Service Training
STUDENT
MATERIALS
Course Materials
C & D SERIES BACKHOE LOADER SYSTEMS
BUILDING CONSTRUCTION PRODUCTS
BCP BHL
8/15/01
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STUDENT NOTES
Student Materials
BCP BHL
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Student Materials
TABLE OF CONTENTS
COURSE DESCRIPTION......................................................................................................4
PRE-COURSE/POST-COURSE ASSESSMENT ..................................................................6
COURSE PLAN/OUTLINE...................................................................................................9
STUDENT LITERATURE CHECKLIST ............................................................................12
MODULE: MACHINE ORIENTATION ............................................................................19
MODULE: ENGINE SYSTEMS .......................................................................................23
MODULE: ELECTRICAL SYSTEM ................................................................................31
MODULE: STANDARD POWER TRAIN .......................................................................40
MODULE: AUTOSHIFT AND POWER SHIFT TRANSMISSIONS ..............................57
MODULE: AXLES AND BRAKES ..................................................................................72
MODULE: ENGINE, ELECTRICAL AND POWER TRAIN TROUBLESHOOTING ...78
MODULE: STEERING AND IMPLEMENT HYDRAULIC SYSTEMS ........................89
MODULE: STEERING AND IMPLEMENT HYDRAULIC SYSTEMS
TROUBLESHOOTING......................................................................................................120
MODULE: ALL WHEEL STEERING ELECTRICAL & HYDRAULIC SYSTEMS ...126
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Student Materials
COURSE DESCRIPTION
C & D Series Backhoe Loader Systems
Course Length: 4 1/2 Days
Course Ends: 4:00 P.M. Fifth Day
Class size: 8 students maximum
CONTENT
WHO SHOULD ATTEND:
• Training Instructors
• Technical Communicators
This course is designed to teach systems used on D series and late model
C series backhoe loaders. This course covers the same information as
covered in the Telehandler and Backhoe Loader Systems Course, but at a
slower pace. This course is recommended for those instructors with
limited experience on backhoes and Load Sensing/ Pressure
Compensated Hydraulics.
Classroom work (approximately 30%) will consist of a product
performance update and a brief review of both systems operation and
testing and adjusting procedures.
Students may be required to do additional homework in the evenings.
Quizzes will be used to monitor student’s progress.
Major systems to be considered and a brief description of lab exercises
are as follows:
• Machine Orientation - Students will operate the vehicle noting the
characteristics of the brakes, transmission, transmission controls,
implement controls, and interaction of the loader function with
steering;
• Engine Labs - Students will identify and locate components, check
high and low idle, torque converter stall, and check engine oil
pressure.
• Electrical Labs - Students will locate various electrical components
and perform proper methods for checking the batteries, starter,
alternator, key start switch and relays. The students will "bug" the
machine to demonstrate the effects of electrical component
malfunction.
• Transmission Labs - Major emphasis is place on power shift
transmission featuring autoshift. The non-power shift transmission
will also be also be covered.
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Student Materials
• Brakes and Axles Lab - Students will perform proper brake
performance checks and will be able to explain power flow through
the drive train and differential lock. Performance checks for All
Wheel Steer will be performed if machine is available..
• Hydraulic System Labs - Students will perform hydraulic system
tests as described in the service module for maximum system
pressure, margin pressure, and low pressure standby. The students
will "bug" the machine to demonstrate the effects of component
malfunction in the pump control valve and the implement circuits.
SKILLS TAUGHT
DIAGNOSTIC TESTS
Upon completion of this course, the student will be able to perform the
following diagnostic tests:
• Test the engine for correct in-chassis operation
• Test the transmission system (including autoshift)
• Test and adjust the implement hydraulic system
• Test the electrical starting and charging system
• test the All Wheel Steer (if available)
KEY DIAGNOSTIC TOOLS USED IN CLASS
• 9U7400 Multitach II Group
• 9U7330 Fluke 87
• 8T0900 AC/DC Clamp- on Ammeter
• 1U5796 Differential Gauge Group
• Electronic Technician (power shift transmission)
SUGGESTED
PREREQUISITE TESTS
SUGGESTED
PREREQUISITE
COURSES
COURSE PRE-REQUISITES
It is suggested that students complete the following prerequisite tests at
least one to two weeks before students take the course.
Students should pass the following pretests with 90% or better.
• Basic ISO Pre-test
SEBV0556
• Basic Hydraulic Pretest
SEBV0557
• Basic Electrical Pretest
SEBV0558
It is suggested that students complete the following courses or equivalent
courses prior to attending.
• Multimedia Course "Fundamentals of Mobile Hydraulics"
TERV9001
• Multimedia Course "Fundamentals of Electricity"
TERV9002
• Multimedia Course "Fundamentals of Drive Trains"
TERV9004
Student can not do. Needs more
training
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Student can perform task but
needs more practice
Student has demonstrated his
competence
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Student Materials
PRE-COURSE/POST-COURSE ASSESSMENT
Use the following assessment to determine if a student either needs to
attend a course and what skills they need to improve. The assessment
then should be used at the completion of the course to measure the
student's progress.
OBJECTIVES
1. Perform a 10 hour/daily machine inspection for a BCP backhoe
loader using the Operation and Maintenance Manual.
2. Using the handout provided and the related service manual modules
locate the following components on a backhoe loader: fuel filter,
governor, fuel shutdown solenoid, priming (lift) pump, water
separator, oil filter, engine oil dipstick, engine oil pressure test port,
engine oil cooler (turbo models only), primary air filter, secondary
air filter, turbocharger (if equipped), air filter indicator, radiator,
water pump, cold start advance solenoid, low idle adjustment screw,
high idle adjustment screw, and temperature regulator housing..
3. Using the handout provided and the related service manual modules,
perform engine tests for engine high idle, low idle, torque converter
stall and engine oil pressure.
4. Using the provided service literature perform tests for the battery,
alternator, and starter on the machine using a voltmeter and clamp on
ammeter.
5. Using the electrical schematic and the provided handout. Draw and
numerically code the wires to correctly connect the components of
the starting and charging system.
6. Locate the following power train hydraulic oil system components
and service points on the machine: fill tube, filter, suction screen,
torque converter housing, transmission directional control selector
lever, transmission control valve, torque converter inlet relief valve,
cold start relief valve ( if equipped), relief valve (C series), AWD
solenoid valve (if equipped) and transmission oil cooler..
Student Materials
Student can not do. Needs more
training
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Student can perform task but
needs more practice
Student has demonstrated his
competence
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7. Locate the following power train hydraulic oil system components
and service points on the machine for a power shift transmission: fill
tube, filter, suction screen, torque converter housing, transmission
directional control selector lever, relief valve, cold start relief valve,
torque converter inlet relief valve, AWD solenoid valve (if equipped),
transmission oil cooler, solenoid no. 1 - Forward High , solenoid no.
2 - Reverse, solenoid no. 3 - Forward Low, solenoid no. 4 - speed
clutch no. 1, solenoid no. 5 - speed clutch no. 2, and solenoid no. 6 speed clutch no. 3.
8. Using the appropriate service manual module, locate the test location
and perform checks on the machine for the following power train
hydraulic oil system pressure: pump supply pressure, torque
converter outlet pressure, torque converter inlet pressure, lube
pressure, FORWARD HIGH clutch , REVERSE clutch, FORWARD
LOW clutch, speed clutch no. 1, speed clutch no. 2 , speed clutch no.
3, and AWD clutch pressure (if equipped).
9. Using the appropriate service manual module, locate the test location
and perform checks on the machine for the following power train
hydraulic oil system pressures: lube pressure, FORWARD clutch
pressure, REVERSE clutch pressure, pump supply pressure, AWD
clutch pressure, and torque converter outlet pressure.
10. On the machine, locate the following: hydraulic tank, hydraulic oil
filter, pump, pump control valve, loader valve group, backhoe valve
group, implement controls, pump supply pressure test port, signal
pressure test port, torque limiter.
11. Perform performance checks and/or adjust: max system pressure,
low pressure standby, and margin pressure.
12. Perform cycle time checks and signal system checks to identify
resolver or pump control problems per the provided handout.
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Student Materials
Post Course Assessment Only - Student should review the above
objective and place checks in those boxes as appropriate. Student
should then sign his name below.
Student's Signature:
Instructor's Signature:
Date:
Instructor's comments:
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Student Materials
COURSE PLAN/OUTLINE
GET ACQUAINTED
MODULE: MACHINE ORIENTATION
- Objectives
- Lesson: Machine Orientation
- Slide presentation
- Shop Lab
- Machine Orientation Quiz
- Module Summary
MODULE: ENGINE SYSTEMS
- Objectives
- Lesson: Engine Systems
- Slide presentation on engine systems
- Cooling system homework assignment
- Shop lab
- Slide presentation on the fuel system
- Lesson: Engine Systems Tests
- Perform engine tests
- Review cooling system homework assignment
- Module Summary
MODULE: ELECTRICAL SYSTEM
- Objectives
- Lesson: Electrical Systems
- Slide presentation on starting and charging system
- Electrical schematic discussion
- Identify electrical components
- Trace electrical schematic
- Lesson: Electrical System Tests
- Starting and charging system components
- Quiz: Electrical System
- Module Summary
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Student Materials
MODULE: POWER TRAIN
- Objectives
- Lesson: Power Train Component Identification
- Slide presentation on power train components
- Identify components on the machine
- Lesson: Transmission Control Valve Component Identification
(Optional)
- Slide presentation on control valve components
- Lesson: Control Valve Operation
- Lesson: Power Train System Tests
- Perform diagnostic tests
- Case Study: Power Train
- Quiz: Power Train
- Module Summary
MODULE: AUTOSHIFT AND POWER SHIFT TRANSMISSION
SYSTEMS
- Objectives
- Lesson: Power Shift System Component Identification and
Operation
- Slide presentation on the power shift system
- Identify components
- Operate system
- Lesson: Power Shift System Tests
- Perform diagnostic tests
- Module Summary
MODULE: AXLES AND BRAKES
- Objectives
- Lesson: Axles and Brakes Component Identification
- Slide presentation on the axles and brake system
- Identify axle and brake system components on the machine
- Lesson: Brake System Tests
- Perform diagnostic tests
- Quiz: Axle and Brakes
- Module Summary
MODULE: ENGINE, ELECTRICAL, AND POWER TRAIN
TROUBLESHOOTING
- Objectives
- Lesson: Troubleshooting
- Install "bugs" in the engine, transmission, and electrical system
- Perform appropriate tests
- Repair systems
- Module Summary
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Student Materials
MODULE: STEERING AND IMPLEMENT HYDRAULIC
SYSTEMS
- Objectives
- Lesson: Basic LS/PC Hydraulics
- Slide presentation on LS/PC hydraulics
- Quiz: LS/PC Hydraulics
- Lesson: Implement Hydraulic System Component Identification
- Slide presentation on the hydraulic systems
- Identify hydraulic system components
- Lesson: Hydraulic Pump Component Identification (optional)
- Lesson: Implement Control Valve Component Identification
(optional)
- Lesson: Implement Hydraulic System Tests
- Perform diagnostic tests
- Case Study: Implement Hydraulic System
- Quiz: Implement Hydraulic System
- Module Summary
MODULE: STEERING AND IMPLEMENT HYDRAULIC
SYSTEMS TROUBLESHOOTING
- Objectives
- Lesson: Troubleshooting
- Install "bugs" in the hydraulic system
- Perform appropriate tests
- Repair systems
- Module Summary
MODULE: ALL WHEEL STEERING ELECTRICAL &
HYDRAULIC SYSTEMS
- Objectives
- Lesson: All Wheel Steer System Component Identification
- Slide presentation on the AWS system
- Identify AWS system components
- Module Summary
COURSE WRAP-UP
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REQUIRED STUDENT
MATERIALS
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Student Materials
STUDENT LITERATURE CHECKLIST
Description
Binder
Form No.
SENR2910
Fluid Power Graphic Symbols
SEEV0529
Know Your Cooling System
SEBD0518
3054 Engine for Cat Built Machines - SOTA
SENR5816
3054B Machine Engine - SOTA
SENR5010
Lucas Fuel System Supplement
SENR6525
C Series
416C Thru 438C Lube and Maintenance Chart
SELU6873
416C Specification Sheet
AEHQ0428
426C Specification Sheet
AEHQ0429
436C Specification Sheet
AEHQ0430
C Series Transmission - Systems Operation.
SENR1204
Power Shift Transmission - Systems Operation
SENR1273
Power Shift Transmission Electronic Control
SENR1274
C Series Axles, Differentials, and Brakes
SENR1259
Hydraulic & Steering System -Systems Operation
SENR1208
Hydraulic & Steering System -Test & Adjust
SENR1272
416C, 426C, 436C Hydraulic System Schematic
SENR1213
416C, 426C, 436C 428C& 438C Electrical Sys.
Schem.(European cab)
RENR2854
416C, 426C, & 436C Series Electrical System
Schematic (for machines built after 1/1/98)
SENR1276
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Student Materials
D Series
416D Specification Sheet
AEHQ5419
420D Specification Sheet
AEHQ5420
430D Specification Sheet
AEHQ5421
D Series Direct Drive Transmission - Spec/SOTA.
RENR3574
Autoshift Transmission - Spec/SOTA
RENR3575
Autoshift Transmission Electronic Control
RENR2869
D Series Axles, Differentials, and Brakes
RENR3577
Hydraulic & Steering System -Systems Operation
RENR3583
Hydraulic & Steering System -Test & Adjust
RENR3584
420D/430D/432D/442D Hydraulic Schematic
RENR3569
416D/424D Hydraulic Schematic
RENR3586
D Series Electrical System Schematic
RENR3587
BHL Auxiliary Hydraulics Electronic Control
RENR3588
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STUDENT REFERENCE
MATERIALS
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Student Materials
Reference Materials
Optional
Battery Test Procedures
SEHS7633
Machine Security System SOTA
RENR2462
C Series
428C Backhoe Loader Specifications
HEHB2072
438C Backhoe Loader Specifications
HEHB2073
428C & 438C Hydraulic Schematic
SENR1210
446B Power Shift Transmission Electronic Control RENR2869
446B Electrical System Schematic.
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RENR2870
416C, 426C, & 436C Series Electrical System
Schematic (for machines built before 1/1/98)
SENR1212
428C and 438C Electrical System Schematic
(European Cab for machines built before 1/1/98))
SENR1210
D Series
424D Backhoe Loader Specifications
428D Backhoe Loader Specifications
438D Backhoe Loader Specifications
432D Backhoe Loader Specifications
442D Backhoe Loader Specifications
416D Hydraulic System Operation
RENR3580
416D Hydraulic System T&A
RENR3581
428D/438D Hydraulic Schematic
RENR3586
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Student Materials
Operation and Maintenance Manuals - at least two copies of the
following O&M Guides should be available until Lube and
Maintenance Charts are made available in order to expedite the
first module.
C Series Operation and Maintenance Guide
SEBU6873
C Series Supplemental O&M Guide
SEBU7250
416D Operation and Maintenance Guide
SEBU7398
420D/430D Operation and Maintenance Guide
SEBU7399
424D/428D/438D Operation and Maintenance Guide SEBU7400
432D/442D Operation and Maintenance Guide
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SEBU7401
Service Manuals - the service manuals will provide answers to questions
on disassembly and assembly of components along with additional
specifications.
416C, 426C, 428C, 436C, and 438C Backhoe Loader Service
Manual
SENR1200
416B, 426B, 428B, 436B, and 438B Backhoe Loader Service
Manual
SENR5800
D Series Service Manual
RENR3570
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Student Materials
C Series Parts Manuals
416C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2388
416C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2549
426C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2551
426C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2597
428C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2385
436C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2559
436C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2601
438C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2387
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D Series Parts Manual
416D Backhoe Loader BFP1-Up
SEBP3202
416D Backhoe Loader BGJ1-Up
SEBP3236
416D Backhoe Loader (G Version) BKG1-Up
SEBP3241
420D Backhoe Loader FDP1-Up
SEBP3203
420D Backhoe Loader BLN1-Up
SEBP3204
420D Backhoe Loader BKC1-Up
SEBP3237
420D Backhoe Loader BMC1-Up
SEBP3238
430D Backhoe Loader BNK1-Up
SEBP3205
430D Backhoe Loader BMC1-Up
SEBP3206
424D Backhoe Loader BGP1-Up, BKR1-Up
SEBP3207
428D Backhoe Loader BLL1-Up, BNB1-Up
SEBP3208
428D Backhoe Loader BMT1-Up, BNS1-Up
SEBP3209
438D Backhoe Loader BPE1-Up, BPN1-Up
SEBP3211
432D Backhoe Loader BLD1-Up
SEBP3210
442D Backhoe Loader BRG1-Up, BRY1-Up
SEBP3212
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Student Materials
Video Tapes
"The DPA Pump" - Check with local fuel injection shops
"Introduction to LS/PC Hydraulics Systems"
SEVN1804
"Introduction to Variable Displacement Pumps and
Controls in LS/PC Hydraulics"
SEVN1837
"Introduction to Pressure Compensated Valves in
LS/PC Hydraulics"
SEVN1900
"C-Series Walk-around"
SEVN4240
"C-Series Power Shift Transmission"
SEVN4241
"Introduction to 416-446 BHLs - LS/PC Hyd."
SEVN1988
"All Wheel Steer Backhoe Loader"
TEVN3230
Laboratory Requirements
Mechanic's Tool Boxes with hand tools (include metric)
The following machines:
1 - 416C/426C/436C backhoe loaders with a standard
transmission
1 - 416C/426C/436C backhoe loaders with a power shift
transmission
1 - 416D backhoe loader with a standard transmission
1 - 420D/430D backhoe loader with a autoshift transmission
NOTE: Corresponding sideshift machines may also be used.
