CS563

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Producto: VIBRATORY COMPACTOR

Modelo: CS-563 VIBRATORY COMPACTOR 8XF
Configuración: CS-563 & CP-563 VIBRATORY COMPACTORS 8XF00001-
00778 (MACHINE) POWERED BY 3116 ENGINE
Pruebas y Ajustes
CP-563 & CS-563 VIBRATORY COMPACTORS VIBRATION SYSTEM
Número de medio -KENR1588-01 Fecha de publicación -01/11/1993 Fecha de actualización -10/10/2001
Testing And Adjusting
Introduction
Reference: For Specifications with illustrations, refer to the Specifications for the CP-563 & CS-563
Vibration System, Form No. KENR1587-01. If the Specifications in Form No. KENR1587-01 are not
the same as listed in the Systems Operation and the Testing And Adjusting, look at the print date on the
front cover of each book. Use the Specifications listed in the book with the latest date.
Troubleshooting
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 4C4892 ORFS Fittings Group can be used to make pressure tests on the vibration 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 mm (in) measuring rule are usable tools.
When any test is made of the vibration system, the hydraulic oil must be at the normal temperature for
operation.
Sudden movement of the machine or release of oil under pressure can

cause injury to persons on or near the machine. To prevent possible
injury, do the procedure that follows before testing and adjusting the
vibration system.
1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.
" Copia Ingeniero Araque"

2. Permit only one operator on the machine. Keep all other personnel either away from the machine or
in view of the operator.
3. Activate the parking brake.
4. Stop the engine.
5. Move the hydraulic control lever to all positions to release any pressure in the hydraulic system.
6. Carefully loosen the filler cap on the hydraulic oil tank to release any pressure in the hydraulic oil
tank.
7. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.
Visual Checks
A visual inspection of the vibration system and its components is the first step when a diagnosis of a
problem is made. Then check the operation of the machine. Finally, check the vibration system with
instruments. Stop the engine, make the following inspections.
Do not check for leaks with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
1. Check the oil level of the hydraulic oil tank.
2. Look for air in the oil that is in the hydraulic oil tank. Do this immediately after the machine is
stopped. Use a clear bottle or container to get a sample of the oil. Look for air bubbles in the oil that is
in the bottle.
3. Check all oil lines, hoses and connections for leaks and damage. Look for oil on the ground under the
machine.
4. Remove and check the hydraulic filter element for foreign materials.
a. Bronze-colored particles give an indication of pump port plate failure.

b. Shiny steel particles give an indication of pump or motor piston failure or motor cam
deterioration.
c. Rubber particles give an indication of a seal or hose failure.
d. Aluminum particles give an indication of steering pump failure.
Checks During Operation

With the engine running, operate the machine in each direction and from low to high speed. Make note
of all noises that are not normal and find their sources. If the operation is not correct, refer to the list of
problems and probable causes.
The checks during operation can be used to find leakage in the system. They can also be used to find a
bad valve, pump or motor. Vibratory frequency can be used to check the condition of the vibration
motors and the pump.
Prior to checking the vibration system, drive the machine backwards and forwards several times
operating the propulsion controls in all speed ranges. While the machine is being driven backwards and
forwards, check the condition of the rubber blocks. The blocks act as an isolator between vibrating and
non-vibrating parts of the machine.
Check for the sound of the relief valves opening. The opening pressures of the relief valves are given in
Relief Valve Pressure Tests in Testing And Adjusting.
Problem: Vibration does not work in high or low amplitude.
Probable Cause:
1. Low charge oil pressure caused by:

a. Low oil level in hydraulic oil tank.
b. Restricted hydraulic filter element.
c. Failure of the steering pump.
d. Charge relief valve adjustment not correct.
e. Failure of the servo control assembly.
f. Failure of the vibration control solenoid valve.
g. Main relief valve setting is not correct or valve does not close.
h. Pump port plate wear causing excessive leakage from the high pressure line into the
pump housing.
j. Motor port plate wear.
2. Failure of the engine accessory drive.
3. Faulty vibratory control switch on the console.
4. Faulty vibratory selector switch on the console.
5. Electrical problem with EDC or the wiring to the EDC.
Problem: Periodic loss of vibration in high or low amplitude.
Probable Cause:
1. Faulty vibratory control switch.

2. Faulty vibratory selector switch.
3. Loose connection in the electric circuit wiring.
Problem: Harsh engagement of vibration.
Probable Cause:
1. Charge circuit relief valve is set too high.

Problem: Slow vibration frequency stopping.
Probable Cause:
1. Main relief valve does not close correctly on the return side of the closed circuit loop line.
Problem: Compactor will not reach maximum vibration frequency.
Probable Cause:
1. Drum oil level is to high.

2. Engine high idle is not correctly adjusted.
3. Frequency gauge (if equipped) is defective or not correctly adjusted.
4. Failure of the steering pump.
5. Charge relief valve adjustment is not correct.
6. Pump port plate wear causing excessive leakage from the high pressure line into the pump
housing.
7. Motor port plate wear.
8. Adjustment of the maximum pump displacement is not correct.
9. Hydraulic oil filter plugged. Charge oil is bypassed to hydraulic oil tank.
10. Failure of the vibratory bearings.
11. Failure of the O-rings for the servo piston assembly.
Problem: Variation in maximum frequency readings between high and low amplitude.
Probable Cause:
1. Incorrect neutral adjustment of the pump servo control assembly.

2. Mechanical failure of the pump servo control assembly.
3. Main relief valve setting is not correct or valve does not close correctly on one side of the loop
line.
4. Failure of the pump swashplate assembly.
Problem: Noisy vibratory mechanism.
Probable Cause:
1. Lack of lubrication oil in the vibrator housing.

