QERQ1018

ITIM for KENR3615

June 2003

Integrated Technical
Instruction Module

CB-534D Vibratory Compactors

Propulsion System
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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Objectives/Student Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Lesson Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Preparation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Visual/Text Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Case Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Posttest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Instructor Answer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

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Introduction
This Integrated Technical Instruction Module (ITIM) contains a portion of the CB-534D Vibratory
Compactors training course. The propulsion system is covered in this ITIM.

Prerequisites
All students should have some overall experience with Caterpillar paving equipment and have a basic
working knowledge of servicing electrical and electronic systems.

Prerequisite tests should be administered at least a few weeks before the participant takes the course.

Participants should pass the following pretests with a score of 90% or better:

Machine Electrical Pretest SEB0558

Basic Hydraulic Pretest SEBV0557

Graphic Fluid Power Symbols (Pretest) SEBV0556

If a participant does not accomplish 90% or better, identify the area of deficiency and then refer to the
pretest for the recommended course or courses for the student to review. After ample review time, the
student should retake the test.

NOTE:
Understanding the operation and function of the propulsion system on the CB-534D Vibratory
Compactors is critical for troubleshooting. It is also important to be able to properly test and
adjust the system.
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Objectives/Student Evaluation
Student Name: ________________________ Instructor(s):_______________________

Course Name: _________________________ Course Number: ___________________

Pretest Score: ________ Posttest Score: ____________

Instructor
Did student accomplish the following objectives? Additional remarks
Yes No
1. Given a CB-534D Vibratory Compactor and the Lab A
Worksheets, locate and identify the components of the
propulsion system during a lab exercise.

2. Given a CB-534D Vibratory Compactor, the appropriate

service literature, and the Lab B Worksheets, perform the
following procedures during a lab exercise:

¥ Relief Valve (Charge)—Test and Adjust

¥ Relief Valve (Main)—Test and Adjust

¥ Relief Valve (Pressure Override)—Test and Adjust

¥ Neutral Start Switch—Adjust

¥ Parking Brake—Test

3. Given all reference material, class notes, and the case

study worksheet, troubleshoot a fault in the propulsion
system.

4. Given all reference material and class notes, trace current

through the propulsion electrical system during a posttest.

5. Given all reference material and class notes, trace oil flow
through the propulsion hydraulic system during a posttest.

6. Given all reference material and class notes, complete the

posttest with at score of 90 percent or higher.

Instructor(s):

________________________ Student Average Good Excellent

________________________ Student met prerequisites

Training Manager: Class Participation

________________________ Desire to Learn

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Lesson Plan
Introduction 15 min.
Discuss objectives and class schedule
Hand out and discuss student material

Visual Presentation: Propulsion System, Component Location 35 min.

Suggested Illustrations: 11, 12, 16, 30, 19, 44, 17/18/20/21/23, 43, 39, 38, 40, 41, 28, 48, 29, 49,
24, 31, 25, 50, 47, 26, 45, 27/32, 46, 60, 22/33, 42, 63, 34, 65, 35, 54, 36, 37

Lab A: Propulsion System, Component Identification 30 min.

Visual Presentation: Propulsion System, System Operation 85 min.

Suggested Illustrations: 11, 67, 13, 14, 15, 59, 58, 61, 62, 56, 55, 57, 51, 52, 53, 64, 66

Lab B: Propulsion System, Testing and Adjusting 60 min.

Case Study 30 min.

Posttest 60 min.
Administer Posttest
Review and Discuss Posttest Results

Total Estimated Time 5.25 hours

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Preparation Checklist
Prior to conducting the training session, gather and review the following CB-534D Vibratory Compactor
material:

__ Specifications, Systems Operation, Testing and Adjusting, CB-534D Vibratory Compactor,

Propel System KENR3615

__ CB-534D Vibratory Compactor New Product Introduction (NPI) QERQ9991

Have at least one copy of the following material available for student and instructor reference during
classroom presentations and laboratory use. The material listed below covers the CB-534D Vibratory
Compactors.

__ Service Manual (complete) KENR3610

__ Hydraulic System Schematic KENR3618

__ Electrical System Schematic KENR3619

__ Operation and Maintenance Manual KEBU7514

__ Parts Manual KEBP0242

Gather the following special tools and materials:

