Testing and Adjusting HIDRAULIC

CP-533C CS-533C Vibratory Compactor 2XN00001-UP (MACHINE) POWERED BY...
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Producto: VIBRATORY COMPACTOR

Modelo: CS-533C VIBRATORY COMPACTOR 2XN
Configuracin: CP-533C CS-533C Vibratory Compactor 2XN00001-UP
(MACHINE) POWERED BY 3116 Engine
Pruebas y Ajustes
CP-533C, CS-533C, CP-563C, CS-563C, CS-573C & CS-583C VIBRAT
Nmero de medio -KENR2599-02 Fecha de publicacin -23/10/1997 Fecha de actualizacin -10/10/2001
Testing And Adjusting
Introduction
Reference: For Specifications with illustrations, refer to the Specifications for the CP-533C, CS-533C,
CP-563C, CS-563C, CS-573C, & CS-583C, Propel System, Form No.KENR2598-02. If the
Specifications in Form No.KENR2598-02 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.
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
propel system:
1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel.
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 handle to all positions to release any pressure in the hydraulic system.
6. Carefully loosen the filler cap on the hydraulic tank to release any pressure in the tank.
7. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
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tightened, removed, or adjusted.
8. Tighten the filler cap on the hydraulic tank.
9. The pressure in the system has now been released and lines or components can be removed.
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 the pressure tests of the propel system. Before
any tests are made, visually inspect the complete hydraulic system for leakage of oil and for parts that
have damage. For some of the tests a magnet, thermometer and a measuring rule (either for inches or
millimeters) are usable tools.
When any test is made of the propel system, the hydraulic oil must be at the normal temperature for
operation.
Troubleshooting
Visual Checks
A visual inspection of the propel 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 propel system with
instruments. Stop the engine. To remove the tank filler cap, slowly turn the filler cap until it is loose. Let
the tank pressure lower before the filler cap is removed. Make the following inspections.
1. Measure the oil level of the hydraulic tank.
2. Look for air in the oil that is in the hydraulic 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.
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.
3. Inspect all oil lines and connections for damage or leaks. Look for oil on the ground under the
machine.
4. Remove the hydraulic filter elements and look for particles removed from the oil by the filter
elements. A magnet will separate ferrous particles from nonferrous particles (port plates, O-ring seals,
etc.)
a. Bronze-colored particles give an indication of pump or motor port plate failure.

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

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. Travel speed can be used to check the condition of the propel motors and the
pump.
Drive the machine backwards and forwards several times. Operate the propel controls in all speed
ranges.
1. Watch the drive drum and wheels. Starting and stopping operations should be progressive. Drum and
wheel rotation should be smooth and regular at all times.
2. Check for noise from the pump and drive motors.
3. Check for the sound of the relief valves opening. The opening pressures of the relief valves are given
in the relief valve pressure tests located in the Testing And Adjusting section of this module.
4. After selecting the travel speed of the compactor, the forward and reverse motion should be identical.
Problem: Propel system engages very slowly when making a shift.
Probable Cause:
* Low charge pressure.

* Plugged stroking orifices in the propel pumps.
* Oil viscosity too thick, oil cold.
Problem: Propel system engages very suddenly when making a shift.
Probable Cause:
* Stroking orifices missing from propel pumps.

* Shuttle valve spool inside motor flushing valve is sticking.
* Servo control spool sticking.
Problem: Propel system operates in one direction only.
Probable Cause:
* Failure of the propel pump servo piston.

* Failure of the propel pump servo valve.
* Failure of the rocker arm section of the pump swashplate assembly.
* One of the multifunction valves is damaged.
* Shuttle valve spool is sticking.
Problem: Propel system does not disengage (zero oil flow) when propel control lever is returned to
neutral.
Probable Cause:
* Failure of the propel pump servo piston.

* Failure of the propel pump servo valve.
* Failure of the rocker arm section of the pump swashplate assembly.
* Incorrect neutral adjustment of the swashplate.
* Incorrect linkage rod adjustment between drum and axle pump controls.
Problem: Parking brake does not release when parking brake button is pulled up.
Probable Cause:
* Failure of the parking brake button.

* Worn or damaged piston seal in the brake group.
* Failure of the parking brake valve.
* Fault in the electric circuit.
* Failure of neutral start switch.
* Failure of neutral start relay.
* Failure of brake relay.
* Steering pump relief valve damaged or incorrectly adjusted.
* Failure of the steering pump.
Problem: Parking brake does not engage when the parking brake button is pushed down.
Probable Cause:
* Failure of the parking brake button.

* Failure of brake relay.
* Worn brake discs.
* Failure of the parking brake valve.
* Fault in the electric circuit.
Problem: External oil leaks from drum or axle propel motors.
Probable Cause:
* Motor case pressure is too high.