2. Failure of the vibration drive shaft.
3. Loose retaining bolts for the vibration motor.
Problem: Hydraulic circuit oil overheats.
Probable Cause:
1. Incorrect type of oil used in the hydraulic system.

2. Hydraulic oil cooler is restricted.
3. Excessive internal leakage in the closed circuit.
4. Not enough charge line pressure.
5. Cooling relief valve pressure setting higher than pump charge relief valve pressure setting.

6. Failure of vibratory shaft bearings which causes extended periods of time over the vibratory
pump high pressure reliefs.
System Tests And Adjustments

Pump Efficiency Check
For any pump test at a given rpm, the pump flow at 690 kPa (100 psi) will be larger than the pump flow
at 6900 kPa (1000 psi). The difference between the pump flow of the two operating pressures is the
flow loss.
Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.
If the percent of flow loss is more than 10%, pump performance is not good enough.
*
The numbers in the examples are for illustration and are not values for any specific pump or pump
condition. See Specifications for pump flow of a new pump at 690 kPa (100 psi) and 6900 kPa (1000
psi).
Machine Test
Install a Flow Meter. For Formula I, measure pump flow at 690 kPa (100 psi) and at 6900 kPa (1000
psi) with the engine at high idle rpm.

Bench Test
If the bench test can be run at 6900 kPa (1000 psi) and at full pump rpm, find the percent of flow loss
using Formula I.
If the bench test cannot be run at 6900 kPa (1000 psi) and 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 part of Formula II. For the bottom part of the formula, run the pump shaft at 2000 rpm. Measure the
pump flow at 690 kPa (100 psi).
Pressure Test Tools
Use the above fittings group for all of the pressure tests that follow. In some procedures, more than one
of the same pressure gauge is required. It may be necessary to use two fittings groups.
Vibratory/Propulsion Pump Charge Relief And

Cooling Valve Pressure Verification Test
NOTE: The hydraulic system cooling is dependent upon flow through the oil cooler and case flushing
of the system motors. To accomplish this, two different charge pressures are measured on the machine.
The first charge pressure which is measured after the charge filter is determined by the charge relief

settings in the vibration pump and the axle and drum propel pumps. A high case pressure reading may
be an indication of excessive internal leakage or an improperly set pump charge relief valve.
A low case pressure reading may be an indication of an improperly set charge relief valve (too high) or
an improperly set charge relief valve (too low) on another circuit.
The second pressure is measured at the vibration cooling valve. This pressure is measured when the
vibratory and propel systems are in use. The setting is referred to as the cooling relief valve setting and
is lower than the charge relief setting. This differential in pressure assures that low pressure oil from the
return side of the closed loop hydraulic circuits constantly flows back to the oil cooler from the
vibration and propulsion cooling valves. This allows cooled and filtered charge pressure to enter the
low pressure side of the closed loop through the makeup check valves in the propulsion pumps.
If the cooling relief valve is set improperly it may cause the hydraulic system to overheat. Case flushing
and cooling of the vibratory and two propel circuits are dependent upon the settings of the these charge
relief valves.
The following procedure should be used to verify the charge relief valves:
NOTE: The hydraulic oil used for the test is a SAE 15 weight with temperature at 38°C (100°F). A
different weight hydraulic oil and temperature will affect the pressure readings.
Vibration Pump
(1) Case drain line. (2) Vibration pump.
1. Disconnect case drain line (1) at vibration pump (2). Install a tee, quick disconnect, and 0 to 2067
kPa (0 to 300 psi) pressure gauge from the fittings group. On the vibration pump adapter that the case
drain line was disconnected. Connect the case drain line to the tee. This pressure gauge will measure
the vibration system case pressure.
Axle and Drum Propulsion Pumps

(3) Axle propulsion pump. (4) Case drain line. (5) Case drain line. (6) Drum propulsion pump.
2. Repeat Step 1 for the axle and drum propel pumps. These will measure the axle and drum system
case pressures.
Parking Brake And Speed Shift Valve (Earlier machines)

(7) Charge pressure test port.
Location At Rear Of Seat (Later machines)

(8) Charge pressure test port.
3. Install a 0 to 4000 kPa (0 to 580 psi) pressure gauge at the brake shift valve for earlier machines.
Install a 0 to 4000 kPa (0 to 580 psi) pressure gauge at the quick disconnect after the filter for later
machines.
Vibratory Cooling Manifold (Earlier machines)

(9) Vibratory cooling manifold. (10) Oil line.

Vibration Cooling Valve (Later machines)
(11) Test port.
4. Install a 0 to 4000 kPa (0 to 580 psi) pressure gauge at the vibratory cooling valve, oil line (10) for
earlier machines. Install a 0 to 4000 kPa (0 to 580 psi) pressure gauge at test port (11), located at the
vibratory cooling valve on later machines.
5. Start and run the engine at high idle 2350 ± 50 rpm until the hydraulic oil temperature reaches 38°C
(100°F). You may turn the steering wheel to go against the steering pivot stops to increase the
temperature.
NOTE: If difficulty is experienced in getting the system temperature up to 38°C (100°F), it may be
necessary to operate the machine. Another method of increasing the system temperature is to
disconnect oil line (2) from the vibration cooling valve and install a plug in the hose and a cap in the
adapter.
6. Once the system reaches 38°C (100°F) remove the plug and cap from the vibratory cooling valve (if
installed previously).
7. Activate the vibratory system momentarily, this shifts the shuttle valve spool in the vibratory cooling
relief valve.
8. Record the three readings: system case, cooling relief valve, and charge pressure. Use the chart
below as a reference:
9. Case pressures recorded are a result of balancing the supply charge flow from the steering pump. A
low case pressure on one system will usually result in another system having a higher case pressure.
High case pressures may be a result of a case drain restriction, higher than normal internal leakage or
an improperly set charge relief valve.
Lower than nominal pressures on all three case pressure gauges would be a result of insufficient
steering pump output or a bypassing charge filter.