__ 1 N/A Mechanic s Tool Box with hand tools

__ 1 N/A Set of lettered or numbered tags for component identification

__ 1 198-4240 Digital Pressure Indicator(1)

__ 1 198-4238 0—34 500 kPa (0-5000 psi) Pressure Sensor(1)

__ 2 198-4239 0—69 000 kPa (0-10,000 psi) Pressure Sensor(1) (3)

__ 2 177-7860 Hose Assembly(2)

__ 4 6V-4143 Coupler(2)

__ 1 8T-0855 0—4000 kPa (0—580 psi) Pressure Gauge(2)

__ 2 8T-0861 0—60 000 kPa (0—8700 psi) Pressure Gauge(2)

__ 2 6V-3989 Fitting(2)

__ 1 6V-9830 Cap Assembly(2)

__ 1 6V-9509 Face Seal Plug(2)

__ 1 4C-6500 Digital Thermometer

__ 1 146-4080 Multimeter

NOTE:
(1)(2)
Either the tools marked (1) or the tools marked (2) can be used. Both sets are not necessary.
(3)
The digital pressure indicator (198-4240) contains one 0—69 000 kPa (0-10,000 psi) pressure
sensor (198-4239), a second must be obtained.
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Visual/Text Reference
The Service Manual module Specifications, Systems Operation, Testing and Adjusting, CB534D Vibratory
Compactor Propel System (Form Number KENR3615) must be used in preparation to teach this course.
This Service Manual Module is included on the ITIM CD (Form Number QERQ1018).

Two visual presentations accompany this package. One contains the illustration from the Systems
Operation Section of the included Service Manual module in the order the illustrations appear; the
second presentation contains the illustrations from the Systems Operation Section but in a suggested
order for presentation. The suggested illustrations list in the lesson plan gives the recommended order in
which to present the material during a training course. The suggested illustrations list can be used to
provide complete training on the system or the visual presentations can be rearranged to suit specific
training needs.

Lab exercises provide the student with an opportunity to locate and identify the system components and
perform testing and adjusting procedures on selected components and systems.

Laboratory Exercises
The pages that follow provide lab exercises to reinforce the visual presentations.

Some lab exercises are the written type with worksheets, while other labs are the traditional "on the iron"
labs. Some answers are provided for the worksheet exercise, while other labs reference the Testing and
Adjusting procedures of the System Operation, Testing and Adjusting module. Answers, when applicable,
are provided in the Instructor Answer Key.

Review and perform the labs before delivering this module.

At the beginning of each lab, have all students review the lab description to be sure the students
understand what to do during the lab.

The labs are:

Lab A: Propulsion System, Component Identification

Lab B: Propulsion System, Testing and Adjusting

NOTE:
Discuss safety procedures with the students for each shop lab. (i.e. safety glasses, clothing).
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Lab A: Propulsion System Component Identification

Lab A Worksheet
Directions: The instructor has attached an identification tag to each component in the propulsion
system. Place the correct letter or number next to the component. During the visual presentation, use this
worksheet to take notes as the location and function of each component is explained.

Example:

_____ Fuses
Location: In compartment at base of right console.
Function: Protects electrical components in propulsion system.

_____ 1. Electronic Control Module (ECM)

Location:
Function:

_____ 2. Propulsion Speed Selector Switch

Location:
Function:

_____ 3. Propulsion Sensor

Location:
Function:

_____ 4. Parking Brake Solenoid

Location:
Function:

_____ 5. Shift Manifold

Location:
Function:

_____ 6. Brake Release Relay

Location:
Function:
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_____ 7. Brake Release Latching Relay

Location:
Function:

_____ 8. Number-two Neutral Start Relay

Location:
Function:

_____ 9. Propulsion Pump

Location:
Function:

_____ 10. Front Propulsion Motor

Location:
Function:

_____ 11. Rear Propulsion Motor

Location:
Function:

_____ 12. Manual Brake Release Pump

Location:
Function:

_____ 13. Thermal Bypass Valve

Location:
Function:
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Lab B: Propulsion System, Testing and Adjusting

Lab B Worksheet
Directions: Using the Service Manual, find the pressure specifications for the following tests. Perform
the tests according to the procedure in the Service Manual.

NOTE:
For the complete procedures, refer to the Service Manual Module Specifications, Systems
Operation, Testing and Adjusting, CB-534D Vibratory Compactor, Propel System (Form
KENR3615).

Machine Model Date

Serial Number Service Meter Hours

PRESSURE TESTS

TESTS SPECIFICATIONS ACTUAL

Relief Valve (Charge)

Relief Valve (Main)

Relief Valve (Pressure

Override)

Neutral Start Switch (Adjust)

Parking Brake (Test)

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Case Study
Directions: Students may use appropriate service literature and class notes to complete this case study.

Situation: You have been sent to the field to troubleshoot a problem on a CB-534D. The only information
you have been given is that the operator is complaining of low power.

Gather Information: List at least three questions you would ask the operator.
1.

2.

3.

Verify: Verify the problem exists. Operate the machine, if possible, to verify the problem exists. Perform
sensory checks such as looking, listening, touching, and smelling.

