R

QESV1318
February 2008

Student Material

PART OF TECHNICAL PRESENTATION QESV1318

CB534D AND CB564D

ASPHALT COMPACTOR
Introduction
February 2008 2 Asphalt Compactor
Student Workbook for QESV1318

Table of Contents

Course Introduction
General Information....................................................................................... 3
Prerequisites ................................................................................................. 3
Visual/Text Reference ................................................................................... 3
Student Workbook......................................................................................... 3
Laboratory Exercises..................................................................................... 3

Machine Introduction
Objectives/Student Evaluation ...................................................................... 4
Posttest ......................................................................................................... 5

Power Distribution and Machine Starting System

Objectives/Student Evaluation ...................................................................... 7
Laboratory Exercises................................................................................... 11
Posttest ....................................................................................................... 15

Machine System
Objectives/Student Evaluation .................................................................... 16
Laboratory Exercises................................................................................... 31
Posttest ....................................................................................................... 34

Propulsion System
Objectives/Student Evaluation .................................................................... 36
Laboratory Exercises................................................................................... 50
Posttest ....................................................................................................... 55

Vibratory System
Objectives/Student Evaluation .................................................................... 57
Laboratory Exercises................................................................................... 67
Posttest ....................................................................................................... 71
February 2008 3 Asphalt Compactor
Course Introduction Student Workbook for QESV1318

Course Introduction
General Information
This Student Workbook 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.

The StudentGuide 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. Contact your trainer to obtain the
appropriate pretests.

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 conjunction with this course. The meeting guide is included on the
Student CD.

Student Workbook
TheStudent Workbook,CB534D and CB564D Asphalt Compactors contains course objectives,
color line art from the training package, lab exercises, and post tests.

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.
February 2008 4 Asphalt Compactor
Machine Introduction Student Workbook for QESV1318

Machine Introduction
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

February 2008 5 Asphalt Compactor
Machine Introduction Student Workbook for QESV1318

Posttest
Directions: Using your notes in the student guide answer the following questions. Circle the best
answer for 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)
February 2008 6 Asphalt Compactor
Machine Introduction Student Workbook for QESV1318

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.
February 2008 7 Asphalt Compactor
Power Distribution and Machine Starting System Student Workbook for QESV1318

Power Distribution and Machine Starting System

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. (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.

Instructor(s): Student Average Good Excellent

_____________________
Student Met Prerequisites
_____________________
Training Manager: Class Participation

_____________________ Desire to Learn

Student Workbook for QESV1318
Asphalt Compactor

CB534D ASPHALT COMPACTOR

ECM CONNECTOR POWER DISTRIBUTION AND MACHINE STARTING
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
1 5 6 10
4 CAN C
11 15 16 20
8

5 CAN SHIELD C
Power Distribution and Machine Starting System

21 25 26 30 19 CONFIGURATION 0" I
31 35 36 40 23 CONFIGURATION 1" I
24 HANDLE PWM I
41 45 46 50
35 NEUTRAL LIGHT O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D POWER DISTRIBUTION AND MACHINE STARTING CIRCUIT

200-BK
690-GN-14
BK-00 135-BU
RD-00 1 646-OR-16
2 631-GY
ELECTRICAL
POS NEG
DISCONNECT A9 10A A7 15A A5 10A A3 20A
SWITCH
110-GN 690-GN-14
112-PU 112-PU 103-YL
BATTERY HIGH-INTENSITY
632-WH-14
RD-00 RELAY
AUXILIARY 200-BK B9 15A B7 10A B5 10A B3 20A
START POST 306-GN-16 112-PU 144-GN 690-GN-14
308-YL-16 123-WH 175-PK 652-YL-14
START RELAY
330-YL

START SWITCH
1 306-GN-16
2
C9 15A C7 10A C5 15A C3 20A
200-BK 2 1

122-BU
5 176-YL 690-GN-14
R
1 308-YL-16 3 112-PU 155-PK
C 2 4
653-GN-14
START AID 3 307-OR-16
181-RD-12 304-WH-12 4 105-BR-16 D9 10A D7 15A D5 10A D3 20A
OFF 5 376-GN NUMBER-ONE
ON 6
ST
S NEUTRAL START 690-GN-14
B
RELAY 134-YL-16
105-BR-16 105-BR-16
308-YL-16 308-YL-16 121-YL-16
S G
117-RD
MAIN POWER

330-YL
1
RD-00
BAT MTR RELAY 112-PU 123-WH 2
1 15 3

114-GN-14
A982-BR

115-PK-16
101-RD-6 2 200-BK

135-BU

105-BR-16

200-BK
LIGHTS 4
MOTOR
101-RD-6 160-PU-8 BREAKER 5 6
50
7 THROTTLE
GLOW PLUG 112-PU 112-PU CONTROL
BREAKER
9

20
STARTER SWITCH
Power Distribution and Machine Starting System

8
117-RD
80 117-RD-6 LIGHTS BREAKER 614-PU
101-RD-6

117-RD
MAIN 330-YL 200-BK
135-BU
ALTERNATOR BREAKER 109-RD-12 15
181-RD-14
CAN A F711-GN FUNCTION LAMPS
PORT B F712-GY
1 C444-YL THROTTLE C A249-BK 123-WH 1 POWER
101-RD-6 80
ALT 2 308-YL-16 200-BK 2 GROUND
BREAKER

181-RD-12
3 403-GN C405-GY 3 OIL PRESSURE
B+ ALTERNATOR CAN RESISTOR 444-YL 4 BATTERY
465-OR 5 LOW CHARGE PRESS
BREAKER A F711-GN E455-BR 6 HYDRAULIC FILTER
109-RD-6 B F712-GY 428-OR 7 HYDRAULIC TEMP
C A249-BK 8
181-RD-12 9
406-PK 10 COOLANT TEMP
308-YL-16 GLOW PLUG 11
JN C9/AH C4
12
COLD-START 308-YL-16 RELAY 135-BU
1 28
TIMING ADVANCE 2 29 200-BK PROPEL SENSOR
SOLENOID M905-WH 135-BU 1 + BATTERY
M904-OR 200-BK 2 GROUND
K708-BU 3 SIGNAL

308-YL-16

A982-BR

105-BR-16

200-BK
T 4

200-BK
384-BU-8 ELECTRONIC CONTROL

308-YL-16
FUEL MODULE (ECM)
SOLENOID THROTTLE CONTROL MODULE
444-YL
403-GN

BATTERY 1 200-BK
308-YL-16 135-BU
1 BATTERY + 2
CAN + 3 711-GN 181-RD-14 1 + POWER IN

200-BK

200-BK
CAN 4 712-GY 200-BK 2 GROUND IN
A919-BU 3 + OUT

308-YL-16
CAN SHIELD 5 A249-BK

1
2
ARC CONFIG 0" 19 M904-OR 4
5
OUT
+ AUX IN

983-BU
SUPPRESSOR CONFIG 1" 23 M905-WH 6 OPEN
HANDLE PWM 24 K708-BU

200-BK
2 NEUTRAL LIGHT 35 330-YL
HOURMETER BATTERY + 47 135-BU A982-BR
1 135-BU

M
BATTERY + 48 THROTTLE
1 GLOW PLUGS BATTERY + 49 135-BU
SOLENOID
BATTERY + 50 135-BU
February 2008

2
3
A
FUEL LIFT PUMP 919-BU B
403-GN 983-BU C
181-RD-14
105-BR-16 105-BR-16 105-BR-16
444-YL 444-YL
200-BK 200-BK 200-BK 200-BK 200-BK
Student Workbook for QESV1318
Asphalt Compactor

CB564D POWER DISTRIBUTION AND MACHINE STARTING CIRCUIT

200-BK
690-GN-14
BK-00 135-BU
RD-00 1 680-GN-18
2 631-GY
ELECTRICAL
POS NEG
DISCONNECT A9 10A A7 15A A5 10A A3 20A
SWITCH
110-GN 690-GN-14
112-PU 112-PU 103-YL
BATTERY HIGH-INTENSITY
632-WH-14
RD-00 RELAY
AUXILIARY 200-BK B9 15A B7 10A B5 10A B3 20A
START POST 306-GN-16 112-PU 144-GN 690-GN-14
308-YL-16 123-WH 175-PK 652-YL-14
START RELAY
START SWITCH
1 306-GN-16
2
C9 15A C7 10A C5 15A C3 20A
200-BK

122-BU
176-YL 690-GN-14
R
1 308-YL-16 112-PU 155-PK
C 2 653-GN-14
START AID 3 306-GN-16
181-RD-12 304-WH-12 4 105-BR-16
OFF 5 376-GN D9 10A D7 15A D5 10A D3 20A
ON 6
S 690-GN-14
ST
B 134-YL-16
105-BR-16 105-BR-16
308-YL-16 308-YL-16 121-YL-16
S G
117-RD
MAIN POWER 1
RD-00
BAT MTR RELAY 112-PU 123-WH 2
1 15 3