If higher than normal case pressure readings are seen on one system perform the pump adjustment
procedure for the three charge relief valves.
Adjusting Vibration/Propulsion Pump Charge

Relief Valves

(1) Vibratory cooling manifold. (2) Oil line.

(1) Vibration cooling valve. (2) Oil line.

Vibration Pump
(3) Case drain line. (4) Vibration pump.
1. Disconnect oil line (2) from vibratory cooling manifold (1) (earlier) and vibration cooling valve (1)
(later). Install plugs in the oil line and cap the ports of the vibratory cooling manifold and vibration
cooling valve.
2. Disconnect case drain line (3) of vibration pump (4). Install a tee, quick disconnect and a 0 to 2070
kPa (0 to 300 psi) pressure gauge from the fittings group on the vibration pump adapter that the case
drain line was disconnected. Connect the case drain oil line to the tee. The pressure gauge will measure
the vibratory system case pressure.
Axle and Drum Propulsion Pumps

(5) Axle propulsion pump. (6) Case drain line. (7) Case drain line. (8) Drum propulsion pump.
3. Repeat Step 2 for the axle and drum propel pumps. These will measure the axle and drum system
case pressures.
4. Install a 0 to 4000 kPa (0 to 580 psi) pressure gauge at the brake shift valve for earlier machines.
Install a 0 to 4000 kPa (0 to 580 psi) pressure gauge at the charge pressure tap, located after the charge
filter on later machines.
5. Install a tachometer on the engine to measure engine speed.
6. Engage the parking brake and put the propulsion lever in the STOP position. Start and run the engine
at high idle (2350 ± 50 rpm) until the hydraulic oil tank temperature reaches 38°C (100°F).
7. Stop the engine. Turn both adjustable charge relief valves for the axle and drum propel pumps
closed. This will allow the shimmable charge relief valve in the vibratory pump initially determine the
system charge pressure.
8. With the engine at low idle of 800 rpm and the hydraulic oil temperature at 38°C (100°F), record the

pressure at the charge filter and vibratory case pressure and determine the difference.
NOTE: A shim stack height of 11.2 mm (.44 in) may be used as a reference point. It should not be
necessary to install more than 12.2 mm (.48 in) stack of shims.
Add shims (to increase pressure) or remove shims (to decrease pressure) to vibration pump charge
relief valve to bring the differential pressure to 2894 ± 138 kPa (420 ± 20 psi). Record the final
pressure at charge pressure port and use this pressure as a reference pressure to set the two propulsion
pump charge relief valves. Stop the engine.
9. Slowly open the charge relief on the axle propel pump approximately three turns. Start the engine
and increase the engine to 1575 rpm. With the hydraulic oil temperature at 38°C (100°F) turn the
adjustable relief valve until the charge filter pressure is the same as the reference pressure recorded in
Step 8. Tighten the locknut to a torque of 46 to 55 N·m (34 to 41 lb ft). Stop the engine.
10. Slowly open the charge relief valve on the drum propulsion propel pump approximately three turns.
Start the engine and increase the engine rpm to 2350 rpm (high idle). With the hydraulic oil
temperature at 38°C (100°F) adjust the adjustable charge relief valve to the charge pressure is 68 kPa
(10 psi) higher than the reference pressure recorded in Step 8. Tighten the locknut to a torque of 46 to
55 N·m (34 to 41 lb ft).

11. Stop the engine and reconnect the oil line from the vibration cooling valve to the hydraulic return
manifold.
12. Finish by performing the verification test. When finished remove all test equipment and reconnect
hoses.
Cooling Relief Valve Pressure Test
Make reference to WARNING on first page of Troubleshooting.
NOTE: This charge pressure should be checked while propelling and running the vibration system. For
this reason, it is recommended that the test be performed outside in an area clear of obstacles and
personnel. The soil should be uncompacted and the hydraulic oil temperature should be 38°C (100°F).
1. Make sure the parking brake is engaged and the propulsion control lever is in the STOP position.

(1) Oil line.

(1) Test port.
2. For earlier machines that do not have a quick disconnect port located at the vibratory cooling
manifold install a tee and quick disconnect after removing oil line (1).
3. Connect a hose and a 0 to 4000 kPa (0 to 580 psi) pressure gauge to quick disconnect on the

vibratory cooling manifold (earlier) or test port (1) on the vibration cooling valve (later). The hose
should be long enough to allow operation of the machine while performing this test.
Control Panel
(2) Vibratory control switch. (3) Propulsion control lever. (4) Vibratory selector switch. (5) Parking brake switch.
4. Start and run the engine at high idle. Engine rpm should be 2350 ± 50 rpm. The hydraulic oil
temperature should be 38°C (100°F).
5. Pull up on parking brake switch (5) to release the parking brake.
6. Move vibratory selector switch (4) to the HIGH AMPLITUDE position.
7. Move propulsion control lever (3) forward to operate the machine in a forward direction and depress
vibratory control switch (2) to the ON position to start the vibration system. Make a note of the reading
on the pressure gauge. The cooling relief valve setting should be 2400 ± 140 kPa (350 ± 20 psi).
NOTE: If there is not enough area to propel the machine or it is necessary to perform this test inside,
this test may be performed with just running the vibration system. It is recommended that the drum be
placed on tires to simulate an uncompacted soil condition. In this condition the cooling relief valve
pressure setting should be 2343 ± 140 kPa (340 ± 20 psi). The lower pressure is a result of reduced oil
flow through the cooling relief valve.

(6) Cooling relief valve.

