

Tachometer (4) or the 133-9905 Frequency
Meter. Compare these values with the reading
from the optional VPM gauge (3).
(1) Vibratory on/off control. (2) Vibratory amplitude control.

least 38C (100F).
STOP position.
2. Move the vibratory amplitude control (2) to the
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
NOTICE
Table 17
Tools Needed
6V-7070 Digital Multimeter (or equivalent)

least 38C (100F).
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
machine movement.
NOTICE
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 obtained, magnetic sensor
(2) may need to be adjusted and/or replaced.
Depress the vibratory control switch on the
propel lever to the OFF position to stop the
vibratory system. Stop the engine.
11. To adjust gap, loosen locknut and turn magnetic
sensor clockwise until it touches gear. Rotate
magnetic sensor (2) counterclockwise one full
turn. The gap between the end of the sensor and
the gear tooth should be 1.57 mm (0.062 inch).
Tighten the locknut.
12. Once the correct reading is obtained, remove
tooling and reinstall hardware.
Index
c
Case Drain Flow for Piston Motor - Test and
Adjust
51

Bench Test
Machine Test
Piston Pump Servo Neutral - Test and Adjust
Fixed Frequency and Variable Frequency
42
43
43
50
50
D
R
Drum
12, 34
E
Eccentric Weight
14
Relief Valve (Charge) - Test and Adjust

Vibratory System OFF
Vibratory System ON
Relief Valve (Piston Pump) - Test and Adjust
High Amplitude
Low Amplitude
43
44
45
45
46
47
G
S
General Information
15
H
Hydraulic Control Neutral (Piston Pump) - Test and
Adjust
49
Variable Frequency
49
Hydraulic Oil Contamination - Test
42
5
Hydraulic Tank
4
4
8
15
T
Table of Contents
Troubleshooting.
3
42
37
37
I
V
Important Safety Information
M
Machine Preparation for Troubleshooting
Manifold Valve
Return Manifold
37
33
34
34
6
P
Piston Motor
Case Flushing
Piston Pump
Main Relief Valve
Servo Piston Assembly
Solenoid Valve
Test At Full Speed
Variable Frequency Electrical Control (If
Equipped)
2000 Caterpillar
All Rights Reserved
9, 32
33
7, 23
26
29
28
7
Variable Frequency Electrical Control - Test and

Adjust (If Equipped)
56
Controller
58
Voltage Regulator Test
56
Vibratory Frequency - Test and Adjust
52
Fixed Frequency
52
Variable Frequency
53
Vibratory Hydraulic System
17
Vibratory System
17, 19,21
Vibratory Magnetic Sensor - Test and Adjust
62
Vibratory Support
10
Tightening Procedure for the Spanner Nut
10
Vibratory System Troubleshooting
39
Operational Checks
39
Probable Causes of Vibratory System
Problems
39
Vibratory Electrical Circuit
40
61
Visual Inspection
38
29
Printed in U.S.A.

Specifications Systems Operation Testing and Adjusting - CS-531D, CP-533D and CS-533D Vibratory Compactors Vibratory System

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Specifications Systems Operation Testing and Adjusting - CS-531D, CP-533D and CS-533D Vibratory Compactors Vibratory System

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KENR3526

CS-531D, CP-533D and CS533D Vibratory Compactors

Important Safety Information

Systems Operation Section

Testing and Adjusting Section

Testing and Adjusting

(2) Torque for breather valve

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

200 x 200 stainless

200 x 200 stainless

Torque for suction screen (5)

(6) Torque for temperature sender

Hydraulic Oil Filter

(1) The oil filter bypass indicator will become red

Manifold Valve and Mounting

(1) Torque for thermal bypass valve .. 48 to 54 N-m

(8) Main loop

Thermal bypass valve (1) begins to close when

(10) Hydraulic tank

Thermal bypass valve (1) is fully closed when the

(12) Diameter of internal orifice

Rotation from the drive end

variable displacement pump

39 cc/rev (2.38 cu in/rev)

internal 8.4 cc (.51 in3)

(2) High pressure relief valves

Note: The charge pressure is measured at the

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

Test At Full Speed

84.9 L/min (22.1 US gpm)

84.1 L/min (21.9 US gpm)

Use 6V-4876 Lubricant on splines.

(5) Solenoid for the fixed frequency pump

Test At Half Speed

Solenoid for the variable frequency pump

42.5 L/min (11.1 US gpm)

42.0 L/min (11.0 US gpm)

Support and Vibratory Drive

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

Note: Motor rotation can be clockwise or

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

(2) Shaft spline

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

5 L/min (1.3 us gpm)

Tightening Procedure for the

2. Install the bearing cone (3) into the cup (10).

Note: The bearing should be clean and dry of all

Part No.: 139-2035, 139-2036

(1) Apply 4C-9507 Retaining Compound to the

(2) Apply 6V-4876 Lubricant to splines. In the

90 15 N.m (66 11 lb ft)

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

Note: In order to fill the reservoir, the position of

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

(6) Rotate the lobe of the weight downward. Orient

Systems Operation Section

Vibratory System Schematic

The vibratory system consists of the following

The variable frequency system is an option for

Right Side Of Engine

Left Side Of Machine

(1) Vibratory pump.

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