Professional Documents
Culture Documents
QESV1318
February 2008
Instructor Material
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
Machine System
Preparation Checklist .................................................................................. 20
Objectives/Student Evaluation .................................................................... 21
Lesson Plan................................................................................................. 22
Laboratory Exercises................................................................................... 23
Posttest ....................................................................................................... 28
February 2008 3 Asphalt Compactor
Instructor Guide for QESV1318
Propulsion System
Preparation Checklist .................................................................................. 30
Objectives/Student Evaluation .................................................................... 31
Lesson Plan................................................................................................. 32
Laboratory Exercises................................................................................... 33
Posttest ....................................................................................................... 39
Vibratory System
Preparation Checklist .................................................................................. 41
Objectives/Student Evaluation .................................................................... 42
Lesson Plan................................................................................................. 43
Laboratory Exercises................................................................................... 44
Posttest ....................................................................................................... 48
February 2008 4 Asphalt Compactor
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.
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.
February 2008 5 Asphalt Compactor
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.
February 2008 6 Asphalt Compactor
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
February 2008 7 Asphalt Compactor
Machine Introduction Instructor Guide for QESV1318
Objectives/Student Evaluation
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
Posttest 10 min.
Administer the posttest
Review and discuss the posttest results
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.
4. The articulation area provides a steering angle of ±75 degrees and allows the frame to oscillate
±4 degrees.
A. True.
B. False.
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.
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
NOTE: Discuss safety procedures with the students for each shop lab (i.e. safety glasses,
clothing).
February 2008 12 Asphalt Compactor
Power Distribution and Machine Starting System Instructor Guide for QESV1318
Objectives/Student Evaluation
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 14
Visual Presentation: Power Distribution and Machine Starting, System Overview 30 min.
Suggested Illustrations: Slides 15-32
Visual Presentation: Power Distribution and Machine Starting, System Operation 20 min.
Suggested Illustrations: Slide 33-34
Posttest 20 min.
Administer the posttest
Review and discuss the posttest results
Laboratory Exercises
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.
___ 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.
February 2008 17 Asphalt Compactor
Power Distribution and Machine Starting System Instructor Guide for QESV1318
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.
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 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.
February 2008 20 Asphalt Compactor
Machine System Instructor Guide for QESV1318
Machine System
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
NOTE: Discuss safety procedures with the students for each shop lab (i.e. safety glasses,
clothing).
February 2008 21 Asphalt Compactor
Machine System Instructor Guide for QESV1318
Objectives/Student Evaluation
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 35
Posttest 30 min.
Administer the posttest
Review and discuss the posttest results
Laboratory Exercises
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.
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).
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 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.
February 2008 29 Asphalt Compactor
Machine System Instructor Guide for QESV1318
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)
D. None of the above.
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)
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)
D. None of the above.
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)
D. None of the above.
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
D. None of the above.
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.
February 2008 30 Asphalt Compactor
Propulsion System Instructor Guide for QESV1318
Propulsion System
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
NOTE: Discuss safety procedures with the students for each shop lab (i.e. safety glasses,
clothing).
February 2008 31 Asphalt Compactor
Propulsion System Instructor Guide for QESV1318
Objectives/Student Evaluation
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 66
Posttest 30 min.
Administer the posttest
Review and discuss the posttest results
Laboratory Exercises
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.
February 2008 34 Asphalt Compactor
Propulsion System Instructor Guide for QESV1318
___ 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.
NOTE: For complete procedures, refer to the service manual module Specifications, Systems
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.
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 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)
February 2008 40 Asphalt Compactor
Propulsion System Instructor Guide for QESV1318
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
D. None of the above.
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
D. None of the above.
8. When a fault is detected, the ECM flashes a fault code on the parking brake indicator.
A. True.
B. False.
February 2008 41 Asphalt Compactor
Vibratory System Instructor Guide for QESV1318
Vibratory System
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
NOTE: Discuss safety procedures with the students for each shop lab (i.e. safety glasses,
clothing).
February 2008 42 Asphalt Compactor
Vibratory System Instructor Guide for QESV1318
Objectives/Student Evaluation
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 93
Posttest 30 min.
Administer the posttest
Review and discuss the posttest results
Laboratory Exercises
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 pressure relief valve (charge vibratory)
2. Test pressure relief valve (main vibratory)
3. Test pressure relief valve (pressure override vibratory)
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 machine’s electrical system prevents the vibrators from operating unless the propulsion
lever is out of the NEUTRAL position.
A. True.
B. False.
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)
D. None of the above.
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)
D. None of the above.