(6) Cooling relief valve.
8. If the cooling relief valve setting is not correct, stop the machine and the engine. Loosen the locknut
on the relief valve on vibration cooling manifold (1) (earlier) and on cooling relief valve (6) at the
vibration cooling valve (later). Turn the adjustment screw clockwise to increase the pressure or
counterclockwise to decrease the pressure. Tighten the locknut and check cooling relief valve pressure
setting again.
9. When the pressure setting for the cooling relief valve is correct, remove the gauge from the test
ports.
NOTE: On later machines this adjustment is factory set.
Main Relief Valve Pressure Test

High Amplitude
NOTE: This main relief pressure should be checked while running the vibratory system. For this
reason, it is recommended that the drum be placed on tires to simulate an uncompacted soil condition.
The hydraulic oil temperature should be 38°C (100°F).
1. Make sure the parking brake is applied, and the propulsion control lever is in the STOP position.

Vibration Cooling Valve
(1) Test port.
2. Connect a 60 000 kPa (8700 psi) pressure gauge to test port (1).
Control Panel
(2) Vibratory control switch. (3) Vibratory selector switch.
4. Start and run the engine at high idle. Engine rpm should be 2350 ± 50 rpm.
5. Look at the gauge and depress vibratory control switch (2) to the ON position to start the vibration
system.
NOTE: The force needed to overcome the inertia of the weights will cause 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 24 000 to 28 250 kPa (3500 to 4100 psi).

Vibration Pump
(4) High amplitude relief valve.
7. If the high amplitude relief valve setting is not correct, high amplitude relief valve (4) must be
replaced.
8. When a new high amplitude relief valve is installed, check the pressure setting again. If it is correct,
stop the engine and remove all tooling.
NOTE: If continued high pressure operation is seen, a problem may exist with the vibration drive
mechanism.
Low Amplitude
NOTE: This main relief pressure should be checked while running the vibratory system. For this
reason, it is recommended that the drum be placed on tires to simulate an uncompacted soil condition.
The hydraulic oil temperature should be 38°C (100°F).

(1) Test port.
2. Connect a 60 000 kPa (8700 psi) pressure gauge to test port (1).
Control Panel
3. Move vibratory selector switch (3) to the LOW AMPLITUDE position.
5. Look at the gauge and depress vibratory control switch (2) to the ON position to start the vibration
system.
NOTE: The force needed to overcome the inertia of the weights will cause the pressure in the vibration
system to momentarily reach to 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 24 000 to 28 250 kPa (3500 to 4100 psi).
Vibration Pump
(4) Low amplitude relief valve.
7. If the low amplitude relief valve setting is not correct, low amplitude relief valve (4) must be
replaced.

8. When a new low amplitude relief valve is installed, check the pressure setting again. If it is correct,
stop the engine and remove all tooling.
Vibratory Amplitude Valve Test

Fixed Frequency
NOTE: Tests should be performed on tires or loose non-compacted soil. Rubber tires are
recommended. Never operate the vibration system when the machine is on concrete.
1. Make sure the parking brake is applied, and the propulsion control lever is in the neutral position.
Vibration Pump
(1) Protective cap. (2) Servo control lines.
2. Disconnect servo control lines (2) from the vibration pump. Install two 7X2444 Swivel Tees and
6V3965 Quick Disconnects in the lines. Connect two 4000 kPa (600 psi) pressure gauges to the swivel
tees and quick disconnects.
3. Start and run the engine at high idle. Look at the 4000 kPa (600 psi) pressure gauges. Both readings
should read zero. If a gauge reading is more than zero repair or replace vibratory amplitude valve as
required. When both pressures are at zero proceed to the vibratory amplitude valve test Step 4.
4. Place the vibratory amplitude switch in high amplitude. With the engine at high idle start the
vibratory system the pressure on lower gauge (bottom side of vibratory pump) should increase to
system charge pressure 3032 ± 138 kPa (440 ± 20 psi) and remain there. The machine vpm should
increase to its maximum valve of 1875 ± 25 vpm. Stop the vibration system by depressing the vibratory
control switch to the OFF position.
5. Place the vibratory amplitude switch in low amplitude. With the engine at high idle start the
vibratory system. The pressure on the upper gauge should (top side of vibratory pump) should increase
to system charge pressure and remain there. The machine vpm should increase to its maximum valve of
1875 ± 25 vpm. Stop the vibration system by depressing the vibratory control switch to the OFF

position.
6. Remove gauges and hardware and reconnect the servo control lines.
Swashplate Neutral Adjustment Procedure

(Fixed Frequency)

(1) Test port. (2) Test port.
2. Remove and plug the hose and cap the adapter.
3. Connect two 60 000 kPa (8700 psi) pressure gauges to test ports (1) and (2).
Vibration Pump
(3) Protective cap. (4) Servo control lines.
4. Disconnect servo control lines (4) from the vibration pump. Plug and cap the hoses. Install a 3445
kPa (500 psi) minimum pressure hose between the two ports where the servo control lines were
connected.

5. Start and run the engine at low idle.
6. Look at the 60 000 kPa (8700 psi) pressure gauges. Both readings should be the same and should be
approximately the same as the charge pressure.
7. If it is necessary to adjust the neutral position of the servo piston, remove protective cap (3). Loosen
the locknut and turn the adjustment screw to get the same pressure reading on each gauge.
8. Stop the engine. Remove the two 60 000 kPa (8700 psi) pressure gauges and replace them with two
4000 kPa (580 psi) pressure gauges or two Tetra gauges.
NOTE: Using a lower pressure gauge may damaged the gauge.
10. Turn the adjustment screw until both pressure gauge readings are the same. Turn the adjustment
screw clockwise until one of the pressure readings starts to increase. Note the position of the
adjustment screw.
11. Now turn the adjustment screw counterclockwise until the reading on the other pressure gauge
begins to increase. Note the position of the adjustment screw. Turn the adjustment screw clockwise
one-half the distance to the first adjustment screw position.
12. Hold the adjustment screw and tighten the locknut to a torque of 18 to 24 N·m (13 to 18 lb ft).
Install protective cap (3).
13. Stop the engine. Remove the pressure gauges from the test ports.
14. Install servo control oil lines (4) on the vibration pump.
Vibration Tachometer Calibrations
Vibration Tachometer
(1) Dial. (2) Small calibration screw.
Compare frequency of the vibratory system on the gauge to that of hand held Vibration Tachometer
773904.
Large dial (1) should be set on #8.

