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Vibration System

Introduction

The vibratory system on the 500E Vibratory Compactors remains mostly


unchanged from the system on the 500D Series machines. The general
location of the pump and the motor in the vibratory system has not been
changed.
The vibratory system covers the following items in this book:

Features
Components
Component location
System operation

The vibratory hydraulic system on the machines shares a common tank


with the following systems: propulsion, steering and fan. The standard
vibratory system provides control for dual amplitude.
The vibratory hydraulic system is a closed loop system. The system
consists of an electronically controlled variable displacement piston
pump, and a fixed displacement piston motor. The pump contains an
integral charge pump. The base of the charge filter is equipped with a
pressure switch. This switch provides an input signal to the ECM. The
signal from the pressure switch is used to operate the hydraulic oil
pressure indicator on the instrument panel. The vibratory charge pressure

switch is wired in a series circuit with the pressure switch which is


located in the base of the propel charge filter.
Drum vibration is created through the rotation of two eccentric weights.
During operation in low amplitude, the eccentric weights are rotated in
one direction. During operation in high amplitude, the eccentric weights
are rotated in the opposite direction. The eccentric weights are partially
filled with steel shot. The direction of drum rotation causes the steel shot
to move. This varies the center of gravity of the weights with respect to
the rotational center of the drive shaft. This variance creates two vibratory
amplitudes.
Case drain oil from the vibratory system is sent to a return manifold.
Here, the oil from the circuit for vibration is combined with return oil
from the circuit for propulsion. The return manifold contains a thermal
bypass valve which controls the flow of oil through the oil cooler.
The vibratory electrical system only allows the vibratory system to be
operated while the machine is operating at high idle. Optional wiring can
also prevent operation of the vibratory system while the selector switch
for propel speed is in HIGH.

Operator Controls
Attain the desired travel speed before you engage the vibratory system. In
order to achieve optimum compaction, low range should be used. In order
to start the vibratory system, the throttle control must be placed in the
HIGH position.
Stop the vibration system when you travel over concrete or pavement that
is hard.

NOTICE
The bearings in the vibratory reservoir for the weight shaft are
lubricated by rotating the drum assembly. Turning the vibratory
system on with the machine not propelling may shorten the vibratory
bearing life.

Vibratory Amplitude Control

Note: In order to start the vibratory system, the vibratory amplitude


control must be set to high amplitude or low amplitude.
The vibratory amplitude control is located on the operator console to the
right of the seat. The control is used to select one of three settings: low
amplitude, high amplitude and off
HIGH - To achieve HIGH amplitude,
push the vibratory control forward.
OFF - To stop the vibration system, push the vibratory control to the
CENTER position.
LOW - To achieve LOW amplitude,
push the vibratory control rearward.

Vibratory On/Off Control

The switch on the top of the propel control lever controls the operation of
the vibration system.
ON - In order to turn on the vibration system, press the switch on the top
of the propel control lever.
OFF - In order to stop the vibration system, press the switch again on the
top of the propel control lever.

Vibratory Gauge (If Equipped)

Vibration per Minute Meter The meter indicates the vibrations per minute of the
vibratory drum. The drum frequency for the CS-533E machines is 1900 vibrations per
minute (VPM) when the machine is set to the high amplitude. The drum frequency for
the CS-533E machines is 2100 vibrations per minute (VPM) when the machine is set
to the low amplitude. The drum frequency for the CP-533E machines is 1900
vibrations per minute (VPM) when the machine is set to the low amplitude or to the
high amplitude.

Location of Electrical Components


Location of Electrical Components

(1) Fuse (vibratory control)


(2) Switch (vibratory on/off control)
(3) Switch (vibratory amplitude control)
(4) Solenoid (vibratory pump)
(5) Speed sensor (vibratory)
(6) Tachometer (vibratory)

Fuse (Vibratory Control)

The fuse for the vibratory control is located in the access panel on the
front side of the operator console.

Switch (Vibratory On/Off Control)

The switch for the vibratory on/off control is located on top of the propel
lever.

Switch (Vibratory Amplitude Control)

The switch for the vibratory amplitude control is located on the right hand
operator console.

Solenoids (Vibratory Pump)

The solenoids for the vibratory control are located on the vibratory pump.

Speed Sensor (Vibratory)

The speed sensor for the vibratory control is located on the right side of
the drum next to the vibratory motor.

Tachometer (Vibratory)

The tachometer for the vibratory function is located on the dash in front
of the steering wheel.

