QESV1318 Inst Guide

R
QESV1318
February 2008
Instructor Material
PART OF TECHNICAL PRESENTATION QESV1318
CB534D AND CB564D

ASPHALT COMPACTOR
Introduction
February 2008 2 Asphalt Compactor
Instructor Guide for QESV1318
Table of Contents
Course Introduction
General Information....................................................................................... 4
Prerequisites ................................................................................................. 4
Visual/Text Reference ................................................................................... 4
Student Workbook......................................................................................... 4
Laboratory Exercises..................................................................................... 5
Machine Introduction
Preparation Checklist .................................................................................... 6
Objectives/Student Evaluation ...................................................................... 7
Lesson Plan................................................................................................... 8
Posttest ......................................................................................................... 9
Power Distribution and Machine Starting System

Preparation Checklist .................................................................................. 11
Objectives/Student Evaluation .................................................................... 12
Lesson Plan................................................................................................. 13
Laboratory Exercises................................................................................... 14
Posttest ....................................................................................................... 19
Machine System
Lesson Plan................................................................................................. 22
Posttest ....................................................................................................... 28
Instructor Guide for QESV1318
Propulsion System
Lesson Plan................................................................................................. 32
Posttest ....................................................................................................... 39
Vibratory System
Lesson Plan................................................................................................. 43
Posttest ....................................................................................................... 48
Course Introduction Instructor Guide for QESV1318
Course Introduction
General Information
This Instructor Guide contains the CB534D and CB564D Asphalt Compactors course. This
package is to be used in conjunction with the Technical Presentation,CB534D and CB564D
Asphalt Compactors and the Student Workbook,CB534D and CB564D Asphalt Compactors.
The Instructor Guide contains the following sections:

• Machine Introduction
• Power Distribution and Machine Starting
• Machine System
• Propulsion System
• Vibratory System
Prerequisites
All students should have some overall experience with Caterpillar equipment and have a basic
working knowledge of electrical and electronic systems. It is recommended that prerequisite tests
be administered at least a few weeks before the course.
NOTE: Understanding the operation and function of the systems on the CB534D and CB564D
Asphalt Compactors is critical for troubleshooting. It is also important to be able to properly test
and adjust the system.
Visual/Text Reference
The Technical Presentation,CB534D and CB564D Asphalt Compactors (Form Number
QESV1318) must be used in preparation to teach this course. The meeting guide is included on
the Student CD. Each section of this Instructor Guide contains a suggested illustration list. This list
gives the recommended order in which to present the material during a training course. The
illustration list can be used as suggested, or rearranged to suit specific training needs.
Student Workbook
One copy of theStudent Workbook,CB534D and CB564D Asphalt Compactors should be printed
and distributed to each student. The student workbook contains course objectives, color line art
from the training package, lab exercises, and post tests. The student should be encouraged to take
notes in their student workbook and to use these notes to complete lab exercises, and/or to
answer test questions. Answers to the lab exercise and tests are not given in the student
workbook.
Course Introduction Instructor Guide for QESV1318
Laboratory Exercises
Each section of this course contains lab exercises which reinforce the visual presentation. Lab
exercises provide the student with an opportunity to locate and identify the system components
and to perform testing and adjusting procedures on selected components and systems. 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 manual. Answers, when
applicable, are provided.
NOTE: Discuss safety procedures with the students for each shop lab.
Machine Introduction Instructor Guide for QESV1318
Machine Introduction
Preparation Checklist
Prior to conducting the training for this section, review the appropriate section in the Technical
Presentation,CB534D and CB564D Asphalt Compactors.
Have at least one copy of the following materials available for the student and instructor reference
during classroom presentations and laboratory use.
___ Service Manual (complete)
___ Operation and Maintenance Manual
___ Parts Manual
Objectives/Student Evaluation
Student Name: ______________________ Instructor(s): _______________________

Course Name: _______________________ Course Number: ____________________
Pretest Score: _______________________ Posttest Score: _____________________
Instructor
Did the student accomplish the following objectives? Additional remarks
Yes No
1. Given all reference material and class notes.
Complete the posttest with a score of 90 percent or
higher.
Instructor(s): Student Average Good Excellent

_____________________
Student Met Prerequisites
_____________________
Training Manager: Class Participation
_____________________ Desire to Learn

Lesson Plan
NOTE: This lesson plan contains a suggested illustration list. This list gives the recommended
order in which to present the material during the training course. The illustration list can be used as
suggested, or rearranged to suit specific training needs.
Introduction 10 min.
Discuss section lesson objectives
Hand out and discuss student material
Suggested Illustrations: Slide 1
Visual Presentation: Machine Introduction, System Overview 40 min.

Suggested Illustrations: Slides 2-13
Posttest 10 min.
Administer the posttest
Review and discuss the posttest results
Total Estimated Time 1.0 hours

Posttest
NOTE: The correct answers are indicated in bold and italic type.
Directions: Have the students use their notes to answer the following questions. Instruct the
students to circle the best answer for each question. Have each student grade another student’s
test. Discuss the answer to each question.
1. The CB534D and CB564D Asphalt Compactors are powered by a Caterpillar engine.
A. 3054C
B. 3045C
C. C6.6
D. C9
2. The front and rear drums of the CB534D and CB564D are hydrostatically driven.
A. True.
B. False.
3. The engine produces a gross power of at RPM.

A. 93 kW (120.6 hp), 2100
B. 97 kW (130 hp), 2200
C. 99 kW (140 hp), 2300
D. 117 kW (150 hp), 2400
4. The articulation area provides a steering angle of ±75 degrees and allows the frame to oscillate
±4 degrees.
A. True.
B. False.
5. The capacity of the water tank is .

A. 100 L (27 U.S. gal)
B. 200 L (58 U.S. gal)
C. 1100 L (290 U.S. gal)
D. 1200 L (300 U.S. gal)
6. The refill capacity of the fuel tank is .

A. 100 L (27 U.S. gal)
B. 200 L (58 U.S. gal)
C. 1100 L (290 U.S. gal)
D. 1200 L (300 U.S. gal)
7. The refill capacity of the crankcase is .