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Student Materials
Tooling Requirements
2-6V3121 Multitach Group or 9U7400 Multitach II Group
2-1U5481 Pressure Gauge Groups
2-1U5482 Pressure Hose and Adapter Groups
2-6V7800 Multimeters or 9U7330 Fluke 87
2-8T0900 AC/DC Clamp- on Ammeter
1-127-8078 Battery Tester
1-4C8054 - Fitting to check fuel transfer pressure
8-6V3965 Nipples
8-3J1907 O-rings
2-8T0856 Pressure Gauge (0 to 870 psi)
4-8T0859 Pressure Gauge (0 to 3600 psi)
1-1U5796 Differential Gauge Group
1-1U5796 Differential Gauge Group
1-Laptop Computer with ET
1-7X1700 Communications Adapter
1-7X1570 Cable - to machine
1-7X1851 Cable - between adapter and PC
2-Stop Watch
1-Tape Measure
1-6V4142 Nipple
1-8C7575 or 8C7576 adapter
2-Mechanic's Tool Boxes and hand tools
Should have access to the following to repair wiring
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
1-154-7151 - New tool for removing top cover to access fuel
pump solenoid on C Series
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Student Materials
MODULE: MACHINE ORIENTATION
The purpose of this module is to make you aware of some of the changes
from the previous model or models and to make you familiar with some
of the service requirements for the machines. The module is composed
of one lesson which includes a quiz.
OBJECTIVES
At the completion of this module you will be able to:
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1. Using the appropriate specalogs, identify machine features on a quiz
for the engine, electrical system, cab, implement hydraulic system,
axles and brakes, and power train. (Underdevelopment)
NOTE: For the following objectives, use the Operation and
Maintenance Guide as a reference during the lab activities.
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2. Perform a 10 hour/daily machine inspection for a Caterpillar
backhoe loader.
3. Identify the following Caterpillar backhoe loader controls: Steering
and implement control levers, steering and brake controls, governor
controls, keystart switch, gauges, and accessory switches and
controls.
4. Locate and read all machine warning labels for operating and
servicing the machine
5. Demonstrate proper machine starting and stopping procedures for a
Caterpillar backhoe loader.
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Student Materials
Lesson: Machine Orientation
BACKGROUND
INFORMATION
Shop Lab
This lesson will help you gain familiarity with the correct machine
maintenance and operation guidelines, plus, machine features and
benefits.
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• View introduction slide presentation
• Perform a 10 hour/daily inspection before starting and or operating the
vehicle using the Machine Walk-around Checklist.
• Identify the following machine controls: Implement control levers,
steering wheel, brake controls, governor controls, keystart switch,
warning indicators, and accessory switches and controls using the
Machine Walk-around Checklist.
• Perform startup and machine shutdown procedures. Operate the
machine (optional) - If feasible, move the vehicle, noting steering &
brake characteristics, transmission shifting, implement control function,
on-the go shifting, etc.
• Operate the implements (optional) - note the operation of the different
functions. Operate two circuits simultaneously.
Operate the "return to dig." If properly adjusted the front bucket edge
should be parallel to the ground. Back drag in FLOAT position.
Notice steering priority. Operate loader lift or bucket circuit then
activate steering. Implements should slow down.
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Materials Needed
Quiz
Materials Needed
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• Remove floor plate and sheet metal (in preparation for later lab
exercises.)
Specalogs (for the machines used)
Operation and Maintenance Chart (if available)
Machine Walk-around Checklist
Operation and Maintenance Guide (for the machine used)
1-Mechanics Tool Box
• Complete "Quiz: Machine Orientation."
Student Quizzes handout
Specalogs (for the machines used)
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Machine Walk-around Checklist
Directions: Use this sheet when performing the machine orientation lab exercise.
Place a check in the blank if the fluid level is acceptable.
C
D
Model
Engine oil level
Transmission oil level
Hydraulic system oil level
Brake system oil level
Cooling system fluid level
Fuel level
Place a check in the blank if acceptable or after task was performed.
Drain water separator
Check seat belt
Check air filter indicator
Place a check in the blank if the indicator, switch or control is working correctly.
Keystart switch
Turn signal
Tachometer
Engine coolant gauge
Power train/converter oil temperature gauge
Fuel level gauge
Parking brake light
Turn signal
Horn
Running lights
Front work lights
Rear work lights
Windshield wipers
Heating and air conditioner controls
Service hour meter
Backup alarm
Student Materials
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Student Materials
Machine Walk-around Checklist - continued
Place a check in the blank after locating and reading the following warnings label on the machine..
C
D
Model
Before operating
Use of ether
Boom/swing area
Loader arm brace
ROPS
Use of Jumpers
Place a check in the blank after locating each of the following controls
NA
NA
Front governor pedal
Steering wheel
Directional shifter
Speed selector or shifter
Directional or transmission neutral lock
Transmission neutralizer switches (both)
All wheel drive (AWD) switch (if equipped)
Transmission Auto/Manual switch (autoshift only)
Differential lock pedal (if equipped)
Brake pedals
Parking brake lever (and release for C)
Loader lift and tilt controls
Attachment lever (mechanical controls)
Attachment switch for IT machine
Rear governor lever
Stabilizer controls
Boom lock lever
Boom lever
Swing lever or pedals
Stick lever
Bucket lever
E-stick/attachment control
Pattern changer lever (if equipped)
Pilot shutoff/hydraulic lock switch (if equipped)
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Student Materials
MODULE: ENGINE SYSTEMS
The purpose of this module is to have you locate and identify engine
components. You will also perform various systems tests for the engine.
This module is composed of two lessons.
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OBJECTIVES
1. Using the handout provided and the related service manual modules
locate the following components on a backhoe loader: fuel filter,
governor, fuel shutdown solenoid, priming (lift) pump, water
separator, oil filter, engine oil dipstick, engine oil pressure test port,
engine oil cooler (turbo models only), primary air filter, secondary
air filter, turbocharger (if equipped), air filter indicator, radiator,
water pump, Cold start advance solenoid, low idle adjustment screw,
high idle adjustment screw, and temperature regulator housing.
2. Identify on the provided handout the following components of the
Standadyne fuel injection pump: fuel pressure regulator valve,
distributor rotor assembly, automatic advance mechanism, fuel return
check valve, metering valve, transfer pump, flyweights, cam ring,
delivery valve, governor spring, plunger, roller,shoes, and orifice
check valve
3. Using the handout provided and the related service materials,
identify and record the engine tests specifications for engine high
idle, low idle, torque converter stall and engine oil pressure.
4. Using the handout provided and the related service manual modules,
perform engine tests for engine high idle, low idle, torque converter
stall and engine oil pressure.
5. (Optional) Using the handout provided and the related service
manual modules, perform engine tests additional checks may include
fuel injector testing, fuel bleed procedures, injection pump timing,
cooling system tests, valve lash adjustment, cylinder compression,
fuel transfer pressure and engine boost (turbo models).
6. As a homework assignment, read "Know Your Cooling System"
(form SEBD0518) and the O&M Manual on the cooling system.
Answer questions on the Cooling System worksheet. The answers
will be reviewed.
7. Identify at least 10 different engine components by matching the
component to its function in a quiz.
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Student Materials
Lesson: Engine Systems
BACKGROUND
INFORMATION
This lesson allows you to become familiar with identifying engine
system components.
This lesson allows you to become familiar with identifying system
components
Classroom Lab
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• Watch a slide presentation on the engine. If available, watch a video on
"The DPA Pump."
• While watching the slide presentation label the Fuel Pump and
Governor Component Checklists I and II.
Shop Lab
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Classroom Lab
❑
• Use the Engine Systems Checklist to locate the engine components on
the machine. Put a check in the blank next to each engine component
located.
• For homework, read "Know Your Cooling System" and refer to the
O&M Manual to complete the Cooling System Review Worksheet.
Suggested reference article:
SM 1/22/96 - SMCS 1395 " Mixing Caterpillar Long Life Coolant
with Conventional Cat Diesel Engine Antifreeze and/or Other
Commercially Available Antifreeze is Not Recommended"
NOTE: The instructor will identify key tests to be used when identifying
cooling system problems, discuss the need for coolant conditioners
and the correct water to antifreeze mix.
Materials Needed
❑
The DPA Pump - Video
Backhoe Loader Engine Systems Checklist
Fuel Pump and Governor Component Checklist
Cooling System Review Worksheet
Related service manual modules
1-Mechanics Tool Box
BCP BHL
8/15/01
- 25 -
Student Materials
Backhoe Loader Engine Checklist
Directions: Use this sheet to take notes during the presentation. During the engine lab, use this sheet
as a checklist when identifying components.
C
D
Model
Fuel filter
Fuel injection pump
Fuel Shutdown Solenoid
Priming (lift) pump )
Primary air filter
Secondary air filter
Oil filter
Water separator w/ fuel filter
Engine oil dipstick
Engine oil pressure test port
Engine oil cooler (turbocharged models only)
Turbocharger (if equipped)
Air filter indicator
Thermal starting aid / Start aid coil
Cold start advance solenoid
Radiator
Water pump
Temperature regulator housing
High idle adjustment screw
Low idle adjustment screw
Engine oil pressure test port
Plug for checking engine boost
Plugs for checking coolant temperatures
Shoes
Orifice Check Valve
Roller
Plunger
Governor Spring
Delivery Valve
Cam Ring
Flyweights
Transfer Pump
Metering Valve
Fuel Return Check Valve
Automatic Advance Mechanism
Distributor Rotor Assembly
Fuel Pressure Regulator Valve
Directions: Fill in blanks with the
correct letter
Fuel Pump and Governor
Component Checklist
L
M
B
A
N
G
E
H
I
C
D
J
"C" SERIES FUEL INJECTION PUMP
K
F
BCP BHL
8/15/01
- 26 Student Materials
BCP BHL
8/15/01
- 27 -
Student Materials
COOLING SYSTEM REVIEW WORKSHEET
Directions: The following are true or false. Enter T for true and F for false. If false, circle the word
or words that make the statement false and replace with a word or words that make the statement
correct.
1. When the engine is cold, the temperature regulator directs the flow of coolant to the
radiator and prevents the flow of coolant back to the water pump.
2. An increase in cooling system pressure will lower the boiling point of the coolant.
3. Rate of heat transfer is measured by the specific heat properties of a given liquid.
4. Water with a high chloride concentration is best for cooling system usage.
5. Coolant conditioner is not necessary in cooling systems that use distilled water.
6. A 40% concentration of antifreeze in water will protect the cooling system to
approximately -40o Fahrenheit.
7. When filling the cooling system, never fill faster than 5 gallons per minute.
8. An engine should never be operated with the temperature regulators removed.
9. When measuring the temperatures in the cooling system, the temperature in the radiator top
tank should be below the coolant boiling point.
10. The temperature of the water pump outlet must be approximately 8o to 20oF above the
temperature in the radiator top tank.
11. The most common cause of engine overcooling is temperature regulators stuck closed.
12. High sulfur fuel will cause increased engine wear during overcooling when the operating
temperature is below 175oF
13. Caterpillar Extended Life Coolant (ELC) or a commercial ELC that meets the Caterpillar
specification (EC-1) is the preferred antifreeze to use in Cat engines.
14. Commercial coolant/antifreeze that only meets the ASTM D3306 specification is
acceptable for use in Caterpillar engines.
15. The service life for the Caterpillar Extended Life Coolant (ELC) is for 5000 hours.
16. Caterpillar Extended Life Coolant (ELC) does not require a frequent addition of a
Supplemental Coolant Additive (SLC) only an extender needs to be added at 3000 hours or
every two years.
17. The effectiveness of the Caterpillar Extended Life Coolant (ELC) is reduced is it is mixed
with other types of antifreeze such as Caterpillar (DEAC).
BCP BHL
8/15/01
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Student Materials
Lesson: Engine System Tests
BACKGROUND
INFORMATION
Shop Lab
This lesson allows you to become familiar with typical engine system
tests
❑
❑
• Perform engine tests for engine high idle, low idle, torque converter
stall, and engine oil pressure. Enter specifications on the worksheet in
the classroom before performing the tests.
• Perform optional checks as required by the instructor: fuel injector
testing, fuel bleed procedures, injection pump timing, cooling system
tests, valve lash adjustment, cylinder compression, and engine boost
(turbo models).
Suggested reference articles:
TIB 3/14/90 - SMCS 1000 "Typical Engine Boost Readings for
Backhoes"
TIB 3/20/96 - SMCS 1050 "Inlet Manifold Pressure for
Turbocharged 3054 Engines in Backhoe Loader Applications"
SM 5/15/88 - SMCS 1062 "Increase Low Idle Setting to Decrease
Muffler Vibration"
SM 11/29/93 - SMCS 1251 " B-Series Backhoe Loader Fuel
Injection Pump and Injector Specifications"
SM 1/9/89 - SMCS 1251 " Rough Combustion ("Miss") At Low Idle
in 4.236 Perkins Engines"
Materials Needed
❑
3054 Engine In Chassis Test Sheet
Related service manual modules
Related engine specifications
1-6V3121 Multitach Group or 9U7400 Multitach II Group
1-1U5481 Pressure Gauge Group
1-1U5482 Pressure Hose and Adapter Group
1-4C8054 - Fitting to check fuel transfer pressure.
1-154-7151 - Tool for removing top cover to access fuel solenoid
1-6V4142 Nipple
1-8C7575 or 8C7576 adapter
1-Mechanics Tool Box
(Optional)
1-5P0957 Coolant and Battery Tester
1-4C6500 Digital Thermometer group
1-8T2700 Blowby/Air Flow Group
BCP BHL
8/15/01
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Student Materials
3054 Engine In Chassis Test Sheet
Machine Model
Name/Code
Machine PIN (S/N)
Transmission S/N
Engine S/N
S.M.H.
VISUAL CHECKS:
Dealer
Customer
Job
Application
Date
Serviceman
Fuel Level
Engine Oil level
Coolant level
Power Train Oil level
Oil/Coolant/Fuel Leaks
Air Filters and Precleaner Inspection
TEST
SPECS
Engine rpm:
ACTUAL
COMMENTS
High Idle
Low Idle
Torque Converter Stall Check - Full throttle with brakes
applied, and transmission engaged in:
Fourth Speed - Forward
Fourth Speed - Reverse
Inlet Manifold Pressure @ TC Stall RPM (reference only)
Fuel Transfer Pressure (High Idle)
Engine RPM at Torque Converter Stall [with temperature
regulator (thermostat) fully opened]
Radiator Top Tank Temperature ºC (ºF)
[Should be less than 43 ºC (110°F) over ambient]
Water Pump Inlet Temperature - ºC (ºF)
[Should be 4.5ºC to 11ºC (8°F to 20°F) less than Top Tank Temperature]
Engine Oil Pressure at:
max rpm
Idle
ADD. CHECKS:
Fuel Type
Engine Oil Type
Antifreeze Protection Temp
Coolant Conditioner %
Battery Voltage
Starter Cold Cranking Amps
Alternator Output Voltage
Note: Remove the engine oil pressure switch and install a pipe thread 8C7575 or 8C7576 adapter and
6V4142 test nipple to check engine oil pressure on B and C backhoes
On D backhoes, use the pre-installed pressure tap.
Use 4C8054 fitting to check fuel transfer pressure on the B & C backhoes
BCP BHL
8/15/01
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Student Materials
3054 Engine In Chassis Test Sheet
Machine Model
Name/Code
Machine PIN (S/N)
Transmission S/N
Engine S/N
S.M.H.
VISUAL CHECKS:
Dealer
Customer
Job
Application
Date
Serviceman
Fuel Level
Engine Oil level
Coolant level
Power Train Oil level
Oil/Coolant/Fuel Leaks
Air Filters and Precleaner Inspection
TEST
SPECS
Engine rpm:
ACTUAL
COMMENTS
High Idle
Low Idle
Torque Converter Stall Check - Full throttle with brakes
applied, and transmission engaged in:
Fourth Speed - Forward
Fourth Speed - Reverse
Inlet Manifold Pressure @ TC Stall RPM (reference only)
Fuel Transfer Pressure (High Idle)
Engine RPM at Torque Converter Stall [with temperature
regulator (thermostat) fully opened]
Radiator Top Tank Temperature ºC (ºF)
[Should be less than 43 ºC (110°F) over ambient]
Water Pump Inlet Temperature - ºC (ºF)
[Should be 4.5ºC to 11ºC (8°F to 20°F) less than Top Tank Temperature]
Engine Oil Pressure at:
max rpm
Idle
ADD. CHECKS:
Fuel Type
Engine Oil Type
Antifreeze Protection Temp
Coolant Conditioner %
Battery Voltage
Starter Cold Cranking Amps
Alternator Output Voltage
Note: Remove the engine oil pressure switch and install a pipe thread 8C7575 or 8C7576 adapter and
6V4142 test nipple to check engine oil pressure on B and C backhoes
On D backhoes, use the pre-installed pressure tap.
Use 4C8054 fitting to check fuel transfer pressure on the B & C backhoes
BCP BHL
8/15/01
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Student Materials
MODULE: ELECTRICAL SYSTEM
The purpose of this module is to make the student locate and identify
electrical system components. Students will also learn how to use the
electrical system schematic to locate components and to trace the starting
and charging circuit. Systems tests for the electrical system will also be
performed by each student. The module is composed of two labs with a
review quiz.
OBJECTIVES
❑
❑
❑
❑
❑
1. Use the electrical schematic and the provided handout to locate (on
the schematic and on the machine) and determine the part number of
the following electrical components: starter motor, alternator,
battery, fuse holder (use main fuse panel or keystart fuse), engine oil
pressure switch, coolant temperature switch, coolant temperature
sender, power train oil temperature sender (converter), fuel level
sender, engine shutdown solenoid, key start switch , start relay, start
aid switch, start aid coil
2. Using the provided service literature perform tests for the battery,
alternator, and starter on the machine using a voltmeter and clamp on
ammeter.
3. Using the electrical schematic and the provided handout. Draw and
numerically code the wires to correctly connect the components of
the starting and charging system.
4. Using the electrical schematic, complete a quiz related to
information found on the schematic and the shop labs.
5. (Optional) Using the provided service literature, demonstrate the
function of the engine shutdown solenoid and start aid switch.