114-GN-14
A982-BR

115-PK-16
101-RD-6 2 200-BK

135-BU

105-BR-16

200-BK
LIGHTS 4
MOTOR
101-RD-6 160-PU-8 BREAKER 5 6
50
7 THROTTLE
GLOW PLUG
10

112-PU 112-PU CONTROL

BREAKER 20
SWITCH
STARTER
Power Distribution and Machine Starting System

8
101-RD-6 117-RD
80 117-RD-6 LIGHTS BREAKER 614-PU
117-RD
MAIN 200-BK
135-BU
ALTERNATOR BREAKER 109-RD-12 15
181-RD-14
C1/C2 FUNCTION LAMPS
376-GN 12 480-GN
E 1 C444-YL THROTTLE 123-WH 1 POWER
ALT I 2 308-YL-16 80 200-BK 2 GROUND
BREAKER

181-RD-12
R 3 403-GN C405-GY 3 OIL PRESSURE
B+ ALTERNATOR 444-YL 4 BATTERY
465-OR 5 LOW CHARGE PRESS
BREAKER E455-BR 6 HYDRAULIC FILTER
109-RD-6 428-OR 7 HYDRAULIC TEMP
8
181-RD-12 9
406-PK 10 COOLANT TEMP
308-YL-16 GLOW PLUG 11
12
COLD-START 308-YL-16 RELAY
TIMING ADVANCE 1
2
SOLENOID

308-YL-16

A982-BR

105-BR-16

200-BK
T

200-BK
384-BU-8

308-YL-16
FUEL
SOLENOID THROTTLE CONTROL MODULE
444-YL
403-GN

308-YL-16
1 181-RD-14 1 + POWER IN

200-BK

200-BK
ARC

308-YL-16
200-BK 2 GROUND IN
A919-BU 3 + OUT
SUPPRESSOR

1
2
4 OUT
5 + AUX IN

983-BU
2 6 OPEN

200-BK
1
HOURMETER A982-BR
ARC

M
THROTTLE
1 SUPPRESSOR GLOW PLUGS SOLENOID
February 2008

2
3 2 A
1 FUEL LIFT PUMP 919-BU B
403-GN 983-BU C
181-RD-14
105-BR-16 105-BR-16 105-BR-16
444-YL 444-YL
200-BK 200-BK 200-BK 200-BK 200-BK
February 2008 11 Asphalt Compactor
Power Distribution and Machine Starting System Student Workbook for QESV1318

Laboratory Exercises

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:
Function:

___ Auxiliary Start Post

Location:
Function:

___ Engine Start Switch

Location:
Function:

___ Main Circuit Breaker

Location:
Function:

___ Alternator Circuit Breaker

Location:
Function:

___ Glow Plug Circuit Breaker

Location:
Function:
February 2008 12 Asphalt Compactor
Power Distribution and Machine Starting System Student Workbook for QESV1318

___ Throttle Circuit Breaker

Location:
Function:

___ Glow Plug Relay

Location:
Function:

___ Start Relay

Location:
Function:

___ Coolant Temperature Switch

Location:
Function:

___ Fuel Solenoid

Location:
Function:

___ Cold-Start Timing Advance Solenoid

Location:
Function:

___ Fuel Lift Pump

Location:
Function:

___ Throttle Control Module

Location:
Function:

___ Alternator
Location:
Function:

___ Starter
Location:
Function:
February 2008 13 Asphalt Compactor
Power Distribution and Machine Starting System Student Workbook for QESV1318

___ Throttle Control Switch

Location:
Function:

___ Power Panel

Location:
Function:

___ Propulsion Sensor

Location:
Function:

___ Main Power Relay

Location:
Function:
February 2008 14 Asphalt Compactor
Power Distribution and Machine Starting System Student Workbook for QESV1318

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.
February 2008 15 Asphalt Compactor
Power Distribution and Machine Starting System Student Workbook for QESV1318

Posttest
Directions: Using your notes in the student guide answer the following questions. Circle the best
answer for 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 16 Asphalt Compactor
Machine System Student Workbook for QESV1318

Machine System
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. (Lab A) Given a CB534D and CB564D Asphalt
Compactor and the Lab A Worksheet, locate and
identify the components of the machine system.
2. (Lab B) Given a CB534D and CB564D Asphalt
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).
3. 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

 Asphalt Compactor
Student Workbook for QESV1318

CB534D AND CB564D STEERING HYDRAULIC SYSTEM

STRAIGHT TRAVEL
STEERING
LINE RELIEF VALVES CYLINDER FAN MOTOR
R L FAN RELIEF VALVE
STEERING AND CHARGE PUMP IN
230 BAR 230 BAR
PRIORITY VALVE
1.0mm
MAKEUP
VALVES 70 BAR
CONTROL SPOOL OUT
I CF
METERING PUMP CHARGE FILTER
17

EF
0.8mm LS
CP
210 BAR
LD 3.5 BAR
ANTICAVITATION FILTER BYPASS
CHECK VALVE VALVE
SOS
180 BAR
INLET CHECK VALVE
P T
SUCTION SCREEN
Machine System

TO VIBRATORY AND PROPULSION

February 2008

PRESSURE DIFFERENTIAL VALVE CHARGE CIRCUITS

 Asphalt Compactor
Student Workbook for QESV1318

CB534D AND CB564D STEERING HYDRAULIC SYSTEM

RIGHT TURN
STEERING
LINE RELIEF VALVES CYLINDER FAN MOTOR
R L FAN RELIEF VALVE
STEERING AND CHARGE PUMP IN
230 BAR 230 BAR
PRIORITY VALVE
1.0mm
MAKEUP
VALVES 70 BAR
CONTROL SPOOL OUT
I CF
METERING PUMP CHARGE FILTER
18

EF
0.8mm LS
CP
210 BAR
LD 3.5 BAR
ANTICAVITATION FILTER BYPASS
CHECK VALVE VALVE
SOS
180 BAR
INLET CHECK VALVE
P T
SUCTION SCREEN
Machine System

TO VIBRATORY AND PROPULSION

February 2008

PRESSURE DIFFERENTIAL VALVE CHARGE CIRCUITS

 Asphalt Compactor
Student Workbook for QESV1318

CB534D ASPHALT COMPACTOR

ECM CONNECTOR DRUM OFFSET SYSTEM
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
1 5 6 10
4 CAN C
19

11 15 16 20 5 CAN SHIELD C
21 25 26 30 10 DRUM OFFSET LEFT I
31 35 36 40 11 DRUM OFFSET RIGHT I
19 CONFIGURATION 0" I
41 45 46 50
23 CONFIGURATION 1" I
30 OFF CENTER I
40 DRUM LEFT O
41 DRUM RIGHT O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Machine System
February 2008
 Asphalt Compactor
Student Workbook for QESV1318

CB564D ASPHALT COMPACTOR

ECM CONNECTOR DRUM OFFSET SYSTEM
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
1 5 6 10
4 CAN C
20

11 15 16 20 5 CAN SHIELD C
21 25 26 30 10 DRUM OFFSET LEFT I
31 35 36 40 11 DRUM OFFSET RIGHT I
19 CONFIGURATION PIN I
41 45 46 50
30 OFF CENTER I
43 DRUM LEFT O
44 DRUM RIGHT O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Machine System
February 2008
 Asphalt Compactor
Student Workbook for QESV1318

CB534D AND CB564D FAULT CODES

DRUM OFFSET SYSTEM
FAULT CODES FOR DRUM OFFSET SYSTEM
FLASH SEQUENCE DIAGNOSTIC SCREEN NAME FAULT DESCRIPTION FAULT LEVEL
2-2 CP_OFFSET_SWITCH_FLT OFFSET SWITCH CENTERING SWITCH INPUT 1
2-8 CP_CCW_OFFSET_FLT COUNTERCLOCKWISE OFFSET SOLENOID FAULT 1
2-9 CP_CW_OFFSET_FLT CLOCKWISE OFFSET SOLENOID FAULT 1
21
Machine System
February 2008
 Asphalt Compactor
Student Workbook for QESV1318

CB534D DRUM OFFSET

OPTIONAL
OFFSET RIGHT
CAN A F711-GN
SOLENOID
PORT B F712-GY
C A249-BK
C928-GY B+ FROM MAIN POWER RELAY 112-PU
200-BK
CAN RESISTOR
A F711-GN 135-BU 112-PU
B F712-GY OFFSET LEFT 15A
C A249-BK SOLENOID ECM FUSE
C929-WH
JN C9/AH C4 200-BK PROXIMITY
SWITCH 10A 112-PU
28 135-BU 135-BU
29 200-BK DRUM OFFSET
22

