QERQ1018

ITIM for KENR3616

June 2003

Integrated Technical
Instruction Module

CB-534D Vibratory Compactors

Vibratory 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Posttest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Instructor Answer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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Introduction
This Integrated Technical Instruction Module (ITIM) contains a portion of the CB-534D Vibratory
Compactors training course. The vibratory 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 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 vibratory 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
vibratory 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

¥ Vibratory Frequency—Test and Adjust

¥Automatic Vibration—Adjust

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

study worksheet, troubleshoot a fault in the vibratory
system.

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

through the vibratory electrical system during a posttest.

5. Given all reference material and class notes, trace oil flow
through the vibratory 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):

________________________

________________________

Training Manager:

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

Visual Presentation: Vibratory System, Component Location 35 min.

Suggested Illustrations: 15, 17, 23, 36, 24/30, 16, 54, 48, 25/26/27, 49, 50, 51, 31, 55, 35, 59, 38,
32/33/34/39/40, 56, 57/58, 46, 28/29//41/42/43/44, 74, 52/53, 79, 80, 81, 82, 83, 76, 77, 78, 45,
47, 37

Lab A: Vibratory System, Component Identification 30 min.

Visual Presentation: Vibratory System, System Operation 105 min.

Suggested Illustrations: 15, 84, 18, 19, 22, 20, 21, 69, 70, 71, 72, 73, 60, 61, 62, 63, 64, 65, 66,
67, 75

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

Case Study 30 min.

Posttest 60 min.
Administer Posttest
Review and Discuss Posttest Results

Total Estimated Time 5.6 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,

Vibratory System KENR3616

__ 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 4C-6500 Digital Thermometer

__ 1 133-0963 Drum Vibration Tachometer

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 Vibratory System (Form Number KENR3616) 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: Vibratory System, Component Identification

Lab B: VIbratory 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: Vibratory System Component Identification

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

_____ 1. Electronic Control Module (ECM)

Location:
Function:

_____ 2. Vibratory ON/OFF Control Switch

Location:
Function:

_____ 3. Vibratory Auto/Manual Selector Switch

Location:
Function:

_____ 4. Vibratory Drum Selector Switch

Location:
Function:

_____ 5. Vibratory High/Low Switch (if equipped)

Location:
Function:

_____ 6. Vibratory Indicator Lamp

Location:
Function:
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_____ 7. Vibratory Tachometer

Location:
Function:

_____ 8. Charge Filter

Location:
Function:

_____ 9. Vibratory Pump

Location:
Function:

_____ 10. Vibratory Valve

Location:
Function:

_____ 11. Rear Drum Solenoid

Location:
Function:

_____ 12. Front Drum Solenoid

Location:
Function:

_____ 13. Flushing Valve

Location:
Function:

_____ 14. Rear Vibratory Motor

Location:
Function:

_____ 15. Front Vibratory Motor

Location:
Function:
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_____ 16. Vibratory Speed Sensors (Front and Rear)

Location:
Function:

_____ 17. Eccentric Weights

Location:
Function:

_____ 18. Thermal Bypass Valve

Location:
Function:
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Lab B: Vibratory 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, Vibratory System (Form
KENR3616).

Machine Model Date

Serial Number Service Meter Hours

PRESSURE TESTS

TESTS SPECIFICATION ACTUAL

Relief Valve (Charge)

Vibratory System OFF

Relief Valve (Charge)

Vibratory System ON

Relief Valve (Main)

Condition One

Relief Valve (Main)

Condition Two

Relief Valve (Pressure

Override) Condition One

Relief Valve (Pressure

Override) Condition Two

Vibratory Frequency
Condition One

Vibratory Frequency
Condition Two

Automatic Vibration
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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 operator reports
that vibrations are transferring through to the machine when the vibratory system is operating.

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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Vibratory System 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?

A. Vibratory pump.
B. Location of vibratory motors.
C. Vibratory control.
D. All of the above.

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

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

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

4. Circle the statement which most accurately describes the location of the vibratory 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 vibratory valve mounted?

A. On the bottom face of the vibratory pump.

B. On the top face of the vibratory pump.
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 MB-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 B or C above.

Directions: Use the following two schematics to answer questions 10—15. Circle the best answer
for each question.
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10. Which of the following contacts are closed when the vibratory drum selector switch in in REAR?

A. 1 and 2, and 4 and 5.

B. 2 and 3, and 5 and 6.

11. TRUE or FALSE: The vibratory auto/manual selector switch controls the front and rear drum
solenoids.

12. TRUE or FALSE: The ECM uses input from the vibratory speed sensors to control the vibratory
system.

13. Which of the following functions does the intercircuit relief valve perform?

A. Limits the maximum pressure in the vibratory system to 24 000 kPa (3480 psi).
B. Prevents vibratory motor cavitation during direction changes when the system is in MANUAL.
C. Opens a passage to the case drain when the vibratory system is OFF.
D. NONE of the above.