BCP BHL
8/15/01
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Student Materials
Lesson: Electrical System
BACKGROUND
INFORMATION
Classroom Lab
This lesson allows you to become familiar with locating electrical system
components on the machine and in using the machine electrical
schematic.
❑
❑
• View a slide presentation on the starting and charging system.
• Use the electrical schematic and to locate and identify the listed
electrical components on the Electrical System Checklist. Record the
schematic coordinates, part number and machine location in the
provided blanks.
NOTE: The instructor will discuss how to use the electrical schematic
for troubleshooting (color coding, switch specification chart), and how
to locate components on the machine.
Shop Lab
❑
Classroom Lab
❑
• Use the checklist to locate the engine and electrical components on the
machine. Put a check in the blank next to each engine component
located or circle the electrical component location letters recorded
previously.
• Use the provided electrical schematic and the Starting and Charging
System Worksheet. Draw and numerically code the wires to correctly
connect the components of the starting and charging system.
NOTE: Depending on which electrical schematic is used, a resistor may
have to be added to the schematic and the alternator ground
modified.
Materials Needed
❑
C Series Electrical System Checklist
C Series Starting and Charging System Sheet
C Series Machine electrical schematic
D Series Electrical System Checklist
D Series Starting and Charging System Sheet
D Series Machine electrical schematic
1-Mechanics Tool Box
BCP BHL
8/15/01
- 33 -
Student Materials
C Series - Electrical System Checklist
Directions: During a lab exercise, use this sheet as a checklist when identifying components on the
machine and for recording information from the electrical schematic.
Machine
Location
Part No.
Schematic
Location Parts Manual Description
Schematic Description
Starter motor
Alternator
Battery
Keystart fuse
Engine oil pressure switch
Power train oil temperature
sender (converter)
Fuel level sender
Engine shutdown solenoid
Key start switch
Start relay
Start aid switch
Thermal start (Start aid) coil
Cold start advance solenoid
5th gear lockout (Override
disable / if equipped)
Power shift control (if equippedECM)
Ride control relay (if equipped)
BCP BHL
5/1/00
- 34 -
Student Materials
"D" Series - Electrical System Checklist
Directions: During a lab exercise, use this sheet as a checklist when identifying components on the
machine and for recording information from the electrical schematic.
Machine
Location
Part No.
Schematic
Location Parts Manual Description
Schematic Description
Starter motor
Alternator
Battery
Keystart fuse
Engine oil pressure switch
Power train oil temperature
sender (converter)
Fuel level sender
Engine shutdown solenoid
Key start switch
Start relay
Start aid switch
Thermal starting aid coil
Cold start advance solenoid
Auto/Manual switch (if
equipped)
Autoshift control (if equipped ECM)
Ride control relay (if equipped)
Backhoe shutoff switch (if
equipped)
15A
10A
25A
CAB RELAY
MAIN
RELAY
112-PU
ACCESSORY RELAY
104-YL
STARTER
S
BAT
MOTOR
MTR
G
POS NEG
POS NEG
SHUTTLE
CONTROL
XSMN LOCK
PK BRK SW
BK UP ALARM
BK UP ALARM
KEY SW
REV SOLENOID
FWD SOLENOID
REV SOL RTN
FWD SOL RTN
XSMN B+
XSMN GROUND
START RELAY
202-BK
15 A
KEY START FUSE
RD-00
START
RELAY
TO DIODE BLOCK
ASSEMBLY
START
AID SW
P
IG
OFF
ST
ACC
ON
COLD START
ADVANCE
SOLENOID
KEY START
SWITCH
TACH
ENGINE
SHUTDOWN
SOLENOID
START AID
COIL
S
B
C
R
A
ALTERNATOR
°T
E
L
- 35 -
COLD START
TEMP SW
B+
309-GY
Directions: Use either RENR2854 or SENR1276 electrical schematic to complete this schematic. Label wires.
C Series Starting and Charging System for Emissions Engine Worksheet
BCP BHL
8/15/01
Student Materials
TO FRONT
LIGHTING
RELAY
FUSE RELAY BLOCK 1
5A
KEY START
TO FUSES
20A
START
RELAY
MAIN
RELAY
A
C
A
C
A
C
A
C
THERMAL START
AID
15 A
POS NEG
BATTERY
GROUND
FORWARD SOL. RETURN
REVERSE SOL. RETURN
FORWARD SOL. OUT
REVERSE SOL. OUT
START RELAY COIL. OUT
KEY START SW. TO BAT.
NEUTRALIZER SW. TO BAT
PARK BRAKE ALARM OUT
PARK BRAKE SW. TO GND
NEUTRAL LOCK SW. TO GND
POS NEG
CBL RD-00
.
1
2
3
4
5
6
7
8
9
10
11
12
101-RD
SHUTTLE
CONTROL
202-BK
°T
1
2
COLD START
TEMP SW.
309-GY
ACTION LAMP
GROUP
A
B
1
2
3
4
START
AID SW.
TACH.
COLD START
ADVANCE
SOLENOID
ALTERNATOR
C
S
B
R
KEY START
SWITCH
ON
ST
OFF
THERMAL
STARTING
AID
FUEL
SHUTDOWN
SOLENOID
ALT
B+
1 2 3
L IG P
- 36 -
START RELAY
ENGINE FUEL
10A
TRANSMISSION
10A
TO FUSES
FUSE RELAY BLOCK 2
TO FUSES
CAB
RELAY
TO HVAC RELAY
TO RR LIGHTING RELAY
TO FUSES
BAT
S
MOTOR
ATTACHMENT
RELAY
STARTER
MTR
G
Directions: Use the machine electrical schematic to complete this schematic. Label all wires.
D Series Starting and Charging System Worksheet
BCP BHL
5/1/00
Student Materials
BCP BHL
8/15/01
- 37 -
Student Materials
Lesson: Electrical System Tests
BACKGROUND
INFORMATION
Shop Lab
This lesson allows you to become familiar with typical on the machine
electrical system tests using a voltmeter and ammeter.
❑
• Perform the following electrical system test on the machine using a
voltmeter, clamp on ammeter, and battery analyzer:
batteries
alternator
starter
Refer to service magazine articles below which are in the 12-V and 24V
Electrical Systems handout for procedures.
a) Batteries - SM 6/20/88
b) Alternator - SM 5/4/87
c) Starter - SM 5/28/90
❑
• Demonstrate the function of the engine shutdown solenoid.
❑
• Perform start aid tests.
❑
• Perform optional checks as required by the instructor (i.e. - key start
switch, bucket kickouts). List the optional tests performed below:
- Key Start Switch - Service Magazine 3/27/89.
- Main Relay - Service Magazine 10/27/86 & 8/29/88.
- Check the diode for proper operation using a multimeter. (B only)
- Identify all relays behind side console on B Series machines
Materials Needed
❑
12-V and 24-V Electrical Systems - Student Reference Materials
Electrical System Tests Worksheet
1-6V7800 Multimeters or 9U7330 Fluke 87
1-8T0900 AC/DC Clamp- on Ammeter
1-127-8078 Battery Tester
1-Mechanics Tool Box
Optional
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
BCP BHL
8/15/01
- 38 -
Student Materials
Electrical System Tests Worksheet
I. Battery Test: Reference - Batteries - SM 6/20/88
Voltage
II. Starter Tests: Reference - Starter - SM 5/28/90
Test A. Check battery voltage at the battery posts while cranking, or attempting to crank.
NOTE: Use the posts representing 12 or 24 Volts. Do not
check voltage on the cable post clamps.
1. Is voltage equal to or greater than what is shown in
Chart A?
Record Voltage ___________
. . . Yes - Go to Test B.
Chart A-Typical System Voltage During
Cranking Versus Ambient Temperature
-23°C To-7°C
(-10°F To 20°F)
-7°C To 10°C
(20°F to 50°F)
10°C To 27°C
(50°F To 80°F)
24 Volt
System
12V to 16V
14V to 18V
16V to 20V
12 Volt
System
6V to 8V
7V to 9V
8V to 10V
Temp.
Test B. Measure starter motor voltage from TP4 to TP5 while cranking, or attempting to crank.
1. Is voltage equal to or greater than that shown in Chart
A?
Record Voltage ___________
. . . Yes - Batteries and starter cables down to motor are
electrically within specifications. Go to Test C.
. . . No - Voltage drop (loss) between batteries and starter
is too great. Go to next step.
NOTE: For this exercise, assume your answer is "NO"
and then perform the next step. Enter results in CHART
B.
2. Measure voltage drops in cranking circuit per Chart B.
Are all voltages within specifications?
. . . Yes - Check engine. Go to Test C.
. . . No - Repair and/or replace faulty electrical
component .
Chart B-Maximum Allowable System
Voltage Drops During Cranking
Absolute Maximum
Voltage Reading
Circuit
24V
12V
Batt. Pos. Post to Starter
0.5V
0.3V
Pos. Post (TP10 to TP6)
Batt. Neg. Post to Starter
1.4V
0.7V
Neg. Post (TP7 to TP5)
Drop Across Only
1.0V
.5V
Disconnect Switch
(TP8 to TP9)
Start Relay Contacts
0.8V
0.4V
(TP3 to TP6)
Solenoid Contacts
0.8V
0.4V
(TP6 to TP4)
III. Alternator Tests: Reference - Alternator - SM 5/4/87
Initial Amperage (step 4.)
Voltage (step 5)
Amperage (step 6)
BCP BHL
8/15/01
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Student Materials
Electrical System Tests Worksheet
I. Battery Test: Reference - Batteries - SM 6/20/88
Voltage
II. Starter Tests: Reference - Starter - SM 5/28/90
Test A. Check battery voltage at the battery posts while cranking, or attempting to crank.
NOTE: Use the posts representing 12 or 24 Volts. Do not
check voltage on the cable post clamps.
1. Is voltage equal to or greater than what is shown in
Chart A?
Record Voltage ___________
. . . Yes - Go to Test B.
Chart A-Typical System Voltage During
Cranking Versus Ambient Temperature
-23°C To-7°C
(-10°F To 20°F)
-7°C To 10°C
(20°F to 50°F)
10°C To 27°C
(50°F To 80°F)
24 Volt
System
12V to 16V
14V to 18V
16V to 20V
12 Volt
System
6V to 8V
7V to 9V
8V to 10V
Temp.
Test B. Measure starter motor voltage from TP4 to TP5 while cranking, or attempting to crank.
1. Is voltage equal to or greater than that shown in Chart
A?
Record Voltage ___________
. . . Yes - Batteries and starter cables down to motor are
electrically within specifications. Go to Test C.
. . . No - Voltage drop (loss) between batteries and starter
is too great. Go to next step.
NOTE: For this exercise, assume your answer is "NO"
and then perform the next step. Enter results in CHART
B.
2. Measure voltage drops in cranking circuit per Chart B.
Are all voltages within specifications?
. . . Yes - Check engine. Go to Test C.
. . . No - Repair and/or replace faulty electrical
component .
Chart B-Maximum Allowable System
Voltage Drops During Cranking
Absolute Maximum
Voltage Reading
Circuit
24V
12V
Batt. Pos. Post to Starter
0.5V
0.3V
Pos. Post (TP10 to TP6)
Batt. Neg. Post to Starter
1.4V
0.7V
Neg. Post (TP7 to TP5)
Drop Across Only
1.0V
.5V
Disconnect Switch
(TP8 to TP9)
Start Relay Contacts
0.8V
0.4V
(TP3 to TP6)
Solenoid Contacts
0.8V
0.4V
(TP6 to TP4)
III. Alternator Tests: Reference - Alternator - SM 5/4/87
Initial Amperage (step 4.)
Voltage (step 5)
Amperage (step 6)
BCP BHL
8/15/01
- 40 -
Student Materials
MODULE: POWER TRAIN
The purpose of this module is to have you locate and identify power train
system components. You will also learn how the transmission control
valve works and explain the function of their components. System tests
for the power train will also be performed by you. The module is
composed of four lessons, a case study and a quiz. One of the lessons is
optional.
OBJECTIVES
❑
❑
❑
❑
❑
1. On a schematic for the C Series machines, identify the following
power train hydraulic oil system components: filter, suction screen,
torque converter, transmission pump, main relief valve, AWD
solenoid valve, cold start relief valve, torque converter inlet relief
valve, transmission control valve, and transmission oil cooler.
Also, identify related pressure test ports: lube pressure, FORWARD
clutch pressure, REVERSE clutch pressure, pump supply pressure,
AWD clutch pressure, and torque converter outlet pressure.
2. On a schematic used in a quiz, identify the location, functions, and
relationships of test ports for pump supply pressure, clutch pressures,
torque converter inlet pressure, torque converter outlet pressure, and
lube pressure.
3. Locate the following power train hydraulic oil system components
and service points on the machine: fill tube, filter, suction screen,
torque converter housing, transmission directional control selector
lever, transmission control valve, torque converter inlet relief valve,
cold start relief valve ( if equipped), relief valve (C series), AWD
solenoid valve (if equipped) and transmission oil cooler and bypass
valve..
4. Using the appropriate service materials, identify and record on the
provided test sheet the specifications for the following power train
hydraulic oil system pressures: lube pressure, FORWARD clutch
pressure, REVERSE clutch pressure, pump supply pressure, AWD
clutch pressure, and torque converter outlet pressure.
5. Using the appropriate service manual module, locate the test location
and perform checks on the machine for the following power train
hydraulic oil system pressures: lube pressure, FORWARD clutch
pressure, REVERSE clutch pressure, pump supply pressure, AWD
clutch pressure, and torque converter outlet pressure.
BCP BHL
8/15/01
- 41 -
❑
❑
Student Materials
6. On a quiz identify the function of the following transmission control
valve components: (underdevelopment)
7. Using provided reference materials and handouts identify potential
system problems caused by malfunctioning components during a
classroom lab exercise. Record your results.
BCP BHL
8/15/01
- 42 -
Student Materials
Lesson: Power Train Hydraulic Component Identification
This lesson will help you gain familiarity with the machine and locate
components and service points.
BACKGROUND
INFORMATION
NOTE: Before operating the machine, a 10 hour or daily inspection should
have been completed which includes checking fluid levels as
specified in the Operation and Maintenance Guide.
Classroom Lab
Shop Lab
❑
❑
❑
❑
❑
• View a slide presentation on power train components
• On C Series Power Train Checklist, identify the following power train
hydraulic oil system components: filter, suction screen, torque
converter, transmission pump, main relief valve, AWD solenoid valve
(if equipped), cold start relief valve, torque converter inlet relief valve,
transmission control valve, and transmission oil cooler and bypass
valve.
• Remove side panels and/or cab floor plates as needed.
• Locate power train oil system components listed on Power Train
Components Checklist Record a check after locating each component.
With C Series Component Checklist I record the correct letter.
• Identify the pressure test locations: lube pressure, FORWARD clutch
pressure, REVERSE clutch pressure, AWD clutch pressure, pump
supply pressure, and torque converter outlet pressure. Record a check
after locating each test location
Suggested reference articles:
SM 1/31/94 - SMCS 3150 "Transmission Control Valve Changes on
Backhoe Loaders" B Series
TIB 1/12/94 - SMCS 3152 " Handling of 7T3130 Pin During Repair
or Servicing of Transmission Control Valve Group"
Materials Needed
❑
Operation and Maintenance Guide
Service Manual
Parts Book
Standard Power Train Component Checklists
C Series and D Series Power Train Component Checklists I & II
Mechanic's Tool Box and hand tools
BCP BHL
8/15/01
- 43 -
Student Materials
Standard Power Train Component Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab,
use this sheet as a checklist when identifying components and pressure test locations.
C
D
Model
Fill tube
Filter
Suction screen
Torque converter housing
Transmission directional control selector lever
Speed selector
Relief valve
Cold start relief valve
Torque converter inlet relief valve
Transmission control valve (if equipped)
Clutch solenoids for autoshift (if equipped)
AWD solenoid valve (if equipped)
Transmission oil cooler bypass valve
Transmission oil cooler
Test Locations:
Lube pressure
FORWARD clutch pressure
REVERSE clutch pressure
Pump supply pressure
Torque converter outlet pressure
Torque converter inlet pressure
AWD clutch pressure (if equipped)
BCP BHL
8/15/01
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Student Materials
C Series and D Series Power Train Component Checklist I
Directions: During a lab, use this sheet as a checklist when identifying components and pressure test
locations.
B
A
C
E
F
D
J
I
K
H
G
Identify Components and Test Ports
Filter
Main Relief Valve
Cold Start Relief Valve (C-Series Only)
Torque Converter Inlet Relief Valve
Transmission Control Valve
AWD Solenoid
Pump Supply Pressure Port
Forward Clutch Pressure Port
Reverse Clutch Pressure Port
Torque Converter Inlet Pressure Port
Torque Converter Outlet Pressure Port
7
6
5
B
1
D
C
A
7
AWD
All WHEEL DRIVE
E
TRANSMISSION
LUBE
POWER TRAIN
HYDRAULIC SYSTEM
F
4
2
H
G
J
I
F
R
3
6
5
- 45 -
4
3
2
1
Identify Test Ports
J
I
H
G
F
E
D
C
B
A
Identify Components
Directions: Fill in the blanks next to the numbers and
letters with the correct term.
C Series Power Train Component Checklist II
BCP BHL
8/15/01
Student Materials
BCP BHL
8/15/01
- 46 -
Student Materials
Lesson: Power Train System Tests
This lesson will allow you gain familiarity performing system checks,
using the Service Manual, and determining if the machine is operating to
specifications.
BACKGROUND
INFORMATION
NOTE: Before operating the machine, a 10 hour or daily inspection should
have been completed which includes checking fluid levels as
specified in the Operation and Maintenance Guide.
Shop Lab
❑
❑
❑
❑
❑
Materials Needed
❑
• Record pressure specifications from the service manual before going to
the shop.
Suggested reference articles:
SM 5/11/87 - SMCS 3000 "New Transmission Group; New
Transmission Relief Valve Adapter." Note: This is the only article
that has complete and understandable transmission pressure for all
backhoes up to the C-Series. On 4WD machines, you may see pump
supply pressure of 250 ± 15 psi. The service manuals tend to
provide incomplete information.
