Professional Documents
Culture Documents
STUDENT NOTES
BCP BHL -3- Student Materials
8/02/02
TABLE OF CONTENTS
COURSE DESCRIPTION......................................................................................................4
COURSE PLAN/OUTLINE...................................................................................................9
COURSE DESCRIPTION
Backhoe Loader Systems
Course Length: 4 1/2 Days
Course Ends: 4:00 P.M. Fifth Day
Class size: 8 students maximum
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
COURSE PRE-REQUISITES
SUGGESTED It is suggested that students complete the following prerequisite tests at
PREREQUISITE TESTS least one to two weeks before students take the course.
Students should pass the following pretests with 90% or better.
• Graphic Fluid Power Symbols Pretest SEBV0556
• Basic Hydraulic Pretest SEBV0557
• Basic Electrical Pretest SEBV0558
SUGGESTED It is suggested that students complete the following self study courses or
PREREQUISITE
COURSES equivalent courses prior to attending.
• "Fundamentals of Mobile Hydraulics" TEMV9001
• "Fundamentals of Electricity" TEMV9002
• "Fundamentals of Drive Trains" TEMV9004
BCP BHL -6- Student Materials
8/02/02
PRE-COURSE/POST-COURSE ASSESSMENT
training
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.
training
❑ ❑ ❑ 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, and torque limiter.
❑ ❑ ❑ 12. Perform cycle time checks and signal system checks to identify
resolver or pump control problems per the provided handout.
BCP BHL -8- Student Materials
8/02/02
Student's Signature:
Instructor's Signature:
Date:
Instructor's comments:
BCP BHL -9- Student Materials
8/02/02
COURSE PLAN/OUTLINE
GET ACQUAINTED
COURSE WRAP-UP
BCP BHL - 12 - Student Materials
8/02/02
❑ D Series
416D Specification Sheet AEHQ5419
❑ D Series
424D Backhoe Loader Specifications
428D Backhoe Loader Specifications
438D Backhoe Loader Specifications
432D Backhoe Loader Specifications
442D Backhoe Loader Specifications
❑ Video Tapes
"The DPA Pump" - Check with local fuel injection shops
❑ Laboratory Requirements
Mechanic's Tool Boxes with hand tools (include metric)
❑ Tooling Requirements
2-6V3121 Multitach Group or 9U7400 Multitach II Group or
2 - 1U6602 Hand held Phototachs.
2-1U5481 Pressure Gauge Groups or 2 - 198-4240 Digital
Pressure Indicator Groups
2-1U5482 Pressure Hose and Adapter Groups
2-6V7800 Multimeters, 9U7330 Fluke 87, 212-2126 Multimeter,
or 146-4080 Multimeter
2-8T0900 AC/DC Ammeter or 155-5176 Ammeter
1-127-8078 Battery Tester or 177-2330 Battery Analyzer
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 or 1 - 198-4240 Digital
Pressure Indicator 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
OBJECTIVES
At the completion of this module you will be able to:
❑ 4. Locate and read all machine warning labels for operating and
servicing the machine
BACKGROUND This lesson will help you gain familiarity with the correct machine
INFORMATION maintenance and operation guidelines, plus, machine features and
benefits.
Shop Lab
❑ • View introduction slide presentation
❑ • Remove floor plate and sheet metal (in preparation for later lab
exercises.)
Materials Needed
❑ 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
Quiz
❑ • Complete "Quiz: Machine Orientation."
Materials Needed
❑ Student Quizzes handout
Specalogs (for the machines used)
5/1/00
BCP BHL
S = Standard O = Option
Student Materials
BCP BHL - 21 - Student Materials
5/1/00
The D-series Backhoe Loader Has Been Updated {1058, 1273, 4203, 7056, 7451}
SMCS - 1058; 1273; 4203; 7056; 7451
Backhoe Loader:
416D (S/N: BFP1-UP)
420D (S/N: BLN1-UP; FDP1-UP)
430D (S/N: BML1-UP; BNK1-UP)
The D-series Backhoe Loader has been updated with new features. The following information
describes the new features that are available. The new features are being installed on current
production machines.
Revised Front Counterweight Group: Refer to Service Magazine, SEPD0601, 22 October 2001, "A
Revised Counterweight Group Is Now in Production". The 120-8482 has been revised. The new front
counterweight group reduces potential damage that is caused by the former 120-8482 Front
Counterweight Group .