A. 9 L (2.4 U.S. gal)
B. 10 L (3 U.S. gal)
C. 100 L (27 U.S. gal)
D. 200 L (58 U.S. gal)
8. The CB564D uses the engine oil pressure switch to determine if the engine is operating.
A. True.
B. False.
9. The CB534D and CB564D are both equipped with two fuel filters.
A. True.
B. False.
10. The vibratory tachometer is driven by the vibratory speed sensors.

A. True.
B. False.
Power Distribution and Machine Starting System Instructor Guide for QESV1318
Power Distribution and Machine Starting System

___ Parts Manual
Gather the following required/optional special tools:

___ Standard mechanic’s toolbox with hand tool
___ Multimeter
NOTE: Discuss safety procedures with the students for each shop lab (i.e. safety glasses,
clothing).

Instructor
Yes No
1. (Lab A) Given a CB534D and CB564D Asphalt
Compactor and the Lab A Worksheet, locate and
identify the components of the power distribution and
machine starting system.
2. (Lab B) Given a CB534D and CB564D Asphalt
Compactor and all reference material and class
notes, troubleshoot a fault in the power distribution
and machine starting system (no worksheet).
3. Given all reference material and class notes,
complete the posttest with a score of 90 percent or
higher.

_____________________
_____________________
_____________________ Desire to Learn

Lesson Plan
Visual Presentation: Power Distribution and Machine Starting, System Overview 30 min.
Lab A: Component Identification 30 min.
Visual Presentation: Power Distribution and Machine Starting, System Operation 20 min.
Suggested Illustrations: Slide 33-34
Lab B: Troubleshooting Group Exercise 40 min.
Posttest 20 min.

Lab A: Component Identification Worksheet

Directions: 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:
___ Electrical Disconnect Switch
Location: The electrical disconnect switch is located in the engine compartment on the right side
of the machine.
Function: The electrical disconnect switch is a keyed switch with two positions. The electrical
system turns on when the electrical disconnect switch is moved clockwise. The switch must be in
the ON position before the engine will start. The entire machine electrical system shuts off when
the switch is moved counterclockwise.
___ Battery
Location: The battery is located in the rear of the machine.
Function: The battery provides 12-volts to the machine electrical system.
___ Auxiliary Start Post

Location: The auxiliary start post is located on the left side of the machine.
Function: The auxiliary start post is connected to the positive terminal of the battery, allowing the
machine to be jump started without the need to remove the battery cover from the rear of the
machine.
___ Engine Start Switch

Location: The engine start switch is located on the right console.
Function: The engine start switch is a keyed, rotary-type switch with four positions. From left to
right, the switch positions are: START AID, OFF, ON, and START. The switch is spring returned
from the START-AID position to the OFF position and from the START position to the ON position.
___ Main Circuit Breaker

Location: The main circuit breaker is mounted on the power panel, located on the left side of the
engine compartment.
Function: The main circuit breaker transfers power from the batteries to the gate of the start relay
and the gate of the main relay.
___ Alternator Circuit Breaker

Location: The alternator circuit breaker is mounted on the power panel, located on the left side of
the engine compartment.
Function: The alternator circuit breaker transfers power from terminal “B+” of the alternator to the
main circuit breaker and to the batteries.
___ Glow Plug Circuit Breaker

Location: The glow plug circuit breaker is mounted on the power panel, located on the left side of
Function: The glow plug relay is energized when the engine start switch is held in the START-AID
position. When this relay is energized, power is transferred to the four glow plugs. One glow plug is
installed in each cylinder.
___ Throttle Circuit Breaker

Location: The throttle circuit breaker is mounted on the power panel, located on the left side of the
engine compartment.
Function: The throttle circuit breaker transfers power to the gate of the start relay and to contact
“1” of the throttle control module.
___ Glow Plug Relay

Location: The glow plug relay is located on the back of the circuit breaker bracket.
Function: The glow plug relay is energized when the engine start switch is held in the START-AID
position. When this relay is energized, power is transferred to the four glow plugs which heat the
intake air.
___ Start Relay

Location: The start relay is located on the back of the circuit breaker bracket.
Function: The start relay controls power distribution to the coil of the starter. This relay must be
energized for the engine to crank. On the CB534D, the number-one neutral start relay controls the
start relay. On the CB564D, the engine start switch controls the start relay.
___ Coolant Temperature Switch

Location: The coolant temperature switch is located on the front-left side of the engine.
Function: This coolant temperature switch receives power from the engine start switch when the
engine start switch is in the ON position. The coolant temperature switch is closed when the
coolant temperature is less than the factory preset temperature. When the switch is closed, power
transfers to the cold-start timing advance solenoid.
___ Fuel Solenoid

Location: The fuel solenoid is located on the right side of the engine, on top of the fuel pump and
governor.
Function: The fuel solenoid receives power when the engine start switch is in the ON position and
in the START position. The fuel solenoid must be energized for the engine to operate. When this
solenoid is de-energized, fuel cannot be delivered to the fuel injectors.
___ Cold-Start Timing Advance Solenoid

Location: The cold-start timing advance solenoid is installed in the fuel pump and governor.
Function: The cold-start timing advance solenoid receives power when the coolant temperature
switch is closed. When energized, this solenoid advances the fuel timing. Advanced fuel timing
reduces white smoke when the machine is started in cold weather.
___ Fuel Lift Pump

Location: The fuel lift pump is located on the front of the engine.
Function: The fuel lift pump is driven by an electric motor. The electric motor receives power from
the engine start switch when the switch is in the ON position and in the START position. The fuel
lift pump draws fuel from the fuel tank. The fuel is pumped through the fuel filter and delivered to
the fuel pump and governor.
___ Throttle Control Module