Perform Visual Inspection: When troubleshooting always perform a visual inspection first. Look for the
obvious. List at least three items that should be inspected during a visual inspection.
4.

5.

6.

State Problem: After verifying a problem exists, state in your own words what the problem is (not
solution).
7.

List Possible Faults: List possible causes of the problem. Identify systems and components that could
be causing the problem, including the obvious.

8.

9.

10.

Test to Determine Root Cause: List the tests that could be performed to find the root cause of the
problem.

11.

12.

Fix Machine: Perform tests if necessary and fix machine.

13.

Verify Repair: After completing the repair, always verify the machine is operating correctly.

14.
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Propulsion System Posttest

Directions: Circle the correct letter indicating the best answer for each question.

1. TRUE or FALSE: The front drum on the CB-534D is hydrostatically driven, and the rear drum is
driven by a mechanical transmission.

2. TRUE or FALSE: The front and rear drive motors are identical.

3. Which pump supplies charge pressure to the propulsion system?

A. Propulsion pump.
B. Vibratory pump.
C. Steering pump.

4. Circle the statement which most accurately describes the location of the propulsion pump.

A. First in series of two pumps driven by the engine flywheel (engine compartment, left side of
machine).
B. Second in series of two pumps driven by the engine flywheel (engine compartment, left side of
machine).
C. First in series of two pumps driven by the water pump drive gear (engine compartment, left side
of machine).
D. Second in series of two pumps driven by the water pump drive gear (engine compartment, left
side of machine).

5. Where can charge pressure be measured?

A. At the inlet side of the charge filter.

B. At the outlet side of the charge filter.
C. At the tap in the M1-port of the steering pump.
D. At the tap in the F-port of the propulsion pump.

6. Where is the charge relief pressure adjusted?

A. At the charge relief valve in the propulsion pump.

B. At the charge relief valve in the vibratory pump.
C. At the charge relief valve in the steering pump.
D. At the charge relief valve in the charge filter base.
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7. Where is the brake release manifold mounted?

A. On the right side of the machine, under the operator platform.

B. On the left side of the machine, under the operator platform.
C. On the right wall of the engine compartment.
D. On the left wall of the engine compartment.

8. TRUE or FALSE: The pressure override relief valve vents pressure spikes from the system into the
charge circuit.

9. Where is the forward circuit pressure measured?

A. At the tap in the MA-port of the pump.

B. At the tap in the MA-port of the rear motor.
C. At the tap in the MA-port of the front motor.
D. Either A or B above.

Directions: Use the following two schematics to answer questions 10—15. Circle the best answer
for each question.
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 REAR CB-534D PROPULSION
06/03

PARKING
BRAKE FLUSHING RELIEF VALVE
U B X
HYDRAULIC SYSTEM
QERQ1018

SERVO PISTON

FROM VIBRATORY PUMP

FROM VIBRATORY
Ø2.0
MOTORS
SHIFT
SPOOL 18 BAR

Ø0.8
FROM CHARGE FILTER
(STEERING SYSTEM)
3.5 BAR
FLUSHING SPOOL
REAR
PROPULSION A T G T
THERMAL BYPASS VALVE
MOTOR

FORWARD COMBINATION VALVE

FRONT BRAKE VALVE
PARKING
BRAKE
15

DIRECTIONAL
A a b CONTROL
VALVE PS P G Fa Fc MB
T2 R T1 T2 B
ø1.8mm
SERVO PISTON
B

T1

FRONT
PROPULSION B SHIFT
450 BAR

MOTOR VALVE 2

ø1.2mm
420 BAR

450 BAR

1 3 POR
VALVE
B T

A
MANUAL BRAKE
RELEASE PUMP X1 X2 MH S MA A
AUX PROPULSION REVERSE COMBINATION VALVE
PUMP
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CB-534D Vibratory Compactors ITIM
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10. What is the state of the following relays when the parking brake switch is ON, and the propulsion
control lever is in NEUTRAL? (Circle the correct answer.)

Brake release relay Energized De-energized

Brake release latching relay Energized De-energized
Number-two neutral start relay Energized De-energized

11. What is the state of the following relays when the parking brake switch is OFF, and the propulsion
control lever is in NEUTRAL? (Circle the correct answer.)

Brake release relay Energized De-energized

Brake release latching relay Energized De-energized
Number-two neutral start relay Energized De-energized

12. What is the state of the following relays when the propulsion control lever is moved out of NEUTRAL
while the parking brake switch is ON? (Circle the correct answer.)

Brake release relay Energized De-energized

Brake release latching relay Energized De-energized
Number-two neutral start relay Energized De-energized

13. TRUE or FALSE: The ECM uses an input signal from the parking brake switch in order to control the
parking brake solenoid.