Improvement to the Single Tilt Loader Circuit: The single tilt loader circuit has been redesigned.
Improvements to the tilt cylinder and to the hydraulic circuit increase the downward force of the tilt
circuit. This change improves the backdragging operation. The increase in downward force improves
stabilization during backhoe operation. Note: The bucket breakout force and the lifting capacity are
not affected by this improvement.
Open Circuit Oil Breather: The Open Circuit Oil Breather is designed for machines as an air
management system for the engine. This option is capable of separating oil from the blowby gases that
are expelled from the crankcase ventilation valve. The oil that is separated is drained into the oil pan.
This option is useful in environmentally sensitive areas. This option is available as a kit. Refer to Table
1 for availability and serial number effectivity. Refer to Special Instruction, REHS1228, "Field
Installation of the Open Circuit Oil Breather Gp (Engine Kit)" for installation of the Breather Group .
Fuel Tank Group: Refer to Service Magazine, SEPD0613, 21 January 2002, "A New Fuel Tank
Group Improves Serviceability" for a complete description of the fuel tank group. The fuel tank group
was introduced in order to increase serviceability. The filler neck is bolted on top of the tank assembly.
The filler neck is coated in order to increase rust protection. The diameter of the filler neck was
increased to 76.2 mm (3 inch). The fuel cap is made from a nonmetallic material. Also, the fuel cap is
lockable. The fuel tank group improves protection against contamination.
Anti-Drift Valves: Anti-Drift Valves are designed to decrease cylinder drift. Anti-Drift Valves are
installed on the following hydraulic circuits: boom cylinder, stick cylinder and extendable stick. The
valves decrease cylinder drift during overnight storage. Also, the valves decrease drift when material is
being lifted or material is being placed.
21L x 24 Rear Tires: The 21L x 24 rear tire is now available for the D-series machine. This option
provides a larger tire for applications that require low ground pressure.
BCP BHL - 22 - Student Materials
5/1/00
Rotating Vandal Cover: The new rotating vandal cover rotates to a closed position in order to
completely protect the gauges and panel switches. The cover is lockable in the closed position. The
new rotating vandal cover provides better security for the gauge panel. Also, the rotating vandal cover
provides better visibility over the side console.
The Parts Manual is Shipped as a CD-ROM: The Parts Manual is shipped as a CD-ROM for each
machine. The 0P-0423 option can be included in the machine order system in order to obtain a paper
copy of the Parts Manual in addition to the CD-ROM.
Hydraulic Cylinders: The elbows for the cylinder ports and the connector assemblies have been
combined into one part number. The hydraulic lines can be attached directly to the rod end of the
cylinder.
BCP BHL - 23 - Student Materials
8/02/02
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
BCP BHL - 24 - Student Materials
8/02/02
Place a check in the blank after locating each of the following controls
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
NA Pattern changer lever (if equipped)
NA Pilot shutoff/hydraulic lock switch (if equipped)
BCP BHL - 25 - Student Materials
8/02/02
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.
❑ 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.
Classroom Lab ❑ • 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
❑ • 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.
Classroom Lab ❑ • 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.
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
5/1/00
BOOST TRANSFER
WATER MAIN
PRESSURE PRESSURE
FUEL TANK SEPARATOR FILTER
REGULATOR
BOOST FEED
CONTROLLER PUMP
SHUTOFF
SOLENOID
INJECTOR
FUEL RETURN
TORQUE
CHECK VALVE VENT ORIFICE
TRIMMER
DELIVERY
VALVE
ROTOR
CAM
RING
ROLLERS TRANSFER
- 28 -
PUMP
METERING
VALVE
PLUNGERS
SHOES
FLAT
AUTOMATIC HYDRAULIC
SCROLL PLATES
ADVANCE HEAD
MECHANISM COLD ADVANCE
DEVICE
ORIFICE
CHECK VALVE
LIGHT LOAD
LATCH
ADVANCE VALVE
VALVE
Student Materials
5/1/00
SCROLL LINK
- 29 -
PLATE SCREEN
TRANSFER
DRIVE PUMP
SHAFT
SHIFTER AND
SLEEVE PLUNGERS
TO INJECTOR
GOVERNOR
FLYWEIGHTS SHOES
SCROLL PLATES
ROLLERS CAM RING AUTOMATIC ADVANCE ORIFICE
MECHANISM CHECK VALVE
Student Materials
BCP BHL - 30 - Student Materials
8/02/02
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.