M905-WH 24 A429-YL 1 FUSE

M904-OR 2
JN C9/AH C4
122-BU
ELECTRONIC CONTROL
MODULE (ECM) PROPULSION LEVER
BATTERY 1 200-BK H751-OR 1 N/O LEFT DRUM OFFSET
BATTERY + 2 135-BU 2 N/C LEFT DRUM OFFSET
CAN + 3 711-GN H750-BR 3 N/O RIGHT DRUM OFFSET
CAN 4 712-GY 4 N/C RIGHT DRUM OFFSET
CAN SHIELD 5 A249-BK 5 + SWITCH COMMON
DRUM OFFSET LEFT 10 H751-OR A305-YL 6 N/O HORN
DRUM OFFSET RIGHT 11 H750-BR 7 N/C HORN
CONFIG 0" 19 M904-OR P979-YL 8 N/O WATER SPRAY
CONFIG 1" 23 M905-WH 9 N/C WATER SPRAY
OFF CENTER 30 A429-OR P978-GN 10 N/O VIBE
DRUM LEFT 40 C929-WH 11 N/C VIBE
DRUM RIGHT 41 C928-GY 12
BATTERY + 47 135-BU
Machine System

BATTERY + 48 135-BU
February 2008

BATTERY + 49 135-BU
BATTERY + 50 135-BU
 Asphalt Compactor
Student Workbook for QESV1318

CB564D DRUM OFFSET

OPTIONAL
OFFSET RIGHT
CAN A F711-GN
SOLENOID
PORT B F712-GY
C A249-BK
C928-GY B+ FROM MAIN POWER RELAY 112-PU
200-BK
CAN RESISTOR
A F711-GN 135-BU 112-PU
B F712-GY OFFSET LEFT 15A
C A249-BK SOLENOID ECM FUSE
C929-WH
200-BK PROXIMITY
A A990-BU 112-PU
B 135-BU 135-BU SWITCH 10A
C 200-BK DRUM OFFSET
23

JC102/JC5 A429-YL 1 FUSE

A990-BU 2
122-BU
ELECTRONIC CONTROL
MODULE (ECM) PROPULSION LEVER
BATTERY 1 200-BK H751-OR 1 N/O LEFT DRUM OFFSET
BATTERY + 2 135-BU 2 N/C LEFT DRUM OFFSET
CAN + 3 711-GN H750-BR 3 N/O RIGHT DRUM OFFSET
CAN 4 712-GY 4 N/C RIGHT DRUM OFFSET
CAN SHIELD 5 A249-BK 135-BU 5 + SWITCH COMMON
DRUM OFFSET LEFT 10 H751-OR A320-OR 6 N/O HORN
DRUM OFFSET RIGHT 11 H750-BR 7 N/C HORN
CONFIG 0" 19 A990-BU P979-YL 8 N/O WATER SPRAY
ZERO DEGREE OFFSET 30 A429-YL 9 N/C WATER SPRAY
DRUM LEFT 43 C929-WH P978-GN 10 N/O VIBE
DRUM RIGHT 44 C928-GY 11 N/C VIBE
BATTERY + 47 135-BU 12
BATTERY + 48 135-BU
Machine System

BATTERY + 49 135-BU
February 2008

BATTERY + 50 135-BU
 Asphalt Compactor
Student Workbook for QESV1318

CB534D AND CB564D DRUM OFFSET OPTION

HOLD OFFSET
CYLINDER
0.6mm AI
PRIORITY SPOOL
BI
P
PILOT-OPENED CHECK VALVES
24

C
1.0mm
10 LPM
X RELIEF VALVE
DRUM OFFSET VALVE
150 BAR
T
Machine System

TO HYDRAULIC TANK
February 2008

TO FAN MOTOR IN-PORT OR P-PORT OF EDGE CUTTER VALVE

FROM EF-PORT OF STEERING PUMP
 Asphalt Compactor
Student Workbook for QESV1318

CB534D AND CB564D DRUM OFFSET OPTION

OFFSET LEFT OFFSET
CYLINDER
0.6mm AI
PRIORITY SPOOL
BI
P
PILOT-OPENED CHECK VALVES
25

C
1.0mm
10 LPM
X RELIEF VALVE
DRUM OFFSET VALVE
150 BAR
T
Machine System

TO HYDRAULIC TANK
February 2008

TO FAN MOTOR IN-PORT OR P-PORT OF EDGE CUTTER VALVE

FROM EF-PORT OF STEERING PUMP
 Asphalt Compactor
Student Workbook for QESV1318

CB534D ASPHALT COMPACTOR

ECM CONNECTOR WATER SPRAY SYSTEM
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
1 5 6 10
4 CAN C
26

11 15 16 20 5 CAN SHIELD C
21 25 26 30 19 CONFIGURATION 0" I
31 35 36 40 22 WATER IN I
23 CONFIGURATION 1" I
41 45 46 50
24 HANDLE PWM I
35 NEUTRAL LIGHT O
45 WATER LEFT O
46 BACK UP O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Machine System
February 2008
 Asphalt Compactor
Student Workbook for QESV1318

CB564D ASPHALT COMPACTOR

ECM CONNECTOR WATER SPRAY SYSTEM
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
4 CAN C
5 CAN SHIELD C
1 5 6 10 8 5 V DC SENSOR + O
27

11 15 16 20 9 SENSOR POWER GROUND I

14 SWITCH WATER PUMP 1 I
21 25 26 30
15 SWITCH WATER PUMP 2 I
31 35 36 40
19 CONFIGURATION PIN ANALOG I
41 45 46 50 22 SWITCH WATER ON/OFF I
24 PROPEL HANDLE SPEED PWM I
28 WATER TIMER POTENTIOMETER I
31 DIGITAL OUT WATER PUMP 1 O
32 DIGITAL OUT WATER PUMP 2 O
33 LIGHT WATER SPRAY O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
Machine System

*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL

February 2008
 Asphalt Compactor
Student Workbook for QESV1318

CB564D FAULT CODES

WATER SPRAY SYSTEM
FAULT CODES FOR WATER SPRAY SYSTEM
FLASH SEQUENCE DIAGNOSTIC SCREEN NAME FAULT DESCRIPTION FAULT LEVEL
4-1 CP_H2O TIMER_FLT WATER TIMER INVALID WORKING RANGE 1
4-2 CP_H2O_TMR_CAL_FLT TIMER CALIBRATION FAULT 1
4-3 CP_H2O_MODE_FLT WATER MODE INVALID INPUT SIGNALS 1
28

4-4 CP_H2O_SWON_FLT WATER SWITCH ON POSITION INVALID INPUT 1

Machine System
February 2008
 Asphalt Compactor
Student Workbook for QESV1318

CB534D WATER SPRAY ELECTRICAL SYSTEM

200-BK 200-BK
C937-WH C937-WH
C923-OR
112-PU B+ FROM MAIN POWER RELAY C936-GY
C922-BR
2 1 2 1
5 5
NUMBER-ONE WATER
112-PU 10A 110-GN 110-GN C905-OR C923-OR SPRAY MOTOR
3 3
C922-BR
WATER SPRAY FUSE 4 4
1 C922-BR
NUMBER-TWO M 2 200-BK
NUMBER-ONE WATER SPRAY RELAY
135-BU WATER SPRAY RELAY

C922-BR
112-PU

200-BK
C923-OR
C937-WH
15A C905-OR
C936-GY C904-GN NUMBER-TWO WATER
ECM FUSE SPRAY MOTOR
110-GN 110-GN
PROPULSION LEVER 1 C923-OR
M 2 200-BK
H751-OR 1 N/O DRUM OFFSET
CAN A F711-GN 2 N/C LEFT DRUM OFFSET
B F712-GY H750-BR 3 N/O RIGHT DRUM OFFSET C905-OR
PORT C A249-BK 4 N/C RIGHT DRUM OFFSET
5 + SWITCH COMMON C904-GN
A305-YL 6 N/O HORN 110-GN
CAN 7 N/C HORN WATER PUMP

C903-BU

C922-BR

200-BK
330-YL

C905-OR

C923-OR
C937-WH
29

RESISTOR P979-YL 8 N/O WATER SPRAY SELECTOR SWITCH

9 N/C WATER SPRAY C935-PU
A F711-GN P978-GN 10 N/O VIBE 11
B F712-GY 11 N/C VIBE
C A249-BK 12 1 2 1 2 13
C903-BU
5 5 14
135-BU 1 + BATTERY C905-OR
3 3
JN C9/ 200-BK 2 GROUND 3
AH C4 K708-BU 3 SIGNAL 4 4
12
28 135-BU 4 C922-BR
29 200-BK DRUM SPRAY NEUTRAL 15
PROPULSION SENSOR LIGHTS RELAY STOP RELAY C905-OR
330-YL 16
C905-OR
M905-WH C935-PU 6
M904-OR WATER SPRAY INDICATOR C923-OR
ELECTRONIC CONTROL 200-BK 200-BK
9
MODULE (ECM) C935-PU 1 WATER SPRAY
200-BK 200-BK 2 GROUND 10
BATTERY 1 C932-YL 3 VIBRATOR A631-BU
BATTERY + 2 135-BU
200-BK 4 GROUND