* Restriction in the oil return line to hydraulic tank.
* Seals damaged due to pressure peaks, use of unapproved hydraulic oil which is not compatible
with the seal material or incorrect tightening torque values.
Problem: Propel system oil overheats.
Probable Cause:
* Incorrect type of oil used in the hydraulic circuit.

* The oil cooler is internally restricted.
* The radiator/oil cooler is externally restricted.
* Excessive internal leakage in circuit which causes low charge line pressure.
* Operating pressures exceeding relief pressures due to mechanical problems.
* Thermal bypass valve malfunction.
Problem: Low charge pressure (Neutral).
Probable Cause:
* Low hydraulic oil level.

* Propel charge filter is in bypass condition.
* Machine high idle is too low.
* Inadequate flow from steering pump.
* Excessive motor case leakage.
* Excessive pump case leakage.
* Parking brake seal leakage.
Problem: Low charge pressure (Propelling).
Probable Cause:
* Excessive motor case leakage.

* Excessive pump case leakage.
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.
Method of finding flow loss:
Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.
Example of finding percent of flow loss:
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.
Formula I:
Bench Test
If the test bench can be run at 6900 kPa (1000 psi) and at full pump rpm, find the percent of flow loss
using Formula I.
If the test bench 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).
Formula II:
Travel Speed Test

NOTE: The machine must be in high speed range for this test.
The oil in the system must be SAE 10W hydraulic oil. The oil temperature must be at 38C (100F) to
get correct results. All speed tests are made with the engine rpm at maximum rpm.
Time the machine in forward and reverse through a 30.5 m (100 ft) timing trap. The vibration system
must be off.
NOTE: The machine must be at top speed through the entire timing trap.
Travel speeds that are the same as those that follow are an indication that the circuit operation is normal.
The relief valves for both charge pump and main line closed circuit must be tested to be sure that the
opening pressure of each is correct.
Travel Time
Low Range ... 4-6 seconds
High Range ... 9-11 seconds
Minimum travel speed:
Forward motion ... 11 km/h (600 ft/min)
Reverse motion ... 11 km/h (600 ft/min)
Times for forward and reverse through the 30.5 m (100 ft) timing trap must match within one second.
If the travel speed is not correct, check the following:
1. Pump efficiency.
2. Setting of the charge system relief valve.
3. Setting of the main line closed circuit relief vavles.
4. Make sure the machine is in high speed range.
5. Make sure the linkage rod between the drum and axle pumps is adjusted correctly.
6. Check axle propel motor for correct minimum displacement adjustment.
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 pressure gauge kits.
Pressure Limiter Test (Multifunction Valve)

Forward Drive
Refer to the WARNING on the first page of Troubleshooting.
NOTE: Do not run the machine against the brake for more than five seconds.
NOTE: Do the Propel Pump Charge Relief Valve Pressure Test before doing the main relief valve test.
1. Make sure that the parking brake is applied. Make sure the propel control lever is in neutral.
Parking Brake And Speed Shift Valve (Operator Platform Raised)

(1) Wire connector (purple wire #777).
2. Disconnect wire connector (1). This allows the parking brake to stay applied during the test.
Drum Pump (Right Side Of Machine)

(2) Test port.
Axle Pump (Right Side Of Machine)

(3) Test port.
3. Connect two 60 000 kPa (9000 psi) pressure gauges from the 4C-4892 ORFS Fittings Group to test
ports (2) and (3).
4. Start the engine and run at high idle.
5. Move the speed selection switch to the HIGH speed position.
6. Release the parking brake.
7. Slowly move the propel control lever forward. Look at the pressure gauge on test port (3) and record
the pressure limiter pressure of the axle propel pump in forward direction. Look at the pressure gauge on
test port (2) and record the pressure limiter pressure of the axle propel pump in forward direction. The
pressure limiter pressure for both the drum and axle propel pumps should be 44 100 to 46 850 kPa (6400
to 6800 psi).
Drum And Axle Pumps (Left Side Of Machine)
CP-533C CS-533C Vibratory Compactor 2XN00001-UP (MACHINE) POWERED ... Pgina 10 de 34
(4) Axle adjustment screw (forward multifunction valve). (5) Drum adjustment screw (forward multifunction valve).
8. If the pressure limiter pressures are not correct, they must be adjusted. Stop the engine. Use the same
procedure to adjust axle and drum propel pumps. Remove the plastic dust plug. Loosen the locknut. Use
an allen wrench to turn axle adjustment screw (4) or drum adjustment screw (5). Rotate the screw
clockwise to increase the pressure or counterclockwise to decrease the pressure. Each complete rotation
of the adjustment screw changes the pressure limiter pressure setting by 9300 kPa (1350 psi). After the
pressure limiter pressure is adjusted correctly, use an allen wrench to hold the adjustment screw, and
tighten the locknut to a torque of 16 Nm (12 lb ft).
9. Check the pressure limiter pressure settings again. If they are correct, remove the pressure gauges
from test ports (2) and (3).
Reverse Drive
NOTE: Do not run the machine against the brake for more than five seconds.
NOTE: Do the Propel Pump Charge Relief Valve Pressure Test before doing the main relief valve test.
1. Make sure that the parking brake is applied. Make sure the propel control lever is in neutral.
Parking Brake Valve (Operator Platform Raised)