7. When filling the cooling system, never fill faster than 5 gallons per minute.
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 - 31 - Student Materials
8/02/02
Shop Lab ❑ • 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.
(Optional)
1-5P0957 Coolant and Battery Tester
1-4C6500 Digital Thermometer group
BCP BHL - 32 - Student Materials
5/1/00
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 - 34 - Student Materials
8/02/02
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 - 35 - Student Materials
8/02/02
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.
BACKGROUND This lesson allows you to become familiar with locating electrical system
INFORMATION components on the machine and in using the machine electrical
schematic.
Classroom Lab
❑ • 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
❑ • 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.
Classroom Lab
❑ • 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
❑ D Series Electrical System Checklist
D Series Starting and Charging System Sheet
D Series Machine electrical schematic
1-Mechanics Tool Box
BCP BHL - 37 - Student Materials
5/1/00
Machine Schematic
Location Part No. Location Parts Manual Description Schematic Description
Starter motor
Alternator
Battery
Keystart fuse
Start relay
Directions: Use the machine electrical schematic to complete this schematic. Label all wires.
BCP BHL
G S
ACTION LAMP
MTR BAT GROUP
101-RD
MOTOR
STARTER 309-GY
1 2 3
L IG P TACH.
CBL RD-00
B+
ATTACHMENT ALT ALTERNATOR
RELAY POS NEG POS NEG
COLD START
TEMP SW.
TO FUSES A
C COLD START
°T ADVANCE
SOLENOID
TO RR LIGHTING RELAY
TO FUSES
BATTERY 1
GROUND 2 202-BK
FORWARD SOL. RETURN 3
REVERSE SOL. RETURN 4 SHUTTLE START
TO FUSES FORWARD SOL. OUT 5
15 A CONTROL AID SW.
REVERSE SOL. OUT 6
THERMAL START START RELAY COIL. OUT 7 THERMAL
10A AID KEY START SW. TO BAT. 8 STARTING
MAIN
TRANSMISSION NEUTRALIZER SW. TO BAT 9
RELAY PARK BRAKE ALARM OUT 10
AID
A PARK BRAKE SW. TO GND . 11
10A
C NEUTRAL LOCK SW. TO GND 12
ENGINE FUEL R
1
START RELAY C OFF
2
S ON
20A 3 ST
START B
4
RELAY
A
KEY START
TO FUSES
C SWITCH
TO FRONT
KEY START LIGHTING
5A RELAY
Student Materials
BACKGROUND This lesson allows you to become familiar with typical on the machine
INFORMATION electrical system tests using a voltmeter and ammeter.
Shop Lab
❑ • 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
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 or 177-2330 Battery Analyzer
1-Mechanics Tool Box
Optional
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
BCP BHL - 40 - Student Materials
8/02/02
Voltage
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 Chart A-Typical System Voltage During
check voltage on the cable post clamps. Cranking Versus Ambient Temperature
1. Is voltage equal to or greater than what is shown in -23°C To-7°C -7°C To 10°C 10°C To 27°C
Chart A? Temp. (-10°F To 20°F) (20°F to 50°F) (50°F To 80°F)
24 Volt 12V to 16V 14V to 18V 16V to 20V
Record Voltage ___________
System
. . . Yes - Go to Test B. 12 Volt 6V to 8V 7V to 9V 8V to 10V
System
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? Chart B-Maximum Allowable System
Voltage Drops During Cranking
Record Voltage ___________
Absolute Maximum
. . . Yes - Batteries and starter cables down to motor are Voltage Reading
electrically within specifications. Go to Test C. Circuit 24V 12V
Batt. Pos. Post to Starter 0.5V 0.3V
. . . No - Voltage drop (loss) between batteries and starter
Pos. Post (TP10 to TP6)
is too great. Go to next step.
Batt. Neg. Post to Starter 1.4V 0.7V
NOTE: For this exercise, assume your answer is "NO" Neg. Post (TP7 to TP5)
and then perform the next step. Enter results in CHART Drop Across Only 1.0V .5V
B. Disconnect Switch
(TP8 to TP9)
2. Measure voltage drops in cranking circuit per Chart B. Start Relay Contacts 0.8V 0.4V
Are all voltages within specifications? (TP3 to TP6)
. . . Yes - Check engine. Go to Test C. Solenoid Contacts 0.8V 0.4V
(TP6 to TP4)
. . . No - Repair and/or replace faulty electrical
component .