614-PU
CAN + 3 F711-GN A249-BK C935-PU
CAN 4 F712-GY F712-GY
CAN SHIELD 5 A249-BK F711-GN INTERMITTENT SPRAY WATER SPRAY TIMER
CONFIG 0 19 M904-OR 135-BU FROM MASTER LIGHT SWITCH
WATER IN 22 P979-YL 135-BU
POTENTIOMETER
CONFIG 1 23 M905-WH 135-BU 4
HANDLE PWM 24 K708-BU 135-BU 1 C937-WH C937-WH
ON TIME
NEUTRAL LIGHT 35 330-YL 135-BU
WATER LEFT 45 C935-PU C936-GY BR A N930-BR N930-BR 5 TO FRONT SPRAY BAR LIGHTS
BACK UP 46 C936-GY P979-YL BK B N929-YL 2 C935-PU
BATTERY + 47 135-BU K708-BU RD C N928-OR
BATTERY + 48 135-BU 330-YL N929-YL 6
TO REAR SPRAY BAR LIGHTS
Machine System

BATTERY + 49 135-BU C935-PU OFF TIME

BATTERY + 50 135-BU 200-BK 200-BK 200-BK 3 200-BK
February 2008

N928-OR 7
200-BK
 Asphalt Compactor
Student Workbook for QESV1318

CB564D WATER SPRAY ELECTRICAL SYSTEM

200-BK 200-BK
C937-WH C937-WH
C923-OR
112-PU B+ FROM MAIN POWER RELAY C935-PU
200-BK 2 1 2 1
5 5
NUMBER-ONE WATER
112-PU 10A 110-GN 110-GN C922-BR 110-GN C923-OR SPRAY MOTOR
3 3
WATER SPRAY FUSE 4 4
1 C922-BR
NUMBER-ONE NUMBER-TWO M 2 200-BK
WATER SPRAY RELAY WATER SPRAY RELAY
112-PU 15A 135-BU
ECM FUSE NUMBER-TWO WATER
SPRAY MOTOR
PROPULSION LEVER 1 C923-OR
135-BU + SWITCH COMMON
M 2 200-BK
ELECTRONIC CONTROL 5
P979-YL 8 N/O WATER SPRAY
MODULE (ECM)
BATTERY 1 200-BK
PROPEL SENSOR
BATTERY + 2 135-BU 135-BU 1 + BATTERY
CAN + 3 F711-GN 200-BK 2 GROUND
WATER PUMP
30

CAN 4 F712-GY K708-BU 3 SIGNAL

CAN SHIELD 5 A249-BK SELECTOR SWITCH
5V DC SENSOR + 8 A926-YL
SENSOR POWER GROUND 9 A925-YL RESISTORS 11 135-BU
SWITCH WATER PUMP 1 14 C903-BU
SWITCH WATER PUMP 2 15 C905-OR 13
CONFIG PIN ANALOG 19 A990-BU A915-OR 1 C903-BU
SWITCH WATER ON/OFF 22 P979-YL 2 14
PROPEL HANDLE SPEED PWM 24 K708-BU A925-YL 3 135-BU
CAN A916-GN 4 3
WATER TIMER POTENTIOMETER 28 N929-YL
DIGITAL OUT WATER PUMP 1 31 C937-WH RESISTOR 5 12
DIGITAL OUT WATER PUMP 2 32 C935-PU F711-GN A926-YL 6
A
LIGHT WATER SPRAY 33 A631-BU F712-GY B 15
BATTERY + 47 135-BU 135-BU
A249-BK C
BATTERY + 48 135-BU 16
C905-OR
BATTERY + 49 135-BU 6
BATTERY + 50 135-BU 135-BU
9
200-BK 200-BK
WATER SPRAY 10

614-PU
20 INDICATOR
A631-BU 1 WATER SPRAY FROM
200-BK 2 GROUND MASTER
LIGHT
SWITCH
INTERMITTENT SPRAY C937-WH
C905-OR
POTENTIOMETER
MODEL CONFIGURATION
Machine System

A990-BL A
February 2008

OR A A916-GN 22 135-BU B
BK B A915-OR 23 200-BK C
WH C N929-YL 24
February 2008 31 Asphalt Compactor
Machine System Student Workbook for QESV1318

Laboratory Exercises

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.

Steering Control
___ Gear Pump (Steering and Charge)
Location:
Function:

___ Charge Filter

Location:
Function:

___ Steering Control Unit (Metering Pump)

Location:
Function:

___ Steering Cylinder

Location:
Function:

___ Fan Motor

Location:
Function:

Drum Offset Control

___ Drum Offset Switch
Location:
Function:

___ Drum Offset Cylinder

Location:
Function:
February 2008 32 Asphalt Compactor
Machine System Student Workbook for QESV1318

___ Drum Offset Manifold

Location:
Function:

Water Spray Control

___ Intermittent Spray Control Dial
Location:
Function:

___ Water Pump Selector Switch

Location:
Function:

___ Water Spray Master Switch

Location:
Function:

___ Water Spray Timer (CB534D Only)

Location:
Function:

___ Water Fill Port

Location:
Function:

___ Water Level Sender

Location:
Function:

___ Water Spray Motor and Pump Group

Location:
Function:

___ Water Spray Bar

Location:
Function:
February 2008 33 Asphalt Compactor
Machine System Student Workbook for QESV1318

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)
February 2008 34 Asphalt Compactor
Machine System Student Workbook for QESV1318

Posttest
Directions: Using your notes in the student guide answer the following questions. Circle the best
answer for 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.

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.
February 2008 35 Asphalt Compactor
Machine System Student Workbook for QESV1318

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)
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 36 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

Propulsion System
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. (Lab A) Given a CB534D and CB564D Asphalt
Compactor and the Lab A Worksheet, locate and
identify the components of the propulsion system.
2. (Lab B) Given a CB534D and CB564D Asphalt
Compactor, the appropriate service literature and
the Lab B Worksheet, perform the following tests of
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
Compactor and all reference material and class
notes, troubleshoot a fault in the propulsion system
(no worksheet).
4. 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

Student Workbook for QESV1318
Asphalt Compactor

CB534D ASPHALT COMPACTOR

ECM CONNECTOR PROPULSION CONTROL
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
4 CAN C
5 CAN SHIELD C
6 BRAKE NORMALLY OPEN I
7 BRAKE NORMALLY CLOSED I
8 5 VOLTS + O
1 5 6 10
9 5 VOLTS I
37

11 15 16 20
12 SHIFT SWITCH I
21 25 26 30 15 PROXIMITY SWITCH I
31 35 36 40 19 CONFIGURATION 0" I
41 45 46 50 23 CONFIGURATION 1" I
24 HANDLE PWM I
27 AUTOMATIC SPEED CONTROL I
34 BRAKE LIGHT O
35 NEUTRAL LIGHT O
37 INTERLOCK SOLENOID O
38 PROPEL FORWARD O
39 PROPEL REVERSE O
42 BRAKE SELECT O
46 BACK UP O
Propulsion System

47 BATTERY + I
February 2008

48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Student Workbook for QESV1318
Asphalt Compactor

CB564D ASPHALT COMPACTOR

ECM CONNECTOR PROPULSION CONTROL
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
4 CAN C
5 CAN SHIELD C
6 BRAKE SWITCH NORMALLY OPEN I
7 BRAKE SWITCH NORMALLY CLOSED I
8 5 VOLTS + O
9 5 VOLTS I
12 SHIFT SWITCH 1" I
1 5 6 10 13 SHIFT SWITCH 2" I
18 ENGINE OIL PRESSURE I
38

11 15 16 20
19 CONFIGURATION PIN I
21 25 26 30
23 NEUTRAL SWITCH I
31 35 36 40 24 PROPULSION HANDLE SPEED PWM I
41 45 46 50 25 HYDRAULIC CHARGE PRESSURE I
27 SPEED DIAL POTENTIOMETER I
34 PARKING BRAKE LIGHT O
35 NEUTRAL LIGHT O
37 SHIFT SOLENOID O
38 PROPULSION FORWARD SOLENOID O
39 PROPULSION REVERSE SOLENOID O
42 BRAKE SOLENOID O
45 INTERLOCK SOLENOID O
46 BACK UP ALARM O
Propulsion System

47 BATTERY + I
February 2008

48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D FAULT CODES

PROPULSION SYSTEM
FAULT CODES FOR PROPULSION SYSTEM
FLASH SEQUENCE DIAGNOSTIC SCREEN NAME FAULT DESCRIPTION FAULT LEVEL
1-1 CP_BRAKE_SW_FLT BRAKE SWITCH INVALID SIGNAL COMBINATION 3
1-2 CP_PROP_HNDL_FLT PROPEL CONTROL HANDLE SIGNAL OUT OF RANGE 3
1-3 CP_SPDCTRL_FLT SPEED CONTROL SIGNAL OUT OF RANGE 1
39