(1) Wire connector with purple wire #777.
2. Disconnect wire connector (1). This will allow the parking brake to stay applied during the test.
Drum Pump (Left Side Of Machine)

(6) Test port.
Axle Pump (Left Side Of Machine)

(7) Test port.
3. Connect two 60 000 kPa (9000 psi) pressure gauges from the 4C-4892 ORFS Fittings Group to test
ports (6) and (7).
4. Start the engine and run at high idle.
6. Release the parking brake.
7. Slowly move the propel control lever in the reverse direction. Look at the pressure gauges on test port
(6) and record the pressure limiter pressure of the drum propel pump. Look at the pressure gauges on
test port (7) and record the pressure limiter pressure of the axle propel pump. The pressure limiter
pressure for both the drum and axle propel pumps should be 44 100 to 46 850 kPa (6400 to 6800 psi).
Drum And Axle Pumps (Right Side Of Machine)

(8) Axle adjustment screw (reverse multifunction valve). (9) Drum adjustment screw (reverse multifunction valve).
8. If the pressure limiter pressures are not correct, they must be adjusted. Stop the engine. Use the same
procedure to adjust the drum and axle propel pumps as necessary. Remove the plastic dust plug. Loosen
the locknut. Use an allen wrench to turn axle adjustment screw (8) or drum adjustment screw (9). Rotate
the selected screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Each
complete rotation of the adjustment screw changes the pressure limiter pressure setting by 9300 kPa
(1350 psi). After the pressure limiter pressure is adjusted correctly, use an allen wrench to hold the
adjustment screw and tighten the locknut to a torque of 16 Nm (12 lb ft).
9. Check the pressure limiter pressure settings again. If they are correct, remove the pressure gauges
from test ports (6) and (7).
Servo Pressure Check
Under Operator Platform

(1) Drum propel pump. (2) Servo test ports.

1. Disconnect wire connector (3). This allows the parking brake to stay applied during the test.
2. Disconnect the pump linkage rod between the two pumps.
3. Remove the plugs from servo test ports (2). Install two 4000 kPa (580 psi) gauges in servo test ports
(2).
4. Start the machine and run at high idle.
5. Observe the pressure on both gauges with the control lever in neutral. The differential pressure
between the two gauges should be zero.
NOTE: There are no adjustable components for the manual displacement control. If the pressure
differential is not zero, then a problem could exist with the servo control valve.
6. Gradually move the control lever forward. The differential pressure between gauges installed in servo
port (2) should increase in proportion to output system pressure. As an example, an output system
pressure of 6890 kPa (1000 psi) will require a differential pressure of 482 kPa (70 psi). The position of
the control lever determines the swashplate angle.
7. Remove the pressure gauges from servo test ports (2) and install the plugs.
Pump Synchronization
Drum Pump
(1) Test port (drum, forward direction). (2) Test port (drum, reverse direction).

(3) Test port for axle pump, forward direction. (4) Test port for axle pump, reverse direction.
NOTE: This test must be performed outside in an area clear of obstacles and personnel.
1. Connect four 0 to 60 000 kPa (0 to 8700 psi) gauges to pressure taps (1), (2), (3) and (4). Mark the
gauges to correspond with the pressure taps. Use lines with enough length so the gauges can be read
from the driver seat.
2. Start and run the engine at high idle until the hydraulic oil temperature reaches 38C (100F). Engine
rpm should be 2350 50 rpm.
3. Move the speed selection switch to the LOW speed position.
4. Release the parking brake and move the propel control lever forward to approximately half way
between neutral and full speed. Record the reading of the gauges connected to pressure taps (1) and (3).
5. Move the propel control lever in reverse to approximately half way between neutral and full speed.
Record the reading of the gauges connected to pressure taps (2) and (4).
NOTE: Depending on the results obtained it may be necessary to record all four pressure gauge
readings while going in one direction. This may help in determining the cause of a propel complaint.
7. Release the parking brake and move the propel control lever forward to approximately half way
between neutral and full speed. Record the reading of the gauges connected to pressure taps (1) and (3).
8. Move the propel control lever in reverse to approximately half way between neutral and full speed.
Record the reading of the gauges connected to pressure taps (2) and (4).
NOTE: The values above are shown for example only. The actual pressures recorded will vary
depending upon material type and looseness of the soil.
Propel Pumps
(5) External linkage rod.
NOTE: The drum and axle pressures for a given direction and travel range should match within 2750
kpa (400 psi). If the values do not match, the following adjustments may be made.
9. Remove linkage (5) between the two pump manual displacement control levers. Both pump levers are
spring biased to the neutral position. Adjust the length of the rod, so that it drops onto both manual
displacement levers.
Axle Propel Motor (Early)