Voltage (step 5)
Amperage (step 6)
BCP BHL - 41 - Student Materials
8/02/02
Voltage
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 Chart A-Typical System Voltage During
check voltage on the cable post clamps. Cranking Versus Ambient Temperature
1. Is voltage equal to or greater than what is shown in -23°C To-7°C -7°C To 10°C 10°C To 27°C
Chart A? Temp. (-10°F To 20°F) (20°F to 50°F) (50°F To 80°F)
24 Volt 12V to 16V 14V to 18V 16V to 20V
Record Voltage ___________
System
. . . Yes - Go to Test B. 12 Volt 6V to 8V 7V to 9V 8V to 10V
System
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? Chart B-Maximum Allowable System
Voltage Drops During Cranking
Record Voltage ___________
Absolute Maximum
. . . Yes - Batteries and starter cables down to motor are Voltage Reading
electrically within specifications. Go to Test C. Circuit 24V 12V
Batt. Pos. Post to Starter 0.5V 0.3V
. . . No - Voltage drop (loss) between batteries and starter
Pos. Post (TP10 to TP6)
is too great. Go to next step.
Batt. Neg. Post to Starter 1.4V 0.7V
NOTE: For this exercise, assume your answer is "NO" Neg. Post (TP7 to TP5)
and then perform the next step. Enter results in CHART Drop Across Only 1.0V .5V
B. Disconnect Switch
(TP8 to TP9)
2. Measure voltage drops in cranking circuit per Chart B. Start Relay Contacts 0.8V 0.4V
Are all voltages within specifications? (TP3 to TP6)
. . . Yes - Check engine. Go to Test C. Solenoid Contacts 0.8V 0.4V
(TP6 to TP4)
. . . No - Repair and/or replace faulty electrical
component .
Voltage (step 5)
Amperage (step 6)
BCP BHL - 42 - Student Materials
8/02/02
OBJECTIVES
❑ 1. On a schematic for the D 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.
❑ 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 - 43 - Student Materials
8/02/02
Materials Needed
❑ Operation and Maintenance Guide
Service Manual
Parts Book
Standard Power Train Component Checklists
D Series Power Train Component Checklists I & II
Mechanic's Tool Box and hand tools
BCP BHL - 45 - Student Materials
8/02/02
D Model
Fill tube
Filter
Suction screen
Speed selector
Relief valve
Test Locations:
Lube pressure
E C
F
D
J
H
G
Filter
Main Relief Valve
Cold Start Relief Valve (C-Series Only)
Torque Converter Inlet Relief Valve
Transmission Control Valve
AWD Solenoid
Identify Components
A R
B
C 5
D
E C 6
F E
F
G F
H D
- 47 -
I
7
AWD
2
1
Identify Test Ports G H
1 A TRANSMISSION
B LUBE
3
2
4 I
3
4
5
6
Student Materials
7
BCP BHL - 48 - Student Materials
8/02/02
Shop Lab
❑ • Record pressure specifications from the service manual before going to
the shop.
- 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
Materials Needed
❑ Power Train Testing and Adjusting Service Manual Module
Backhoe Loader Transmission Test Sheets
Torque Converter Stall Test Handout
1-1U5481 Pressure Test Gauge Group or 1 - 198-4240 Digital
Pressure Indicator 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 - 49 - Student Materials
8/02/02
VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
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 - 50 - Student Materials
8/02/02
VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
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 - 51 - Student Materials
8/02/02
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.
If all the torque converter stall readings are out of specification, then
the torque converter or engine is probably at fault.
Engine Check
• Check 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 or fuel setting may be misadjusted.
If the high idle is too high and the rack or fuel 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.
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.
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 - 54 - Student Materials
8/02/02
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 When troubleshooting always perform a visual inspection first. Look for
Inspection 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 - 55 - Student Materials
8/02/02
Tooling needed:
BCP BHL - 56 - Student Materials
8/02/02
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 - 57 - Student Materials
8/02/02
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.
OBJECTIVES
❑ 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).
❑ 10. Using the appropriate service manual module, perform checks on the
machine for the autoshift transmission control system using a PC
equipped with ET.
BCP BHL - 60 - Student Materials
8/02/02
Classroom Lab
❑ • View a slide presentation on power train components
Shop Lab
❑ • Remove side panels and/or cab floor plates as needed.