Location: The throttle control module is located on the front of the engine.
Function: The throttle control module controls the throttle solenoid.The throttle control module
receives power from the throttle circuit breaker.
___ Alternator
Location: The alternator is located at the rear of the engine. The engine compartment cover
provides access to this components.
Function: When the engine is operating, the alternator provides power to the alternator circuit
breaker. The alternator circuit breaker protects the machine electrical system. The alternator is
rated at 80 amps. The engine block provides the ground for the alternator.
___ Starter
Location: The starter is located at the rear of the engine. The engine compartment cover provides
access to this components.
Function: The start relay controls the power supply circuit to the coil of the starter. When the start
relay is de-energized, the coil of the starter is de-energized. When the coil of the start relay is
energized, the coil of the starter is energized, and the starter cranks the engine.
___ Throttle Control Switch

Location: The throttle control switch is located on the right console.
Function: The throttle control switch is a rocker switch with two positions. This switch limits the
engine to two speeds—low idle and high idle. The top position of the switch is the HIGH-IDLE
position, and the bottom position is the LOW-IDLE position. When this switch is in the HIGH-IDLE
position, voltage is transferred to contact “5” of the throttle control module.
___ Power Panel

Location: The fuse and relay bank are located in the power panel at the base of the right console.
Function: The fuse bank contains four rows of fuses arranged in four columns. The relay banks
are split in two banks of four relays.
___ Propulsion Sensor

Location: The propulsion sensor is located inside the right console.
Function: The propulsion sensor monitors the position of the propulsion lever. The sensor
converts the position of the propulsion lever to an electrical impulse. The impulse takes the form of
a pulse-width-modulated signal with a duty cycle between approximately 9 percent and 91
percent. The lowest duty cycle of the signal corresponds to the full-reverse position of the
propulsion lever, and the highest duty cycle corresponds to the full-forward position of the
propulsion lever. When the propulsion lever is in the NEUTRAL position, the duty cycle is
approximately 50 percent.
Contact “1” of the propulsion lever sensor receives power from the ECM fuse. Contact “2” of the
sensor is grounded. Contact “3” of the propulsion lever sensor sends an input signal to terminal
“24” of the ECM. On the CB534D, the ECM prevents the machine from starting when the
propulsion lever is out of the NEUTRAL position.
___ Main Power Relay

Location: The main power relay is located inside the right console.
Function: The main power relay is energized when the engine start switch is in the ON position or
in the START position. When the coil is energized, power is distributed to the following places: the
light circuit breaker, the parking break light circuit breaker, the water spray fuse, the vibratory
system fuse, the gauge fuse, the rotary beacon fuse, the recorder fuse, and the backup alarm
fuse.
Lab B: Troubleshooting, Group Exercise

Directions: Divide the students into two or three small groups as class size permits. Have each
group identify a non-destructive fault that has been installed on the machine for this lab. Have each
group troubleshoot the fault, list the particular symptoms the fault would cause, and possible
repairs. When the fault has been successfully determined and corrected, have each group present
its findings to the rest of the class. Encourage the students to use the appropriate reference
materials when troubleshooting. Repeat this exercise until all the students demonstrate an in-
depth knowledge of the system.
Posttest
1. The machine is equipped with a single -volt battery which provides -volts to the
machines electrical system.
A. 12, 12
B. 24, 24
C. 12, 24
D. 24, 12
2. When the throttle control switch is in the LOW-IDLE position, the throttle control module is
active.
A. True.
B. False.
3. On the CB534D, the machine starting circuit contains components which ensure that the
machine will not start if the propulsion lever is out of the NEUTRAL position.
A. True.
B. False.
4. The engine is equipped with glow plugs. The glow plugs are installed in the
cylinder head of the engine.
A. three
B. four
C. five
D. six
5. The glow plug relay is energized when the engine start switch is held in the
position.
A. OPERATE
B. START-AID
C. RUN
D. OFF
6. The auxiliary start post is connected to the positive terminal of the battery, allowing the machine
to be jump started without the need to remove the battery cover from the rear of the machine.
A. True.
B. False.
Machine System Instructor Guide for QESV1318
Machine System
___ Parts Manual

___ Multimeter
___ 198-4234 Digital Pressure Indicator
___ 198-4237 Pressure Sensor 0-3450 kPa (0-500 psi)
___ 198-4239 Pressure Sensor 0-25 000 kPa (0-3600 psi)
___ 177-7860 Hose Assembly
___ 6V-4143 Coupler
___ 6V-3989 Fitting
___ 4C-6500 Digital Thermometer
clothing).

Instructor
Yes No
identify the components of the machine system.
Compactor, the appropriate service literature and
the Lab B Worksheet, perform the following tests of
the machine system. Follow the procedures in the
service manual.
• Test relief pressure (steering)
higher.

_____________________
_____________________
_____________________ Desire to Learn

Lesson Plan
Visual Presentation: Machine System, System Overview 90 min.

Suggested Illustrations: Slides 36-40, 43-48, 53-64
Visual Presentation: Machine System, System Operation 90 min.

Suggested Illustrations: Slide 41-42, 49-52, 65
Lab B: Testing and Adjusting 40 min.
Posttest 30 min.


explained.
Steering Control
___ Gear Pump (Steering and Charge)
Location: The steering and charge pump is located in the front of the engine compartment, on the
right side of the machine.
Function: The engine drives this gear-type pump. The steering and charge pump draws oil from
the hydraulic tank through a suction screen. The suction port is on the bottom face of the pump.
The steering and charge pump provides the flow to operate the steering system and the cooling
fan motor and also provides charge oil to the propulsion hydraulic system and the vibratory
hydraulic system.
___ Charge Filter

Location: The charge filter is located on the right side of the engine compartment.
Function: The base of the charge filter contains two taps: the charge pressure tap and the
hydraulic oil S•O•S tap. The filter base also contains a bypass valve, and two pressure switches.
The pressure switch senses pressure in the outlet line from the charge filter. This normally closed
pressure switch operates the low charge pressure indicator on the instrument panel. Actuation
pressure of the switch is 1400 kPa (200 psi).
___ Steering Control Unit (Metering Pump)

Location: The steering control unit is located under the steering wheel.
Function: The steering control unit consists of a control section and a metering section. The
control section contains the steering control spool, an inlet check valve, an anticavitation check
valve, and line relief and makeup valves. The metering section contains a gerotor pump.
___ Steering Cylinder