Small calibration screw (2) can be used to calibrate the gauge. A 2.0 mm (5/64) allen wrench should be
used to adjust the small calibration screw. On earlier machines the console cover must be removed to
gain access to the calibration screw. On later machines, an access hole is available on the bottom side
of the console.
Vibratory Frequency Test

(Machines With Vibratory Amplitude Valve/Fixed Frequency)
NOTE: Tests should be performed on tires or loose dirt. Tires are recommended. Never operate the
vibration system when the machine is on concrete.
NOTE: The oil in the system must be SAE 10W hydraulic oil. The oil temperature must be 38°C (100°
F) to get correct results. The vibratory frequency should be measured after the vibration system has run
for 15 minutes.
1. Make sure the parking brake is applied and the propulsion control lever is in the STOP position.
Control Panel

Gauge Panel
(3) Vibrations per minute (vpm) gauge (optional).
4. Depress vibratory control switch (1) to the ON position to start the vibration system. Read the
vibrations per minute (vpm) from optional gauge (3) and/or read the vpm from the 773904 vibration
tachometer. The maximum vpm setting for high amplitude should be 1875 ± 25 vpm.
5. Depress the vibratory control switch to the OFF position to stop the vibration system. If the
maximum vpm setting is not correct, the high amplitude limiter on the vibration pump servo must be
adjusted.
Vibration Pump
(4) High amplitude limiter. (5) Vibration pump. (6) Low amplitude limiter.
6. To adjust the maximum vpm setting for high amplitude, adjust high amplitude limiter (4) on the
servo of vibration pump (5).
7. Hold the adjustment screw in place with a screwdriver and loosen the locknut. To decrease the
number of vibrations per minute (vpm), turn the adjustment screw clockwise. To increase the number
of vibrations per minute (vpm), turn the adjustment screw counterclockwise. Hold the adjustment screw
and tighten the locknut to a torque of 5.4 to 9.5 N·m (48 to 84 lb in).

Control Panel
8. Move vibratory selector switch (2) to the LOW AMPLITUDE position.
Gauge Panel
(3) Vibrations per minute (vpm) gauge (optional).
vibrations per minute (vpm) from optional gauge (3) and/or read the vpm from the 773904 vibration
tachometer. The maximum vpm setting for low amplitude should be 1875 ± 25 vpm.
11. Depress the vibratory control switch to the OFF position to stop the vibration system. If the
maximum vpm setting is not correct, the low amplitude limiter on the vibration pump servo must be
adjusted.

Vibration Pump
(4) High amplitude limiter. (5) Vibration pump. (6) Low amplitude limiter.
12. To adjust the maximum vpm setting for low amplitude, adjust low amplitude limiter (6) on the
servo of vibration pump (5).
13. Hold the adjustment screw in place with a screwdriver and loosen the locknut. To decrease the
number of vibrations per minute (vpm), turn the adjustment screw clockwise. To increase the number
of vibrations per minute (vpm), turn the adjustment screw counterclockwise. Hold the adjustment screw
and tighten the locknut to a torque of 5.4 to 9.5 N·m (48 to 84 lb in).
Vibration Amplitude Valve Coil Resistance

Procedure (Fixed Frequency)
1. Disconnect the negative battery cable from the negative (-) battery terminal.
2. Disconnect the wire connector for the vibration amplitude valve.

End View Of Wire Connector From Vibration Amplitude Valve
(1) Low amplitude energized pin. (2) High amplitude energized pin. (3) Ground pin. (4) Ground pin.
Measuring Resistance Of High Amplitude Coil

(5) Multimeter. (6) Vibration Amplitude Valve. (7) High amplitude coil.
3. Connect one of the leads from multimeter (5) to high amplitude energized pin (2). Connect the
remaining multimeter lead to ground pin (3).
4. Measure the resistance across two the pins. Resistance for high amplitude coil (7) should be 39.3 ± 2
ohms.

Measuring Resistance Of Low Amplitude Coil
(5) Multimeter. (6) Vibration Amplitude Valve. (8) Low amplitude coil.
5. Connect one of the leads from multimeter (5) to low amplitude energized pin (1). Connect the
6. Measure the resistance across two the pins. Resistance for the low amplitude coil should be 39.3 ± 2
ohms.
7. If either resistance reading is not correct, replacement of the coil is necessary.

Measuring Resistance Between High Amplitude Coil And Ground
(5) Multimeter. (6) Vibration Amplitude Valve. (7) High amplitude coil.
8. Connect one of the leads of multimeter (5) to high amplitude energized pin (2) and the other
multimeter lead to an electrical ground.
9. Measure the resistance between high amplitude pin (2) and the electrical ground. The multimeter
should read OL (open limit).