SM 7/25/88 - SMCS 3101 " Torque Converter Stall Specifications"
Series II and earlier
SM 7/25/88 - SMCS 3101 " Torque Converter Stall Speeds on
Backhoe Loaders" B Series
• Remove side panels and/or cab floor plates as needed.
• Perform a torque converter stall test with the transmission in THIRD
gear and at high idle. (See the Torque Converter Stall Test Sheet.)
- Test should also be done for REVERSE.
• Perform pressure checks for both directional clutches.
- Test at high and low idle, brakes on, directional shift lever in
NEUTRAL.
• Check torque outlet pressure and lube pressure. Optional: Check AWD
clutch pressure
Power Train Testing and Adjusting Service Manual Module
Backhoe Loader Transmission Test Sheets
Torque Converter Stall Test Handout
1-1U5481 Pressure Test Gauge Group
1-1U5482 Hose and Fitting Group
5-6V3965 Nipples
5-3J1907 O-rings
1-6V3121 Multi-tach Group or 9U7400 Multitach Group
2-Mechanic's Tool Boxes and hand tools
BCP BHL
8/15/01
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Student Materials
Backhoe Loader Transmission Test Sheet
Machine Model _______________________
Name/Code
________________________
Mach. S/N (PIN) _____________________
Trans. S/N
_________________________
Engine S/N
_________________________
S.M.U. ______________________________
Dealer __________________________________
Customer _______________________________
Job ____________________________________
Application ______________________________
Date ___________________________________
Serviceman ______________________________
VISUAL CHECKS
Oil Level
Oil Type
Oil Leaks
Air/H2O in Oil
_______
_______
_______
_______
Suction Screen
Oil Filter
Abrasives in Oil
Debris in Pan
_______
_______
_______
_______
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT
PRESSURE TEST
PRESSURES
LEVER
SPEC
LOW IDLE
ACTUAL
Pump Supply
N
Forward Clutch
F
Reverse Clutch
R
Lube
N
T. C. Inlet
N
XXXX
T. C. Outlet (T.C. Stall)
4th/Fwd
XXXX
AWD Clutch Pressure
N
PRESSURE TEST
SHIFT
LEVER
T. C. Outlet (T. C. stall)
4th/FWD
T. C. Outlet (T. C. stall)
4th/REV
SPEC
HIGH IDLE
ACTUAL
XXXX
XXXX
ENGINE SPEED
SPEC
ACTUAL
NOTE: Depending on which service publication is used, specifications may not always be provided
for both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As
the machine attempts to drive through the brakes, the machine will not move.
BCP BHL
8/15/01
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Student Materials
Backhoe Loader Transmission Test Sheet
Machine Model _______________________
Name/Code
________________________
Mach. S/N (PIN) _____________________
Trans. S/N
_________________________
Engine S/N
_________________________
S.M.U. ______________________________
Dealer __________________________________
Customer _______________________________
Job ____________________________________
Application ______________________________
Date ___________________________________
Serviceman ______________________________
VISUAL CHECKS
Oil Level
Oil Type
Oil Leaks
Air/H2O in Oil
_______
_______
_______
_______
Suction Screen
Oil Filter
Abrasives in Oil
Debris in Pan
_______
_______
_______
_______
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT
PRESSURE TEST
PRESSURES
LEVER
SPEC
LOW IDLE
ACTUAL
Pump Supply
N
Forward Clutch
F
Reverse Clutch
R
Lube
N
T. C. Inlet
N
XXXX
T. C. Outlet (T.C. Stall)
4th/Fwd
XXXX
AWD Clutch Pressure
N
PRESSURE TEST
SHIFT
LEVER
T. C. Outlet (T. C. stall)
4th/FWD
T. C. Outlet (T. C. stall)
4th/REV
SPEC
HIGH IDLE
ACTUAL
XXXX
XXXX
ENGINE SPEED
SPEC
ACTUAL
NOTE: Depending on which service publication is used, specifications may not always be provided
for both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As
the machine attempts to drive through the brakes, the machine will not move.
BCP BHL
8/15/01
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Student Materials
TORQUE CONVERTER STALL CHECK HANDOUT
The following information describes the steps in performing a Torque
Converter Stall Speed check and provides additional troubleshooting
information. Torque Converter Stall Speed is a check to help determine
poor engine, torque converter, or transmission performance.
NOTE: Before performing a Torque Converter Stall test move the
machine to an open area and make sure the brakes are operating properly.
Torque Converter Stall Check
• Connect a multi-tach to the engine.
• Warm up machine to normal operating temperatures.
• Run at high idle.
Note the high idle rpm. If the high idle rpm differs significantly from
the high idle specification, then an engine problem may exist.
• Apply the brakes.
• Shift the transmission into FORWARD and a high speed range. The
multitach will show the converter stall speed.
If full load rpm is within specification and the torque converter stall
speed is high, the torque converter is probably slipping.
Stall in the other direction and a different speed range before
assuming the torque converter is at fault.
If all the engine checks are within specifications and the converter
stall speed is low when compared to full load rpm, overheating will
probably occur and the components of the torque converter are
rubbing. The temperature of the torque converter oil must be
observed and not allowed to overheat.
• Shift the transmission to FORWARD and a speed starting with the
higher speed ranges and moving to the lower speed ranges.
• Run the engine at full throttle.
• Apply the brakes to stop the power train shaft and gear rotation. Note
the engine speed for each speed range. Do the same for REVERSE.
The torque converter stall speed should be within specifications for
each speed and direction combination selected.
BCP BHL
8/15/01
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Student Materials
If the converter stall speed is within specification for some speed and
direction combinations and not for others, the transmission clutch is
slipping. For the combinations out of specification, the torque
converter stall speeds will be high. On some machines, clutch
slippage can be easily identified by noting if the drive wheels or tracks
are stationary and the universal joint or coupling is rotating while in
torque converter stall. Checks of P1 and P2 pressure for each speed
and direction selected can confirm transmission clutch slippage.
NOTE: The 631E, 637E and 769C are exceptions to the rule. These
machines have a low disc plate stack height which will allow slippage
when the piston bottoms out at the end of the piston travel. The drive
shaft will rotate even though the torque converter is stalled. Pressure
readings will still be good.
If all the torque converter stall readings are out of specification, then
the torque converter or engine is probably at fault.
Additional Torque Converter Checks
• Leakage may also be a necessary check for some machines.
Scavenge Pump Check
• Stall the torque converter for 1 to 2 minutes using a stop watch.
• Turn off the machine.
• Remove the torque converter drain plug and drain into an empty half
barrel.
• The maximum leakage should be between .5 to 1.5 gallons.
Converter Leakage Check
• With the drain plug removed, repeat the torque converter stall test for
30 seconds.
• Allow the oil to drain into a empty barrel.
• Determine the leakage per minute and then check with the technical
communicator for the maximum leakage permitted for the machine
being tested. This specification is not commonly published.
If leakage is excessive, the torque converter is at fault.
NOTE: This test cannot be done on machines equipped with
automotive- type torque converters and also on some machines where the
torque converter is part of the transmission.
BCP BHL
8/15/01
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Student Materials
Engine Check
• Check engine set point to determine full load rpm.
NOTE: On some engines, set point cannot be checked. As a "rule of
thumb," finding engine rpm where maximum boost occurs can also
determine full load rpm and if the governor is working correctly. The
rule may not be applicable for all engines.
If the full load rpm is not correct, adjusting high idle may bring the
full load rpm back within specifications. Adjustments to the high idle
must be within the high idle specification tolerance range.
If, after adjusting high idle, full load rpm is not within specifications
the engine rack setting may be misadjusted.
If the high idle is too high and the rack setting is correct, a torque
converter problem might exist or the governor spring is suspect
causing an increase in the percentage of speed droop.
If high idle is low, poor engine performance may be indicated.
Also, check the governor control linkage for correct adjustment.
Knowing what set point is (or where maximum boost occurs) along
with high idle rpm will indicate if the engine is performing within
specifications. If any of these checks are below specification, the
problem may be insufficient power from the engine.
NOTE: Factory fuel or fuel used in colder climates is diluted with
kerosene. These fuels will not produce as many BTU's, so stall
readings will be lower.
On some engines, specifications for set point or boost may not be
available. The only easy checks of engine performance then are high
and low idle.
BCP BHL
8/15/01
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Student Materials
Power Train Case Study
DIRECTIONS
Students should use the service manual and class notes to complete the
exercise. Have the students answer the questions on the Power Train
Troubleshooting Worksheets. Discuss the exercise with the students after
they have had time to answer the exercise questions.
SITUATION
The following exercise is based on a possible field complaint.
The operator of a 426D backhoe loader reported to his supervisor that the
machine performance was poor when using the loader. He told the
supervisor that the machine wasn't able to push loads while filling as well
as it was a couple of weeks ago .
BCP BHL
8/15/01
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Student Materials
Power Train System Troubleshooting Worksheet
ISOLATE PROBLEM
Gather Information
The first step in in a troubleshooting process is to gather information
before starting any work on the machine. If possible talk to the operator.
Also, check the repair history of the machine and the Caterpillar Service
Information Retrieval System (SIRS). List at least three questions you
would ask an operator to help in determining a problem exists? Possible
answers:
Verify
Verify the problem exists. Operate the machine to duplicate the problem,
preferably under similar operating conditions. Compare the operation to
a known good machine. Perform sensory checks such as looking,
listening, touching, smelling to verify a problem exists.
Perform Visual
Inspection
When troubleshooting always perform a visual inspection first. Look for
the obvious. List at least three typical items that should be inspected
during a visual inspection for. Possible answers:
State Problem
After verifying a problem exists, state in your own words what the
problem is. Caution: Do not identify the solution. Possible answer:
BCP BHL
8/15/01
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Student Materials
Power Train System Troubleshooting Worksheet (cont'd)
LIST POSSIBLE
FAULTS
Devise tests and
determine root cause
The next step in the process is to list all of the possible causes of the
problem. Identify all systems and components that could be causing the
problem, including the least obvious. List at least four things that could
be checked. Possible answers:
Now, create a list of tests should be performed and describe what the
tests would determine. Prioritize the tests as to which sequence they
should be performed in. As a general rule, always do the easiest tests
first. Also, list diagnostic tooling required. Identify at least four tests to
perform. (NOTE: the rankings are only suggested.)
Tooling needed:
BCP BHL
8/15/01
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Student Materials
Power Train System Troubleshooting Worksheet (cont'd)
Tooling needed:
Tooling needed:
Tooling needed:
Tooling needed:
Tooling needed:
REPAIR FAULT
After isolating the component, which you suspect from your test results is
causing the problem, either adjust or replace the component.
BCP BHL
8/15/01
- 56 -
Student Materials
Power Train System Troubleshooting Worksheet (cont'd)
Circle the best response:
If during your tests you discovered that the both the Reverse clutch
pressure and the Forward clutch pressure were 1450 kPA (210 psi),
which component would you change?
1. Main relief valve
2. Cold start relief valve
3. Implement pump
4. Both clutches
5. None of the above
If during your tests you discovered that the torque converter stall rpm
was high in both directions and engine high idle was set correctly.
Which of the following would you least likely expect to be the cause of
the problem?
1. Type of fuel
2. Transmission pump
3. The main relief valve
4. The Forward directional clutch
5. The power train oil level
VERIFY REPAIR
After completing the repair, always verify the machine is operating
correctly. List at least three things you would do to make sure the repair
was done correctly.
1.
2.
3.
4.
Don't forget to fill the service report after completing the job.
BCP BHL
8/15/01
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Student Materials
MODULE: AUTOSHIFT AND POWER SHIFT
TRANSMISSIONS
The purpose of this module is to have you locate and identify power train
system components. You will also learn how the power shift
transmission control valve and the power shift control module work and
explain the function of their components. The autoshift feature will also
be covered. System tests for the power train will also be performed by
you. The module is composed of two lessons, a case study and a quiz.
One of the lessons is optional.
OBJECTIVES
❑
1. On a schematic, identify the following power train hydraulic oil
system components: transmission control valve, filter, oil cooler,
pump suction screen, torque converter, torque convertor inlet relief
valve, lubrication circuit, cooler bypass valve and flow control valve.
❑
2. On a schematic used in a quiz, identify the location , functions, and
relationships of test ports for pump supply pressure, clutch pressures,
torque convertor inlet pressure, torque converter outlet pressure, and
lube pressure.
❑
3. Locate the following power train hydraulic oil system components
and service points on the machine: fill tube, filter, suction screen,
torque converter housing, transmission directional control selector
lever, relief valve, cold start relief valve, torque converter inlet relief
valve, AWD solenoid valve (if equipped), transmission oil cooler and
bypass, solenoid no. 1 - Forward High , solenoid no. 2 - Reverse,
solenoid no. 3 - Forward Low, solenoid no. 4 - speed clutch no. 1,
solenoid no. 5 - speed clutch no. 2, and solenoid no. 6 - speed clutch
no. 3.
❑
4. Using the appropriate service materials, identify and record on the
provided test sheet the specifications for the following power train
hydraulic oil system pressures: pump supply pressure, torque
converter outlet pressure, torque converter inlet pressure, lube
pressure, FORWARD HIGH clutch , REVERSE clutch, FORWARD
LOW clutch, speed clutch no. 1, speed clutch no. 2 , speed clutch no.
3, and AWD clutch pressure (if equipped). Record a check after
locating each test location.
BCP BHL
8/15/01
- 58 -
❑
❑
❑
❑
❑
❑
Student Materials
5. Using the appropriate service manual module, locate the test location
and perform checks on the machine for the following power train
hydraulic oil system pressure: pump supply pressure, torque
converter outlet pressure, torque converter inlet pressure, lube
pressure, FORWARD HIGH clutch , REVERSE clutch, FORWARD
LOW clutch, speed clutch no. 1, speed clutch no. 2 , speed clutch no.
3, and AWD clutch pressure (if equipped).
6.
On a quiz identify the function of the following power shift
transmission components: (Underdevelopment).
7. Using provided reference materials and handouts, identify potential
system problems caused by malfunctioning components during a lab
exercise.
8. Locate the electronic power shift components (if equipped) and test
points on the machine.
9. Using the provided handout, operate a machine equipped with a
power shift transmission and determine the correct machine status
for the conditions given.
10. Using the appropriate service manual module, perform checks on the
machine for the autoshift transmission control system (if equipped)
using a PC equipped with ET.
BCP BHL
8/15/01
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Student Materials
Lesson: Power shift Transmission Hydraulic Component
Identification
BACKGROUND
INFORMATION
This lesson will help you gain familiarity with the machine and locate
components and service points.
NOTE: Before operating the machine, a 10 hour or daily inspection should
have been completed which includes checking fluid levels as
specified in the Operation and Maintenance Guide.
Classroom Lab
Shop Lab
❑
❑
❑
❑
❑
• View a slide presentation on power train components
• Color in the shift condition provided by the instructor.
• Remove side panels and/or cab floor plates as needed.
• On the machine use Power Shift Transmission Checklist and identify
the following power train hydraulic oil system components: fill tube,
filter, suction screen, torque converter housing, transmission directional
control selector lever, relief valve, cold start relief valve, torque
converter inlet relief valve, AWD solenoid valve (if equipped),
transmission oil cooler any bypass valve, solenoid no. 1 - Forward
High, solenoid no. 2 - Reverse, solenoid no. 3 - Forward Low, solenoid
no. 4 - speed clutch no. 1, solenoid no. 5 - speed clutch no. 2, and
solenoid no. 6 - speed clutch no. 3. Record a check after locating each
test location.
• Identify the pressure test locations: pump supply pressure, torque
converter outlet pressure, torque converter inlet pressure, lube pressure,
FORWARD HIGH clutch , REVERSE clutch, FORWARD LOW
clutch, speed clutch no. 1, speed clutch no. 2 , speed clutch no. 3, and
AWD clutch pressure (if equipped). Record a check after locating each
test location.
Materials Needed
❑
Operation and Maintenance Guide
Service Manual
Parts Book
Power Shift/Autoshift Component Checklist
Autoshift Operations
Power shift/Autoshift Power Train Components worksheet
Autoshift Electronic Control Component Checklist
Mechanic's Tool Box and hand tools
BCP BHL
8/15/01
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Student Materials
Power Shift/Autoshift Transmission Component Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab,
use this sheet as a checklist when identifying components and pressure test locations.
D
Model
Solenoid No. 1 - FORWARD HIGH
Solenoid No. 2 - REVERSE
Solenoid No. 3 - FORWARD LOW
Solenoid No. 4 - speed clutch No. 1
Solenoid No. 5 - speed clutch No. 2
Solenoid No. 6 - speed clutch N.o. 3
All wheel drive solenoid (if available)
Pressure regulator valve
Torque converter inlet relief valve
Transmission speed sensor
Electronic Control Module (ECM)
Electronic Technician (ET) connector
Diagnostic indicator lamp
Test Locations:
Pump supply pressure
FORWARD HIGH clutch pressure
FORWARD LOW clutch pressure
Speed clutch No. 1
Speed clutch No. 2
Speed clutch No. 3
REVERSE pressure tap
Lube pressure tap
All-Wheel Drive clutch pressure tap (if available)
BCP BHL
5/1/00
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Student Materials
AUTOSHIFT OPERATION
Locate and identify the following components before operating the machine:
Key start switch
Shift lever
Throttle
Brake pedal
Steering wheel
Horn
NOTE: Connect the ET tool to the service connector to determine the gear the machine shifts to.
Before starting the machine: FASTEN SEAT BELT
1. Place the auto/manual switch in the MANUAL position and the neutralizer switch in the OFF
position. Place the shift lever in FIRST SPEED FORWARD. Start the machine.
Did the machine start?
Yes
No
2. Move the shift lever to the NEUTRAL position. Start the machine.
Did the machine start?
Yes
No
Drive machine along test range:
3. Shift the transmission through all FORWARD and REVERSE gears.
Did the transmission shift through all gears?