Location: The machine is equipped with a single steering cylinder. The steering cylinder is located
in the articulation area on the right side of the machine.
Function: When oil is directed into the rod end of the steering cylinder, the machine turns right.
When oil is directed into the head end of the steering cylinder, the machine turns left. The steering
cylinder provides a steering angle of ±40 degrees.
___ Fan Motor

Location: The fan motor is a gear motor with a fixed displacement. This motor is located behind
the engine.
Function: The fan motor is connected to the cooling fan. The priority valve in the steering and
charge pump directs excess flow to the fan motor.
Drum Offset Control

___ Drum Offset Switch
Location: The drum offset switch is located on the propulsion control lever, on the right console.
Function: This switch is a three-position, momentary switch. The center position of the drum
offset switch is the HOLD position, the right position is the OFFSET-RIGHT position, and the left
position is the OFFSET-LEFT position. The switch is spring returned to the HOLD position. The
ECM monitors the signal from the drum offset switch and the drum offset proximity switch to
control the drum offset solenoids. When the drum offset switch is moved out of the HOLD position,
the ECM directs an output signal to the appropriate drum offset solenoid, and the offset cylinder
extends or retracts. The ECM continues the output signal until the operator releases the drum
offset switch or the proximity switch reaches the center position.
___ Drum Offset Cylinder

Location: The drum offset cylinder is located under the machine, on the left side.
Function: The drum offset system allows the front drum to be laterally moved in order to provide a
maximum offset between the front and rear drums of ±170 mm (±6.65 in).
___ Drum Offset Manifold

Location: The drum offset manifold is located at the front of the engine compartment.
Function: This manifold contains two solenoids: the offset left solenoid and the offset right
solenoid. The ECM controls these solenoids. The manifold also contains a priority valve, a flow
control valve, two pilot-opened check valves, and a relief valve.
Water Spray Control

___ Intermittent Spray Control Dial
Location: The intermittent spray control dial is located on the lower left side of the instrument
panel.
Function: The intermittent spray control dial is connected to a potentiometer. On the CB534D, this
potentiometer works in conjunction with the water spray timer to set the time intervals of the water
spray system. On the CB564D, the potentiometer provides an input signal to the ECM, and the
ECM controls the time intervals for the water spray system. When the intermittent spray control dial
is in the center of its travel range, the water system is cycled ON for 20 seconds and OFF for 20
seconds. As the dial is rotated counterclockwise from center, the time ON decreases and time
OFF increases on a 40-second interval. At the end of the dial’s counterclockwise rotation, the
water spray system does not operate. As the dial is rotated clockwise from the center position, the
time ON increases and the time OFF decreases. At the end of the dial’s clockwise rotation, the
water spray system is continuously ON.
___ Water Pump Selector Switch

Location: The water pump selector switch is located on the lower left side of the instrument panel.
Function: The water pump selector switch is a rocker switch with three positions. This switch
allows the operator to choose which water pump to use. The right position operates the number-
one water pump and motor group, the center position is AUTOMATIC, and the left position
operates the number-two water pump and motor group. When the water pump selector switch is in
AUTOMATIC, the number-one water pump and motor group operates while the machine is
traveling forward, and the number-two water pump and motor group operates while the machine is
traveling in reverse. When the water spray system is operating, the system will automatically stop
when the propulsion lever is moved into the NEUTRAL position, and restart when the propulsion
lever is moved out of the NEUTRAL position.
___ Water Spray Master Switch

Location: The water spray master switch is located in the on the propulsion lever.
Function: When this normally open, push-button, momentary switch is actuated, the ECM
receives an input signal. The ECM tracks the number of impulses from the water spray master
switch to determine the status of the water spray system—with an odd number, the system is ON;
with an even number, the system is OFF.
___ Water Spray Timer (CB534D Only)

Location: The water spray timer is located on the right console.
Function: The water spray timer works in conjunction with the intermittent spray control
potentiometer to set the time intervals of the water spray system. The time interval is determined
by the position of the potentiometer. When the timer is in the off cycle, the water spray system is
off. When the timer is in the on cycle, the timer energizes the coil of the number-one water spray
relay, and power is available at the water pump selector switch.
___ Water Fill Port

Location: The water fill port is located in front of the operator’s station.
Function: The fill port of the water tank contains a mesh filter which prevents large debris from
entering the tank. The refill capacity of the water tank is 1100 L (290 U.S. gal).
___ Water Level Sender

Location: The water level sender is installed in the top of the water tank, on the right side of the
machine. The sender is located at the rear of the tank.
Function: The water level sender is a resistance-type sender. The water level sender drives the
water level gauge on the instrument panel. The resistance through the water level sender when the
water tank is empty is 240 Ohms. The resistance through the water level sender when the water
tank is full is 30 Ohms.
___ Water Spray Motor and Pump Group

Location: The water spray motor and pump group is a single unit. The machine is equipped with
two motor and pump groups. Both motor and pump groups are located in the articulation area, on
the right side of the machine.
Function: The motor and pump groups have an electric motor which drives a diaphragm-type
pump. Both motor and pump groups draw water from the machine water tank through the water
filter and supply water to the front and rear spray bars. Only one motor and pump group operates
at a time. The electrical system determines which motor and pump group is operational.
___ Water Spray Bar

Location: A water spray bar is located behind the access doors at the front and the rear of the
machine.
Function: The spray bars are made of polyethylene material to prevent corrosion. Each spray bar
contains evenly spaced nozzles across the width of the drum. Each nozzle is equipped with a
corrosion-resistant strainer to protect the nozzle from debris. Tools are not required to disassemble
and clean the nozzles.
Lab B: Pressure Testing and Adjusting Worksheet

Directions: Perform the tests according to the procedures in the service manual.
NOTE: For complete procedures, refer to the service manual module Specifications, Systems
Operation, Testing and Adjusting,CB534D and CB564D Asphalt Compactors, Machine System.
1. Test relief valve pressure (steering).
Machine Model Date
Serial Number Service Hour Meter
Test Specifications Actual