(6) Minimum displacement adjustment screw.
Drum Propel Motor (Early)

(7) Minimum displacement adjustment screw.
10. If the pressure differential is greater than 2750 kPa (400 psi) in high range, adjust the motor
minimum displacement. Adjust the motor which has the lower system pressure by turning minimum
displacement adjustment screw (6) or (7) out 1/2 turn at a time. This will decrease the motor
displacement and should decrease the system pressure differential.
NOTE: Testing has shown that setting the minimum displacement adjustment screw on the drum motor
to a dimension of 21 mm (0.83 in) and 19 mm (0.75 in) on the axle motor will result in the pressures
being within the 2750 kPa (400 psi) tolerance.
11. If one of the gauges shows 2062 to 2750 kPa (300 to 400 psi) for that direction of travel, the propel
pump is not going on stroke or a mechanical problem exists with that propel pump.
NOTE: For early model machines equipped with only a minimum displacement adjustment screw,
proceed to Step 14.
NOTE: The following adjustments are to be performed on later model machines equipped with both a
minimum and maximum displacement adjustment screw.
Axle Propel Motor (Later)

(6) Minimum displacement adjustment screw. (8) Maximum displacement adjustment screw.
Drum Propel Motor (Later)

(7) Minimum displacement adjustment screw. (9) Maximum displacement adjustment screw.
12. If the pressure differential is greater than 2750 kPa (400 psi) in low range, adjust the motor
maximum displacement. Adjust the motor which has the lower system pressure by turning maximum
displacement adjustment screw (8) or (9) out 1/2 turn at a time. This will decrease the swashplate angle
of the motor, increase the system pressure and decrease the differential pressure between the two
systems.
NOTE: Testing has shown that setting the maximum displacement adjustment screw on the drum motor
to a dimension of 14 mm (0.55 in), and 27 mm (1.06 in) on the axle motor will result in the pressures
being within the 2750 kPa (400 psi) tolerance.
13. If the machine develops system pressure while in neutral, refer to the Procedure for Determining
Drum/Axle Pump Neutral Swashplate Condition.
NOTE: System pressure should normally be greater than charge pressure for the direction selected. As
an example, going forward, both drum and axle forward gauges would read 800 - 1 000 psi in low range.
If one of these gauges, shows less than or equal to charge pressure, it may be an indication that the pump
is not developing hydraulic flow due to an electrical or mechanical problem. At the same time lower
pressure is noted on the forward gauge, a higher than charge pressure value may be shown on the
reverse gauge. This would be an indication that this circuit is being pushed by the opposite circuit, thus
having the same effect of turning the motor into a pump. In this situation, refer to the troubleshooting
guide for additional assistance.
14. When the pressure difference for all four propel conditions is less than 2750 kPa (400 psi), remove
the pressure gauges from the pressure taps.
NOTE: If significant adjustments have been made to the motor displacement adjustment screws to
obtain the correct Pump Synchronization pressure, it is recommended that the machine Travel Speed
Test be performed.
Neutral Start Switch Adjustment

1. Make sure the propel control lever is in the neutral position.
Drum Pump
(1) Neutral start switch. (2) Neutral start switch locknut. (3) Screws.
2. Attach a continuity checker to two screws (3) on the end of neutral start switch (1). Turn the neutral
start switch counterclockwise until electrical continuity is obtained. Turn the neutral start switch
counterclockwise an additional 1/4 turn after continuity has been obtained.
3. Hold the neutral start switch in place, and tighten neutral start switch locknut (2) to a torque of 27
Nm (20 lb ft).
4. With the continuity checker attached to the neutral start switch, move the propel control lever in each
direction to assure continuity is broken when the propel control lever is not in the neutral position.
Neutral Start Switch Check And Eccentric Plug

Adjustment
NOTICE
Starting the engine when the neutral start switch is removed from the
displacement control valve will result in damage to the control valve.
NOTE: Do not disturb any locknuts or adjustments on the neutral start switch other than those described
in this procedure. Disturbing other components could result in the engine being able to start in other than
the neutral position. If other adjustments are disturbed during replacement, the neutral start switch
operation must be checked.
Control in neutral position.