1-4 CP_FWD_SOLENOID_FLT FORWARD EDC SOLENOID NOT DETECTED OR SHORT 3

1-5 CP_RVS_SOLENOID_FLT REVERSE EDC SOLENOID NOT DETECTED OR SHORT 3
1-6 CP_PROP_HNDL_CAL_FLT PROPEL CONTROL OUT OF CALIBRATION 1
1-7 CP_SPDCTRL_CAL_FLT SPEED CONTROL OUT OF CALIBRATION 1
1-8 CP_FWD_SOLENOID_CAL_FLT FORWARD EDC OUT OF CALIBRATION 1
1-9 CP_RWD_SOLENOID_CAL_FLT REVERSE EDC OUT OF CALIBRATION 1
3-1 CP_BRAKE_SOLENOID_FLT BRAKE SOLENOID NOT DETECTED OR SHORT 3
3-2 CP_SHUNT-FLT INTERLOCK SOLENOID NOT DETECTED OR SHORT 3
5-1 (1) CP_PROPEL_MODE_FLT PROPEL MODE INVALID SIGNAL 1
(2)
5-2 CP_NEUTRAL_FLT NEUTRAL FAULT PROPEL SENSOR AND PROXIMITY SWITCH 3
5-2 (1) CP_NEUTRAL_FLT SPEED VALVE OPEN OR SHORT 3
5-3 CP_SPEED_SOL_FLT MACHINE TYPE INVALID PIN COMBINATION 3
5-4 CP_BACKHP_ALM_FLT BACKUP ALARM ALARM OR RELAY NOT DETECTED 1
Propulsion System

5-5 (1) CP_NEUTRAL_FLT NEUTRAL FAULT PROPEL SENSOR AND PROXIMITY SWITCH 3
NOTES: (1) CB564D ONLY
February 2008

(2) CB534D ONLY

Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D PROPULSION PUMP

FEEDBACK CONTROL DIRECTION
LEVER ORIFICE CONTROL
VALVE
SERVO
COMBINATION
PISTON
VALVE
40
Propulsion System

SWASHPLATE ROTATING
GROUP
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D PROPULSION PUMP

PROPORTIONAL OVERRIDE RELIEF AND COMBINATION VALVES
CHECK
VALVE
P.O.R. VALVE
SPRING
SPOOL
41

PISTON
SHUTTLE SPOOL RELIEF CARTRIDGES
SPINDLE
Propulsion System

TOWING
February 2008

VALVE
ADJUSTMENT
Student Workbook for QESV1318
Asphalt Compactor

CB534D (REAR) AND CB564D PROPULSION MOTOR

NEUTRAL
MINIMUM DISPLACEMENT LIMITER CONTROL SPOOL
BARREL ASSEMBLY
PISTON
SHIFT PORT
CHECK VALVE
FLUSHING RELIEF VALVE
42

CONTROL PLATE
ROD
MAXIMUM DISPLACEMENT LIMITER FLUSHING BLOCK
ACTUATOR PISTON
FLUSHING SPOOL
Propulsion System
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D (REAR) AND CB564D PROPULSION MOTOR

FORWARD, LOW SPEED
MINIMUM DISPLACEMENT LIMITER CONTROL SPOOL
BARREL ASSEMBLY
PISTON
SHIFT PORT
CHECK VALVE
FLUSHING RELIEF VALVE
43

CONTROL PLATE
ROD
MAXIMUM DISPLACEMENT LIMITER FLUSHING BLOCK
ACTUATOR PISTON
FLUSHING SPOOL
Propulsion System
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D PROPULSION ELECTRICAL SYSTEM

U735-GY
U734-GN
K726-BU
419-YL
K725-GN
112-PU 15A 155-PK PARKING BRAKE
SWITCH
BRAKE FUSE 1 2 REVERSE FORWARD
155-PK U735-GY SOLENOID SOLENOID
155-PK 3 4
112-PU 135-BU U734-GN
15A SHIFT SWITCH X1
419-YL
ECM FUSE 200-BK
1
X2 K725-GN 1
2 200-BK 2
117-RD 15A 121-YL 155-PK 3
751-GN K726-BU 1
BACKUP ALARM FUSE 4
200-BK 200-BK 2
B+ FROM MAIN POWER RELAY

B+ FROM MAIN CIRCUIT BREAKER

5 6 321-BR
BACKUP ALARM 777-PU
ARC SUPPRESSOR 7
200-BK
321-BR
1 A925-YL
2 A915-OR 200-BK
614-PU 8
3 A926-YL
4 A916-GN 777-PU 1
200-BK 2
A F711-GN C926-GY 200-BK PARKING BRAKE
CAN B F712-GY 2 1 SOLENOID
PORT C A249-BK 5
121-YL 321-BR 751-GN
SHIFT
44

3
CAN AUTOMATIC SPEED
RESISTOR
4 SOLENOID
CONTROL
A F711-GN POTENTIOMETER BACKUP
B F712-GY ALARM RELAY
C A249-BK 751-GN 1
A916-GN 200-BK 2
A OR
A915-OR B BK
ELECTRONIC CONTROL A914-OR C WH
MODULE (ECM)
BATTERY 1 200-BK 135-BU 751-GN 1
BATTERY + 2 135-BU 135-BU 200-BK 2
CAN + 3 711-GN 135-BU JN C9/
CAN 4 712-GY 135-BU AH C4 135-BU 1 + BATTERY ARC SUPPRESSOR
CAN SHIELD 5 A249-BK 135-BU 200-BK 2 GROUND
BRAKE NO 6 U734-GN C936-GY 17 K708-BU 3 SIGNAL C729-BU
BRAKE NC 7 U735-GY A914-BU 16 4
+5 VOLTS 8 A926-YL M904-OR 28 135-BU
5 VOLTS 9 A925-YL M905-WH 29 200-BK INTERLOCK
SHIFT SWITCH 12 751-GN 200-BK
PROPULSION SENSOR SOLENOID
PROX SWITCH 15 F877-WH K708-BU
CONFIG 0" 19 M904-OR F877-WH
CONFIG 1" 23 M905-WH U735-GY PROXIMITY SWITCH
HANDLE PWM 24 K708-BU U734-GN
AUTO SPEED CTRL 27 A914-BU K725-GN 200-BK A C729-BU 1
BRAKE LIGHT 34 419-YL K726-BU F877-WH B 200-BK 2
NEUTRAL LIGHT 35 330-YL 777-PU 135-BU C
INTERLOCK SOL 37 C729-BU 751-GN
Propulsion System

PROPEL FORWARD 38 K726-BU C729-BU

PROPEL REVERSE 39 K725-GN 330-YL
BRAKE SELECT 42 777-PU 419-YL C729-BU 1
BACK UP 46 C936-GY A926-YL 200-BK 2
BATTERY + 47 135-BU A925-YL BRAKE AND NEUTRAL
February 2008

BATTERY + 48 135-BU 711-GN INDICATOR ARC SUPPRESSOR

BATTERY + 49 135-BU 712-GY
BATTERY + 50 135-BU A249-BK 419-YL 1 PARKING BRAKE
200-BK 2 GROUND
330-YL 3 NEUTRAL
200-BK 4 GROUND
Student Workbook for QESV1318
Asphalt Compactor

CB564D PROPULSION ELECTRICAL SYSTEM

U735-GY
U734-GN
112-PU 15A 155-PK 419-YL
K726-BU
BRAKE FUSE SHIFT SWITCH PARKING
K725-GN
BRAKE SWITCH
112-PU 15A 175-PK
1
2
K708-BU
JOINT CUTTER FUSE 135-BU 3
155-PK
1 2
U735-GY
3 4
112-PU 135-BU
4 155-PK U734-GN REVERSE FORWARD
15A 135-BU
5 6
K709-BU
X1
SOLENOID SOLENOID
ECM FUSE
X2 K725-GN 1

419-YL
7

200-BK
200-BK 200-BK 2
117-RD 15A 121-YL K726-BU 3
200-BK 4
BACKUP ALARM FUSE 614-PU
B+ FROM MAIN POWER RELAY

B+ FROM MAIN CIRCUIT BREAKER

8
777-PU
RESISTORS 200-BK
321-BR
BACKUP ALARM
1 A915-OR
2 CHARGE PRESSURE
3 A925-YL 321-BR
4
SWITCH
A916-GN 200-BK
5 200-BK A
6 A926-YL B 777-PU 1
465-OR C 200-BK 2
A F711-GN
PARKING BRAKE
CAN B F712-GY SOLENOID
PORT C A249-BK
AUTOMATIC SPEED 751-GN
ENGINE OIL CONTROL
45