Test relief valve
pressure (steering)
Posttest
1. The main relief valve in the steering and charge pump limits the pressure the pump can generate
to a maximum of .
A. 450 kPa (80 psi)
B. 22 00 kPa (3265 psi)
C. 6500 kPa (943 psi)
D. 21 000 ± 2000 kPa (3050 ± 290 psi)
2. The steering cylinders and a vertical pin in the articulation area allow for a ±30-degree steering
angle.
A. True.
B. False.
3. The pressure switch located in the outlet line of the charge filter is normally closed. Actuation
pressure of the switch is .
A. 650 kPa (94 psi)
B. 1400 kPa (200 psi)
C. 19 000 kPa (2755 psi)
D. 20 000 kPa (2900 psi)
4. The priority valve in the steering pump directs oil to the steering control unit.
A. True.
B. False.
5. The pressure switch in the base of the charge filter senses the pressure differential across the
filter. If the pressure differential is greater than , the pressure switch closes,
causing the hydraulic oil filter indicator on the instrument panel to illuminate and an alarm to
sound.
A. 345 ± 35 kPa (50 ± 5 psi)
B. 600 ± 25 kPa (99 ± 4 psi)
C. 18 000 ± 2000 kPa (2610 ± 290 psi)
D. None of the above.
6. The main relief valve in the steering control unit limits the maximum pressure available to the
steering control unit to .
A. 345 ± 35 kPa (50 ± 5 psi)
B. 600 ± 25 kPa (99 ± 4 psi)
C. 18 000 ± 2000 kPa (2610 ± 290 psi)
7. The fan motor contains a relief valve which limits the motor inlet pressure to approximately
.
A. 1400 kPa (200 psi)
B. 7000 kPa (1010 psi)
C. 19 000 kPa (2755 psi)
D. 20 000 kPa (2900 psi)
8. The drum offset switch is normally open.

A. True.
B. False.
9. The drum offset system allows the front drum to be laterally moved in order to provide a
maximum offset between the front and rear drums of .
A. ±17 mm (±.65 in)
B. ±170 mm (±6.65 in)
C. ±1170 mm (±16.65 in)
10. The drum offset manifold contains a relief valve which limits the maximum pressure available to
the drum offset cylinder to .
A. 345 ± 35 kPa (50 ± 5 psi)
B. 600 ± 25 kPa (99 ± 4 psi)
C. 15 000 ± 1500 kPa (2180 ± 218 psi)
11. When the intermittent spray control dial is in the center of its travel range, the water system is
cycled ON for seconds and OFF for seconds.
A. 20, 20
B. 20, 40
C. 60, 20
12. As the intermittent spray control dial is rotated counterclockwise from center, the time ON
decreases and time OFF increases on a 20-second interval.
A. True.
B. False.
Propulsion System Instructor Guide for QESV1318
Propulsion System
___ Parts Manual

___ Multimeter
___ 198-4238 Pressure Sensor 0-34 500 kPa (0-5000 psi)
___ 198-4239 Pressure Sensor 0-69 000 kPa (0-10 000 psi)
___ 6V-4143 Coupler
___ 8T-0855 Pressure Gauge 0-4000 kPa (0-580 psi)
___ 8T-0861 Pressure Gauge 0-60 000 kPa (0-8700 psi)
___ 6V-3989 Fitting
___ 6V-9830 Cap Assembly
___ 6V-9509 ORFS Plug
clothing).

Instructor
Yes No
identify the components of the propulsion system.
and adjustments to the propulsion system. Follow
the procedures in the service manual.
• Test relief valve pressure (charge)
• Test relief valve pressure (main)
• Test relief valve pressure (pressure override).
3. (Lab C) Given a CB534D and CB564D Asphalt
notes, troubleshoot a fault in the propulsion system
(no worksheet).
higher.

_____________________
_____________________
_____________________ Desire to Learn

Lesson Plan
Visual Presentation: Propulsion, System Overview 60 min.

Visual Presentation: Propulsion, System Operation 60 min.

Lab C: Troubleshooting Group Exercise 60 min.
Posttest 30 min.


explained.
___ Propulsion Lever

Location: The propulsion lever is located on the console to the right of the operator’s seat.
Function: The propulsion lever controls the machine’s speed and travel direction. A sensor
detects the position of the lever. The sensor sends an input signal to the ECM, which, in turn,
determines the chosen travel direction and speed. The sensor is located inside the right operator’s
console.
___ Propulsion Sensor

Location: The propulsion sensor is located inside the right operator’s console.
Function: The propulsion sensor monitors the position of the propulsion lever. The sensor
converts the position of the propulsion lever to an electrical impulse. The impulse takes the form of
a pulse-width modulated signal with a duty cycle between approximately 9 percent and 91 percent.
The lowest duty cycle of the signal corresponds to the full-reverse position of the propulsion lever,
and the highest duty cycle corresponds to the full-forward position of the propulsion lever. When
the propulsion lever is in the NEUTRAL position, the duty cycle is approximately 50 percent.
___ Parking Brake Switch

Location: The parking brake switch is on the console to the right of the operator’s seat.
Function: The parking brake switch is a push-button switch with two positions. The parking brake
switch is in the ON position when the switch is pushed in. The switch is in the OFF position when
the switch is pulled out. The parking brake switch contains an integral indicator. The indicator is
illuminated when the switch is in the ON position.
Contact “1” and contact “3” of the parking brake switch receive power from the brake fuse. Contact
“2” of the switch is connected to terminal “7” of the ECM. Contact “4” of the switch is connected to
terminal “6” of the ECM. When the parking brake switch is in the OFF position, contact “1” and
contact “2” of the switch are closed. When the parking brake switch is in the ON position, contact
“3” and contact “4” of the switch are closed. When the ECM determines that the parking brake
switch is in the ON position, the ECM disengages the propulsion system.
___ Shift Switch