14. On the hydraulic schematic, pressure oil is sent into the RIGHT or LEFT side (circle the correct
answer) of the servo piston in the rear propulsion motor when the propulsion speed switch is in
HIGH.

15. TRUE or FALSE: The gate valve in the manual brake release pump must be open during normal
operation.
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Instructor Answer Key

The following section contains answers to the lab exercises, case study, and posttest. Some lab
exercises, for example, adjusting the hydraulic pressures, do not have a specific answer and are
represented by N/A (not applicable).

Lab A

1. Location: Inside right console.

Function: Monitors input components to control machine propulsion.
2. Location: On right console.
Function: Controls shift solenoid, and provides input to ECM. ECM uses input with other input signals
to control machine speed.
3. Location: Inside right console.
Function: Monitors position of propulsion lever and provides input to ECM. ECM uses input with other
input signals to control machine speed.
4. Location: In propulsion pump housing (engine compartment, left side of machine).
Function: Controls parking brake. Solenoid energized, brake released.
5. Location: Mounted to left wall of engine compartment.
Function: Contains shift solenoid which controls speed range of rear propulsion motor. Solenoid
energized, motor in high speed range.
6. Location: In compartment at base of right console.
Function: Controls current flow to parking brake solenoid and parking brake contact of ECM. Works
with parking brake switch, brake release latching relay, and number-two neutral start relay.
7. Location: In compartment at base of right console.
Function: Controls current flow to coil of brake release relay. Works in conjunction with number-two
neutral start relay to ensure brakes remain engaged when parking brake switch moved to
OFF while propulsion lever out of NEUTRAL.
8. Location: In compartment at base of right console.
Function: Controls current flow to gate of brake release latching relay. ECM energizes number-two
neutral start relay while propulsion lever in NEUTRAL. Relay energized, power not
available at gate of brake release latching relay.
9. Location: First in series of two pumps driven by engine flywheel (engine compartment, left side of
machine).
Function: Electronically controlled, variable-displacement, axial-piston pump provides flow to
propulsion motors.
10. Location: On left side of front drum.
Function: Fixed-displacement motor drives front drum.
11. Location: On right side of rear drum.
Function: Two-speed motor with integral flushing valve drives rear drum.
12. Location: Mounted to left wall of engine compartment.
Function: Used to manually release parking brakes.
13. Location: In return manifold (back wall of engine compartment, left side of machine).
Function: Temperature transducer with bypass spool and relief valve. Controls oil flow through oil
cooler, and limits cooler inlet pressure.
Lab B

N/A
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Case Study

NOTE:
To simulate this problem on the machine, turn the pressure override relief valve counterclockwise
three turns. Ensure that the pressure override relief valve is set to the proper specification before
the machine is returned to service.
1. Have the operator describe the conditions under which the problem occurs. Ask about unusual
noises and/or odors, and ask about recent changes in application. Ask if the problem is equal during
forward and reverse operation. Look for clues in the description which may prompt additional
questions.
2. When was the hydraulic oil and filter last changed, and has any other work been performed on the
machine recently.
3. Is the machine exhibiting other symptoms?
4. Hydraulic oil levels, hydraulic oil leaks, and/or air in the hydraulic oil.
5. Manual brake release pump (ensure that needle valve is fully open).
6. Engine fluid levels for evidence of engine problem.
7. N/A
8. Low charge pressure.
9. Parking brakes dragging or not released.
10. Low system pressure.
11. Test charge pressure.
12. Test main relief valve and pressure override relief valve.
13. Adjust the pressure override relief valve.
14. After the pressure override relief valve was adjusted, machine operation returned to normal.

Posttest

1. FALSE: Both the front and rear drums are hydrostatically driven.

2. FALSE: The rear motor is a two-speed motor and the front motor is a fixed-displacement motor. The
rear motor also contains a flushing valve; the front motor does not contain a flushing valve.

3. C

4. A

5. B

6. B

7. D

8. FALSE: The pressure override relief valve acts as the main relief valve for the circuit. The relief
section of the combination valve removes pressure spikes from the system.

9. A

10. Brake release relay Energized

Brake release latching relay Energized
Number-two neutral start relay Energized
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11. Brake release relay De-energized

Brake release latching relay De-energized
Number-two neutral start relay Energized

12. Brake release relay Energized

Brake release latching relay Energized
Number-two neutral start relay De-energized

13. FALSE: The ECM does not control the parking brake solenoid. The parking brake solenoid is
controlled by the following components: parking brake switch, brake release relay, brake latching
relay, and number-two neutral start relay.

14. Right

15. TRUE: If the valve is closed, charge oil cannot reach the brake cylinders, and the parking brake
switch has no control over the brakes.