CAN PRESSURE SWITCH SHIFT

POTENTIOMETER SOLENOID
RESISTOR ARC SUPPRESSOR
405-GY 200-BK
A F711-GN
B F712-GY 751-GN 1
C A249-BK 751-GN 200-BK 2
1
A916-GN 200-BK 2
A OR
A915-OR B BK
ELECTRONIC CONTROL A914-OR C WH
MODULE (ECM) K709-BU C729-BU
K708-BU
BATTERY 1 200-BK 135-BU INTERLOCK
BATTERY + 2 135-BU 135-BU 200-BK ARC SUPPRESSOR
CAN + 3 F711-GN 135-BU SOLENOID
135-BU 135-BU 1 + BATTERY C729-BU 1
CAN 4 F712-GY
CAN SHIELD 5 A249-BK 135-BU 200-BK 2 GROUND 200-BK 2
BRAKE NO 6 U734-GN C936-GY 710-GN 3 SIGNAL
BRAKE NC 7 U735-GY A914-OR 4
C729-BU
+5 VOLTS 8 A926-YL 1
A990-BU 200-BK 2
5 VOLTS 9 A925-YL PROPULSION SENSOR
SHIFT SWITCH 1 12 K708-BU 200-BK
SHIFT SWITCH 2 13 K709-BU 710-GN
ENGINE OIL PRESS 18 405-GY F877-WH PROXIMITY SWITCH
CONFIG PIN 19 A990-BU 330-YL C936-GY

200-BK
NEUTRAL SWITCH 23 F877-WH 465-OR 200-BK A
PROPEL HANDLE PWM 24 710-GN 405-GY F877-WH B BACKUP
CHARGE PRESSURE SWITCH 25 465-OR 175-PK C
SPEED DIAL POTENTIOMETER 27 A914-OR 419-YL ALARM RELAY
2 1
PARKING BRAKE LIGHT 34 419-YL U735-GY
NEUTRAL LIGHT 35 330-YL U734-GN 5
SHIFT SOL 37 751-GN K725-GN 121-YL 321-BR
3
Propulsion System

PROPEL FORWARD SOL 38 K726-BU K726-BU

PROPEL REVERSE SOL 39 K725-GN 777-PU 4
BRAKE SOL 42 777-PU 751-GN BRAKE AND NEUTRAL
INTERLOCK SOL 45 C729-BU C729-BU INDICATOR
BACK UP ALARM 46 C936-GY
February 2008

BATTERY + 47 135-BU A926-YL 419-YL MODEL CONFIGURATION

135-BU A925-YL 1 PARKING BRAKE
BATTERY + 48 200-BK 2 GROUND
BATTERY + 49 135-BU F711-GN 330-YL A990-BL A
135-BU F712-GY 3 NEUTRAL B
BATTERY + 50 200-BK 4 GROUND 135-BU
A249-BK 200-BK C
Student Workbook for QESV1318
Asphalt Compactor

CB534D PROPULSION HYDRAULIC SYSTEM

NEUTRAL
REAR
PARKING
BRAKE FLUSHING RELIEF VALVE
U B X
INTERLOCK
VALVE
SERVO PISTON
FROM VIBRATORY PUMP
FROM VIBRATORY
1.4
MOTORS
SHIFT
SPOOL 18 BAR
0.8
FROM CHARGE FILTER
(STEERING SYSTEM)
3.5 BAR
REAR
PROPEL FLUSHING SPOOL
MOTOR
A T G T
THERMAL BYPASS VALVE
FORWARD COMBINATION VALVE
FRONT BRAKE VALVE
PARKING
46

BRAKE
DIRECTIONAL
A a b CONTROL
VALVE PS P G Fa Fc MB
T2 R T1 T2 B
1.07mm
SERVO PISTON
B
T1

450 BAR
FRONT
PROPEL
MOTOR B SHIFT
VALVE 2

425 BAR
450 BAR
1.2mm
1 3 POR
VALVE
B T
A
Propulsion System

MANUAL BRAKE
RELEASE PUMP X1 X2 MH S MA A
AUX PROPEL PUMP REVERSE COMBINATION VALVE
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB564D PROPULSION HYDRAULIC SYSTEM

NEUTRAL
REAR
PARKING
BRAKE FLUSHING RELIEF VALVE
U B X
FROM VIBRATORY PUMP
INTERLOCK
VALVE
SERVO PISTON FROM VIBRATORY
MOTORS
1.4 0.8
SHIFT
SPOOL 18 BAR
3.5 BAR
REAR THERMAL BYPASS VALVE
PROPEL FLUSHING
MOTOR SPOOL FROM CHARGE FILTER
A T G T (STEERING SYSTEM)
SHIFT FORWARD COMBINATION VALVE
VALVE BRAKE VALVE
MANUAL BRAKE 2
RELEASE PUMP
47

DIRECTIONAL
a b CONTROL
VALVE PS P G Fa Fc MB
R T1 T2 B
T
1 3 SERVO PISTON
B B
1.07mm

450 BAR
AUX
FRONT
PARKING
BRAKE FLUSHING RELIEF VALVE
U B X

425 BAR
450 BAR
1.2mm
SERVO PISTON
POR
VALVE
1.4 A
SHIFT
Propulsion System

SPOOL 18 BAR
X1 X2 MH S MA A
REVERSE COMBINATION VALVE
February 2008

FRONT FLUSHING PROPEL PUMP

PROPEL SPOOL
MOTOR
A T G T
Student Workbook for QESV1318
Asphalt Compactor

CB534D PROPULSION HYDRAULIC SYSTEM

FORWARD, LOW SPEED
REAR
PARKING
BRAKE FLUSHING RELIEF VALVE
U B X
INTERLOCK
VALVE
SERVO PISTON
FROM VIBRATORY PUMP
FROM VIBRATORY
1.4
MOTORS
SHIFT
SPOOL 18 BAR
0.8
FROM CHARGE FILTER
(STEERING SYSTEM)
3.5 BAR
REAR
PROPEL FLUSHING SPOOL
MOTOR
A T G T
THERMAL BYPASS VALVE
FORWARD COMBINATION VALVE
FRONT BRAKE VALVE
PARKING
48

BRAKE
DIRECTIONAL
A a b CONTROL
VALVE PS P G Fa Fc MB
T2 R T1 T2 B
1.07mm
SERVO PISTON
B
T1

450 BAR
FRONT
PROPEL
MOTOR B SHIFT
VALVE 2

425 BAR
450 BAR
1.2mm
1 3 POR
VALVE
B T
A
Propulsion System

MANUAL BRAKE
RELEASE PUMP X1 X2 MH S MA A
AUX PROPEL PUMP REVERSE COMBINATION VALVE
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D PROPULSION HYDRAULIC SYSTEM

REVERSE, HIGH SPEED
REAR
PARKING
BRAKE FLUSHING RELIEF VALVE
U B X
INTERLOCK
VALVE
SERVO PISTON
FROM VIBRATORY PUMP
FROM VIBRATORY
1.4
MOTORS
SHIFT
SPOOL 18 BAR
0.8
FROM CHARGE FILTER
(STEERING SYSTEM)
3.5 BAR
REAR
PROPEL FLUSHING SPOOL
MOTOR
A T G T
THERMAL BYPASS VALVE
FORWARD COMBINATION VALVE
FRONT BRAKE VALVE
PARKING
49

BRAKE
DIRECTIONAL
A a b CONTROL
VALVE PS P G Fa Fc MB
T2 R T1 T2 B
1.07mm
SERVO PISTON
B
T1

450 BAR
FRONT
PROPEL
MOTOR B SHIFT
VALVE 2

425 BAR
450 BAR
1.2mm
1 3 POR
VALVE
B T
A
Propulsion System

MANUAL BRAKE
RELEASE PUMP X1 X2 MH S MA A
AUX PROPEL PUMP REVERSE COMBINATION VALVE
February 2008
February 2008 50 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

Laboratory Exercises

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.

___ Propulsion Lever

Location:
Function:

___ Propulsion Sensor

Location:
Function:

___ Parking Brake Switch

Location:
Function:

___ Shift Switch

Location:
Function:

___ Low Charge Pressure Indicator

Location:
Function:

___ Engine Oil Pressure Indicator

Location:
Function:

___ Speedometer
Location:
Function:

___ Hydraulic Oil Filter Plugged Indicator

Location:
Function:
February 2008 51 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

___ Hydraulic Oil Temperature Indicator

Location:
Function:

___ Parking Brake Indicator

Location:
Function:

___ Neutral Indicator

Location:
Function:

___ Thermal Bypass Valve (Return Manifold)

Location:
Function:

___ Hydraulic Oil Cooler

Location:
Function:

___ Propulsion Pump

Location:
Function:

___ Park Brake Solenoid

Location:
Function:

___ Interlock Solenoid

Location:
Function:

___ Brake Manifold

Location:
Function:

___ Shift Manifold

Location:
Function:
February 2008 52 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

___ Propel Motor (Rear)

Location:
Function:

___ Propel Motor (Front)

Location:
Function:
February 2008 53 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

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, 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

Serial Number Service Hour Meter

Test Specifications Actual

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
February 2008 54 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

Lab C: 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.
February 2008 55 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

Posttest
Directions: Using your notes in the student guide answer the following questions. Circle the best
answer for 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)

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.
February 2008 56 Asphalt Compactor
Propulsion System Student Workbook for QESV1318

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 57 Asphalt Compactor
Vibratory System Student Workbook for QESV1318