Location: The shift switch is on the console to the right of the operator’s seat.
Function: On the CB534D, The shift switch directly controls the shift solenoid. The ECM uses the
input from the shift switch to determine the appropriate speed map to use in order to control
machine speed.
On the CB564D, the ECM fuse distributes power to contact “2” and contact “5” of the shift switch.
Contact “1” of the switch is connected to terminal “12” of the ECM. Contact “6” of the switch is
connected to terminal “13” of the ECM. When the shift switch is in the LOW-SPEED position, the
circuit at terminal “12” of the ECM is complete. When the shift switch is in the HIGH-SPEED
position, the circuit at terminal “13” of the ECM is complete. The ECM uses the input from the shift
switch control the shift solenoid and to determine the appropriate speed map to use in order to
control machine speed.
___ Low Charge Pressure Indicator

Location: The low charge pressure indicator is located in the indicator cluster on the left side of
the instrument panel.
Function: A pressure switch in the outlet line of the charge filter controls this indicator—the
indicator illuminates when the charge pressure is low. On the CB564D, when this indicator is
illuminated, the ECM disables the propulsion system.
___ Engine Oil Pressure Indicator

Location: The engine oil pressure indicator is located in the indicator cluster on the left side of the
instrument panel.
Function: The engine oil pressure indicator is illuminated when the engine oil pressure is low. On
the CB564D, the ECM disables the propulsion system when the engine oil pressure indicator is
illuminated.
___ Speedometer
Location: The speedometer is located in the center of the instrument panel.
Function: The I-terminal of the speedometer receives power from the gauge fuse and the S-
terminal receives an input signal from the propulsion speed sensor. The speedometer is grounded
at the G-terminal.
___ Hydraulic Oil Filter Plugged Indicator

Location: The hydraulic oil filter plugged indicator is located in the indicator cluster on the left side
of the instrument panel.
Function: The hydraulic oil filter plugged indicator alerts the operator when the charge filter is
plugged. The pressure switch in the base of the charge filter controls this indicator.
___ Hydraulic Oil Temperature Indicator

Location: The hydraulic oil temperature indicator is located in the indicator cluster on the left side
of the instrument panel.
Function: The temperature switch in the hydraulic tank controls the hydraulic oil temperature
indicator. When the temperature of the hydraulic oil is greater than the actuation temperature of the
switch, the indicator illuminates.
___ Parking Brake Indicator

Location: The parking brake indicator is located on the right side of the instrument panel.
Function: The ECM controls the parking brake indicator. The parking brake indicator is illuminated
when the ECM has engaged the brake. The ECM also uses the parking brake indicator to flash
diagnostic information to the operator.
___ Neutral Indicator

Location: The neutral indicator is located on the right side of the instrument panel.
Function: The ECM controls the neutral indicator. The ECM directs an output signal to the neutral
indicator when the propulsion lever is in the NEUTRAL position.
___ Thermal Bypass Valve (Return Manifold)

Location: The thermal bypass manifold is inside the return manifold located on the right side of
Function: Case drain lines from the propulsion pump, propulsion motors, vibratory pump, and
vibratory motors are connected to the return manifold. Oil from these lines is combined and
directed to the thermal bypass valve inside the manifold.
___ Hydraulic Oil Cooler

Location: The hydraulic oil cooler is part of the cooling package. This component is located at the
rear of the machine. The engine compartment cover provides access to the oil cooler.
Function: Oil from the return manifold is sent through the hydraulic oil cooler. Oil from the outlet
side of the cooler is directed into the hydraulic tank.
___ Propulsion Pump

Location: The propulsion pump is located in the engine compartment.
Function: The propulsion pump is the first in a series of two pumps which are driven by the engine
flywheel—the propulsion pump is driven by the engine, and the vibratory pump is splined to the
propulsion pump. The propulsion pump is electronically controlled, variable-displacement, axial-
piston pump. The ECM controls the pump by directing output signals to the forward and/or reverse
solenoids on the pump.
___ Park Brake Solenoid

Location: The park brake solenoid is mounted to the propulsion pump.
Function: The parking brake solenoid on the propulsion pump controls the parking brakes. When
the solenoid is de-energized, the parking brakes are engaged, and when the solenoid is
energized, the parking brakes are released.
___ Interlock Solenoid

Location: The interlock solenoid is mounted to the interlock manifold located on the rear main
frame at the front of the engine compartment.
Function: The interlock solenoid is controlled by the ECM. When the interlock solenoid is
energized, charge oil is directed to the displacement control spool in the propulsion pump.
___ Brake Manifold

Location: The brake manifold is mounted to the rear main frame at the front of the engine
compartment, on the left side of the machine.
Function: The parking brakes can be manually released when the needle valve is closed, and the
hand pump is operated.
___ Shift Manifold

Location: The shift manifold is mounted to the rear main frame at the front of the engine
compartment, on the left side of the machine.
Function: The shift solenoid is installed in the shift manifold. The shift solenoid is an on/off device
which controls the speed range of the rear propulsion motor on the CB534D and both propulsion
motors on the CB564D. The ECM controls the shift solenoid.
When the shift solenoid is de-energized, the motor operates in the low range. When the solenoid is
energized, charge oil is directed to the shift spool in the propulsion motor, and the motor operates
in the high range.
___ Propel Motor (Rear)

Location: The rear drum motor is located on the right side of the drum. The front drum motor is
located on the left side of the drum. The front drum motor and the rear drum motor on the CB534D
are different. Both drum motors on the CB564D are identical to the rear drum motor on the
CB534D, except that the front drum motor on the CB564D is not equipped with a speed sensor
Function: The drum motors on the CB564D and the rear drum motor on the CB534D are piston
motors with two speeds. The motors drive the corresponding drum through a planetary gear
reducer. The planetary gear reducer contains an integral parking brake.
___ Propel Motor (Front)

Location: The front propulsion motor on the CB534D is a bent axis motor with a fixed
displacement. The motor is located on the left side of the front drum.
Function: The front propulsion motor drives the front drum through a planetary gear reducer. The
planetary gear reducer contains an integral parking brake.