14. TRUE or FALSE: When the vibratory system is operating, the flushing relief valve setting controls
charge pressure.

15. What pressure will register at the MP-tap in the vibratory valve when the vibratory system is
operating in REAR DRUM FORWARD?

A. Pump supply pressure.

B. Reduced pump supply pressure.
C. Charge pressure.
D. Case drain pressure.
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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: Inside right console.

Function: Monitors input components to control vibratory pump.

2. Location: Trigger switch on front of propulsion control lever.

Function: Master switch for vibratory system. Provides input to ECM. ECM uses input with other input
signals to control vibratory system.

3. Location: Instrument panel, left side, top switch.

Function: Provides input to ECM. In MANUAL with vibratory system ON, vibratory motors operate
continuously. In AUTOMATIC with vibratory system ON, vibratory motors operate only when
machine moves.

4. Location: Instrument panel, left side, second switch from top.

Function: Controls front and rear motor selector solenoids. Also directs signal from front motor speed
sensor to vibratory tachometer during front drum operation.

5. Location: Instrument panel, left side, bottom switch.

Function: Controls dual amplitude vibratory system.

6. Location: Instrument panel, left side, bottom left indicator.

Function: Illuminates when vibratory system ON. Controlled by ECM.

7. Location: Instrument panel, right side, bottom gauge.

Function: Measures vibratory frequency. Driven by vibratory motor speed sensors.

8. Location: Right side of engine compartment.

Function: Filters charge oil from steering system. Serves vibratory and propulsion systems.

9. Location: Second 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 vibratory
motors.

10. Location: Mounted to top face of vibratory pump (engine compartment, left side of machine).
Function: Contains intercircuit relief valve, front drum solenoid, rear drum solenoid, and flushing valve.

11. Location: On rear face of vibratory valve (C927-PU wire).

Function: Controlled by vibratory drum selector switch. When energized, connects inlet and outlet
sides of front motor, preventing front motor from operating.

12. Location: On rear face of vibratory valve (C926-BU wire).

Function: Controlled by vibratory drum selector switch. When energized, connects inlet and outlet
sides of rear motor, preventing rear motor from operating.

13. Location: On left face of vibratory valve.

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Function: Directs oil from low-pressure circuit to case drain, cleaning and cooling oil in the vibratory
and propulsion circuits.

14. Location: Rear drum, left side.

Function: Bi-directional, fixed-displacement, piston-type motor drives eccentric weights in rear drum.

15. Location: Front drum, right side.

Function: Bi-directional, fixed-displacement, piston-type motor drives eccentric weights in front drum.

16. Location: On front and rear vibratory motors.

Function: Frequency-type sensor drives vibratory tachometer. Rear sensor provides input when
vibratory drum selector switch in REAR, both sensors provide input when selector switch in
DUAL DRUM, and front sensor provides input when selector switch in FRONT.

17. Location: Inside each drum.

Function: Operated by vibratory motors. Provide variable amplitude vibration.

18. 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

NA

Case Study

NOTE:
To simulate this problem on the machine, turn the forward servo displacement limiter (on top face
of pump) clockwise three turns. Ensure that the forward servo displacement limiter 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 if the problem is
equal during forward and reverse operation. (The operator should indicate that the problem occurs
in forward only.) Look for clues in the description which may prompt additional questions.
2. Ask if both drums are set to the same amplitude.
3. Ask if any recent service work has been performed.
4. Check amplitude settings on both drums.
5. Operate the machine and watch for vibratory run-on. (This indicates a relief valve is out-of-
specification. This problem will not cause vibratory run-on.)
6. Check fluid levels and look for oil leaks and/or damaged hoses.
7. N/A
8. The amplitude wheels are out of balance.
9. Forward-circuit pressure is out of specification.
10. The pump is not generating sufficient flow in the forward circuit.
11. Test forward relief pressure and intercircuit relief pressure.
12. Check the vibratory frequency. (This test will show a low forward frequency.)
13. Adjust the vibratory frequency.
14. After the vibratory frequency is adjusted, machine operation returns to normal.
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Posttest
1. D

2. TRUE

3. C

4. B

5. B

6. B

7. B

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. B

11. FALSE: The vibratory auto/manual selector switch does not control the front and rear drum
solenoids the vibratory drum selector switch does.

12. FALSE: The vibratory speed sensors do not provide input to the ECM. These sensors simply provide
the signal to drive the vibratory tachometer.

13. D

14. TRUE

15. A