Vibratory System
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. (Lab A) Given a CB534D and CB564D Asphalt
Compactor and the Lab A Worksheet, locate and
identify the components of the vibratory hydraulic
system.
2. (Lab B) Given a CB534D and CB564D Asphalt
Compactor, the appropriate service literature and
the Lab B Worksheet, perform the following tests of
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
Compactor and all reference material and class
notes, troubleshoot a fault in the vibratory hydraulic
system (no worksheet).
4. 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

Student Workbook for QESV1318
Asphalt Compactor

CB534D ASPHALT COMPACTOR

ECM CONNECTOR VIBRATORY CONTROL
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
4 CAN C
1 5 6 10 5 CAN SHIELD C
16 VIBRATOR AUTOMATIC I
58

11 15 16 20
17 VIBRATOR HIGH I
21 25 26 30
19 CONFIGURATION 0" I
31 35 36 40 23 CONFIGURATION 1" I
41 45 46 50 24 HANDLE PWM I
29 VIBRATOR ON I
36 VIBRATOR LIGHT O
43 VIBRATOR FORWARD O
44 VIBRATOR REVERSE O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Vibratory System
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB564D ASPHALT COMPACTOR

ECM CONNECTOR VIBRATORY CONTROL
TERMINALS OF ECM
TERMINAL FUNCTION TYPE*
1 BATTERY O
2 BATTERY + I
3 CAN + C
4 CAN C
1 5 6 10 5 CAN SHIELD C
16 VIBRATOR AUTOMATIC I
59

11 15 16 20
17 VIBRATOR HIGH I
21 25 26 30
19 CONFIGURATION PIN I
31 35 36 40 24 HANDLE PWM I
41 45 46 50 26 VIBRATORY SYSTEM CONFIGURE I
29 VIBRATOR ON I
36 VIBRATOR LIGHT O
40 VIBRATOR FORWARD O
41 VIBRATOR REVERSE O
47 BATTERY + I
48 BATTERY + I
49 BATTERY + I
50 BATTERY + I
*I = INPUT TERMINAL; O = OUTPUT TERMINAL; C = CAN TERMINAL
Vibratory System
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D FAULT CODES

VIBRATORY SYSTEM
FAULT CODES FOR VIBRATORY SYSTEM
FLASH SEQUENCE DIAGNOSTIC SCREEN NAME FAULT DESCRIPTION FAULT LEVEL
(1)
6-1 CP_VIBECONFIG_FLT VIBRATORY CONFIGURATION NOT CORRECT 1
6-2 CP_VIBEFWD_FLT VIBRATORY FORWARD SOLENOID FAULT 1
6-3 CP_VIBEREV_FLT VIBRATORY REVERSE SOLENOID FAULT 1
60

(1)
6-4 CP_VIBEHILOW_FLT VIBRATORY AMPLITUDE SIGNAL INVALID INPUT 1
NOTES: (1) CB564D ONLY
Vibratory System
February 2008
Student Workbook for QESV1318
Asphalt Compactor

CB534D VIBRATORY ELECTRICAL SYSTEM

C926-BU
C927-PU
AMPLITUDE
103-YL SELECTOR
112-PU B+ FROM MAIN POWER RELAY
DRUM SELECTOR SWITCH SWITCH
VIBRATORY MODE (OPTIONAL)
1
C926-BU
CONTROL SWITCH
2
112-PU 10A 103-YL
3 1 1
C927-PU 2 2
VIBRATORY FUSE 4
B439-RD 103-YL C906-PU
3 3
5 6 4 4
112-PU 15A 123-WH 103-YL

C933-GN
7

C926-BU
C927-PU
5 6 5 6
GAUGE FUSE FROM LIGHT MASTER SWITCH 614-PU
7 7
8 200-BK
112-PU 135-BU 614-PU 614-PU 8 8
15A 200-BK 200-BK
B440-WH 440-WH 200-BK
ECM FUSE 123-WH

C925-GN
C926-BU

C906-PU
C927-PU

X982-PU
C924-YL
C933-GN C933-GN

200-BK
614-PU
B440-WH
B439-RD
PROPULSION LEVER 614-PU
S
H751-OR 1 N/O DRUM OFFSET 123-WH I G 200-BK
CAN A F711-GN 2 N/C LEFT DRUM OFFSET
B F712-GY H750-BR 3 N/O RIGHT DRUM OFFSET VIBRATORY
PORT C A249-BK 4 N/C RIGHT DRUM OFFSET
5 + SWITCH COMMON TACHOMETER
A305-YL 6 N/O HORN 614-PU
CAN 7 N/C HORN FRONT MOTOR
RESISTOR P979-YL 8 N/O WATER SPRAY
61

C926-BU
C927-PU
SPEED SENSOR

200-BK
9 N/C WATER SPRAY
A F711-GN P978-GN 10 N/O VIBE
B F712-GY 11 N/C VIBE B439-RD 1
C A249-BK 12 200-BK 2

C925-GN

C906-PU
C906-PU

X982-PU
C924-YL
135-BU 1 + BATTERY 200-BK
JN C9/ 200-BK 2 GROUND
AH C4 K708-BU 3 SIGNAL B440-WH 1
4

C926-BU
C927-PU
28 135-BU 200-BK 2

200-BK
29 C21 C18

1
2

1
2
PROPULSION SENSOR
REAR MOTOR
M905-WH TWO AMPLITUDE OR
M904-OR VIBRATORY INDICATOR SPEED SENSOR VERSA VIBE MACHINES:
ELECTRONIC CONTROL CONNECT C18 TO C20 AND
MODULE (ECM) C935-PU 1 WATER SPRAY 200-BK
CONNECT C19 TO C21
BATTERY 1 200-BK 200-BK 2 GROUND FIVE AMPLITUDE MACHINE:
135-BU C932-YL 3 VIBRATOR

C926-BU
CONNECT C18 TO C21 AND

C927-PU
BATTERY + 2 200-BK 4 GROUND

200-BK
CAN + 3 711-GN A249-BK FRONT MOTOR REAR MOTOR CONNECT C19 TO C20
CAN 4 712-GY 712-GY
A249-BK 711-GN SELECTOR SOLENOID SELECTOR SOLENOID

1
2

1
2
CAN SHIELD 5
VIBRATOR AUTO 16 C933-GN 200-BK REVERSE FORWARD C19 C20
VIBRATOR HIGH 17 X982-PU 135-BU SOLENOID SOLENOID
M904-OR

K918-GN
K919-YL

T825-YL
A990-BU

X982-PU
CONFIG 0" 19 135-BU
CONFIG 1" 23 M905-WH 135-BU
HANDLE PWM 24 K708-BU 135-BU
VIBRATOR ON 29 P978-GN 135-BU
C932-YL C933-GN K918-GN 1 C926-BU 1 C927-PU 1
VIBRATOR LIGHT 36
VIBRATOR FWD 43 A990-BU P978-GN 200-BK 2 200-BK 2 200-BK 2
VIBRATOR REV 44 T825-YL K708-BU K919-YL 3
Vibratory System

BATTERY + 47 135-BU C932-YL 200-BK 4

C927-PU
BATTERY + 48 135-BU T825-YL
C926-BU C926-BU
February 2008

BATTERY + 49 135-BU A990-BU

BATTERY + 50 135-BU X982-PU 200-BK 200-BK 200-BK
K919-YL
K918-GN
T825-YL
A990-BU
X982-PU
Student Workbook for QESV1318
Asphalt Compactor

CB564D VIBRATORY ELECTRICAL SYSTEM

C926-BU
C927-PU
103-YL
112-PU B+ FROM MAIN POWER RELAY AMPLITUDE
DRUM SELECTOR SWITCH VIBRATORY MODE SELECTOR
1
C926-BU
CONTROL SWITCH SWITCH
2
112-PU 10A 103-YL
3 1 1
C927-PU 2 2 C925-GN
VIBRATORY FUSE 4
B439-RD 103-YL C906-PU
3 3
C924-YL
5 6 4 4
112-PU 15A 123-WH 103-YL

C933-GN
7

C926-BU
C927-PU
5 6 5 6
614-PU X982-PU
GAUGE FUSE FROM LIGHT MASTER SWITCH
7 7
8 200-BK
112-PU 135-BU 614-PU 614-PU 8 614-PU 8
15A 200-BK 200-BK
B440-WH 200-BK
ECM FUSE 123-WH 123-WH
C933-GN C933-GN VIBRATORY
TACHOMETER

B439-RD
CAN A F711-GN PROPULSION LEVER 614-PU
B F712-GY LIGHT
PORT C A249-BK H751-OR 1 N/O DRUM OFFSET
A 200-BK
B 123-WH 614-PU 1
2 N/C LEFT DRUM OFFSET C B440-WH
H750-BR 3 N/O RIGHT DRUM OFFSET 200-BK 2
CAN 4 N/C RIGHT DRUM OFFSET
RESISTOR 135-BU 5 + SWITCH COMMON VIBRATORY
320-OR 6 N/O HORN TACHOMETER
A F711-GN 7 N/C HORN
B F712-GY P979-YL 8 N/O WATER SPRAY
62