Operation, Testing and Adjusting,CB534D and CB564D Asphalt Compactors, Propulsion System.
1. Test relief valve pressure (charge), forward and reverse
2. Test relief valve pressure (main), forward and reverse
3. Test relief valve pressure (pressure override), forward and reverse.
Machine Model Date

Test relief valve
pressure (charge),
forward
Test relief valve
pressure (charge),
reverse
Test relief valve
pressure (main),
forward
Test relief valve
pressure (main),
reverse
Test relief valve
pressure (pressure
override), forward
Test relief valve
pressure (pressure
override), reverse
Lab C: Troubleshooting, Group Exercise

Posttest
1. The drive systems consist of two, variable-displacement, piston-type propulsion pumps and a
single piston-type hydraulic motor for the machine.
A. True.
B. False.
2. The operator can release the parking brakes when the propulsion lever is out of the NEUTRAL
position.
A. True.
B. False.
3. The rear drum motor contains a flushing valve. The flushing valve spool directs oil from the low-
pressure side of the drum propulsion loop to the flushing relief valve. When the pressure in the
low pressure side of the propulsion loop is greater than , the flushing relief valve
opens.
A. 1700 kPa (250 psi)
B. 1800 kPa (260 psi)
C. 42 000 ± 2000 kPa (6230 ± 290 psi)
D. 45 000 ± 2000 kPa (6530 ± 290 psi)
4. The drum motors on the CB564D and the rear drum motor on the CB534D are piston motors
with two speeds.
A. True.
B. False.
5. When the pressure in the high-pressure circuit is greater than , the pressure
unseats the piston and moves the valve spool until the passage from the charge circuit is open
to the case drain.
A. 1700 kPa (250 psi)
B. 1800 kPa (260 psi)
C. 42 000 ± 2000 kPa (6230 ± 290 psi)
D. 45 000 ± 2000 kPa (6530 ± 290 psi)
6. When the automatic speed control dial is in the position, the machine remains
in neutral.
A. MINIMUM-SPEED
B. HIGH-SPEED
C. LOW-SPEED
7. The propulsion sensor converts the position of the propulsion lever to an electrical impulse. The
impulse takes the form of a pulse-width modulated signal with a duty cycle between
approximately percent and percent. When the propulsion lever is in the
NEUTRAL position, the duty cycle is approximately percent.
A. 5, 11, 100
B. 7, 71, 75
C. 9, 91, 50
8. When a fault is detected, the ECM flashes a fault code on the parking brake indicator.
A. True.
B. False.
Vibratory System Instructor Guide for QESV1318
Vibratory System
___ Parts Manual

___ Multimeter
___ 198-4237 Pressure Sensor 0-3450 kPa (0-500 psi)
___ 198-4239 Pressure Sensor 0-69 000 kPa (0-10 000 psi)
___ 6V-4143 Coupler
___ 8T-0855 Pressure Gauge 0-4000 kPa (0-580 psi)
___ 8T-0861 Pressure Gauge 0-60 000 kPa (0-8700 psi)
___ 6V-3989 Fitting
___ 6V-9830 Cap Assembly
___ 6V-9509 ORFS Plug
clothing).

Instructor
Yes No
identify the components of the vibratory hydraulic
system.
and adjustments to the vibratory hydraulic system.
Follow the procedures in the service manual.
• Test pressure relief valve (charge vibratory)
• Test pressure relief valve (main vibratory)
• Test pressure relief valve (pressure override
vibratory)
3. (Lab C) Given a CB534D and CB564D Asphalt
notes, troubleshoot a fault in the vibratory hydraulic
system (no worksheet).
higher.

_____________________
_____________________
_____________________ Desire to Learn

Lesson Plan
Visual Presentation: Vibratory Hydraulic, System Overview 60 min.

Visual Presentation: Vibratory Hydraulic, System Operation 60 min.

Suggested Illustrations: Slide 103-108
Lab C: Troubleshooting Group Exercise 30 min.
Posttest 30 min.


explained.
___ Vibratory Mode Control Switch
Location: The vibratory mode control switch is located on the left side of the instrument panel.
Function: The vibratory mode control switch is a rocker switch with two positions. This switch
allows the operator to choose between manual and automatic operation of the vibratory system.
The left position of the switch is the MANUAL position, and the right position is the AUTOMATIC
position. When the switch is in the MANUAL position and the vibratory system is ON, the vibratory
motors operate when the propulsion lever is out of the NEUTRAL position. When the switch is in
the AUTOMATIC position, the vibratory motors only operate when the machine is moving above a
set speed. The vibratory system will not activate when the propulsion lever is in the NEUTRAL
position.
___ Drum Selector Switch

Location: The drum selector switch is located on the left side of the instrument panel.
Function: This rocker switch with three-positions allows the front and rear vibratory motors to be
independently or simultaneously operated. The left position is the REAR position. The center
position is the DUAL DRUM position. The right position is the FRONT position. Power transfers
from the vibratory fuse to contact “2” of the drum selector switch. Contact “1” of the switch is
connected to the front motor selector solenoid. Contact “3” of the switch is connected to the rear
motor selector solenoid. The drum selector switch also controls which of the vibratory speed
sensors provides the input signal to the vibratory tachometer. The rear vibratory speed sensor is
connected to contact “5” of the drum selector switch, and the front vibratory speed sensor is
connected to contact “6.” When the drum selector switch is in the REAR position and the DUAL
DRUM position, the rear speed sensor directs the input signal to the vibratory tachometer. When
the switch is in the FRONT position, the front speed sensor provides the input signal to the
tachometer.
___ Amplitude Selector Switch

Location: The amplitude selector switch is located on the left side of the instrument panel.
Function: If the machine is equipped with the two-amplitude system, the amplitude selector switch
(3) is located in the space below the drum selector switch. The amplitude selector switch is a
rocker switch with two-positions. The left position is the HIGH-AMPLITUDE, LOW-FREQUENCY
position. The right position is the LOW-AMPLITUDE, HIGH-FREQUENCY position. The switch has
two poles.
___ Vibratory Tachometer

Location: The vibratory tachometer is located on the right side of the instrument panel.
Function: The drum selector switch controls which of the vibratory speed sensors provides the
input signal to the vibratory tachometer.
___ Vibratory Master Switch