Materials Needed
❑ Operation and Maintenance Guide
Service Manual
Parts Book
Power Shift/Autoshift Component Checklist
Autoshift Operations
Autoshift Power Train Components worksheet
Autoshift Electronic Control Component Checklist
Mechanic's Tool Box and hand tools
BCP BHL - 61 - Student Materials
8/02/02
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 - 62 - Student Materials
5/1/00
AUTOSHIFT OPERATION
Locate and identify the following components before operating the machine:
NOTE: Connect the ET tool to the service connector to determine the gear the machine shifts to.
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
6. When in FIRST SPEED FORWARD, keep the accelerator pedal depressed and depress and
hold the neutralizer switch momentarily.
Did the engine pull against the brake? Yes No
Did the transmission go to NEUTRAL? Yes No
Stop the machine. Place the auto/manual switch in the AUTO position.
9. Shift the transmission through all FORWARD and REVERSE gears.
Did the transmission shift through all gears? Yes No
11. When driving FORWARD in SECOND SPEED, remove foot from accelerator.
Did the transmission shift to FIRST FORWARD? Yes No
To what speed did the transmission shift? .
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 No
A
J PARKING BRAKE SWITCH
AUTO/MANUAL SWITCH A D
NEUTRAL LOCK SWITCH RIDE CONTROL DISABLE
C
D
REGULATED
PRESSURE
E
ORIFICE
5 6 2 1 3 4
F
- 64 -
3 HI SOLENOID
G R VALVE 1
2 LO
F FORWARD
TORQUE G
CONVERTER
H INLET
E
Student Materials
Autoshift Electronic Control Component Checklist
8/02/02
Directions: Record a check next to each component after locating it on the machine. Or if using multiple machines, record the model
BCP BHL
number. All components may not be on every machine. NOTE: Power shift transmissions are the same except for the software.
ELECTRONIC
SWITCH
SPEED CLUTCH 2
TRANSMISSION No. 5 SOLENOID
TRANSMISSION OUTPUT
BACKUP START SPEED SENSOR
ALARM RELAY CONTROL SPEED CLUTCH 3
No. 6 SOLENOID
AUTO/MANUAL
SWITCH (AETC)
PARK BRAKE
ALARM RELAY
RIDE CONTROL
DISABLE SWITCH
RIDE CONTROL
RELAY
DOWNSHIFT/
NEUTRALIZER SWITCH DIAGNOSTIC
INDICATOR and
DATA LINK
SERVICE PORT
Student Materials
BCP BHL - 66 - Student Materials
5/1/00
BACKGROUND This lab measures your ability to perform the Autoshift transmission tests
INFORMATION on Backhoe Loaders.
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 ❑ 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)or
1 - 198-4240 Digital Pressure Indicator Group
1-1U5482 Hose and Fitting Group (If not using Dataview)
1-9U7400 Multitach Group (If not using Dataview)
BCP BHL - 67 - Student Materials
5/1/00
ENGINE SPEED
PRESSURE TEST LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Pressure
Lube Pressure
FORWARD HIGH
REVERSE
FORWARD LOW
Speed Clutch 1
Speed Clutch 2
Speed Clutch 3
Comments:
BCP BHL - 68 - Student Materials
5/1/00
ENGINE SPEED
PRESSURE TEST LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
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
Comments:
BCP BHL - 69 - Student Materials
5/1/00
BACKHOE LOADERS
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.
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 When troubleshooting always perform a visual inspection first. Look for
Inspection 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 - 72 - Student Materials
5/1/00
LIST POSSIBLE The next step in the process is to list all of the possible causes of the
FAULTS 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 Now, create a list of tests should be performed and describe what the
determine root cause 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 - 73 - Student Materials
5/1/00
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?
2.
3.
4.
5.
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.
Shop Lab ❑ • View slide presentation on the axle and brake system
Materials Needed
❑ Operation & Maintenance Guide
Service Manual
Parts Book
Axle and Brake Component Checklist
Brake Schematic
1-Mechanic's Tool Boxes and hand tools
BCP BHL - 76 - Student Materials
8/02/02
D Model
Brake pedals
Reservoir
Brake lamp
AWD solenoid
TO BRAKE TO BRAKE
PISTON PISTON
SUPPLY PORT
VALVE STEM
PLUNGER
COMPENSATION PLUNGER
VALVE
BRIDGE PIPE
PUSH ROD
BCP BHL - 78 - Student Materials
8/02/02
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 now turn at same speed.