C A249-BK 9 N/C WATER SPRAY FRONT MOTOR

P978-GN 10 N/O VIBE
SPEED SENSOR

C926-BU
C927-PU

X982-PU
11 N/C VIBE

200-BK
MODEL 12
B439-RD 1
CONFIGURATION 200-BK 2
PIN PROPULSION SENSOR
A A A990-BU 200-BK
B B 135-BU 135-BU 1 + BATTERY B440-WH
C C 200-BK 200-BK 2 GROUND
J-C102 J-C5 710-GN 3 SIGNAL 1
4 B440-WH TWO AMPLITUDE OR VERSA
200-BK 2
VIBE TM MACHINES:
CONNECT J-C4 TO J-C101
ELECTRONIC CONTROL VIBRATORY INDICATOR REAR MOTOR FIVE AMPLITUDE MACHINE:
MODULE (ECM) A631-BU 1 WATER SPRAY SPEED SENSOR CONNECT J-C4 TO J-C100
J-C2 A-C20 200-BK 2 GROUND
BATTERY 1 200-BK A990-BU 200-BK
BATTERY + 2 135-BU 5 C932-YL 3 VIBRATOR
200-BK 4 GROUND
CAN + 3 F711-GN A249-BK FRONT MOTOR REAR MOTOR
CAN 4 F712-GY F712-GY
A249-BK F711-GN SELECTOR SOLENOID SELECTOR SOLENOID
CAN SHIELD 5 VIBRATORY
VIBRATOR AUTO 16 C933-GN 200-BK
VIBRATOR HIGH 17 X982-PU 135-BU CONTROL
CONFIG PIN 19 A990-BU 135-BU SOLENOID
HANDLE PWM 24 710-GN 135-BU
K918-GN

C
A
B

A
B
VIBRATOR SYS CONFIG 26 T825-YL 135-BU 1
VIBRATOR ON 29 P978-GN 135-BU 200-BK 2
VIBRATOR LIGHT 36 C932-YL C933-GN C926-BU 1 C927-PU 1 J-C100 J-C101
VIBRATOR FWD 40 K918-GN P978-GN 200-BK 2 200-BK 2

C
A
B
VIBRATOR REV 41 K919-YL 710-GN
K919-YL 3 J-C4
BATTERY + 47 135-BU C932-YL 4 C927-PU
200-BK
Vibratory System

BATTERY + 48 135-BU T825-YL

C926-BU C926-BU

T825-YL
135-BU
200-BK
BATTERY + 49 135-BU K918-GN
BATTERY + 50 135-BU K919-YL 200-BK 200-BK 200-BK
February 2008

X982-PU 200-BK
T825-YL
135-BU
X982-PU
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D VIBRATORY HYDRAULIC SYSTEM

OFF
0.8
DIRECTIONAL
b a CONTROL FORWARD COMBINATION VALVE
VALVE
R T1 T2 PS Mb
CHARGE RELIEF VALVE TO PROPULSION SYSTEM
SERVO PISTON 1.8
1.0
G
VIBRATORY
PUMP
25 BAR POR VALVE
63

X1 X2 Ma
FRONT VIBRATORY SELECTOR VALVE B
REVERSE COMBINATION VALVE
FROM SHIFT VALVE REAR VIBRATORY
SELECTOR VALVE A FRONT VIBRATORY
A MOTOR
FROM PROPEL MOTORS CASE DRAIN
FROM PROPEL PUMP CASE DRAIN
B
0.8
CP
3.5 BAR 240 BAR
B
T P MP
THERMAL BYPASS VALVE
A

2.0
Vibratory System

INTERCIRCUIT RELIEF VALVE REAR

FLUSHING SPOOL VIBRATORY

18 BAR
February 2008

MOTOR
FROM CHARGE FILTER
(STEERING SYSTEM)
FLUSHING RELIEF VALVE
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D VIBRATORY HYDRAULIC SYSTEM

BOTH DRUMS, FORWARD
0.8
DIRECTIONAL
b a CONTROL FORWARD COMBINATION VALVE
VALVE
R T1 T2 PS Mb
CHARGE RELIEF VALVE TO PROPULSION SYSTEM
SERVO PISTON 1.8
1.0
G
VIBRATORY
PUMP
25 BAR POR VALVE
64

X1 X2 Ma
FRONT VIBRATORY SELECTOR VALVE B
REVERSE COMBINATION VALVE
FROM SHIFT VALVE REAR VIBRATORY
SELECTOR VALVE A FRONT VIBRATORY
A MOTOR
FROM PROPEL MOTORS CASE DRAIN
FROM PROPEL PUMP CASE DRAIN
B
0.8
CP
3.5 BAR 240 BAR
B
T P MP
THERMAL BYPASS VALVE
A

2.0
Vibratory System

INTERCIRCUIT RELIEF VALVE REAR

FLUSHING SPOOL VIBRATORY

18 BAR
February 2008

MOTOR
FROM CHARGE FILTER
(STEERING SYSTEM)
FLUSHING RELIEF VALVE
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D VIBRATORY HYDRAULIC SYSTEM

FRONT DRUM, FORWARD
0.8
DIRECTIONAL
b a CONTROL FORWARD COMBINATION VALVE
VALVE
R T1 T2 PS Mb
CHARGE RELIEF VALVE TO PROPULSION SYSTEM
SERVO PISTON 1.8
1.0
G
VIBRATORY
PUMP
25 BAR POR VALVE
65

X1 X2 Ma
FRONT VIBRATORY SELECTOR VALVE B
REVERSE COMBINATION VALVE
FROM SHIFT VALVE REAR VIBRATORY
SELECTOR VALVE A FRONT VIBRATORY
A MOTOR
FROM PROPEL MOTORS CASE DRAIN
FROM PROPEL PUMP CASE DRAIN
B
0.8
CP
3.5 BAR 240 BAR
B
T P MP
THERMAL BYPASS VALVE
A

2.0
Vibratory System

INTERCIRCUIT RELIEF VALVE REAR

FLUSHING SPOOL VIBRATORY

18 BAR
February 2008

MOTOR
FROM CHARGE FILTER
(STEERING SYSTEM)
FLUSHING RELIEF VALVE
Student Workbook for QESV1318
Asphalt Compactor

CB534D AND CB564D VIBRATORY HYDRAULIC SYSTEM

REAR DRUM, FORWARD
0.8
DIRECTIONAL
b a CONTROL FORWARD COMBINATION VALVE
VALVE
R T1 T2 PS Mb
CHARGE RELIEF VALVE TO PROPULSION SYSTEM
SERVO PISTON 1.8
1.0
G
VIBRATORY
PUMP
25 BAR POR VALVE
66

X1 X2 Ma
FRONT VIBRATORY SELECTOR VALVE B
REVERSE COMBINATION VALVE
FROM SHIFT VALVE REAR VIBRATORY
SELECTOR VALVE A FRONT VIBRATORY
A MOTOR
FROM PROPEL MOTORS CASE DRAIN
FROM PROPEL PUMP CASE DRAIN
B
0.8
CP
3.5 BAR 240 BAR
B
T P MP
THERMAL BYPASS VALVE
A

2.0
Vibratory System

INTERCIRCUIT RELIEF VALVE REAR

FLUSHING SPOOL VIBRATORY

18 BAR
February 2008

MOTOR
FROM CHARGE FILTER
(STEERING SYSTEM)
FLUSHING RELIEF VALVE
February 2008 67 Asphalt Compactor
Vibratory System Student Workbook for QESV1318

Laboratory Exercises

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.
___ Vibratory Mode Control Switch
Location:
Function:

___ Drum Selector Switch

Location:
Function:

___ Amplitude Selector Switch

Location:
Function:

___ Vibratory Tachometer

Location:
Function:

___ Vibratory Master Switch

Location:
Function:

___ Piston Pump (Vibratory)

Location:
Function:

___ Piston Motor (Rear)

Location:
Function:

___ Piston Motor (Front)

Location:
Function:
February 2008 68 Asphalt Compactor
Vibratory System Student Workbook for QESV1318

___ Vibratory Speed Sensor

Location:
Function:
February 2008 69 Asphalt Compactor
Vibratory System Student Workbook for QESV1318

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 pressure relief valve (charge vibratory)
2. Test pressure relief valve (main vibratory)
3. Test pressure relief valve (pressure override vibratory)

Machine Model Date

Serial Number Service Hour Meter

Test Specifications Actual

Test pressure relief
valve (charge
vibratory), forward
Test pressure relief
valve (charge
vibratory), reverse
Test pressure relief
valve (main vibratory),
forward
Test pressure relief
valve (main vibratory),
reverse
Test pressure relief
valve (pressure
override vibratory),
forward
Test pressure relief
valve (pressure
override vibratory),
reverse
February 2008 70 Asphalt Compactor
Vibratory System Student Workbook for QESV1318

Lab C: 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.
February 2008 71 Asphalt Compactor
Vibratory System Student Workbook for QESV1318

Posttest
Directions: Using your notes in the student guide answer the following questions. Circle the best
answer for 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.

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)
D. None of the above.

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.