Location of Hydraulic Components


Location of the Components

(1) Charge filter


(2) Vibratory pump
(3) Vibratory motor
(4) Thermal bypass and return manifold
(5) Hydraulic oil cooler

Charge Filter

The charge filter for the vibratory system is located on the left side of the
machine inside the steps for the operator. Hydraulic oil filter (1) will filter
all charge oil before the oil is routed to the vibratory system.

Vibratory Pump

Vibratory pump (2) is located underneath the operator platform. The


vibratory propel pump sends oil to the vibratory motor.
Reference: See Systems Operation, "Piston Pump (Vibratory System)"
for more information on the axle propel pump.

Vibratory Motor

Vibratory motor (3) is located on the right side of the drum. The vibratory
motor is a piston motor that controls the vibration of the drum.
Reference: See Systems Operation, "Piston Motor (Vibratory System)"
for more information on the vibratory motor.

Vibratory Electrical System


The electrical system for the vibratory system consists of the
following components:
Switch (vibratory on/off control)
Switch (vibratory amplitude control)
Solenoid (vibratory pump)
Speed sensor (vibratory)
Tachometer (vibratory)

Switch (Vibratory On/Off Control)

The switch for the vibratory on/off control is the main on/off switch for
the vibratory system. The switch is a two-position push button switch.

Switch (Vibratory Amplitude Control)

The switch for the vibratory amplitude control enables the high/low
setting of the vibratory system.
The switch is a three-position rocker switch. The switch completes the
circuit to the high amplitude solenoid or the switch completes the circuit
to the low amplitude solenoid.

Solenoids (Vibratory Pump)

The solenoids for the vibratory control will control the angle of the
swashplate of the vibratory piston pump. The solenoids move the
swashplate to the maximum angle for vibrations per minute of 1900 50
for the CP-533E in high amplitude and 1920 50 for the CS-533Ein high
amplitude. Both machines produce 2100 50 vibrations per minute in
low amplitude. The solenoids have a resistance of approximately
24Ohms.

Speed Sensor (Vibratory)

The speed sensor monitors the speed of the eccentric weight within the
drum. The speed sensor produces an analog signal. The signal is sent to
the vibratory tachometer.

Tachometer (Vibratory)

The tachometer for the vibratory system displays vibrations per minute.
The tachometer is an analog type gauge. The analog signal that is read by
the tachometer will deflect the meter in order to read the vibrations per
minute.

Piston Pump (Vibratory System)

(1) Servo piston


(2) Direction control valve
(3) Makeup and relief valve
(4) Port plate
(5) Barrel Assembly
(6) Piston
(7) Swashplate
(8) Drive shaft
(AA) Activated components
(AB) Tank pressure
(AC) Charge pressure

The vibratory pump is similar to the propel pumps. A few differences


exist for the vibratory pump. The vibratory pump has a direction control
that is a solenoid operated valve. There is no feedback link for the
swashplate control. The combination valve in the pump contains no
function for towing.
The vibratory pump is controlled by two solenoids. One solenoid controls
the high amplitude, and one solenoid controls the low amplitude. When a
particular control solenoid is energized, charge oil is directed into the
corresponding chamber for the servo piston, and the opposite chamber for
the servo piston is open to the pump case. The swashplate moves to the
maximum angle in order to provide flow to the vibratory motor.

High Pressure Relief Valve


The high pressure relief valve provides two functions for the
vibratory circuit:
High pressure relief valve
Makeup check valve
The maximum working pressure of each loop line of the closed circuit is
limited to 35000 3000 kPa (5075 435 psi) by these valves. This valve
is a direct acting type. The valve limits the main circuit pressure to
specified values above the charge pressure.

High Pressure Relief Valve

Oil from the vibratory pump flows through relief valve (2) at the oil
passage. High pressure oil enters the passage and the oil acts on the
collars (4) and (7). The force of spring (6) keeps the valve closed until the
oil pressure in the high pressure side of the main loop circuit reaches
relief pressure. After the relief pressure is reached, the pressure moves
spindle (5) downward while the pressure compresses spring (6). The
relief oil flows from the high pressure side to the low pressure side of the
main loop. The oil flows through the gap between spindle (5) and collar
(7). The arrows show this flow in illustration 2. High pressure oil enters
the low pressure side of the main loop circuit until the force of spring (6)
seats spindle (5) and collar (7).