Release the differential lock pedal. The Differential lock will remain
engaged until the left brake pedal is released.
Optional:
❑ • On, perform proper brake bleed procedures as per the service manual.
Materials Needed
❑ Axle, brake and steering service manual modules
1-Mechanic's Tool Boxes and hand tools
BCP BHL - 79 - Student Materials
5/1/00
Problem: Caterpillar has received a number of communications from dealers showing concern about
the amount of brake pedal travel on the D-Series Backhoe Loaders.
Solution: The mechanical advantage of the brake pedal system was changed on the D- Series Backhoe
Loader in order to reduce the brake effort required to stop the machine. The D-Series pedals have a
mechanical advantage of 11.8 to 1 verses the C-Series, which had a mechanical advantage of 7 to 1.
Due to the increases mechanical advantage of the D-series, the force necessary to achieve the same
braking is less.
One of the side affects of this change is that the brake pedal must travel farther on the D-Series than on
the C-Series in order to achieve the same braking. For example, on the C-Series the brake pedal may
go hard after an inch or so of pedal movement, the D-series pedal must travel much farther in order to
achieve the same braking. In some cases, the brake pedal of a D-series backhoe loader will only be an
inch or so from the firewall of the cab.
Reference: RENR3576 Axles, Differentials & Brakes Specifications for the D-series Backhoe Loader
and
RENR3577 Axles, Differentials & Brakes System Operation, Testing and Adjusting for the D-series
Backhoe Loader
Checking the Brake System of the D-series Backhoe Loader
1. Raise the tractor off of the ground using the stabilizers and front loader bucket.
2. Perform a torque converter stall test in 2nd gear and at high idle.
3. Check the brakes (both pedals applied) should be able to stop or prevent the wheels from turning
without the brake pedal touching the firewall. If the wheels turn during this test or if it is necessary
to touch the firewall to stop the wheels from turning, please perform the following checks or
procedures:
Check the "free play" in the pedals
Brake "free play" must be between 5 to 10 mm (approximately 1/4 inch) measured at the pedal.
Measure "free play" of each brake pedal individually. Depress each pedal by hand until resistance is
encountered. Because of the large mechanical advantage of the pedal system, this dimensions is
critical. Too much free play may allow the pedals to touch the firewall.
BCP BHL - 80 - Student Materials
5/1/00
If the "free play" is found to be out of specification, and adjustments have been made, the pedals must
be stroked individually approximately 6 times, and "free play" rechecked to assure some clearance
does exist.
Make sure there is some distance between the push rod and the master cylinder piston.
Bleed brake system to remove any trapped air.
If the "free play" is correct and the pedals still contact the firewall during the 2nd gear stall test, the
brakes will have tobe bled (purged) in order to remove any air that may remain in the brake system.
COPYRIGHT 2001 CATERPILLAR ALL RIGHTS RESERVED
BCP BHL - 81 - Student Materials
8/02/02
OBJECTIVES
Shop Lab ❑ • 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.
Materials Needed
❑ 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 or 2 - 198-4240 Digital
Pressure Indicator Groups
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 - 83 - Student Materials
8/02/02
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 - 84 - Student Materials
8/02/02
Voltage
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. Chart A-Typical System Voltage During
Cranking Versus Ambient Temperature
1. Is voltage equal to or greater than what is shown in
-23°C To-7°C -7°C To 10°C 10°C To 27°C
Chart A?
Temp. (-10°F To 20°F) (20°F to 50°F) (50°F To 80°F)
Record Voltage ___________ 24 Volt 12V to 16V 14V to 18V 16V to 20V
System
. . . Yes - Go to Test B.
12 Volt 6V to 8V 7V to 9V 8V to 10V
System
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 ___________ Chart B-Maximum Allowable System
Voltage Drops During Cranking
. . . Yes - Batteries and starter cables down to motor are
Absolute Maximum
electrically within specifications. Go to Test C.