(1) Neutral start switch. (2) Neutral start switch locknut. (4) Eccentric plug locknut. (5) Pin. (6) Eccentric plug. (7) Cam slot.
Propel pumps
(8) Pressure ports. (9) Control handle.
1. Connect a continuity checker to the screws on the end of neutral start switch (1).
2. Be sure the propel control lever is in the neutral position. Electrical continuity should now be
obtained. Verify by observing the continuity checker.
For the neutral start switch to operate properly and continuity to be established, pin (5) located in
eccentric plug (6) must engage in cam slot (7) in the internal control mechanism.
When control handle (9) is moved in either direction, pin (5) is forced out of cam slot (7) and actuates
the neutral start switch to interrupt the circuit. The continuity should be interrupted with an equal
amount of handle rotation in both directions.
Alternate Designs For A Eccentric Plug Adjustment Tool.

(A) 25.4 mm (1.00 in) (Minimum). (B) 12.7 mm (.50 in). (C) 1.6 mm (.06 in) (D) 1.6 mm (.06 in). (E) 25.4 mm (1.00 in)
(Minimum). (F) 12.7 mm (.50 in). (G) 3.18 mm (.125 in). (H) 1.6 mm (.06 in).
3. If continuity can not be verified in neutral, determine the direction of the handle rotation (clockwise
or counterclockwise) necessary to establish continuity. Pin (5) which engages in cam slot (7) is mounted
in eccentric plug (6) which allows for adjustment.
4. Fabricate one of the adjustment tools shown in the above picture for rotating eccentric plug (6).
5. While holding neutral start switch (1), loosen neutral start switch locknut (2) and remove the neutral
start switch. Note the slots in eccentric plug (6) for the adjustment tool. Loosen eccentric plug locknut
(4) while holding the eccentric plug in place with the adjustment tool.
Eccentric Plug Adjustment.

(4) Eccentric plug locknut. (5) Pin. (6) Eccentric plug.
6. If it is necessary to rotate control handle (9) clockwise to obtain electrical continuity, use the
adjustment tool to rotate eccentric plug (6) to move pin (5) down (or toward the pump).
If a counterclockwise rotation of the control handle was necessary to obtain electrical continuity, rotate
the eccentric plug to move the pin up (or away from the pump). Only a small amount of adjustment in
either direction is needed to center the pin in the cam slot (7).
Turn eccentric plug (6) a maximum of 1/4 turn while frequently stopping to check maximum depth of
pin (5) into the eccentric plug. In most cases it can be determined that the pin has engaged in the slot,
either by feel or depth gauge, within the first 1/4 turn.
7. While holding eccentric plug (6) in place with the adjustment tool, tighten eccentric plug locknut (4)
to a torque of 27 Nm (20 lb ft).
8. Install the neutral start.
9. Make certain the control is in the neutral position. If the neutral start switch is being replaced with the
control removed from the pump, neutral can be verified by rotating control handle (9) until pin (5) is
engaged in cam slot (7).
10. Recheck neutral start switch electrical continuity to determine if additional adjustment to the
eccentric plug is necessary.
If further adjustment is required, continue rotation up to additional 1/4 turn.
NOTE: Do not exceed 1/2 turn total or 180 from the initial pin position. Doing so will turn the
eccentric plug into or out of the housing beyond specifications.
If too much adjustment was made, turn the eccentric plug 1/8 turn in the opposite direction.
Again, install the neutral start switch and check for electrical continuity.
Brake Efficiency Check
NOTE: Do the Pressure Limiter Pressure Test before doing the brake efficiency check.

1. Disconnect wire connector (1). This will allow the parking brake to stay applied during the test.
2. Position the high/low speed switch to LOW range.
Drum Pump (Right Side Of Machine)

(2) Test port.

(3) Test port.
3. Connect a 60 000 kPa (8700 psi) pressure gauge from the 4C-4892 ORFS Fittings Group to test ports
(2) and (3).
4. Start and run the engine at high idle until the hydraulic oil temperature reaches 38C (100F). Engine
rpm should be 2350 50 rpm.
5. Release the parking brake. Slowly move the propel control lever forward until the pressure reaches
24800 kPa (3600 psi) or the drum begins to turn.
NOTE: The axle wheels must not spin during this test. If wheel spin is a problem, move to a location
with better soil density.
6. If the pressure is less than 25 000 kPa (3600 psi), it is an indication that the discs in the axle and drum
brakes are worn and need to be replaced or repaired.
No-Spin Differential Operation Test