Measuring Resistance Between Low Amplitude Coil And Ground
(5) Multimeter. (6) Vibration Amplitude Valve. (8) Low amplitude coil.
10. Connect one of the leads of multimeter (5) to low amplitude energized pin (1) and the other
11. Measure the resistance between low amplitude pin (1) and the electrical ground. The multimeter
should read OL (open limit).
12. If the multimeter readings are not correct, the coil(s) should be replaced.
13. After the tests and/or repairs are completed, remove the multimeter leads from the vibration
amplitude valve coils.
14. Connect the wire connector to the vibration amplitude valve.
15. Connect the negative battery cable to the negative (-) battery terminal.
Vibration Motor Case Leakage Test

NOTE: The oil in the system must be SAE 10W hydraulic oil. The oil temperature must be 38°C (100°
F) to get correct results.
1. Make sure the parking brake is applied and the propulsion control lever is in the STOP position.
Make sure the vibratory control switch on the propulsion control lever is in the OFF position.
Vibration Motor
(1) Vibration motor. (2) Case drain hose to hydraulic tank. (3) Case drain hose from vibration pump.
2. Disconnect hoses (2) and (3) from vibration motor (1). Use a union to connect the hoses together.
Connect hoses to the fittings from which hoses (2) and (3) were removed. Put the other end of the hoses
in a 19 liter (5 U.S. Gallons) container.
3. Move the vibratory selector switch to the HIGH AMPLITUDE position.
4. Start and run the engine at high idle until the hydraulic oil temperature reaches 38°C (100°F). Engine
rpm should be 2350 ± 50 rpm.
5. Depress the vibratory control switch to the ON position to start the vibration system. At the same
time the switch is depressed, move the hoses to a second 19 liter (5 U.S. Gallons) container. At the end
of one minute, move the hoses back to the first container.
6. Depress the vibratory control switch to the OFF position to stop the vibration system. Stop the
engine.
7. Measure the amount of oil in the second container. If there is more than 4 liters (1 U.S. Gallons), the
vibration motor has too much internal leakage and must be repaired or replaced.
8. Remove all test tooling and connect hoses (2) and (3) to vibration motor (1).
Vibration Speed Adjustment

Machines With Variable Frequency

1. Make sure the parking brake is applied and the propulsion control lever is in neutral.
Control Panel
(1) Vibratory control switch. (2) Vibration per minute (vpm) control dial. (3) Vibratory selector switch.
3. Turn vibrations per minute (vpm) control dial (2) clockwise to the maximum vpm position.
4. Start and run the engine at 2350 rpm (high idle).
Gauge Panel
(4) Vibrations per minute (vpm) gauge.
vibrations per minute (vpm) from gauge (4). The reading for maximum vpm setting should be 1875 ±
25 vpm.
6. Depress the vibratory control switch to the OFF position to stop the vibration system. Turn vpm
control dial (2) counterclockwise to the minimum vpm position.

vibrations per minute (vpm) from gauge (4). The reading for minimum vpm setting should be 1400 ±
50 vpm.
8. Depress the vibratory control switch to the OFF position to stop the vibration system.
9. If the maximum or minimum vpm settings are not correct, the vpm potentiometers must be adjusted.
The electrical circuits on the listed machines have gone through three changes.
(8XF1-222 and 1YJ1-129)
The first generation of machines has two potentiometers in the circuit. One potentiometer controls the
amperage to Electronic Displacement Control (EDC) on the vibratory pump for setting maximum
frequency (vibrations per minute) in high and low amplitude. The second potentiometer controls
amperage to EDC for setting minimum frequency. The chart lists the specifications for the high and
low frequency (vpm).
Use the following wiring schematic and photo to locate and identify the potentiometers for adjustments
on these machines.

Wiring Schematic Of Lever Panel Area
Location of Potentiometers
(5) Maximum vpm potentiometer. (6) Adjustment screw. (7) Adjustment screw. (8) Minimum vpm potentiometer.
10. To adjust the vpm potentiometers, remove the four bolts that hold the control panel in place and
move the control panel to the side.
11. If the maximum vpm setting is not correct, adjust potentiometer (5). To increase the maximum vpm
setting, loosen the locknut and turn adjustment screw (6) clockwise. To decrease the maximum vpm
setting, turn the adjustment screw counterclockwise.
NOTE: Maximum VPM should be adjusted before the minimum VPM.
12. If the minimum vpm setting is not correct, adjust potentiometer (8). To increase the minimum vpm
setting, loosen the locknut and turn adjustment screw (7) clockwise. To decrease the minimum vpm
setting, turn the adjustment screw counterclockwise.

13. After the maximum and minimum vpm settings are adjusted, check the settings again. When the
settings are correct, tighten the locknut on the potentiometer and position the control panel and install
the four bolts that hold it in place.
(8XF223-487, 7GG1-171, 1YJ130-262, 5AJ1-58)
The second generation of machines has one potentiometer in the circuit which is used to set the
minimum frequency (vpm) for both high and low amplitude. The upper potentiometer has been
eliminated and a set of mechanical stop bolts replace it to set the maximum frequency (vpm) in high
and low amplitude.
To make adjustments to the vibration system, use the following adjustment procedure.
View Of Servo Housing And Adjustment Bolts.

(9) Top servo stop bolt. (10) Locknut. (11) Bottom servo stop bolt.
Use following wiring schematic and photo to locate and identify the potentiometer for adjustments on
these machines.