Yes
No
4. When driving forward in FIRST SPEED, shift to REVERSE.
Did the transmission shift to FIRST SPEED REVERSE?
Yes
No
Stop the machine
5. When in FIRST SPEED FORWARD, keep the brake pedal depressed and depress the
accelerator pedal.
Did the engine pull against the brake?
Yes
No
BCP BHL
5/1/00
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Student Materials
6. When in FIRST SPEED FORWARD, keep the accelerator pedal depressed and depress and
hold the neutralizer switch momentarily.
Yes
Did the engine pull against the brake?
Did the transmission go to NEUTRAL?
No
No
Yes
Drive the machine along test range:
7. Drive forward in THIRD SPEED, press the DOWNSHIFT switch momentarily.
Did the transmission shift down?
Yes
No
8. Drive forward in SECOND SPEED, press the DOWNSHIFT switch momentarily.
Did the transmission shift down?
Yes
No
Stop the machine. Place the auto/manual switch in the AUTO position.
9. Shift the transmission through all FORWARD and REVERSE gears.
No
Yes
Did the transmission shift through all gears?
Drive machine along test range:
10. When driving forward in FIRST SPEED, shift to REVERSE.
Did the transmission shift to FIRST REVERSE?
Yes
No
.
To what speed did the transmission shift?
11. When driving FORWARD in SECOND SPEED, remove foot from accelerator.
Did the transmission shift to FIRST FORWARD?
To what speed did the transmission shift?
Yes
No
.
12. When driving forward in FOURTH SPEED, remove foot from accelerator.
Did the transmission shift down?
Yes
No
.
To what speed did the transmission shift?
13. Drive FORWARD in THIRD SPEED, press the downshift switch momentarily.
Did the transmission shift down?
Yes
Return machine to starting point for next student.
No
K
J
I
H
G
F
E
D
C
B
A
Identify Components:
Directions: Fill in the blanks next to
the letters with the correct term.
I
PUMP SUPPLY
F
SUCTION
SCREEN
NEUTRAL LOCK SWITCH
AUTO/MANUAL SWITCH
RIDE CONTROL SWITCH
J
Power Shift / Autoshift Power Train Components
2
LUBE
TRANSMISSION
LUBE
5
3
6
ORIFICE
B
R
E
2
A
DATA LINK
SERVICE PORT
H
FORWARD
HI
1
LO
1
TORQUE
CONVERTER
OUTLET
TORQUE
CONVERTER
INLET
SOLENOID
VALVE
3
PARKING BRAKE SWITCH
C
4
REGULATED
PRESSURE
G
RIDE CONTROL DISABLE
D
DOWNSHIFT/NEUTRALIZER SWITCH
BCP BHL
8/15/01
- 63 Student Materials
LOADER LOCK
RELAY
KEY START
SWITCH
BACKUP
ALARM
START
RELAY
CONTROL
LEVER
SHIFT
(AETC)
CONTROL
TRANSMISSION
ELECTRONIC
AUTOSHIFT
DIAGNOSTIC
INDICATOR and
DATA LINK
SERVICE PORT
RIDE CONTROL
RELAY
PARK BRAKE
ALARM RELAY
SPEED CLUTCH 3
No. 6 SOLENOID
SPEED CLUTCH 2
No. 5 SOLENOID
SPEED CLUTCH 1
No. 4 SOLENOID
FORWARD LOW
No. 3 SOLENOID
REVERSE
No. 2 SOLENOID
FORWARD HIGH
No. 1 SOLENOID
- 64 -
DOWNSHIFT/
NEUTRALIZER SWITCH
RIDE CONTROL
DISABLE SWITCH
AUTO/MANUAL
SWITCH
TRANSMISSION OUTPUT
SPEED SENSOR
NEUTRAL LOCK
SWITCH
PARKING BRAKE
SWITCH
RIDE CONTROL
SWITCH
CAT DATA LINK
AUTOSHIFT TRANSMISSION CONTROL SYSTEM
Directions: Record a check next to each component after locating it on the machine. Or if using multiple machines, record the model
number. All components may not be on every machine. NOTE: Power shift transmissions are the same except for the software.
Autoshift Electronic Control Component Checklist
BCP BHL
8/15/01
Student Materials
BCP BHL
5/1/00
- 65 -
Student Materials
Power shift / Autoshift Transmission System Pressure Tests
This lab measures your ability to perform the Autoshift transmission tests
on Backhoe Loaders.
BACKGROUND
INFORMATION
Shop Lab
❑
• Enter the correct specifications from the service manual module on the
lab worksheets.
❑
• Using the procedures in the correct service manual module, test each
pressure on the machine and record the results using Dataview. Use ET
to verify which gear the machine shifts to and to verify other
parameters.
❑
MATERIALS
NEEDED
❑
• Review results with the instructor.
Transmission test sheets
Service manual module
Pen or pencil
PC with Dataview, Electronic Technician, and SIS software
5-4C6819 or 1434065 Pressure Sensors
1-9U5140 Photo Tach
Assorted Dataview cables
Electronic Technician
Dataview
Communication adapter and cables
5-6V3965 Nipples
5-3J1907 O-rings
Mechanic's Tool Boxes and hand tools
1-1U5481 Pressure Test Gauge Group (If not using Dataview)
1-1U5482 Hose and Fitting Group (If not using Dataview)
1-9U7400 Multitach Group (If not using Dataview)
BCP BHL
5/1/00
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Student Materials
Power Shift/Autoshift Transmission System Pressure Tests
Machine Model ________________________
Name/Code ____________________________
Machine PIN (S/N) ______________________
Transmission S/N ______________________
Engine S/N ____________________________
S.M.H. ________________________________
Dealer ____________________________
Customer__________________________
Job ______________________________
Application ________________________
Date______________________________
Serviceman ________________________
ENGINE SPEED
PRESSURE TEST
LOW IDLE
SPEC
Pump Pressure
Lube Pressure
All Wheel Drive Pressure
Torque Converter Inlet (optional)
FORWARD HIGH
Torque Converter Outlet (at T.C. Stall)
REVERSE
FORWARD LOW
Speed Clutch 1
Speed Clutch 2
Speed Clutch 3
Torque converter Stall RPM
Comments:
ACTUAL
HIGH IDLE
SPEC
ACTUAL
BCP BHL
5/1/00
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Student Materials
Power Shift / Autoshift Transmission System Pressure Tests
(continued)
ENGINE SPEED
PRESSURE TEST
LOW IDLE
SPEC
Pressure difference between Pump and
FORWARD LOW
Pressure difference between Pump and
FORWARD HIGH
Pressure difference between Pump and
REVERSE
Pressure difference between Pump and Clutch 1
Pressure difference between Pump and Clutch 2
Pressure difference between Pump and Clutch 3
Pressure difference between Pump and
All Wheel Drive Clutch
Comments:
ACTUAL
HIGH IDLE
SPEC
ACTUAL
BCP BHL
8/15/01
- 68 -
Student Materials
Autoshift Transmission Case Study
DIRECTIONS
You may use the service manual and class notes to complete the case
study. Answer the questions on the Case Study Worksheets. Discuss the
case study with the instructor after you have answered the case study
questions.
The following exercise is based on a possible field complaint.
SITUATION
The operator of a backhoe loader equipped with an Autoshift
Transmission reported to his supervisor that the machine had a
transmission problem. He told the supervisor that the Autoshift feature
was not working. The only gears available were FIRST FORWARD and
THIRD FORWARD. The machine would not move in REVERSE.
BCP BHL
5/1/00
- 69 -
Student Materials
Autoshift Power Train System Troubleshooting Worksheet
ISOLATE PROBLEM
Gather Information
Verify
Perform Visual
Inspection
The first step in in a troubleshooting process is to gather information
before starting any work on the machine. If possible talk to the operator.
Also, check the repair history of the machine and the Caterpillar Service
Information Retrieval System (SIRS). List at list three questions you
would ask an operator to help in identifying a problem exists? Possible
answers:
Verify the problem exists. Operate the machine to duplicate the problem,
preferably under similar operating conditions. Compare the operation to
a known good machine. Perform sensory checks such as looking,
listening, touching, smelling to verify a problem exists.
When troubleshooting always perform a visual inspection first. Look for
the obvious. List at least three typical items that should be inspected
during a visual inspection for. Possible answers:
After verifying a problem exists, state in your own words what the
problem is. Caution: Do not identify the solution. Possible answer.
State Problem
BCP BHL
5/1/00
- 70 -
Student Materials
Autoshift Power Train Troubleshooting Worksheet (cont'd)
LIST POSSIBLE
FAULTS
Devise tests and
determine root cause
The next step in the process is to list all of the possible causes of the
problem. Identify all systems and components that could be causing the
problem, including the least obvious. List at least four things that could
be checked. Possible answers:
Now, create a list of tests should be performed and describe what the
tests would determine. Prioritize the tests as to which sequence they
should be performed in. As a general rule, always do the easiest tests
first. Also, list diagnostic tooling required. Identify at least three tests to
perform. (Note: The rankings are only suggested.)
Tooling needed:
Tooling needed:
Tooling needed:
BCP BHL
5/1/00
- 71 -
Student Materials
Autoshift Power Train Troubleshooting Worksheet (cont'd)
Tooling needed:
REPAIR FAULT
Answer the following questions:
If during your tests you discovered that the FORWARD LOW clutch was
shorted to the battery, could that be the cause of the problem? If so, how
and what would the next step be?
VERIFY REPAIR
After completing the repair, always verify the machine is operating
correctly. List at least three things you would do to make sure the repair
was done correctly.
1.
2.
3.
4.
5.
Do not forget to fill our the service report after completing the job.
BCP BHL
8/15/01
- 72 -
Student Materials
MODULE: AXLES AND BRAKE
The purpose of this module is to have you locate and identify axle and
brake components. You will also learn how the brake control valves
work and axles components work. System tests and/or adjustments for
the brakes will also be performed. The module is composed of two
lessons.
OBJECTIVES
❑
❑
❑
1. On the machine, locate the components listed on the Axle and Brake
System Component Checklist for a backhoe loader..
2. Perform power shift brake system checks as per the service manual
if an AWD machine is available..
3. (Optional) Perform differential lock system checks as per the
provided handout.
BCP BHL
8/15/01
- 73 -
Student Materials
Lesson: Axle and Brake Component Identification
BACKGROUND
INFORMATION
Shop Lab
This lesson will help you gain familiarity with the machine and locate
components and service points.
❑
• View slide presentation on the axle and brake system
❑
• Remove side panels and/or cab floor plates as needed.
❑
Materials Needed
❑
• Locate components listed on the Axle and Brake Component Checklist.
Record a check after locating each component.
Operation & Maintenance Guide
Service Manual
Parts Book
Axle and Brake Component Checklist
Brake Schematic
AWS Service Brake System (C-Series Only)
1-Mechanic's Tool Boxes and hand tools
BCP BHL
8/15/01
- 74 -
Student Materials
Axle and Brake System Component Checklist
Directions: During a lab exercise, use this as a checklist when identifying components.
C
D
Model
Brake pedals
Parking brake control
Parking brake disc and pads
Differential lock pedal
Brake disc inspection plugs
Brake bleed screws
Reservoir
Brake lamp
Differential fill plug
Differential drain plug
Front AWD Differential fill plug
Front AWD Differential drain plug
AWD solenoid
AWD control switch
BCP BHL
8/15/01
- 75 -
Student Materials
Brake Master Cylinders
BRAKE MASTER CYLINDERS
RIGHT BRAKE
RELEASED
LEFT BRAKE
ENGAGED
TO BRAKE
PISTON
FROM
RESERVOIR
TO BRAKE
PISTON
SUPPLY PORT
VALVE STEM
PLUNGER
COMPENSATION
VALVE
PLUNGER
BRIDGE PIPE
PUSH ROD
SPOOL
RELIEF
VALVE
FROM/TO STEERING
PRIORITY VALVE
FROM TANK
SHUTOFF
VALVE
INLET
CHECK
VALVE
MAKEUP
VALVE
RESERVOIR
CHECK
VALVE
STABILITY ORIFICE
STEERING AND
BRAKE RESOLVER
FROM/TO
HMU
LOAD SENSING
LINE
REAR
BRAKES
FROM IMPLEMENT PUMP
- 76 -
Note: C Series Only
PISTON
PISTON
CHAMBER
PISTON RING
CHECK VALVE
ALL WHEEL STEER SERVICE BRAKE SYSTEM
BCP BHL
8/15/01
Student Materials
BCP BHL
8/15/01
- 77 -
Student Materials
Lesson: Axle and Brake System Tests
This lesson will allow you gain familiarity performing system checks,
using the Service Manual, and determining if the machine is operating to
specifications.
BACKGROUND
INFORMATION
Shop Lab
❑
• Remove side panels and/or cab floor plates as needed.
❑
• Differential Lock (rear wheels off of ground), First Forward at low idle.
Drag the left brake so the left wheel turns slower than the right wheel,
but is not fully stopped. Depress the differential pedal. Both wheels
should receive now turn at same speed.
Release the differential lock pedal. The Differential lock will remain
engaged until the left brake pedal is released.
❑
❑
Materials Needed
❑
Optional
• On Band C Series, perform proper brake bleed procedures as per the
service manual.
• Misadjust parking brakes to reduce brake performance. Perform proper
parking brake adjustment procedures as per the service manual.
Axle, brake and steering service manual modules
1-Mechanic's Tool Boxes and hand tools
BCP BHL
8/15/01
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Student Materials
MODULE: ENGINE, ELECTRICAL, AND
POWER TRAIN TROUBLESHOOTING
The purpose of this module is to have you identify system problems
within the engine, electrical and power train systems, perform tests and
then make repairs and adjustments to return the machine to normal
operation. This module consists of one lesson.
OBJECTIVES
❑
❑
❑
1. Using information from previous modules, perform the appropriate
engine, electrical and power train tests to determine system
problems.
2. Using information from previous modules and repair or adjust the
system.
3. Record results of your findings and provide a spoken classroom
report.
BCP BHL
8/15/01
- 79 -
Student Materials
Lesson: Engine, Electrical, and Power Train
Troubleshooting
BACKGROUND
INFORMATION
Shop Lab
This lesson will allow you gain familiarity performing system checks,
using the Service Manual to determining if the machine is operating to
specifications. If the machine is not performing to specification, make
the appropriate adjustments or repairs.
❑
❑
❑
Materials Needed
❑
• Split into Two Groups with One Machine per Group.
• "Bug" systems already discussed. Allow the following:
1 problem in engine/fuel system
1 problem in transmission
2 electrical problems
Note: Bug transmission, then the engine, and then the electrical
system. Make sure "bugs" do create a problem.
• Exchange Machines and Do the Following:
- Verify the problems exists.
- Devise the necessary diagnostic and performance tests to isolate
the problem.
- Perform the tests.
- Analyze the results.
- Repair the problem.
- Verify that the problem is solved.
Related service manual modules
3054 Engine In Chassis Test Sheet
Electrical System Tests Worksheet
Backhoe Loader Transmission Test Sheets
Student Troubleshooting Analysis worksheets
12-V and 24-V Electrical Systems - Student Reference Materials
2-6V3121 Multitach Group or 9U7400 Multitach II Group
2-1U5481 Pressure Test Gauge Group
2-1U5482 Hose and Fitting Group
10-6V3965 Nipples
5-3J1907 O-rings
2-6V7800 Multimeters or 9U7330 Fluke 87
2-8T0900 AC/DC Clamp- on Ammeter
2-Mechanic's Tool Boxes and hand tools
Optional
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
BCP BHL
8/15/01
- 80 -
Student Materials
3054 Engine In Chassis Test Sheet
Machine Model
Name/Code
Machine PIN (S/N)
Transmission S/N
Engine S/N
S.M.H.
VISUAL CHECKS:
Dealer
Customer
Job
Application
Date
Serviceman
Fuel Level
Engine Oil level
Coolant level
Power Train Oil level
Oil/Coolant/Fuel Leaks
Air Filters and Precleaner Inspection
TEST
SPECS
Engine rpm:
ACTUAL
COMMENTS
High Idle
Low Idle
Torque Converter Stall Check - Full throttle with brakes
applied, and transmission engaged in:
Fourth Speed - Forward
Fourth Speed - Reverse
Inlet Manifold Pressure @ TC Stall RPM (reference only)
Fuel Transfer Pressure (High Idle)
Engine RPM at Torque Converter Stall [with temperature
regulator (thermostat) fully opened]
Radiator Top Tank Temperature ºC (ºF)
[Should be less than 43 ºC (110°F) over ambient]
Water Pump Inlet Temperature - ºC (ºF)
[Should be 4.5ºC to 11ºC (8°F to 20°F) less than Top Tank Temperature]
Engine Oil Pressure at:
max rpm
Idle
ADD. CHECKS:
Fuel Type
Engine Oil Type
Antifreeze Protection Temp
Coolant Conditioner %
Battery Voltage
Starter Cold Cranking Amps
Alternator Output Voltage
Note: Remove the engine oil pressure switch and install a pipe thread 8C7575 or 8C7576 adapter and
6V4142 test nipple to check engine oil pressure.
Use 4C8054 fitting to check fuel transfer pressure on the B & C backhoes
BCP BHL
8/15/01
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Student Materials
Electrical System Tests Worksheet
I. Battery Test: Reference - Batteries - SM 6/20/88
Voltage
II. Starter Tests: Reference - Starter - SM 5/28/90
Test A. Check battery voltage at the battery posts while cranking, or attempting to crank.
NOTE: Use the posts representing 12 or 24 Volts. Do not
check voltage on the cable post clamps.
1. Is voltage equal to or greater than what is shown in
Chart A?
Record Voltage ___________
. . . Yes - Go to Test B.
Chart A-Typical System Voltage During
Cranking Versus Ambient Temperature
-23°C To-7°C
(-10°F To 20°F)
-7°C To 10°C
(20°F to 50°F)
10°C To 27°C
(50°F To 80°F)
24 Volt
System
12V to 16V
14V to 18V
16V to 20V
12 Volt
System
6V to 8V
7V to 9V
8V to 10V
Temp.