1. With the engine not running, raise the axle until all wheels are not contacting the ground surface.
Place blocking stands under the axle so the wheels can be blocked.
2. With the help of an assistant on the opposite side, start the test by rotating both wheels in a forward
direction as far as possible. Both wheels should stop after rotating a short distance.
3. While the assistant holds the right wheel locked forward against the stop, rotate the left wheel in a
backward direction. Listen for an indexing or clicking sound. (The right wheel must be held firmly
against the stop or the left wheel will not disengage freely.) Grasp the left wheel to stop its rotation.
Then, move it slightly forward (toward the stop). The NO-SPIN differential should lock up.
4. Rotate both wheels in a backward direction as far as possible. Both wheels should stop after rotating a
short distance.
5. While the assistant holds the right wheel locked against the stop in the backward direction, rotate the
left wheel in a forward direction. Listen for an indexing or clicking sound. (The right wheel must be held
firmly against the stop or the left wheel will not disengage freely.) Grasp the left wheel to stop its
rotation. Then, move it slightly backward (toward the stop). The NO-SPIN differential should lock up.
6. Repeat Steps 2, 3, 4 and 5 with the left wheel blocked against the stop and rotating the right wheel
both in forward and reverse.
7. The steps are completed successfully if the rotated wheels disengage easily by hand, they rotate freely
and evenly, and a faint indexing or clicking sound is heard. The NO-SPIN differential is installed
correctly and is functioning correctly.
8. If either wheel does not rotate freely in either direction, recheck each assembly step. If the problem is
not corrected after this procedure, repair or replace the NO-SPIN differential.
9. Check to see that both wheels of the no-spin differential equipped axle are driving. Make this test
under load, so that engine torque is applied through the no-spin differential with the wheels on the
ground. One way to achieve this load is to drive up to a solid obstruction (on loose dirt or gravel, if
possible) and attempt to spin both wheels together. Perform this test in forward and reverse.
NOTICE
Do not operate the machine if both wheels of the no-spin differential
equipped axle are not driving. The differential may be damaged
10. On a flat surface, with good traction, drive the machine in a tight circle in forward and reverse to be
sure that the outside wheel is free to overrun (the outside tire does not scuff). A clicking or indexing
sound may be heard. The sound of gear reengagement may also be heard upon completion of the turn.
This is normal.
Charge Pressure (Neutral and Propelling)
1. Stop the machine and apply the parking brake.
2. Remove lower panels and raise seat.
Right Side Of Machine

(1) Test Port. (2) Linkage rod. (3) Propel charge filter.
Left Side Of The Machine

(4) Loop balance lines.
3. Disconnect both ends of both loop balance lines (4) (between the axle and propel pumps). Use steel
caps and plugs to the pumps to prevent oil leakage.
4. Install 6V-3121 multitach group.
5. Install 4C-6500 temperature probe into hydraulic tank.

6. Disconnect linkage rod (2) between axle and drum propel pumps.
7. Disconnect wire connector (5) for brake release solenoid. This will allow the machine to propel
against the parking brake when the brake button is released and the propel handle is moved forward.
Switch High/Low speed switch to HIGH.
8. Install a 600 psi gauge at test port (1) located after propel charge filter (3). The pressure recorded in
this test is limited by the propel charge relief valve. Connect four 0 to 60 000 kPa (0 to 8700 psi) gauges
to the high pressure taps for the drum and axle pumps. (See Propel Pump Synchronization Test.)
9. Start and run the machine at high idle until the hydraulic oil reaches 38C (100F).
10. Record the system charge pressure. Charge pressure should be 2750 138 kPa (400 20 psi).
11. If the charge pressure is not correct, proceed to the procedure for adjusting propel charge pressure.
12. If the charge pressure in Step 10 is correct, release the parking brake switch and stroke the manual
displacement control lever for the axle pump by using the propel lever.
NOTE: These pressures should be recorded with 10 333 kPa (1500 psi) gauges on the axle and drum
pumps.
Charge Pressure Propelling
13. Move the propel handle to stroke the axle pump. Maintain a minimum pressure of 10 342 kpa (1500
psi) while propelling against the brake forward and reverse. Record the charge pressure at test port (1)
located after propel charge filter (3).
14. Propel system charge pressure while propelling should be 137 35 kPa (15 5 psi) less than
pressure recorded in Step 10.
15. Manually stroke (by hand) the drum drive pump manual displacement control lever, forward and
reverse. Propel system charge pressure while propelling should be 137 35 kPa (15 5 psi) less than
pressure recorded in Step 10.
NOTE: Propel system charge pressures too low may be an indicator of excessive pump or motor
internal leakage or a malfunctioning motor shuttle relief valve. An orifice size of 2.0 mm (0.078 in) in
the shuttle relief valve gives the circuit the correct pressure drop while propelling. Propel system charge
pressures which do not decrease while propelling may be an indicator of a flushing valve spool or
shuttle relief valve malfunction.
16. If both propel system charge pressures in neutral and while propelling are correct, remove tooling
and reconnect loop balance line (4).
Charge Pressure Adjustment Procedure

(Neutral)
Right Side Of Machine

(1) Test port.
Drum Pump (Left Side Of Machine)

(2) Charge relief valve.
2. Install a 4134 kPa (600 psi) pressure gauge at test port (1) located after the propel charge filter. This is
for reading the propel pump charge pressure.
3. Install 6V-3121 Multitach to measure engine rpm.
4. Install 4C-6500 Temperature Probe into hydraulic tank.
Axle Pump (Left Side Of The Machine)