Wiring Schematic Of Lever Panel Area
(5) Potentiometer removed.
Location Of Potentiometer
(5) Maximum vpm potentiometer eliminated. Use stop bolts at vibratory pump to set maximum vpm in high and low
amplitude. (7) Adjustment screw and locknut. (8) Minimum vpm potentiometer for high and low amplitude.
1. Place the drum on rubber tires or non-compacted soil to verify and adjust the maximum and
minimum frequency in both high and low amplitude. The following specifications should be used:

2. Turn the frequency rheostat to the fully clockwise position for maximum frequency and place the
amplitude select switch in HIGH amplitude. Turn top servo stop bolt (11) at the pump IN or OUT to
achieve 1800 ± 25 vpm at full engine rpm (1875 ± 25 vpm if drum is on tires). When adjustment
produces the correct setting, tighten lock nut (10) on the stop bolt.
3. Place the amplitude select switch at LOW amplitude. Turn bottom servo stop bolt (9) at the pump IN
or OUT to achieve 1800 ± 25 vpm at full engine rpm (1875 ± 25 vpm if drum is on tires). When
adjustment produces the correct setting, tighten lock nut (10) on the stop bolt.
NOTE: Engine High Idle is 2350 ± 50 rpm.
4. Turn the frequency rheostat to the full counterclockwise position for minimum frequency. Place the
amplitude select switch to HIGH amplitude. Use the lower potentiometer to set the minimum frequency
to 1400 ± 25 vpm. Place the amplitude select switch to LOW amplitude. Use the lower potentiometer to
set the minimum frequency to 1400 ± 25 vpm.
5. When adjustments are made to the potentiometer settings, tighten the locknut on the potentiometer.
(8XF488-UP, 7GG172-UP, 1YJ263-UP, 5AJ59-UP)
The third generation of machines adds a second potentiometer (1G6251) in the circuit to set the
minimum frequency in low amplitude (upper potentiometer). The lower potentiometer is used to set
minimum frequency in high amplitude. The mechanical stop bolts at the vibratory pump are still used
to set the maximum frequency for both high and low amplitude.
A different weight assembly is used in this configuration to help in eliminating drum decoupling (the
point at which the drum loses contact with the ground). The different weights produce a lower
amplitude in the low amplitude range.
To make adjustments to the vibration system, with two potentiometers and the stop bolts at the
vibratory pump, use the following procedure.
Use following wiring schematic and photo to locate and identify the potentiometers for adjustments on
these machines.

Wiring schematic Of Lever Panel Area
Location Of Potentiometers
(5) Minimum vpm potentiometer for LOW amplitude. (6) Adjustment screw and locknut. (7) Adjustment screw and locknut.
(8) Minimum vpm potentiometer for HIGH amplitude.
1. Place the drum of the compactor on tires or on non-compacted soil. Turn the frequency rheostat to
the fully clockwise position for maximum frequency and place the amplitude select switch in HIGH
amplitude. Turn the upper servo bolt at the pump IN or OUT to achieve 1800 ± 25 vpm at full engine
rpm (1875 ± 25 vpm if drum is on tires). When adjustment produces the correct setting, tighten the lock
nut on the stop bolt.
2. Place the amplitude select switch at LOW amplitude. Turn the lower servo stop bolt at the pump IN
or OUT to achieve 1800 ± 25 vpm at full engine rpm (1875 ± 25 vpm if drum is on tires). When
adjustment produces the correct setting, tighten the lock nut on the stop bolt.
3. Turn the frequency rheostat to the full counterclockwise position for minimum frequency. Place the
amplitude select switch to HIGH amplitude. Use the lower potentiometer to set the minimum frequency

to 1400 ± 25 vpm. Place the amplitude select switch to LOW amplitude. Use the upper potentiometer to
set the minimum frequency to 1400 ± 25 vpm.
4. When adjustments are made to all potentiometer settings, tighten the locknuts on the potentiometers.
NOTE: Access for the potentiometer adjustment can be made at two access holes in the right hand side
console, just above the main circuit breaker reset button. The potentiometers have a straight slot for
adjustment.

Electrical Displacement Control (EDC) Neutral Adjustment
NOTE: It will be necessary to position the vibratory drum on tires or non-compacted soil while
running this procedure. Never operate the vibration system when the machine is on concrete.
1. Make sure the parking brake is applied and the propulsion control lever is in neutral.
Vibration Pump
(1) Servo port plug. (2) Wire connector for electrical displacement control (EDC).
1. Disconnect wire connector (2).
2. Remove servo port plug (1) from both sides of the servo control assembly. Install a 4000 kPa (600
psi) gauge in each servo port.

EDC Neutral Adjustment
(3) Electrical displacement control (EDC). (4) Locknut. (5) Adjustment screw.
3. Start and run the engine at low idle rpm.
4. Loosen locknut (4) on EDC (3), and slowly turn adjustment screw (5) until both gauge readings are
the same.
5. Turn the adjustment screw clockwise until one of the pressure gauge readings starts to increase. Note
the position of the adjustment screw.
6. Now turn adjustment screw (5) counterclockwise until the reading on the other pressure gauge begins
to increase. Note the position of the adjustment screw. Turn the adjustment screw one-half the distance
to the first screw setting.
7. Hold adjustment screw (5) and tighten locknut (4) to a torque of 2.8 to 3.4 N·m (25 to 30 lb in).
8. Stop the engine. Remove the gauges and install plug (1) on both sides of the servo control assembly.
Connect wire connector (2).
NOTE: The swashplate neutral adjustment procedure should be performed prior to doing the electrical
displacement control null adjustment. The swashplate neutral adjustment will affect the gauge readings.
Swashplate Neutral Adjustment Procedure


NOTE: It will be necessary to position the vibratory drum on tires or non-compacted soil while
running this procedure. Never operate the vibration system when the machine is on concrete.
NOTE: Make sure the parking brake is applied, and the propulsion control lever is in neutral.

(1) Vibration cooling valve. (2) Hose.
1. Remove and plug hose (2) and cap adapter at vibratory cooling valve (1). This hose is the one which
runs from the vibratory cooling valve to the hydraulic tank return manifold.

(3) Quick Disconnect. (4) Quick Disconnect.
2. Install pressure gauges 51675 kPa (7500 psi) on quick disconnects (3) and (4) in the vibratory
cooling valve. These are the ones used to measure vibratory system pressure.