Test B. Measure starter motor voltage from TP4 to TP5 while cranking, or attempting to crank.
1. Is voltage equal to or greater than that shown in Chart A?
Record Voltage ___________
. . . Yes - Batteries and starter cables down to motor are
electrically within specifications. Go to Test C.
. . . No - Voltage drop (loss) between batteries and starter
is too great. Go to next step.
NOTE: For this exercise, assume your answer is "NO"
and then perform the next step. Enter results in CHART
B.
2. Measure voltage drops in cranking circuit per Chart B.
Are all voltages within specifications?
. . . Yes - Check engine. Go to Test C.
. . . No - Repair and/or replace faulty electrical
component .
Chart B-Maximum Allowable System
Voltage Drops During Cranking
Absolute Maximum
Voltage Reading
Circuit
24V
12V
Batt. Pos. Post to Starter
0.5V
0.3V
Pos. Post (TP10 to TP6)
Batt. Neg. Post to Starter
1.4V
0.7V
Neg. Post (TP7 to TP5)
Drop Across Only
1.0V
.5V
Disconnect Switch
(TP8 to TP9)
Start Relay Contacts
0.8V
0.4V
(TP3 to TP6)
Solenoid Contacts
0.8V
0.4V
(TP6 to TP4)
III. Alternator Tests: Reference - Alternator - SM 5/4/87
Initial Amperage (step 4.)
Voltage (step 5)
Amperage (step 6)
BCP BHL
8/15/01
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Student Materials
Backhoe Loader Transmission Test Sheet
Machine Model _______________________
Name/Code
________________________
Mach. S/N (PIN) _____________________
Trans. S/N
_________________________
Engine S/N
_________________________
S.M.U. ______________________________
Dealer __________________________________
Customer _______________________________
Job ____________________________________
Application ______________________________
Date ___________________________________
Serviceman ______________________________
VISUAL CHECKS
Oil Level
Oil Type
Oil Leaks
Air/H2O in Oil
_______
_______
_______
_______
Suction Screen
Oil Filter
Abrasives in Oil
Debris in Pan
_______
_______
_______
_______
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT
PRESSURE TEST
PRESSURES
LEVER
SPEC
LOW IDLE
ACTUAL
Pump Supply
N
Forward Clutch
F
Reverse Clutch
R
Lube
N
T. C. Inlet
N
XXXX
T. C. Outlet (T.C. Stall)
4th/Fwd
XXXX
AWD Clutch Pressure
N
PRESSURE TEST
SHIFT
LEVER
T. C. Outlet (T. C. stall)
4th/FWD
T. C. Outlet (T. C. stall)
4th/REV
SPEC
HIGH IDLE
ACTUAL
XXXX
XXXX
ENGINE SPEED
SPEC
ACTUAL
NOTE: Depending on which service publication is used, specifications may not always be provided
for both speed ranges.
Hint: Raise the rear wheels off of the ground using the stabilizers to check transmission pressures to
reduce the chance of driving through the brakes during a test.
BCP BHL
8/15/01
- 83 -
Student Materials
Backhoe Loader Transmission Test Sheet
Machine Model _______________________
Name/Code
________________________
Mach. S/N (PIN) _____________________
Trans. S/N
_________________________
Engine S/N
_________________________
S.M.U. ______________________________
Dealer __________________________________
Customer _______________________________
Job ____________________________________
Application ______________________________
Date ___________________________________
Serviceman ______________________________
VISUAL CHECKS
Oil Level
Oil Type
Oil Leaks
Air/H2O in Oil
_______
_______
_______
_______
Suction Screen
Oil Filter
Abrasives in Oil
Debris in Pan
_______
_______
_______
_______
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT
PRESSURE TEST
PRESSURES
LEVER
SPEC
LOW IDLE
ACTUAL
Pump Supply
N
Forward Clutch
F
Reverse Clutch
R
Lube
N
T. C. Inlet
N
XXXX
T. C. Outlet (T.C. Stall)
4th/Fwd
XXXX
AWD Clutch Pressure
N
PRESSURE TEST
SHIFT
LEVER
T. C. Outlet (T. C. stall)
4th/FWD
T. C. Outlet (T. C. stall)
4th/REV
SPEC
HIGH IDLE
ACTUAL
XXXX
XXXX
ENGINE SPEED
SPEC
ACTUAL
NOTE: Depending on which service publication is used, specifications may not always be provided
for both speed ranges.
Hint: Raise the rear wheels off of the ground using the stabilizers to check transmission pressures to
reduce the chance of driving through the brakes during a test.
BCP BHL
8/15/01
- 84 -
Student Materials
Power shift/Autoshift Transmission System Pressure Tests
Machine Model ________________________
Name/Code ____________________________
Machine PIN (S/N) ______________________
Transmission S/N ______________________
Engine S/N ____________________________
S.M.H. ________________________________
Dealer ____________________________
Customer__________________________
Job ______________________________
Application ________________________
Date______________________________
Serviceman ________________________
ENGINE SPEED
PRESSURE TEST
LOW IDLE
SPEC
Pump Pressure
Lube Pressure
All Wheel Drive Pressure
Torque Converter Inlet (optional)
FORWARD HIGH
Torque Converter Outlet (at T.C. Stall)
REVERSE
FORWARD LOW
Speed Clutch 1
Speed Clutch 2
Speed Clutch 3
Torque converter Stall RPM
Comments:
ACTUAL
HIGH IDLE
SPEC
ACTUAL
BCP BHL
5/1/00
- 85 -
Student Materials
Power Shift / Autoshift Transmission System Pressure Tests
(continued)
ENGINE SPEED
PRESSURE TEST
LOW IDLE
SPEC
Pressure difference between Pump and
FORWARD LOW
Pressure difference between Pump and
FORWARD HIGH
Pressure difference between Pump and
REVERSE
Pressure difference between Pump and Clutch 1
Pressure difference between Pump and Clutch 2
Pressure difference between Pump and Clutch 3
Pressure difference between Pump and
All Wheel Drive Clutch
Comments:
ACTUAL
HIGH IDLE
SPEC
ACTUAL
BCP BHL
8/15/01
- 86 -
Student Troubleshooting Analysis
STEP 1 - MAKE SURE PROBLEM EXISTS:
STEP 2 - STATE THE PROBLEM:
STEP 3 - VISUAL INSPECTION:
STEP 4 - LIST ALL POSSIBLE CAUSES:
1.
2.
3.
4.
5.
STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
STEP 6 - ISOLATE AND ELIMINATE:
STEP 7 - REPAIR MACHINE:
STEP 8 - VERIFY FIX:
Student Materials
BCP BHL
8/15/01
- 87 -
Student Troubleshooting Analysis
STEP 1 - MAKE SURE PROBLEM EXISTS:
STEP 2 - STATE THE PROBLEM:
STEP 3 - VISUAL INSPECTION:
STEP 4 - LIST ALL POSSIBLE CAUSES:
1.
2.
3.
4.
5.
STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
STEP 6 - ISOLATE AND ELIMINATE:
STEP 7 - REPAIR MACHINE:
STEP 8 - VERIFY FIX:
Student Materials
BCP BHL
8/15/01
- 88 -
Student Troubleshooting Analysis
STEP 1 - MAKE SURE PROBLEM EXISTS:
STEP 2 - STATE THE PROBLEM:
STEP 3 - VISUAL INSPECTION:
STEP 4 - LIST ALL POSSIBLE CAUSES:
1.
2.
3.
4.
5.
STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
STEP 6 - ISOLATE AND ELIMINATE:
STEP 7 - REPAIR MACHINE:
STEP 8 - VERIFY FIX:
Student Materials
BCP BHL
8/15/01
- 89 -
Student Materials
MODULE: IMPLEMENT HYDRAULIC
SYSTEMS
The purpose of this module is to have you locate and identify hydraulic
system components. You will also learn how the implement control
valves work and explain the function of their components. You will also
perform system tests for the hydraulic system. The first part of the
module is a review of basic "load sensing/pressure compensated"
hydraulics. The module is composed of five lessons, a case study and
two quizzes. Two of the lessons are optional.
OBJECTIVES
❑
❑
❑
❑
❑
1. On a quiz, identify system characteristics of Load Sensing and
Pressure Compensation. Also determine system pressures and
pressure differences at various locations on provided quiz
schematics.
2. Locate on the schematic the following: hydraulic tank, hydraulic
filter, pump, pump control valve, cooler, steering priority valve,
HMU, tilt control valve, lift control valve, auxiliary control valves,
stabilizer control, swing control valve, boom control valve, bucket
control valve and boom control valve.
3. On the machine, locate the following: hydraulic tank, hydraulic oil
filter, pump, pump control valve, loader valve group, backhoe valve
group, implement controls, pump supply pressure test port, signal
pressure test port, torque limiter.
4. (Optional) D&A a hydraulic pump and pump control valve and
demonstrate verbally to the instructor that the student understands
the functions of all components (if components are available). These
components may include line reliefs, makeup valves, check valves,
and main control spools, resolvers, and flow compensators.
5. (Optional) D&A an implement control valve and demonstrate
verbally to the instructor that the student understands the functions
of all components (if components are available). These components
may include line reliefs, makeup valves, check valves, and main
control spools, resolvers, and flow compensators.
BCP BHL
8/15/01
- 90 -
❑
❑
❑
❑
❑
❑
Student Materials
6. Perform performance checks and/or adjust: max system pressure,
low pressure standby, and margin pressure and the torque limiter
instructor directions.
7. Perform cycle time checks and signal system checks to identify
resolver or pump control problems per the provided handout.
8. Using provided reference materials and handouts, identify potential
system problems caused by a improperly operating hydraulic system
during a case study.
9. (Optional) Perform performance checks and/or adjust the torque
limiter per instructor directions.
10. On a quiz, match state of pump (i.e. upstroke, destroke, low pressure
standby, stall) to operational condition.
11. On a quiz, match the purpose or feature of the following
components: the steering priority flow control valve, the restrictor
valve, primary resolver, secondary resolver, make up valve, line
relief, advance signal passage, pressure reducing valve, swash plate,
lock valve, orifice check valve, pressure compensator, bias piston
and flow compensator.
BCP BHL
8/15/01
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Student Materials
Lesson: Load Sensing/Pressure Compensated Hydraulics
BACKGROUND
INFORMATION
Quiz
This lesson will help you gain familiarity with Load Sensing/Pressure
Compensated Hydraulics. LS/PC systems typically used closed center
implement control valves.
❑
• Complete the quiz at the back of the LS/PC Student Handout after
participating in the classroom review
NOTE: Remove side panels and/or cab floor plates as needed.
Materials Needed
❑
LS/PC Student Handout with Quiz
BCP BHL
8/15/01
- 92 -
Student Materials
Lesson: Implement Hydraulic System Component
Identification
BACKGROUND
INFORMATION
This lesson will help you gain familiarity with the machine and locate
components and service points.
Classroom Lab
❑
Shop Lab
❑
• While watching the slide presentation on the implement hydraulic
system, locate on the schematic the following: hydraulic tank,
hydraulic filter, pump, pump control valve, cooler, steering priority
valve, HMU, tilt control valve, lift control valve, auxiliary control
valves, stabilizer control, swing control valve, boom control valve,
bucket control valve and boom control valve using.Implement
Hydraulic System Component Checklist II, and III
• On the machine, locate the following: hydraulic tank, hydraulic oil
filter, pump, pump control valve, loader valve group, backhoe valve
group, implement controls, pump supply pressure test port, signal
pressure test port, torque limiter using.Implement Hydraulic System
Component Checklist I,II, and III. Record a check after locating each
component..
NOTE: Remove side panels and/or cab floor plates as needed.
Materials Needed
❑
Hydraulic System Testing and Adjusting Service Manual Module
Hydraulic System Component Checklists I, II, and III
C Series Hydraulic System Component Checklist
BCP BHL
8/15/01
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Student Materials
Hydraulic System Component Checklist I
Directions: Use this sheet to take notes during the presentation (i.e. location, functions) . During a lab
exercise, use this as a checklist when identifying components.
D
C
Model
Hydraulic tank
Hydraulic oil filter(s)
Pump
Pump control valve
Loader valve group
Backhoe valve group
Stabilizer valve group
N/A
Implement controls
Pump supply pressure test port
Signal pressure test port
Torque Limiter
NA
Stabilizer lock valves (center pivot machines only
N/A
Pilot accumulator (if equipped)
N/A
Ride control accumulator (if equipped)
N/A
Auxiliary control ECM (if equipped)
Directions: Label all valves, the tanks, filters, cooler, pump, and HMU.
- 94 -
C Series Hydraulic System Component Checklist
INLET
MANIFOLD
END
COVER
416C, 426C, AND 436C BACKHOE LOADER
HYDRAULIC SYSTEM
BCP BHL
8/15/01
Student Materials
Directions: Label all valves, the tank, pump, filter, cooler, resolver, and HMU.
416C/426C/436C Hydraulic System Component Checklist
BCP BHL
8/15/01
- 95 Student Materials
LOADER
LIFT
STEERING
RESOLVER
HMU
STICK
TORQUE
LIMITER
SECONDARY
RESOLVER
PRIMARY
RESOLVER
CONNECTED TO
SWASHPLATE
PUMP
CONTROL
VALVE
RESOLVER
LEFT
RIGHT
BUCKET
STABILIZER STABILIZER
LOADER SECTION
LOADER
TILT
LOADER
AUX.
ORIFICE
SWING
BOOM
BACKHOE SECTION
Directions: Use for troubleshooting resolver problems.
416C/426C/436C Signal Network
BCP BHL
8/15/01
- 96 Student Materials
Directions: Label all valves (including the shutoff valve), the tank, pump, filter, cooler,
resolver, and HMU.
428C/438C Hydraulic System Component Checklist
BCP BHL
8/15/01
- 97 Student Materials
ORIFICE
STEERING
RESOLVER
STICK
TORQUE
LIMITER
PUMP
CONTROL
VALVE
SECONDARY
RESOLVER
PRIMARY
RESOLVER
CONNECTED TO
SWASHPLATE
RESOLVER
BUCKET
- 98 -
LOADER SECTION
HMU
RIGHT
STABILIZER
LOADER
LIFT
LEFT
STABILIZER
LOADER
TILT
SWING
LOADER
AUX.
BOOM
BACKHOE SECTION
Directions: Use for troubleshooting resolver problems.
428C/438C Signal Network
BCP BHL
8/15/01
Student Materials
- 99 -
MANIFOLD
INLET
MANIFOLD
END
COVER
Directions: Label all valves (including shutoff valve and backflow check valve), tank, pump, filter, cooler,, pilot accumulator and HMU.
420D/430D Hydraulic System Component Checklist
BCP BHL
5/1/00
Student Materials
PILOT OIL
LOADER SECTION
LOADER
TILT
SMU
SWING
LOADER
LIFT
BOOM
STICK
E-STICK
LEFT
RIGHT
STABILIZER STABILIZER
BUCKET
- 100 -
LIFT PILOT
VALVE
AUX
SECONDARY
RESOLVER
LOADER
AUX.
TORQUE
LIMITER
ORIFICE
PRIMARY
RESOLVER
CONNECTED TO
SWASHPLATE
PUMP
CONTROL
VALVE
BACKHOE SECTION
PILOT CONTROLLED LOADER VALVES
Directions: Use for troubleshooting resolver problems.
D Series Signal Network
BCP BHL
5/1/00
Student Materials
BCP BHL
8/15/01
- 101 -
Student Materials
Lesson: Hydraulic Pump and Pump Control Valve
Component Identification (Optional)
This lesson allows you to gain hands on experience with the hydraulic
pump and pump control valve and their components.
BACKGROUND
INFORMATION
Shop Lab
❑
❑
Materials Needed
• Disassemble the hydraulic pump and pump control valve. Lay out all
components.
• Identify and state the purpose of the components using the Backhoe
Hydraulic Component Checklist and either the Series II Hydraulic
Pump Component Checklist or the B Series Hydraulic Pump
Component Checklist. (Circle the component letter after identifying
each component.).
❑
• Assemble the hydraulic pump and pump control valve.
❑
Backhoe Hydraulic Component Checklist
Hydraulic Pump Component Checklist
Torque Limiters - Student Reference Materials
Related service manual modules
Parts Book
Hydraulic pump and pump control valve - for BCP backhoe
loaders or similar
Mechanic's Tool Box with hand tools
Class notes
BCP BHL
8/15/01
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Student Materials
Backhoe Hydraulic Components Checklist
Directions: Use this sheet to take notes during the presentation (i.e. location, functions) . During the
lab, use this as a checklist when identifying components.
C
D
Pump Control Valve
Margin spool
Check valve
Pressure cut-off
Torque Limiter
Hydraulic Pump
Large actuator
Small actuator and bias spring
Swash plate
Piston and barrel assembly
Drive shaft
Implement Control Valve
Main control spool
Advance signal passage
Primary resolver
Secondary resolver
Flow control valve
Load check valve
Main control spool
Line relief valve
Makeup valve
BCP BHL
8/15/01
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Student Materials
Hydraulic Pump Components Checklist
Directions: Fill in the blanks with the correct response. Use this sheet to take notes during the
presentation.
I
A
PUMP
OUTPUT
SIGNAL
B
C
D
H
G
E
F
A
B
C
D
E
F
G
H
I
BCP BHL
8/15/01
- 104 -
Student Materials
Lesson: Implement Control Valve Component
Identification (Optional)
This lesson allows you to gain hands on experience with the implement
control valve and its components.
BACKGROUND
INFORMATION
Shop Lab
❑
❑
❑
❑
Materials Needed
❑
• Disassemble the implement control valve. Lay out all components.
• Identify and state the purpose of the components using the Backhoe
Hydraulic Component Checklist and the Implement Control Valve
Component Checklist . (Circle the component letter after identifying
each component.).
• Assemble the implement control valve.
