QERQ1018

ITIM for KENR3617

June 2003

Integrated Technical
Instruction Module

CB-534D Vibratory Compactors

Machine Systems
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Posttest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Instructor Answer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

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Introduction
This Integrated Technical Instruction Module (ITIM) contains a portion of the CB-534D Vibratory
Compactors training course. The steering and water spray systems are 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 SEBV0558

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 steering and water spray systems on the CB-
534D Vibratory Compactors is critical for troubleshooting. It is also important to be able to
properly test and adjust the systems.
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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
steering 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:

¥ Fan Motor Speed (Radiator Cooling)—Test and Adjust

¥ Relief Valve (Steering)—Test and Adjust

¥ Relief Valve (Offset)—Test and Adjust

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

study worksheet, troubleshoot a fault in the vibratory
system.

4. Given a CB-534D Vibratory Compactor and the Lab C

Worksheets, locate and identify the components of the
water spray system during a lab exercise.

5. Given all reference material and class notes, trace

current through the steering and water spray electrical
systems during a posttest.

6. Given all reference material and class notes, trace oil

flow through the steering hydraulic system during a
posttest.

7. 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: Steering System, Component Location 20 min.

Suggested Illustrations: 33/34/68, 35, 43, 48, 49, 50, 61, 51, 65, 52, 54, 53, 38,
44/46/72/82/84/85, 59, 57, 47/55, 60, 45/56, 58

Lab A: Steering System, Component Identification 30 min.

Visual Presentation: Steering System, System Operation 55 min.

Suggested Illustrations: 33/34/68, 62, 64, 36, 37, 63, 66, 39, 40, 41, 42

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

Visual Presentation: Water Spray System, Component Location 15 min.

Suggested Illustrations: 33/34/68, 81, 70, 44/46/72/82/84/85, 75, 76, 73, 71/83/86, 77, 74, 87, 78,
88, 79, 89, 80

Lab C: Water Spray System, Component Identification 30 min.

Visual Presentation: Water Spray System, System Operation 15 min.

Suggested Illustrations: 33/34/68, 90, 69

Case Study 30 min.

Posttest 60 min.
Administer Posttest
Review and Discuss Posttest Results

Total Estimated Time 5.5 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,

Machine Systems KENR3617

__ 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 1U-6602 Photo-Tach Group

__ 1 4C-6500 Digital Thermometer

__ 1 198-4240 Digital Pressure Indicator(1)

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

__ 1 177-7860 Hose Assembly(2)

__ 2 6V-4143 Coupler(2)

__ 1 8T-0859 0—25 000 kPa (0—3600 psi) Pressure Gauge(2)

__ 1 6V-3989 Fitting(2)

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 Machine System (Form Number KENR3617) 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: Steering System, Component Identification

Lab B: Steering System, Testing and Adjusting

Lab C: Water Spray System Component Location

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

Lab A Worksheet
Directions: The instructor has attached an identification tag to each component in the steering 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 steering system.

_____ 1. Hydraulic Tank

Location:
Function:

_____ 2. Steering Pump

Location:
Function:

_____ 3. Steering Control Unit

Location:
Function:

_____ 4. Steering Cylinder

Location:
Function:

_____ 5. Fan Motor

Location:
Function:

_____ 6. Charge Filter

Location:
Function:
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_____ 7. Electronic Control Module (ECM)

Location:
Function:

_____ 8. Drum Offset Switch

Location:
Function:

_____ 9. Drum Offset Solenoids

Location:
Function:

_____ 10. Drum Offset Proximity Switch

Location:
Function:

_____ 11. Drum Offset Cylinder

Location:
Function:
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Lab B: Steering 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, Machine Systems (Form
KENR3617).

Machine Model Date

Serial Number Service Meter Hours

PRESSURE TESTS

TESTS SPECIFICATIONS ACTUAL

Fan Motor Speed (Radiator

Cooling)

Relief Valve (Steering)

Relief Valve (Offset)

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Lab C: Water Spray System Component Identification

Lab C Worksheet
Directions: The instructor has attached an identification tag to each component in the water spray
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 water spray system.