Vibration Pump
(5) Top servo port.
3. Install a low pressure 3445 kPa (500 psi) minimum hose and needle valve between the servo port (5)
and the bottom servo port, on the opposite end. This will cross port the servos and remove the effects of
any control pressure on the servo piston.
4. Start the engine and slowly accelerate it to full rpm. Stroke the pump in both directions several times
and then stop the vibratory system.
5. With the servo cross-port line installed and the needle valve open, note the system pressure gauge
readings with engine running at low idle. The difference in the system pressure gauge readings is the
offset pressure.
NOTE: To achieve finer gauge resolution, lower pressure gauges will be required. 51 675 kPa (7500
psi) gauges are used at the beginning to prevent gauge damage.
6. If the offset pressure is not zero, remove the protective cap and loosen the servo locknut with an
11/16 hex wrench. Turn the servo adjustment screw with a 3/16 internal hex wrench to decrease the
highest system pressure to half of the offset pressure.
7. Close the needle valve (disconnect the servo cross port line/plug the servo ports) and remove the low
pressure gauges installed in Step 5. Stroke the pump in both directions. Return the pump to neutral
(non-vibratory) and open the needle valve (reinstall the cross port line) this will allow the servo spring
to locate the swashplate in the neutral position.
8. Reinstall the low pressure gauges and note the system pressure gauge readings. If the offset pressure
is not zero (0), repeat Steps 6 through 8.
9. Once the swashplate neutral has been found, hold the servo adjustment screw from turning and
torque the servo lock nut to 17.6 to 24.4 N·m (13 to 18 lb ft).
10. Stop the engine. Remove all gauges and reconnect the hose from the vibratory cooling valve to the
hydraulic return tank manifold.
Electrical Displacement Control Coil Resistance Procedure

1. Disconnect the negative battery cable from the negative (-) battery terminal.
2. Disconnect the wire connector from the EDC.
End View Of Wire Connector From EDC

(1) Low amplitude energized pin. (2) High amplitude energized pin. (3) Ground pin. (4) Ground pin.

Measuring Resistance Of The Coils
(5) Electrical Displacement Control (EDC). (6) Multimeter.
3. Connect one of the leads from multimeter (6) to high amplitude energized pin (2). Connect the
4. Measure the resistance across two the pins. Resistance for the high amplitude coil should be 19.5 ± 3
ohms.
5. Connect one of the leads from multimeter (6) to low amplitude energized pin (1). Connect the
6. Measure the resistance across two the pins. Resistance for the low amplitude coil should be 15.5 ± 3
ohms.
7. If either resistance reading is not correct, replacement of the electrical displacement control (EDC) is
necessary.

Measuring Resistance Between Coil And Ground
(7) Electrical Displacement Control (EDC). (8) Multimeter.
8. Connect one of the leads of multimeter (8) to low amplitude energized pin (1) and the other
9. Measure the resistance between pin (1) and the electrical ground. The multimeter should read OL
(open limit).
10. Repeat the measurement in Steps 8 and 9 for pins (2), (3), and (4). If the multimeter readings are
not correct, the electrical displacement control (EDC) should be replaced.
11. After the tests and/or repairs are completed, remove the multimeter leads from the EDC.
12. Connect the wire connector to the EDC.
13. Connect the negative battery cable to the negative (-) battery terminal.
Copyright 1993 - 2018 Caterpillar Inc. Fri Jun 15 16:56:54 EST 2018
Todos los derechos reservados.
Red privada para licenciados del SIS.

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Producto: VIBRATORY COMPACTOR

Testing And Adjusting

Sudden movement of the machine or release of oil under pressure can

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3. Activate the parking brake.

4. Stop the engine.

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

a. Bronze-colored particles give an indication of pump port plate failure.

Checks During Operation

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Problem: Vibration does not work in high or low amplitude.

1. Low charge oil pressure caused by:

Problem: Periodic loss of vibration in high or low amplitude.

1. Faulty vibratory control switch.

Problem: Harsh engagement of vibration.

1. Charge circuit relief valve is set too high.

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Problem: Compactor will not reach maximum vibration frequency.

1. Drum oil level is to high.

1. Incorrect neutral adjustment of the pump servo control assembly.

Problem: Noisy vibratory mechanism.

1. Lack of lubrication oil in the vibrator housing.

Problem: Hydraulic circuit oil overheats.

1. Incorrect type of oil used in the hydraulic system.

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System Tests And Adjustments

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Pressure Test Tools

Vibratory/Propulsion Pump Charge Relief And

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Axle and Drum Propulsion Pumps

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Parking Brake And Speed Shift Valve (Earlier machines)

Location At Rear Of Seat (Later machines)

Vibratory Cooling Manifold (Earlier machines)

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Adjusting Vibration/Propulsion Pump Charge

Vibratory Cooling Manifold (Earlier machines)

Vibration Cooling Valve (Later machines)

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Axle and Drum Propulsion Pumps

5. Install a tachometer on the engine to measure engine speed.

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Cooling Relief Valve Pressure Test

Make reference to WARNING on first page of Troubleshooting.

Vibratory Cooling Manifold (Earlier machines)

Vibration Cooling Valve (Later machines)

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5. Pull up on parking brake switch (5) to release the parking brake.

6. Move vibratory selector switch (4) to the HIGH AMPLITUDE position.

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Vibration Cooling Valve (Later machines)

NOTE: On later machines this adjustment is factory set.

Main Relief Valve Pressure Test

Make reference to WARNING on first page of Troubleshooting.

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3. Move vibratory selector switch (3) to the HIGH AMPLITUDE position.

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Make reference to WARNING on first page of Troubleshooting.

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3. Move vibratory selector switch (3) to the LOW AMPLITUDE position.