• (Optional) Disassemble and assemble any additional hydraulic system
components. Use Backhoe Hydraulic Components Reference I, II and
III. Lay out all components. List additional components D&A below:
Backhoe Hydraulic Component Checklist
Implement Control Valve Component Checklist
Service Manual
Parts Book
Implement control valve - for BCP backhoe loaders or similar
Additional hydraulic components (optional)
Mechanic's Tool Box with hand tools
Class notes
BCP BHL
8/15/01
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Student Materials
Implement Control Valve Components Checklist
Directions: Fill in the blanks with the correct response. Use this sheet to take notes during the
presentation.
CLOSED CENTER CONTROL VALVE
FROM
PREVIOUS
VALVE
HOLD
B
HEAD
END
ROD
END
E
A
TO TANK
TO TANK
F
D
C
TO NEXT
VALVE
A
B
C
D
E
F
FROM
PUMP
BCP BHL
8/15/01
- 106 -
Student Materials
Lesson: Implement Hydraulic System Tests
This lesson will allow you gain familiarity performing system checks,
using the Service Manual, and determining if the machine is operating to
specifications.
BACKGROUND
INFORMATION
NOTE: Before operating the machine, perform a 10 hour or daily
inspection.
Shop Lab
❑
• Record pressure specifications from the service manual before going to
the shop.on the Hydraulic System Test Sheet
❑
❑
• Check implement cycle times. Refer to service manual or latest service
literature.
❑
• Mis-adjust Margin Pressure/Low Pressure Standby per instructor
recommendations and then recheck cycle times before adjusting back
to correct specifications.
❑
❑
❑
• Check torque limiter setting
• Perform Margin Pressure, Low Pressure Standby, and Maximum
System pressure checks as per classroom discussion and service
manual.
• Demonstrate how a malfunctioning secondary resolver can be identified
using handout provided. Demonstrate on chalkboard and on machine.
• Demonstrate how a malfunctioning primary resolver can be identified
using handout provided. Demonstrate on chalkboard and on machine.
Optional
❑
Materials Needed
❑
• Check line reliefs as per service manual. Adjust bucket positioner cam
and switch as per service manual.
Backhoe Hydraulic System Tests sheets
B & C Series Backhoe Loader Hydraulic System Lab Sheet
Backhoe System Testing
Troubleshooting the Resolver Network on Series II, B & C Series
Backhoe Loaders
Related service manual modules
2-8T0856 Pressure Gauge (0 to 870 psi)
2-8T0859 Pressure Gauge (0 to 3600 psi) or 1-1U5796
Differential Gauge Group
1-1U5482 Hose and Fitting Group
1-Stop Watch
1-Tape Measure
2-Mechanic's Tool Boxes and hand tools
BCP BHL
8/15/01
- 107 -
Student Materials
SYSTEM TESTING
System Tests
The performance of the 416-446 hydraulic systems can be easily tested. Two pressure gauge fittings
are installed on the hydraulic oil pump.
Before performing any pump tests or making adjustments to the pump control valve, measure and
record the machine cycle times. If the cycle times are within specification, checking low pressure
standby or margin pressure may not be required unless the system is overheating. Cycle time checks
will also indicate if all or some of the implements in the system are operating within specification.
This information can be helpful in determining if the pump or the implement is at fault. If all cycle
times are too slow, margin pressure may be set too low. If the machine is too responsive, the margin
pressure may be set too high.
Connect an 8T0859 gauge to each pressure fitting. The oil lines for the gauges should be long enough
so the gauges can be observed from the operator's station.With the gauges installed, follow the testing
and adjusting procedures in the Service Manual for maximum system pressure and low pressure
standby. When performing the margin pressure test, follow the Service Manual Procedures with the
following exceptions:
1. Using a 6V8731 Union in the tilt circuit is not required (Has been removed from more current
publications)
2. Stall the steering circuit on backhoes. This circuit has a signal limiter set below the pump
cutoff. Do the test at high idle. Disregard doing test at 1450 rpm. Values are basically the
same at either engine speed.
If margin pressure needs to be adjusted, the following method is quicker and safer for the mechanic:
1. Compare margin pressure to low pressure standby.
2. Mentally add to or subtract from low pressure standby about the same amount required to set
margin pressure to specification. Since both pressures are adjusted by the same screw, an
adjustment to one also affects the other. This relationship, however, is not linear.
3. Make this adjustment to the flow compensator (margin spool) while the machine is in low
pressure standby.
4. Recheck margin pressure after adjusting low pressure standby.
NOTE: In most cases, just adjusting standby pressure to the median ± 15 psi will be sufficient.
Checking margin pressure with two high pressure gages is not as accurate as checking and adjusting
standby pressure with a single lower pressure gage.
BCP BHL
8/15/01
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Student Materials
Backhoe Loader Hydraulic System Lab Sheet
Perform the Following Tasks:
• Warm up hydraulic system.
• Record initial system pressures below:
Spec
Actual
Low pressure standby
Maximum system pressure
Margin pressure
Steering system pressure
Swing circuit pressure (D-Series)
Pilot circuit Pressure (D-Series)
• Invert front bucket fully and lower to the ground. Record cycle times for loader lift below:
Loader lift cycle time specification
Test One
Test Two
Test Three
Average Cycle time
• Adjust Low Pressure Standby by 150 psi. Record cycle times for loader lift below:
Test One
Test Two
Test Three
Average Cycle time
• Adjust Low Pressure Standby to 300 psi above previous setting. Record cycle times for loader lift
below:
Test One
Test Two
Test Three
Average Cycle time
• Reset Low Pressure Standby to 320 psi. for the B series, 350 psi for the C series, and 470 psi for the
D series. Recheck cycle times and margin pressure.
Test One
Average Cycle time
Margin Pressure
Describe your conclusions:
Test Two
Test Three
STMG 746
6/01
- 109 -
Serviceman's Handout No. 18
BACKHOE LOADER HYDRAULIC TESTS
PRESSURE TEST
SPEC
ACTUAL
ADJUSTED
Low Pressure Standby
RUN ALL TESTS AT
MAXIMUM RPM
Margin Pressure
Maximum System Pressure
MACHINE AT NORMAL
OPERATING
TEMPERATURES
Pilot Pressure
Steering Circuit Pressure
Swing Circuit Pressure
CYCLE TIMES
TEST
1ST
L
O
A
D
E
R
Bucket Dump
Tilt Back
Regenerative Dump
(for parallel lift)
Float
Raise
Bucket Dump
Bucket Load (Curl)
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
B
A
C
K
H
O
E
E-Stick Extend
E-Stick Retract
Left Stabilizer Up
Left Stabilizer Down
Right Stabilizer Up
Right Stabilizer Down
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
2ND
3RD
4TH
AVG.
SPEC
BCP BHL
8/15/01
- 110 -
Student Materials
BACKHOE LOADER HYDRAULIC TESTS
PRESSURE TEST
SPEC
ACTUAL
ADJUSTED
Low Pressure Standby
RUN ALL TESTS AT
MAXIMUM RPM
Margin Pressure
Maximum System Pressure
MACHINE AT NORMAL
OPERATING
TEMPERATURES
Pilot Pressure
Steering Circuit Pressure
Swing Circuit Pressure
CYCLE TIMES
TEST
1ST
L
O
A
D
E
R
Bucket Dump
Tilt Back
Regenerative Dump
(for parallel lift)
Float
Raise
Bucket Dump
Bucket Load (Curl)
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
B
A
C
K
H
O
E
E-Stick Extend
E-Stick Retract
Left Stabilizer Up
Left Stabilizer Down
Right Stabilizer Up
Right Stabilizer Down
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
2ND
3RD
4TH
AVG.
SPEC
BCP BHL
8/15/01
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Student Materials
Troubleshooting the Resolver Network on C and D Series Backhoe Loaders
The signal network can be easily checked. Start the engine and warm up the hydraulic oil. Run the engine at
LOW idle for this check. Connect at least a 3500 psi gauge to the signal line pressure tap. Operate each control
lever in the following order:
416C/426C/436C backhoes built before July of 2000
1. Auxiliary - 8th valve (if equipped).
2. Boom
3. Swing
4. Left Stabilizer (as when positioned to operate the backhoe).
5. Right Stabilizer
6. Backhoe bucket
7. Stick
8. Extendable stick (if equipped)
9. Multi-purpose bucket (if equipped)
10. Loader bucket tilt.
11. Loader lift
12. Steering
416C/426C/436C backhoes built after July of 2000
Due to the changes in the signal line routings and the additional resolver, the valve groups need to be
treated as being independent of each other, much like what is done with motor graders.
1. Auxiliary - 8th valve (if equipped).
2. Boom
3. Swing
4. Left Stabilizer (as when positioned to operate the backhoe).
5. Right Stabilizer
6. Backhoe bucket
7. Stick
8. Extendible stick (if equipped)
9. Resolver between valve stacks
1. Multi-purpose bucket (if equipped)
2. Loader bucket tilt.
3. Loader lift
4. Steering
5. Resolver between valve stacks
NOTE: The above valve order is different on B and Series II machines. Also be cautious of the controls on
non-standard configured machines. These controls may be confusing if you are use to the standard control
pattern
Work each implement against a load. Watch the gauge. Maximum system pressure should be seen for all
circuits except for boom down and for steering. By using the gauge, small leakage problems such as cut or
missing seals can be detected.
➥
BCP BHL
8/15/01
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Student Materials
428C/438C backhoes built before July of 2000
1. Extendible stick (if equipped)
2. Stick
3. Backhoe bucket
4. Right Stabilizer
5. Left Stabilizer (as when positioned to operate the backhoe).
6. Swing
7. Boom
8. Auxiliary - 8th valve (if equipped).
9. Multi-purpose bucket (if equipped)
10. Loader bucket tilt.
11. Loader lift
12. Steering
428C/438C backhoes built after July of 2000
1. Extendible stick (if equipped)
2. Stick
3. Backhoe bucket
4. Right Stabilizer
5. Left Stabilizer (as when positioned to operate the backhoe).
6. Swing
7. Boom
8. Auxiliary - 8th valve (if equipped).
9. Resolver between valve stacks
1. Multi-purpose bucket (if equipped)
2. Loader bucket tilt.
3. Loader lift
4. Steering
5. Resolver between valve stacks
D Series Backhoes
1. Multi-purpose bucket (if equipped)
2. Loader bucket tilt.
3. Loader lift
4. Steering
5. Right Stabilizer
6. Left Stabilizer (as when positioned to operate the backhoe).
7. Extendible stick (if equipped)
8. Stick
9. Backhoe bucket
10. Swing
11. Boom
12. Auxiliary - 8th valve (if equipped).
➥
BCP BHL
8/15/01
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Student Materials
SECONDARY RESOLVERS - TWO OR MORE VALVE SECTIONS
If two or more control valves in series next to each other fail to work normally, the problem may be in the
secondary resolver of the first implement that is closer to pump supply that works properly. This control valve's
secondary resolver is allowing signal pressure from any implement further from pump supply to leak through it
to either the rod or head end signal passage of that control valve to tank. This leakage may be caused by a the
ball not seating properly due to debris or a damaged seat. When this control valve is operated the ball will seat
against the drain side of its resolver and function normally.
This holds true unless the ball is missing; there is debris preventing the ball from seating properly on either side
of the resolver; or the seal is missing or leaking. In this case operate the first control valve that functions
normally and the next valve further from pump supply to it at the same time. If the second valve still doesn't
function properly, then the second valve probably has the bad secondary resolver.
A simpler method, when multiple valves malfunction, is to operate the malfunctioning valve farthest from the
pump and at the same time start going through the previously mentioned valve order. The first valve that makes
both implements work is the one with bad secondary resolver. What is happening is the farthest valve is sending
a signal and the valve with a bad seal or missing ball is sending a signal. When both signals meet at the valve
with the bad secondary resolver the seal has no impact on the signal that now goes to the pump and it also has
no effect on the flow control spool in the stick flow control spool (pressure reducing valve).
PRIMARY VS. SECONDARY RESOLVER
NOTE: The following discussion pertains only to those valves with flow control or pressure reducing valves in
them.
If only one valve section function either fails to work in one or both directions; or works slowly in one or both
directions, the primary or secondary resolver in that control valve may be bad. To determine which one is bad
do the following check. Stall an implement further away from the pump than the valve in question. This will
force the ball in the secondary resolver to seat away from the drain side of the resolver. This eliminates the
possibility of a leak on the drain side of the secondary resolver. Now operate the suspect valve while holding
the other implement in stall. If it is still operating slow in one or both directions, then the primary resolver
maybe bad.
If the primary resolver is bad then the pressure bleed off caused by the bad resolver is effecting the operation of
the flow control (pressure reducing valve) in the valve body. The effective force (signal pressure + spring)
trying to open up the valve to allow flow to the cylinder is insufficient to meet the cylinder load requirement so
the implement has slow response.
Normally, if an implement is slow in both directions, the problem is probably in the secondary resolver. If an
implement is slow in one direction it is typically caused by a bad primary resolver (caused by debris or bad
seals).
ADDITIONAL COMMENTS
Other causes of malfunctioning valve sections might be misadjusted linkage, a broken flow control (pressure
reducing valve) spring, the flow control spool in wrong or bad line relief and/or make-up valves.
If there is debris in the system. It is recommended that you flush the system by removing all of the balls in the
secondary resolvers of the backhoe section and operate the implements. Enough flow will be supplied to flush
the debris to tank.
Also when troubleshooting, consider how the force of gravity might effect the operation of the implement in
question when troubleshooting the hydraulic system. You may jump to the wrong conclusion.
BCP BHL
8/15/01
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Student Materials
416C/426C/436C SIGNAL NETWORK FOR MACHINES BUILT AFTER 7/2000
BACKHOE SECTION
BOOM
SWING
LEFT
STABILIZER
RIGHT
STABILIZER
BUCKET
STICK
PRIMARY
RESOLVER
SECONDARY
RESOLVER
ORIFICE
LOADER
AUX.
LOADER
TILT
LOADER
LIFT
PUMP
CONTROL
VALVE
HMU
RESOLVER
LOADER SECTION
TORQUE
LIMITER
STEERING
RESOLVER
CONNECTED TO
SWASHPLATE
428C/438C SIGNAL NETWORK FOR MACHINES BUILT AFTER 7/2000
BACKHOE SECTION
BOOM
SWING
LEFT
STABILIZER
RIGHT
STABILIZER
BUCKET
STICK
PRIMARY
RESOLVER
SECONDARY
RESOLVER
ORIFICE
LOADER
AUX.
LOADER
TILT
LOADER
LIFT
PUMP
CONTROL
VALVE
HMU
RESOLVER
LOADER SECTION
STEERING
RESOLVER
TORQUE
LIMITER
CONNECTED TO
SWASHPLATE
BCP BHL
8/15/01
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Student Materials
Hydraulic System Case Study
DIRECTIONS
Students should use the service manual and class notes to complete the
exercise. Have the students answer the questions on the Troubleshooting
Exercise Worksheet. Discuss the exercise with the students after they
have had time to answer the exercise questions.
SITUATION
The following exercise is based on a possible field complaint.
The customer's 416C Backhoe Loader with 627 service hours has poor
implement response.
After checking fluid levels, the mechanic checks implement cycle times.
All implements in the backhoe section were very slow. The boom raise
was the slowest at 60 seconds.
BCP BHL
8/15/01
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Student Materials
Hydraulic System Troubleshooting Worksheet
ISOLATE PROBLEM
Gather Information
The first step in in a troubleshooting process is to gather information
before starting any work on the machine. If possible talk to the operator.
Also, check the repair history of the machine and the Caterpillar Service
Information Retrieval System (SIRS). List at least three questions you
would ask an operator to help in determining a problem exists? Possible
answers:
Verify
Verify the problem exists. Operate the machine to duplicate the problem,
preferably under similar operating conditions. Compare the operation to
a known good machine. Perform sensory checks such as looking,
listening, touching, smelling to verify a problem exists.
Perform Visual
Inspection
When troubleshooting always perform a visual inspection first. Look for
the obvious. List at least three typical items that should be inspected
during a visual inspection for. Possible answers:
State Problem
After verifying a problem exists, state in your own words what the
problem is. Caution: Do not identify the solution. Possible answer:
BCP BHL
8/15/01
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Student Materials
Hydraulic System Troubleshooting Worksheet (continued)
LIST POSSIBLE
FAULTS
The next step in the process is to list all of the possible causes of the
problem. Identify all systems and components that could be causing the
problem, including the least obvious. List at least four things that could
be checked. Possible answers:
Devise tests and
determine root cause
Now, create a list of tests should be performed and describe what the
tests would determine. Prioritize the tests as to which sequence they
should be performed in. As a general rule, always do the easiest tests
first. Also, list diagnostic tooling required. Identify at least four tests to
perform. (NOTE: the rankings are only suggested.)
Tooling needed:
Tooling needed:
Tooling needed:
BCP BHL
8/15/01
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Student Materials
Hydraulic System Troubleshooting Worksheet (continued)
Tooling needed:
Tooling needed:
Tooling needed:
REPAIR FAULT
After isolating the component, which you suspect from your test results is
causing the problem, either adjust or replace the component.
Circle the best response:
If during your tests you discovered that the maximum system pressure
was only 6900 kPa (1000 psi). Which one of the following components
would you adjust or replace?
1. Margin spring setting
2. Pressure cut-off
3. Steering signal pressure limiter
4. Torque limiter
If during your tests you discovered that standby pressure was correct and
engine high idle was also set correctly. Which of the following would
you least likely expect to be the cause of the problem?
1. The torque limiter
2. The secondary resolver closest to the pump control
3. The margin spring setting
4. The pressure cutoff spring setting
BCP BHL
8/15/01
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Student Materials
Hydraulic System Troubleshooting Worksheet (continued)
VERIFY REPAIR
After completing the repair, always verify the machine is operating
correctly. List at least three things you would do to make sure the repair
was done correctly.
1.
2.
3.
4.
5.
Don't forget to fill the service report after completing the job.