Location: The vibratory master switch is a trigger-type switch located on the propulsion control
lever.
Function: The vibratory master switch is normally open. When the trigger is actuated, the ECM
receives an input signal. The ECM tracks the number of impulses it receives from the vibratory
master switch to determine the status of the vibratory system—with an odd number, the system is
ON; with an even number, the system is OFF.
___ Piston Pump (Vibratory)

Location: The vibratory pump is located in the engine compartment. The vibratory pump is
splined to the propulsion pump.
Function: The vibratory pump on the CB534D and the vibratory pump on the CB564D are similar
but not identical. The vibratory pumps are also similar to the propulsion pump on these machines.
The ECM controls the vibratory pump by directing a fixed signal to the vibratory pump solenoids.
Solenoid reactions move the displacement control spool in the pump to control the flow of charge
oil which acts against either side of the servo cylinder. The position of the servo cylinder controls
the position of the swashplate in the pump.
___ Piston Motor (Rear)

Location: The rear vibratory motor is located on the left side of the rear drum.
Function: The standard motor is a piston-type motor with a fixed displacement. The motor used
on machines with a Versa Vibe system is a fixed-displacement, piston-type motor with a bent axis.
The vibratory motor directly drives the vibratory weight shaft.
___ Piston Motor (Front)

Location: The front motor is located on the right side of the front drum.
Function: The front vibratory motor is identical to the rear motor.
___ Vibratory Speed Sensor

Location: A vibratory speed sensor is located at the front and rear vibratory motors.
Function: The vibratory speed sensors provide the input signals to operate the vibratory
tachometer. The drum selector switch controls which of the sensors provides the input the
tachometer.

Operation, Testing and Adjusting,CB534D and CB564D Asphalt Compactors, Machine System.
1. Test pressure relief valve (charge vibratory)
2. Test pressure relief valve (main vibratory)
3. Test pressure relief valve (pressure override vibratory)
Machine Model Date

Test pressure relief
valve (charge
vibratory), forward
valve (charge
vibratory), reverse
valve (main vibratory),
forward
valve (main vibratory),
reverse
valve (pressure
override vibratory),
forward
valve (pressure
override vibratory),
reverse
Lab C: Troubleshooting, Group Exercise

Posttest
1. The machine’s electrical system prevents the vibrators from operating unless the propulsion
lever is out of the NEUTRAL position.
A. True.
B. False.
2. On machines equipped with a two-amplitude system or a five-amplitude system, the relief

setting of the combination valves limits the pressure in the high-pressure circuit to
.
A. 350 kPa (7 psi)
B. 3500 kPa (220 psi)
C. 35 500 kPa (5150 psi)
3. Each drum contains a single eccentric weight. The weight is located in a sealed housing inside
the drum and is connected to the vibratory motor output shaft.
A. True.
B. False.
4. On machines equipped with the Versa-Vibe system the relief setting of the combination valve is
.
A. 40 000 kPa (5800 psi)
B. 41 000 kPa (5900 psi)
C. 42 000 kPa (6000 psi)
5. The vibratory master switch located on the front of the propulsion lever serves as the master
switch for the vibratory system.
A. True.
B. False.
6. When the vibratory system is operating, and the pressure in the low-pressure side of the loop is
greater than , the flushing relief valve opens, directing flow from the low-
pressure side of the loop into the case drain to cool and clean the vibratory loop.
A. 6500 - 8500 kPa (943 - 1233 psi)
B. 1800 kPa (260 psi)
C. 15 000 ± 500 kPa (2180 ± 73 psi)

QESV1318 Inst Guide

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PART OF TECHNICAL PRESENTATION QESV1318

CB534D AND CB564D

Power Distribution and Machine Starting System

The Instructor Guide contains the following sections:

Student Name: ______________________ Instructor(s): _______________________

Instructor(s): Student Average Good Excellent

_____________________ Desire to Learn

Visual Presentation: Machine Introduction, System Overview 40 min.

Total Estimated Time 1.0 hours

3. The engine produces a gross power of at RPM.

5. The capacity of the water tank is .

6. The refill capacity of the fuel tank is .

7. The refill capacity of the crankcase is .

10. The vibratory tachometer is driven by the vibratory speed sensors.

Power Distribution and Machine Starting System

Gather the following required/optional special tools:

Student Name: ______________________ Instructor(s): _______________________

Instructor(s): Student Average Good Excellent

_____________________ Desire to Learn

Lab A: Component Identification 30 min.

Lab B: Troubleshooting Group Exercise 40 min.

Total Estimated Time 2.3 hours

Lab A: Component Identification Worksheet

___ Auxiliary Start Post

___ Engine Start Switch

___ Main Circuit Breaker

___ Alternator Circuit Breaker

___ Glow Plug Circuit Breaker

___ Throttle Circuit Breaker

___ Glow Plug Relay

___ Start Relay

___ Coolant Temperature Switch

___ Fuel Solenoid

___ Cold-Start Timing Advance Solenoid

___ Fuel Lift Pump

___ Throttle Control Module

___ Throttle Control Switch

___ Power Panel

___ Propulsion Sensor

___ Main Power Relay

Lab B: Troubleshooting, Group Exercise

Gather the following required/optional special tools:

Student Name: ______________________ Instructor(s): _______________________

Instructor(s): Student Average Good Excellent

_____________________ Desire to Learn

Visual Presentation: Machine System, System Overview 90 min.

Lab A: Component Identification 60 min.

Visual Presentation: Machine System, System Operation 90 min.

Lab B: Testing and Adjusting 40 min.

Total Estimated Time 5.2 hours

Lab A: Component Identification Worksheet

___ Charge Filter

___ Steering Control Unit (Metering Pump)

___ Steering Cylinder

___ Fan Motor

Drum Offset Control

___ Drum Offset Cylinder

___ Drum Offset Manifold

Water Spray Control

___ Water Pump Selector Switch

___ Water Spray Master Switch

___ Water Spray Timer (CB534D Only)

Student Name: Instructor(s): _

Student Name: Instructor(s): _

Student Name: Instructor(s): _

Student Name: Instructor(s): _

Student Name: Instructor(s): _