Makeup Check Valve

Oil from the vibratory pump flows through relief valve (2) at the oil flow
passages. The force of spring (3) and the oil pressure in the passage keeps
collar (7) closed.
Charge pressure acts on the bottom of collar (7) and spindle (5). When
the oil pressure in the passage drops below the charge pressure, collar (7)
and spindle (5) move upward compressing spring (3) .
The charge oil flows through the gap. The closed loop circuit will be
replenished with the makeup oil. The arrows show this flow in illustration
3. Charge oil continues to replenish the low pressure side of the circuit
with the make up oil until the pressure in the oil passage becomes greater
than the charge pressure.

Vibratory Control Valve

The control valve is attached to the vibratory pump. The valve is a threeposition solenoid. The valve is a four-way directional control valve. The
solenoid control valve directs oil to the servo circuit of the vibratory
pump.
When current is supplied to either solenoid (2) or (4), the solenoid moves
valve spool (3). The controlled oil passes across valve spool (3). The oil
exits the passage to the hydraulic servo.
When the vibratory circuit is not activated, current flow to the solenoid
(2) or (4) is interrupted. The force of springs (1) moves valve spool (3) to
the center position.
The force of each spring (1) is identical. Springs (1) balance each other.
The springs also maintain the center position of valve spool (3).

Servo Piston Assembly

The servo control assembly controls swashplate angle (12) of the


vibratory pump. Servo housing (8) is an integral part of the vibratory
pump. The servo housing contains the servo piston (9) .
The charge circuit supplies control oil to control valve (10) on the
vibratory pump. The control valve regulates the servo piston (9) by
directing the oil flow which enters the servo housing. The control valve
also acts on servo piston (9). Linear movement of the servo piston
mechanically controls the rotational movement of swashplate (12) with
joint pin (7). When the servo piston moves, the angle of the swashplate
changes in the pump.
The flow of the pump output is zero when the swashplate angle is zero.
The swashplate angle is zero when the servo piston is in the center
position. The servo piston will return to the center positions when the
control valve (10) is not energized. The servo piston is mechanically
centered by springs (17). The center position of the servo piston can be
adjusted by loosening locknut (14) and turning piston rod (16) .
The pump flow is controlled by the servo piston. The maximum pump
output is determined when the swashplate is at the maximum angle. The
maximum swashplate angle is controlled by limiting the travel of the
servo piston. Adjust stroke limiter screw (15) in order to control the travel
of the servo piston. There are two stroke limiter screws. The stroke
limiter screws are located on each end of the servo housing.

Piston Motor (Vibratory System)

(1) Flushing relief valve


(2) Port plate
(3) Piston
(4) Swashplate
(5) Shaft

The vibratory motor is a fixed displacement hydraulic motor. Oil flows to


the motor and from the motor through hoses that are attached to the end cap.
High pressure oil from the pump enters the motor through the end cap. The
oil will pass through port plate (2) and the oil will act on piston (3). The
piston is one ofseven pistons in the assembly of the cylinder block.
As the pistons react to the high pressure oil, the cylinder block and the
pistons rotate as an assembly. Oil flows through the center of the piston and
through the piston slipper in order to create a film of oil between the piston
slipper and the swashplate. This helps prevent wear. The cylinder block is
splined to shaft (5). Rotating torque is transferred to the shaft. The
displacement of the motor is controlled by the angle of the fixed swashplate
(4). The nonadjustable swashplate angle is machined into the motor housing

Case Flushing

Lubrication for the internal moving parts is done with the normal internal
leakage oil. The case flushing and the cooling of the pump and the motor
is accomplished by the flushing circuit.
The flushing circuit oil is supplied by the charge circuit. The oil that
flows over the charge relief valve allows continuous flushing of the
vibratory pump. Case flushing of the motor occurs during the pump
stroke. The oil travels through the motor flushing valve.
Oil enters the motor and oil exits the motor through loop lines (10). The
pilot oil from the loop lines flows to both ends of shuttle spool (7). The
flow is through pilot oil passages (9). The high pressure side of the circuit
shifts the shuttle spool. The shift of the shuttle spool allows the low
pressure oil of the loop lines to flow through the flushing relief valve (1).
The oil flushes the motor housing and flows to the return manifold
through line (8). The thermal bypass valve directs the oil through the oil
cooler or to the hydraulic tank. The temperature of the oil will determine
the direction of the oil.
In order to flush the motor housing, the flow rate of the oil in the flushing
relief valve (8) must be 4.9 L/min (1.3 US gpm).