(3) Charge relief valve.
5. Start the machine and run at high idle until hydraulic temperature reaches 38C (100F).
6. Stop the machine.
7. Turn charge relief valves (2) and (3) to the closed position.
8. Open charge relief valve (3), three to four turns.
9. Start the engine and run the engine at 1175 rpm.
10. With the hydraulic oil at 38C (100F), adjust charge relief valve (3) to 2551 138 kPa (370 20
psi). Tighten the locknut to a torque of 46 to 55 Nm (38 to 41 lb ft).
11. Stop the engine.
12. Open charge relief valve (2), three to four turns.
13. Start the machine and set the engine at high idle (2350 50 rpm).
14. With the hydraulic oil at 38C (100F), adjust charge relief valve (2) to 2750 138 kPa (400 20
psi). Tighten the locknut to a torque of 46 to 55 Nm (34 to 41 lb ft).
15. Stop the engine and remove all tooling.
Drum Motor Case Leakage Test
Drum Propel Motor (Left Side of The Drum)

(1) Fabricated hose. (2) Hose assembly. (3) Drum propel motor. (4) Flow meter.
2. Disconnect hose assembly (2) from drum propel motor (3).
3. Install fabricated line (1) to motor (3), and flow meter (4) to hose assembly (2).
4. Install 4C-6500 Temperature Probe into the hydraulic tank. Operate the machine until the oil
temperature reaches 38C (100F).
5. Disconnect the electrical lead (#777 purple wire) for the brake release solenoid. This allows the
machine propel system to propel against the parking brake when the brake release button is applied.
Place the machine in high range.
6. Install two 51 675 kPa (7500 psi) gauges, one on the forward gauge and one on the reverse gauge, for
the drum propel pump.
7. With the parking brake applied and the machine propel lever in neutral, read the amount of oil
flowing through flow meter (4). The flow should be less than 1.0 gpm.
8. Activate the parking brake release button and slowly move the propel handle forward until 11 024
kPa (1500 psi) is noted on the gauge.
9. Have an assistant read the amount of flow at flow meter (4). Hydraulic oil flow should be 2.3 .5
gpm greater than the value read in Step 7. The maximum flow allowable is 3.8 gpm.
10. Repeat Step 9 four times rotating the drum assembly 90 after each reading.
NOTE: It is necessary to reconnect the electrical lead (#777 purple wire) for the brake release solenoid
to release the brake and rotate the drum.
11. Repeat Steps 8, 9 and 10 in reverse.
12. If there is more than 3.8 gpm, the drum propel motor and/or flushing valve has too much leakage
and should be repaired or replaced.
13. Remove all test tooling and hose assembly (2) to the hydraulic motor.
Axle Motor Case Leakage Test
Axle Motor
(1) Hose assembly. (2) Axle drive motor.
2. Disconnect hose assembly (1) from axle drive motor (2).
Right Side Engine Compartment

(3) Fabricated line. (4) Flow meter.
3. Install fabricated line (3) to motor (2), and flow meter (4) to hose assembly (1).
4. Install 4C-6500 Temperature Probe into the hydraulic tank. Operate the machine until the oil
temperature reaches 38C (100F).
5. Disconnect the electrical lead for the brake release solenoid. This allows the machine propel system to
propel against the parking brake when the brake release button is applied. Place the machine in high
range.
6. Install two 51 675 kPa (7500 psi) gauges, one on the forward gauge and one on the reverse gauge, for
the axle propel pump.
7. With the parking brake applied and the machine propel lever in neutral, read the amount of oil
flowing through flow meter (4). The flow should be less than 1.0 gpm.
8. Activate the parking brake release button and slowly move the propel handle forward until 11 024
kPa (1500 psi) is noted on the gauge.
9. Have an assistant read the amount of flow at flow meter (4). Hydraulic oil flow should be 2.3 .5
gpm greater than the value read in Step 7. The maximum flow allowable is 3.8 gpm.
10. Repeat Step 9 four times rotating the rear axle 90 degrees after each reading.
NOTE: It is necessary to reconnect the electrical lead (#777 purple wire) for the brake release solenoid.
11. Repeat Steps 8, 9 and 10 in reverse.
12. If there is more than 3.8 gpm, the rear axle motor and/or flushing valve has too much leakage and
should be repaired or replaced.
13. Remove all test tooling and hose assembly (1) back to the hydraulic motor.
Procedure To Determine Drum/Axle Pump

Neutral Swashplate Condition
NOTE: Pump servo check should be done prior to performing this procedure.
1. Raise platform or cab.
2. Clean area around drum and axle pumps.
Propel Pump (Right Side Of Machine)