_____ 1. Electronic Control Module (ECM)

Location:
Function:

_____ 2. Water Spray Timer

Location:
Function:

_____ 3. Water Spray On/Off Switch

Location:
Function:

_____ 4. Water Spray Potentiometer

Location:
Function:

_____ 5. Water Spray Pump Selector Switch

Location:
Function:

_____ 6. Number-one Water Spray Relay

Location:
Function:
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_____ 7. Number-two Water Spray Relay

Location:
Function:

_____ 8. Neutral Stop Relay

Location:
Function:

_____ 9. Drum Spray Lights Relay

Location:
Function:

_____ 10. Water Spray Indicator

Location:
Function:

_____ 11. Water Spray Motors

Location:
Function:
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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 machine is overheating.

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 the machine.

13.

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

14.
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Machine Systems Posttest

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

1. Which of the following components and/or features of the CB-534D have been changed from the
CB-534C? (Circle each correct answer.)

A. Steering pump.
B. Steering control unit.
C. Cooling fan control.
D. All of the above.

2. TRUE or FALSE: The CB-534D has a 50:50 articulation ratio.

3. The steering pump supplies oil to which of the following? (Circle each correct answer.)

A. Propulsion charge system.

B. Fan motor.
C. Water spray motor.
D. All of the above.

4. Circle the statement which most accurately describes the location of the steering 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. Front, right side of the engine.
D. Front, left side of engine

5. Where can steering supply pressure be measured?

A. At the pressure tap in the outlet line of the steering pump.

B. At the pressure tap in the outlet side of the charge filter.
C. At the tap in the P-port of the steering control unit.
D. At the priority valve.

6. Where is the steering supply pressure adjusted?

A. At the priority valve.

B. At the fan relief valve.
C. At the pressure differential valve in the steering control unit.
D. Steering supply pressure is factory-set and cannot be adjusted.
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7. TRUE or FALSE: The steering control spool governs the rate of a turn, and the metering pump
controls the direction of a turn.

8. Which of the following best describes the drum offset specification?

A. Offset a maximum of 169 mm (6.65 in) to left only.

B. Offset a maximum of 169 mm (6.65 in) to right only.
C. Offset a maximum of 169 mm (6.65 in) either right or left.
D. Offset to left a maximum of 169 mm (6.65 in) and offset to right a maximum of 85 mm (3.3 in).

9. Where is the drum offset solenoid located?

A. On the drum offset manifold at the rear of the engine compartment.

B. On the drum offset manifold at the front of the engine compartment.
C. On the drum offset manifold, under the operator s platform, near the drum offset cylinder.
D. On the steering pump.

Directions: Use the following three schematics to answer questions 10—15. Circle the best
answer for each question.
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CB-534D STEERING HYDRAULIC SYSTEM

STEERING
LINE RELIEF VALVES CYLINDER FAN MOTOR
R L FAN RELIEF VALVE
STEERING AND CHARGE PUMP IN

230 BAR 230 BAR

PRIORITY VALVE

Ø1.0mm
MAKEUP
VALVES 70 BAR

CONTROL SPOOL OUT

I CF
CHARGE FILTER
16

METERING PUMP
EF

Ø0.8mm LS

CP
210 BAR
LD 3.5 BAR
RELIEF VALVE
ANTICAVITATION FILTER BYPASS
CHECK VALVE VALVE
SOS
SUCTION SCREEN
180 BAR
INLET CHECK VALVE
P T

TO VIBRATORY AND PROPEL

PRESSURE DIFFERENTIAL VALVE CHARGE CIRCUITS
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CB-534D Vibratory Compactors ITIM
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CB-534D DRUM OFFSET OPTION

OFFSET
CYLINDER
ø0.8mm AI
PRIORITY SPOOL
BI
P
18

PILOT-OPENED CHECK VALVES

C
ø1.0mm
10 LPM

X RELIEF VALVE

DRUM OFFSET VALVE

150 BAR
T

TO HYDRAULIC TANK
TO FAN MOTOR IN-PORT OR P-PORT OF EDGE CUTTER VALVE
FROM EF-PORT OF STEERING PUMP
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CB-534D Vibratory Compactors ITIM
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10. TRUE or FALSE: The ECM uses input from the coolant temperature sensor to control the speed
of the fan motor.