BCP BHL
8/15/01
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Student Materials
MODULE: STEERING AND IMPLEMENT
HYDRAULIC SYSTEM TROUBLESHOOTING
The purpose of this module is to have you identify system problems
within the steering and implement hydraulic system, perform tests and
then make repairs and adjustments to return the machine to normal
operation. This module consists of one lesson.
OBJECTIVES
❑
❑
❑
1. Using information from previous modules, perform the appropriate
engine, electrical and power train tests to determine system
problems.
2. Using information from previous modules and repair or adjust the
system.
3. Record results of your findings and provide a spoken classroom
report.
BCP BHL
8/15/01
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Student Materials
Lesson: Steering and Implement Hydraulic System
Troubleshooting
BACKGROUND
INFORMATION
Shop Lab
This lesson will allow you gain familiarity performing system checks,
using the Service Manual to determining if the machine is operating to
specifications. If the machine is not performing to specification, make
the appropriate adjustments or repairs.
❑
❑
❑
Materials Needed
❑
• Split into Two Groups with One Machine per Group.
• "Bug" systems already discussed. Allow two "bugs" to be installed in
the system.
• Exchange Machines and Do the Following:
- Verify the problems exists.
- Devise the necessary diagnostic and performance tests to isolate
the problem.
- Perform the tests.
- Analyze the results.
- Repair the problem.
- Verify that the problem is solved.
Related service manual modules and reference materials
Backhoe Hydraulic System Tests sheets
2-8T0856 Pressure Gauge (0 to 870 psi)
2-8T0859 Pressure Gauge (0 to 3600 psi) or 1-1U5796
Differential Gauge Group
1-1U5482 Hose and Fitting Group
1-Stop Watch
1-Tape Measure
2-Mechanic's Tool Boxes and hand tools
BCP BHL
- 122 -
Student Materials
BACKHOE LOADER HYDRAULIC TESTS
PRESSURE TEST
SPEC
ACTUAL
ADJUSTED
Low Pressure Standby
RUN ALL TESTS AT
MAXIMUM RPM
Margin Pressure
Maximum System Pressure
MACHINE AT NORMAL
OPERATING
TEMPERATURES
Pilot Pressure
Steering Circuit Pressure
Swing Circuit Pressure
CYCLE TIMES
TEST
1ST
L
O
A
D
E
R
Bucket Dump
Tilt Back
Regenerative Dump
(for parallel lift)
Float
Raise
Bucket Dump
Bucket Load (Curl)
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
B
A
C
K
H
O
E
E-Stick Extend
E-Stick Retract
Left Stabilizer Up
Left Stabilizer Down
Right Stabilizer Up
Right Stabilizer Down
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
2ND
3RD
4TH
AVG.
SPEC
BCP BHL
- 123 -
Student Materials
BACKHOE LOADER HYDRAULIC TESTS
PRESSURE TEST
SPEC
ACTUAL
ADJUSTED
Low Pressure Standby
RUN ALL TESTS AT
MAXIMUM RPM
Margin Pressure
Maximum System Pressure
MACHINE AT NORMAL
OPERATING
TEMPERATURES
Pilot Pressure
Steering Circuit Pressure
Swing Circuit Pressure
CYCLE TIMES
TEST
1ST
L
O
A
D
E
R
Bucket Dump
Tilt Back
Regenerative Dump
(for parallel lift)
Float
Raise
Bucket Dump
Bucket Load (Curl)
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
B
A
C
K
H
O
E
E-Stick Extend
E-Stick Retract
Left Stabilizer Up
Left Stabilizer Down
Right Stabilizer Up
Right Stabilizer Down
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
2ND
3RD
4TH
AVG.
SPEC
BCP BHL
8/15/01
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Student Troubleshooting Analysis
STEP 1 - MAKE SURE PROBLEM EXISTS:
STEP 2 - STATE THE PROBLEM:
STEP 3 - VISUAL INSPECTION:
STEP 4 - LIST ALL POSSIBLE CAUSES:
1.
2.
3.
4.
5.
STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
STEP 6 - ISOLATE AND ELIMINATE:
STEP 7 - REPAIR MACHINE:
STEP 8 - VERIFY FIX:
Student Materials
BCP BHL
8/15/01
- 125 -
Student Troubleshooting Analysis
STEP 1 - MAKE SURE PROBLEM EXISTS:
STEP 2 - STATE THE PROBLEM:
STEP 3 - VISUAL INSPECTION:
STEP 4 - LIST ALL POSSIBLE CAUSES:
1.
2.
3.
4.
5.
STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
STEP 6 - ISOLATE AND ELIMINATE:
STEP 7 - REPAIR MACHINE:
STEP 8 - VERIFY FIX:
Student Materials
BCP BHL
8/15/01
- 126 -
Student Materials
MODULE: ALL WHEEL STEERING
ELECTRICAL & HYDRAULIC SYSTEMS
The purpose of this module is to have you identify All Wheel Steer
electrical and hydraulic components This module consists of one lesson.
OBJECTIVES
❑
❑
1. Locate on the schematic the following: IRM shutoff valve, IRM
right valve, IRM left valve, thermal relief, valve, lock valve, and
pilot poppet valves.
2. On the machine, locate the following: All Wheel Steer Control
Valve, Rear Axle Position Gage, Rear Position Micro-switch,
Pressure Switch, Rear Axle Position Sender, and AWS Select Switch
BCP BHL
8/15/01
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Student Materials
Lesson: All Wheel Steer System Component Identification
BACKGROUND
INFORMATION
This lesson will help you gain familiarity with the machine and locate
components and service points.
Classroom Lab
❑
Shop Lab
❑
• While viewing the slide presentation, locate on the AWS System
Checklist II the following: IRM shutoff valve, IRM right valve, IRM
left valve, thermal relief, valve, lock valve, and pilot poppet valves.
• On the machine, locate the following: All Wheel Steer Control Valve,
Rear Axle Position Gage, Rear Position Micro-switch, Pressure Switch,
Rear Axle Position Sender, and AWS Select Switch using AWS System
Checklist I and II , plus the AWS Electrical Schematic. Record a check
after locating each component..
NOTE: Remove side panels and/or cab floor plates as needed.
Materials Needed
❑
AWS System Checklist I and II
B Series AWS Electrical Schematic.
C Series AWS Electrical Schematic.
Related service manual module
2-Mechanic's Tool Boxes and hand tools
BCP BHL
8/15/01
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Student Materials
All Wheel Steer System Component Checklist I
Directions: Use this sheet to take notes during the presentation (i.e. location, functions) . During a lab
exercise, use this as a checklist when identifying components.
C
D
Model
All Wheel Steer Control Valve Group
Rear Axle Position Gage
Rear Position Micro-switch
Pressure Switch
Rear Axle Position Sender
AWS Select Switch
J
I
H
C
FROM BACKHOE
VALVE GROUP
A
B
FROM BRAKE
VALVE
H
STEERING PRIORITY
VALVE
AUXILIARY
TILT
LIFT
G
TO BACKHOE
VALVE GROUP
E
D
F
K
I
TST 1
TO BRAKE
VALVE
J
PILOT
POPPET
VALVES
TST 2
HAND METERING
UNIT
ALL WHEEL STEER
CONTROL VALVE
GROUP
CROSSOVER
LINE RELIEF
VALVES
ALL WHEEL STEER SYSTEM
BACKHOE LOADER
FRONT AXLE
- 129 -
G
F
E
D
C
B
A
REAR
AXLE
Directions: Fill in the blanks
with the correct response. Use
this sheet to take notes during the
presentation.
All Wheel Steer
Components Checklist II
BCP BHL
8/15/01
Student Materials
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
H770-BR
G726-GY
F872-BU
H769BR
F871-PU
H768-BR
E764-OR
H767-BR
E764-OR
H767-BR
1
2
429-YL
200-BK
H767-BR
429-YL
200-BK
H770-BR
H768-BR
H769-BR
G726-GY
F871-PU
F872-BU
E764-OR
BK-16
RD-16
BU-16
PRESSURE
SWITCH
A
B
C
4
1
3
6
2
5
9
7
8
10
11
12
INDEPENDENT REAR
MANEUVERING SWITCH
789-BR
V
V
4
5
1
2
3
8
7
6
10
1
4
2
7
3
5
8
6
9
136-GN
200-BK
123-WH
766-GN
G796-YL
G795-OR
F874-PK
F877-WH
G797-BU
G798-PU
ARC
SUPPRESSOR
1
2
2
1
5
6
3
4
1
2
1
2
ENGINE ON
2
5
4
6
1
3
2
5
3
4
6
1
DIODE ASSEMBLY
G742-GN
G743-OR
G798-PU
G797-BU
F877-WH
F874-PK
H770-BR
F872-BU
G797-BU
G798-PU
G743-OR
G742-GN
6
2
3
7
1
4
5
8
GRD
SEND
IGN
REAR AXLE
POSITION
GAUGE
136-GN
200-BK
F874-PK
F877-WH
F871-PU
H768-BR
G726-GY
H769-BR
INDICATOR
LAMP
AWS SELECT
SWITCH
1
2
ALL WHEEL STEER ELECTRICAL SYSTEM
H770-BR
G726-GY
G742-GN
G743-OR
136-GN
200-BK
H769-BR
F872-BU
F877-WH
G798-PU
H768-BR
F871-PU
F874-PK
G797-BU
SHUTOFF
RELAY
IRM RIGHT
RELAY
IRM LEFT
RELAY
- 130 -
BK
PK
REAR AWS
POSITION SENDER
IRM SHUTOFF SOLENOID
VALVE
1
2
IRM RIGHT SOLENOID
VALVE
1
2
IRM LEFT SOLENOID
VALVE
LOCK SOLENOID
VALVE
CIRCLE STEER
SOLENOID VALVE
1
2
TRANSMISSION
NEUTRALIZER
SWITCH
C Series All Wheel Steer
BCP BHL
8/15/01
Student Materials
Service Training
Course Materials
COURSE REFERENCE
MATERIALS
C SERIES BACKHOE LOADER DIAGNOSTICS
BUILDING CONSTRUCTION PRODUCTS
Service Training
Course Materials
COURSE REFERENCE
MATERIALS
TORQUE LIMITERS
B & C SERIES BACKHOE LOADER
BUILDING CONSTRUCTION PRODUCTS
BCP BHL
8/15/01
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Student Materials
416C - 438C HYDRAULIC PUMP
TORQUE LIMITER OPEN
TORQUE
LIMITER
SIGNAL
FLOW
COMPENSATOR
PUMP
OUTPUT
PRESSURE
COMPENSATOR
416B-438B/416C-438C Torque Limiter
Torque limiter were on backhoes were introduced at the introduction of
the B series. The torque limiter will destroke the pump at certain flow
and pressure demands to prevent the engine from stalling. The hydraulic
pumps on the B and C series machines were designed to provide as much
flow as possible without having an additional increase in engine
horsepower.
The current C series machines have gone back to the original design of
torque limiters used on the B series machines. When the C series
machines were introduced they were equipped with a differently designed
torque limiter. This torque limiter did not meet expectations and was
replaced.
➥
BCP BHL
8/15/01
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Student Materials
If the pump is at maximum flow and the signal pressure increases above
the torque limiter setting, the torque limiter opens and directs some of the
signal oil to the tank. A pressure drop occurs across the orifice in the
signal line which results in a slight loss of the actual signal pressure. The
margin spool then moves up and allows supply oil to the large actuator
piston. The pump will then destroke. The torque limiter will maintain
control over the swashplate as long as the signal pressure remains the
same or increases for the high flow demanded. During this condition, the
torque limiter remains open and continues to meter some of the signal oil
to the tank.
The reduced pump flow will be at a sufficient level to maintain the input
torque setting. If the cylinder pressure continues to increase, the torque
limiter will destroke the pump more.
In summary, full pump supply pressure is always available. However,
flow is regulated to maintain a required maximum input torque from the
engine. Full pump flow is available when the signal pressure is below
the torque limiter setting.
BCP BHL
8/15/01
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Student Materials
IMPLEMENT AND STEERING PUMP
TORQUE LIMITER REDUCES FLOW
PUMP
OUTPUT
SIGNAL
MARGIN
SPOOL
TORQUE
LIMITER
PASSAGE TO
TANK
• Torque limiter
operation
- Destrokes pump as
pressure increases
- Spring force varies
with swashplate
angle
LARGE ACTUATOR
SMALL ACTUATOR
AND BIAS SPRING
416C-438C Torque Limiter - Original Production
The torque limiter monitors the pump swashplate angle and the pump
signal pressure. The torque limiter will not allow the pump to go to full
stroke as system pressure increases above the torque limiter setting. The
allowable pump displacement is inversely proportional to the pump
discharge pressure. The higher the pressure, the less pump flow is
available.
The pressure setting of the torque limiter varies with the swashplate
angle. The greater the swashplate angle, the lower the pressure setting.
If the pump is at maximum flow and the signal pressure increases above
the torque limiter setting, the torque limiter opens and directs some of the
signal oil to the tank through a slot in the torque limiter spool. A
pressure drop occurs across the orifice in the signal line which results in
a slight loss of the actual signal pressure. The margin spool then moves
up and allows supply oil to the large actuator piston. The pump will then
destroke.
BCP BHL
8/15/01
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Student Materials
TORQUE LIMITER
NORMAL
ADJUSTMENT
SCREW
SIGNAL
SPRING
SLEEVE
SLOT
SPOOL
ACTUATOR
PISTON
REDUCED
FLOW
PASSAGE TO
TANK
SIGNAL
• Maintains input torque
setting
The torque limiter will maintain control over the swashplate as long as
the signal pressure remains the same or increases for the high flow
demanded. During this condition, the torque limiter remains open and
continues to meter some of the signal oil to the tank.
The reduced pump flow will be at a sufficient level to maintain the input
torque setting. If the cylinder pressure continues to increase, the torque
limiter will again open and destroke the pump more.
In summary, full pump supply pressure is always available. However,
flow is regulated to maintain a required maximum input torque from the
engine. Full pump flow is available when the signal pressure is below
the torque limiter setting.
BCP BHL
8/15/01
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ENGINE RPM VS. THE TORQUE
LIMITER SETTING
Student Materials
E
N
G
I
N
E
Engine RPM and the torque limiter setting
are directly proportional to one another.
At points A and B the input torque is the
same; However, at the higher low idle
engine speed for point B, the torque limiter
setting can be set higher.
B
R
P
M
A
TORQUE LIMITER
SETTING
SYSTEM PRESSURE VS. FLOW RATE
The allowable pump displacement is inversely proportional to the pump discharge pressure. For line B
at 43 gpm (maximum flow) as shown here, the system pressure is less than maximum system pressure.
If the system pressure increases the maximum flow rate is reduced by the torque limiter. The pump at
the higher operating pressure is now in the torque limiter control range. As pressure continues to
increase the flow rate is further reduced.
S
Y
S
T
E
M
P
R
E
S
S
U
R
E
3000 PSI
A
TORQUE LIMITER
CONTROL RANGE
B
B
FLOW RATE
43 GPM
A
BCP BHL
8/15/01
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Student Materials
416B-438B Torque Limiter Adjustments
Adjustments to the torque limiter can be made, but are not usually
required.
To determine if the torque limiter is at fault or whether the engine is at
fault, try the following.
Check torque converter stall. If the torque stall specification is incorrect
and the implement hydraulics is causing the engine to stop, then probably
the engine is at fault. DO NOT ADJUST THE TORQUE LIMITER.
If torque converter stall specification is correct, but the hydraulic system
causes the engine to die. The torque limiter may to be adjusted. Before
adjusting the torque limiter make sure that pump standby pressure,
maximum system pressure and margin pressure are correct.
1) Check Low Idle and adjust to above 950 rpm. Set at least to 970.
The fuel pump low idle spring tends to droop after a number of hours are
put on the machine.
2) Operate boom down at low idle against the boom stop. If the
hydraulic system does not cause the engine to stall, no further adjustment
is required.
3) If the engine still stalls. Back out the torque limiter to reduce the
spring setting.
4) Operate boom down at low idle against the boom stop. Increase the
torque limiter setting until the engine stalls. Back out the torque limiter
about a quarter of a turn.
5) Restart machine. Operate boom down at low idle against the boom
stop. If the engine does not stall the torque limiter has been adjusted
correctly.
NOTE: If more precise adjustments of the torque limiter are
required refer to the service manual and follow the steps for using a
flow meter.
BCP BHL
8/15/01
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Student Materials
416C-438C Torque Limiter Adjustments For Machines
Equipped with B Torque Limiter and D Series Machines
Adjustments to the torque limiter can be made, but are not usually
required. NOTE: B procedures do not work on the C because of a
lower boom line relief setting.
To determine if the torque limiter is at fault or whether the engine is at
fault, try the following.
Check torque converter stall. If the torque stall specification is incorrect
and the implement hydraulics is causing the engine to stop, then probably
the engine is at fault. DO NOT ADJUST THE TORQUE LIMITER.
If torque converter stall specification is correct, but the hydraulic system
causes the engine to die. The torque limiter may to be adjusted. Before
adjusting the torque limiter make sure that pump standby pressure,
maximum system pressure and margin pressure are correct.
1) Check Low Idle and adjust to above 950 rpm. Set at least to 970.
The fuel pump low idle spring tends to droop after a number of hours are
put on the machine.
2) Run machine at lower idle, turn on AC (if equipped),apply brakes,
place transmission in second gear forward, operate loader raise and stall
bucket dump for IT machines. For single tilt machines, operate raise and
rackback. If the hydraulic system does not cause the engine to stall, no
further adjustment is required.
3) If the engine still stalls. Back out the torque limiter to reduce the
spring setting.
4) Run machine at lower idle, apply brakes, place transmission in second
gear forward, operate loader raise and bucket dump. Increase the torque
limiter setting until the engine stalls. Back out the torque limiter about a
quarter of a turn.
5) Restart machine. Repeat step 2. If the engine does not stall the
torque limiter has been adjusted correctly.
NOTE: If more precise adjustments of the torque limiter are
required refer to the service manual and follow the steps for using a
flow meter.
For early production C machines without the B torque limiter refer
to the service manual.