Support and Vibratory Drive

The drum assembly contains two eccentric weights (2). The eccentric
weights are connected to individual splined shafts. Vibratory motor (3) is
splined to the shaft of the right eccentric weight, and the shafts of the
right and left eccentric weights are connected by coupling shaft (4) .
When the vibratory system is ON, the vibratory motor rotates the
eccentric weights by rotating the splined shafts. Since the center of
gravity of the eccentric weights is not at the center of the shafts, rotation
of the eccentric weights causes the drum to vibrate.

Eccentric weight (2) is partially filled with steel shot (5). When the
vibratory switch is placed in the HIGH AMPLITUDE mode, the eccentric
weight rotates in one direction. The steel shot is captured in one area of
the weight compartment, as shown above.
The weight of the steel shot in this position increase the fixed eccentricity
of the weight. The drum assembly will then vibrate in the HIGH
AMPLITUDE mode.

When the vibratory switch is placed in the LOW AMPLITUDE mode,


eccentric weight (2) rotates in the opposite direction. This causes steel
shot (5) to be captured in the opposite area of the weight compartment, as
shown above.
The weight of the steel shot in this position offsets the fixed eccentricity
of the weight. This causes the drum assembly to vibrate in the LOW
AMPLITUDE mode.

Electrical Schematic
The following schematic is a simplified diagram of the vibratory system. The
diagram is electrically correct.
The schematic does not show all possible harness connectors. Always see the
Electrical System Schematic in the Service Manual for the machine for an
accurate electrical schematic of a particular machine.

(1) Throttle Switch


(2) Fuse 6 (10A)
(3) Vibratory On/Off Switch
(4) Vibratory Select Switch
(5) Vibratory Tachometer
(6) Vibratory Tachometer Sensor
(7) Vibratory Pump Solenoids

Hydraulic Schematic
Operation of the Vibratory System

This graphic shows the vibratory hydraulic system when the control
switch for the vibratory amplitude is OFF. The charge pump generates
flow when the engine is running. Charge oil flows to charge filter (6) .
Filtered charge oil travels to combination valves (10) , direction control
valve (2) , charge relief valve (9) , and vibratory pump (1) .
With the control switch for the vibratory amplitude OFF, the direction
control valve is in the center position, and both sides of the pump servo
are open to the pump case. The swashplate in the vibratory pump remains
at a minimum angle, and the vibratory motor does not rotate.
Charge pressure is controlled by the relief valve in the axle propel pump.
The relief valve in the axle propel pump is set at 1600 kPa (232 psi). The
2500 kPa (363 psi) relief in the drum and vibratory pumps are only safety
relief valves.
Charge pressure acts against the makeup valve. If the pressure in either
the loops for the high amplitude or low amplitude falls below charge

pressure, the makeup valve will open and charge oil will flow into the
loop.
Since the machine is not moving, the flushing spool in the vibratory
motor remains in the center position.

Vibratory System ON

This graphic shows the vibratory hydraulic system when the control
switch for the vibratory system is ON, and the control switch for the
vibratory amplitude is in LOW amplitude.
In this condition, the low amplitude solenoid is energized, and the left
valve section of the direction control valve is active. Charge oil enters the
servo piston cavity of the low amplitude side of the pump, and the oil
then overcomes the force of the spring. This will cause the pump servo
piston to change the angle of the swashplate.
Supply oil from the low amplitde side of vibratory pump (1) flows to the
low amplitude side of vibratory motor (5) . This causes the motor to
rotate. After turning the motor, oil that is reduced pressure will return to
the side of the vibratory pump with high amplitude. This completes the
circuit.

Supply oil also flows to the combination valves, to flushing spool (3) ,
and to flushing relief valve (4) . The combination valve in the circuit for
low amplitude remains seated and the relief valve will remain closed
when the pressure in the circuit for low amplitude is between charge
pressure and relief pressure.
Oil in the circuit for low amplitude acts against the top of the flushing
spool, and oil in the circuit for high amplitude acts against the bottom.
The flushing valve spool moves downward. This allows oil in the circuit
for high amplitude to flow across the spool to the relief passage of the
flushing valve. When the pressure in the circuit for high amplitude is
greater than 1600 kPa (232 psi), the flushing valve will open in order to
allow oil that is in the circuit for high amplitude to flow through the case
drain lines for the vibratory motor.
When the pressure in the loop for high amplitude falls below charge
pressure, the makeup valve will open. This causes charge oil to flow into
the loop for high amplitude. When the pressure in the loop for high
amplitude rises above charge pressure, the makeup valve closes.
Note: The orifice in the flushing relief valve ensures that the charge
pressure will be controlled by the charge relief valve in the axle propel
pump.