11. Which of the following functions does the line relief and makeup valves in the steering control
unit perform?

A. Limit steering supply pressure to 23 000 kPa (3333 psi).

B. Allow machine steering with a dead engine.
C. Relieve shock loads in the steering cylinder and allow oil from the high-pressure side of cylinder
to flow to the low-pressure side in order to prevent cylinder cavitation.
D. All of the above.

12. Classify the following as input or output terminals of the ECM:

Terminal Input or Output

22
23
24
30
40

13. Which of the following functions does the priority spool in the drum offset manifold perform?
(Circle each correct answer.)

A. Limits the maximum pressure in the drum offset system to 15 000 kPa (2170 psi).
B. Provides priority flow to the steering control unit.
C. Provides the fan motor priority flow over the drum offset system.
D. Provides the drum offset system priority flow over the fan motor.

14. TRUE or FALSE: The drum offset manifold provides a load-sensing signal to the steering pump.

15. TRUE or FALSE: When the machine is equipped with the drum offest option, the relief valve in
the drum offset manifold controls the steering supply pressure.

16. When the water spray switch is in AUTOMATIC,

A. the number-one water spray pump and motor group operates when the machine is traveling in
forward, and the number-two water spray pump and motor group operates when the machine is
traveling in reverse.
B. the number-one water spray pump and motor group operates when the machine is traveling in
reverse, and the number-two water spray pump and motor group operates when the machine is
traveling in forward.
C. the number-one water spray pump continuously operates, except for when the propulsion lever is
in NEUTRAL.
D. the number-two water spray pump continuously operates, except for when the propulsion lever is
in NEUTRAL.
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17. TRUE or FALSE: The water spray system only operates when the water spray on/off switch is
held.

Directions: Use the following schematic to answer questions 18—20. Circle the best answer for
each question.

18. TRUE or FALSE: The number-two water spray relay is energized when the propulsion lever is in
reverse.

19. Which of the following components have an impact on the state of the coil of the number-one
water spray relay? (Circle each correct answer.)

A. ECM.
B. Water spray timer.
C. Water spray potentiometer.
D. Water pump selector switch.

20. TRUE or FALSE: The number-one water spray relay, number-two water spray relay, and water
spray neutral relay should never be simultaneously energized.
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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 NA (not applicable).

Lab A

1. Location: Right side of engine compartment.

Function: Serves as oil reservoir for steering, propulsion, and vibratory hydraulic systems.
2. Location: Front, right side of engine.
Function: Fixed-displacement, gear-type pump provides flow to operate steering, fan motor, drum
offset, and edge cutter. Also provides charge oil to propulsion and vibratory hydraulic
circuits. Priority valve in pump ensures steering receives priority flow.
3. Location: At base of steering wheel.
Function: Consists of steering control spool and metering pump. Steering control spool governs
direction of turn, and metering pump controls rate of turn.
4. Location: Right side of machine, articulation area.
Function: Single steering cylinder controls machine articulation.
5. Location:Engine compartment, rear of machine.
Function: Fixed-displacement, gear-type motor drives cooling fan.
6. Location: Right side of engine compartment.
Function: Filters charge oil from steering system. Serves vibratory and propulsion systems.
7. Location: Inside right console.
Function: Monitors input components to control drum offset.
8. Location: Right console, on propulsion control lever.
Function: Three-position, momentary-type switch provides input to ECM. ECM uses input with input
from drum offset proximity switch to control drum offset solenoids.
9. Location: On drum offset manifold, front of engine compartment. Offset right solenoid, C928-GY wire;
offset left solenoid, C929-WH wire.
Function: ECM controls drum offset solenoids. When energized, solenoids direct oil into and open
return passage from drum offset cylinder.
10. Location: Mounted to drum offset cylinder, left side of machine.
Function: Provides input to ECM when drum in center position.
11. Location: Articulation area, left side of machine.
Function: Laterally moves drum to provide maximum offset of 169 mm (6.65 in).