(1) Loop balance lines
3. Disconnect loop balance lines (1) between axle and drum pumps. Use steel caps and plugs to prevent
oil leakage.
4. Disconnect the linkage rod between axle and drum propel pumps.
5. Install two 51 675 kPa (7500 psi) pressure gauges to quick disconnects for axle or drum drive pump.
6. Apply the parking brake. Start machine and run at high idle. Wait 45 seconds, then observe the two
pressure gauges for the axle or drum drive pump with the parking brake applied.
NOTE: A typical gauge reading with the machine in neutral and engine at high idle would be 2750 kPa
(400 psi). Because of this, it may be necessary to use gauges with a lower pressure range.
7. Record pressures from the axle (drum) forward and axle (drum) reverse gauges.
The pressures recorded on both the axle (drum) forward and reverse gauges should be within 1378 kPa
(200 psi).
8. If the pressures are not within 1378 kPa (200 psi), the pump should be removed and repaired or
replaced.
NOTE: Adjustment of the swashplate neutral setting requires removal and disassembly of the pump.
See the Disassembly and Assembly Module.
9. Stop the engine and remove all tooling.
Thermal Bypass Valve Check
Right Side Engine Compartment

(1) Hose assembly to oil cooler.
2. Remove right side of the engine compartment lower panel.
3. Drain the oil tank.
4. Remove hose assembly (1) to oil cooler and install flow meter, line and temperature probe.
5. Start the machine and observe the amount of flow through flow meter. There should be 13.2 1.9
liter/min (3.5 .5 gpm) flow with the hydraulic oil temperature below 65C (150F).
6. Continue to run the machine until the oil temperature reaches 65C (150F), the thermal bypass valve
should begin to send hydraulic oil to the oil cooler.
7. At 71C (160F), the thermal bypass valve should be fully open the flow meter should read 64
liter/min (17 gpm) with the engine at high idle.
8. If the total flow through the oil cooler is not correct, a problem may exist with the thermal bypass
valve, with the steering pump, or the vibratory charge pump output. Verify the problem by checking the
other components.
9. Once the correct flow is obtained stop the machine and remove all tooling.
Copyright 1993 - 2010 Caterpillar Inc. Mon Oct 4 10:53:07 EST 2010
Todos los derechos reservados.
Red privada para licenciados del SIS.

Testing and Adjusting HIDRAULIC

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Testing and Adjusting HIDRAULIC

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CP-533C CS-533C Vibratory Compactor 2XN00001-UP (MACHINE) POWERED BY...

Producto: VIBRATORY COMPACTOR

Testing And Adjusting

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

3. Activate the parking brake.

4. Stop the engine.

tightened, removed, or adjusted.

8. Tighten the filler cap on the hydraulic tank.

1. Measure the oil level of the hydraulic tank.

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

Checks During Operation

2. Check for noise from the pump and drive motors.

Problem: Propel system engages very slowly when making a shift.

* Low charge pressure.

Problem: Propel system engages very suddenly when making a shift.

* Stroking orifices missing from propel pumps.

Problem: Propel system operates in one direction only.

* Failure of the propel pump servo piston.

* Shuttle valve spool is sticking.

* Failure of the propel pump servo piston.

* Failure of the parking brake button.

* Failure of the parking brake button.

Problem: External oil leaks from drum or axle propel motors.

* Motor case pressure is too high.

Problem: Propel system oil overheats.

* Incorrect type of oil used in the hydraulic circuit.

Problem: Low charge pressure (Neutral).

* Low hydraulic oil level.

Problem: Low charge pressure (Propelling).

* Excessive motor case leakage.

System Tests And Adjustments

Method of finding flow loss:

Example of finding percent of flow loss:

Travel Speed Test

Low Range ... 4-6 seconds

High Range ... 9-11 seconds

Minimum travel speed:

Forward motion ... 11 km/h (600 ft/min)

Reverse motion ... 11 km/h (600 ft/min)

If the travel speed is not correct, check the following:

2. Setting of the charge system relief valve.

3. Setting of the main line closed circuit relief vavles.

4. Make sure the machine is in high speed range.

6. Check axle propel motor for correct minimum displacement adjustment.

Pressure Test Tools

Pressure Limiter Test (Multifunction Valve)

Refer to the WARNING on the first page of Troubleshooting.

Parking Brake And Speed Shift Valve (Operator Platform Raised)

Drum Pump (Right Side Of Machine)

Axle Pump (Right Side Of Machine)

4. Start the engine and run at high idle.

5. Move the speed selection switch to the HIGH speed position.

6. Release the parking brake.

Drum And Axle Pumps (Left Side Of Machine)

Refer to the WARNING on the first page of Troubleshooting.

Parking Brake Valve (Operator Platform Raised)

Drum Pump (Left Side Of Machine)

Axle Pump (Left Side Of Machine)

4. Start the engine and run at high idle.

5. Move the speed selection switch to the HIGH speed position.

6. Release the parking brake.

Drum And Axle Pumps (Right Side Of Machine)

Servo Pressure Check

Refer to the WARNING on the first page of Troubleshooting.