Lab B

NA

Lab C

1. Location: Inside right console.

Function: Monitors input from water spray master switch and propulsion sensor to control water spray
system. Output components include: water spray timer (contact 2), number-two water
spray relay (coil), neutral stop relay (coil), drum spray lights relay (coil), and water spray
indicator.
2. Location: Inside right console.
Function: Works in conjunction with water spray potentiometer to set water spray intervals.
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3. Location: On propulsion control lever, outboard pushbutton switch.

Function: Momentary-type switch provides input to ECM. ECM monitors number of pulses from
switch no pulses and/or even number, water spray system OFF; odd number, system ON.
4. Location: Instrument panel, left side.
Function: Works in conjunction with water spray timer to set water spray intervals.
5. Location: Instrument panel, left side.
Function: Three-position rocker switch controls water pump and motor groups. Right position,
number-one water pump and motor group operates; left position, number-two water and
motor group operates; center position, number-one water pump and motor operates during
forward travel and number-two water pump and motor operates during reverse travel.
6. Location: In compartment at base of right console.
Function: Distributes power to water pump selector switch. Controlled by water spray timer.
7. Location: In compartment at base of right console.
Function: Distributes power to either water spray motor when system is in AUTOMATIC. Controlled
by ECM.
8. Location: In compartment at base of right console.
Function: Distributes power to gate of number-two water spray relay with system in AUTOMATIC and
propulsion lever out of NEUTRAL. Controlled by ECM.
9. Location: In compartment at base of right console.
Function: Distributes power to drum lights when water system operating. Controlled by ECM.
10. Location: Instrument panel, left side.
Function: Illuminates when water spray system operates. Controlled by ECM.
11. Location: Articulation area, right side of machine, under operator s platform.
Function: Electric motor drives diaphragm-type pump which draws water from tank and distributes to
spray bars. Machine equipped with two motors, only one operates at a time.

Case Study

NOTE:
To simulate this problem on the machine, turn the fan motor relief valve counterclockwise three
turns. Do not allow the machine to overheat during the testing process. Ensure that the fan motor
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 machine overheats. Ask about unusual
noises and/or odors, and ask about recent changes in application. Look for clues in the description
which may prompt additional questions.
2. What warning indicators are illuminated when the machine is overheating?
3. Is the machine exhibiting other symptoms?
4. Engine coolant and hydraulic oil levels.
5. Oil leaks and/or air in the hydraulic oil.
6. Restriction across the cooling fins.
7. N/A
8. Electrical fault in engine coolant temperature switch and/or hydraulic oil temperature switch circuits
(machine is not actually overheating).
9. Engine cooling or lubrication system problem.
10. Slow fan speed.
11. Measure coolant and hydraulic oil temperature. If normal, check switch input to ECM.
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12. Measure fan speed.

13. Overheating was confirmed. The fan-speed test indicated that the fan speed was low.
14. After the fan speed was adjusted, operating temperatures returned to normal.

Posttest

1. A, B, C, D

2. TRUE

3. A, B

4. C

5. A

6. D

7. FALSE: The steering control spool governs the direction of a turn, and the metering pump controls the
rate of a turn.

8. C

9. B

10. FALSE: The fan motor is not electronically controlled.

11. C

12. Input, Input, Input, output, output

13. D

14. FALSE: The drum offset manifold does not provide a load-sensing signal to the steering pump.

15. FALSE: The relief valve in the drum offset manifold has no impact on the steering pump supply
pressure.

16. A

17. FALSE: The ECM monitors the input from the switch. When the ECM has received zero or an even
number of input signals from the switch, the water spray system is OFF; with an odd number of input
signals, the water spray system is ON.

18. TRUE

19. A, B, C

20. TRUE