Voltage Reading
. . . No - Voltage drop (loss) between batteries and starter Circuit 24V 12V
is too great. Go to next step. Batt. Pos. Post to Starter 0.5V 0.3V
Pos. Post (TP10 to TP6)
NOTE: For this exercise, assume your answer is "NO"
and then perform the next step. Enter results in CHART Batt. Neg. Post to Starter 1.4V 0.7V
B. Neg. Post (TP7 to TP5)
Drop Across Only 1.0V .5V
2. Measure voltage drops in cranking circuit per Chart B. Disconnect Switch
Are all voltages within specifications? (TP8 to TP9)
Start Relay Contacts 0.8V 0.4V
. . . Yes - Check engine. Go to Test C. (TP3 to TP6)
. . . No - Repair and/or replace faulty electrical Solenoid Contacts 0.8V 0.4V
component . (TP6 to TP4)
Voltage (step 5)
Amperage (step 6)
BCP BHL - 85 - Student Materials
8/02/02
VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
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 - 86 - Student Materials
8/02/02
VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
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 - 87 - Student Materials
8/02/02
ENGINE SPEED
PRESSURE TEST LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Pressure
Lube Pressure
FORWARD HIGH
REVERSE
FORWARD LOW
Speed Clutch 1
Speed Clutch 2
Speed Clutch 3
Comments:
BCP BHL - 88 - Student Materials
5/1/00
ENGINE SPEED
PRESSURE TEST LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
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
Comments:
BCP BHL - 89 - Student Materials
8/02/02
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:
BCP BHL - 90 - Student Materials
8/02/02
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:
BCP BHL - 91 - Student Materials
8/02/02
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:
BCP BHL - 92 - Student Materials
8/02/02
OBJECTIVES
❑ 10. On a quiz, match state of pump (i.e. upstroke, destroke, low pressure
standby, stall) to operational condition.
Quiz
❑ • 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 - 95 - Student Materials
8/02/02
Classroom 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
Shop Lab
❑ • 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.
Materials Needed
❑ Hydraulic System Testing and Adjusting Service Manual Module
Hydraulic System Component Checklists I, II, and III
Hydraulic System Component Checklist
BCP BHL - 96 - Student Materials
8/02/02
D D Model
Hydraulic tank
Pump
Implement controls
Torque Limiter
Directions: Label all valves (including shutoff valve and backflow check valve), tank, pump, filter, cooler,, pilot accumulator and HMU.
BCP BHL
END
COVER
- 97 -
INLET
MANIFOLD
MANIFOLD
Student Materials
D Series Signal Network
5/1/00
ORIFICE
TORQUE
LIMITER
- 98 -
SECONDARY
RESOLVER LEFT RIGHT
CONNECTED TO
SWASHPLATE STABILIZER STABILIZER
LIFT PILOT
LOADER SECTION
VALVE
PILOT OIL
Student Materials
BCP BHL - 99 - Student Materials
8/02/02
BACKGROUND This lesson allows you to gain hands on experience with the hydraulic
INFORMATION pump and pump control valve and their components.
Shop Lab
❑ • 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.).
Margin spool
Pressure cut-off
Torque Limiter
Hydraulic Pump
Large actuator
Swash plate
Drive shaft
Primary resolver
Secondary resolver
Makeup valve
BCP BHL - 101 - Student Materials
8/02/02
SIGNAL PUMP B
OUTPUT
C
H
G
E
F
I
BCP BHL - 102 - Student Materials
8/02/02
BACKGROUND This lesson allows you to gain hands on experience with the implement
INFORMATION control valve and its components.
Shop Lab
❑ • 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.).
Materials Needed
❑ 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 - 103 - Student Materials
8/02/02
HEAD ROD
B END END
E
TO TANK
TO TANK
D
FROM
C PUMP
TO NEXT
VALVE
F
BCP BHL - 104 - Student Materials
8/02/02
BACKGROUND This lesson will allow you gain familiarity performing system checks,
INFORMATION using the Service Manual, and determining if the machine is operating to
specifications.
Shop Lab ❑ • Record pressure specifications from the service manual before going to
the shop.on the Hydraulic System Test Sheet
Optional
❑ • Check line reliefs as per service manual. Adjust bucket positioner cam
and switch as per service manual.
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:
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.
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.
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• 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 or more. 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 460 psi for the
D series. Recheck cycle times and margin pressure.
Test One Test Two Test Three
Average Cycle time
Margin Pressure
CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L
O Tilt Back
A Regenerative Dump
(for parallel lift)
D
E Float
R Raise
Bucket Dump
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
E-Stick Extend
B
A E-Stick Retract
C
K Left Stabilizer Up
H
O Left Stabilizer Down
E
Right Stabilizer Up
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
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BACKHOE LOADER HYDRAULIC TESTS
CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L
O Tilt Back
A Regenerative Dump
(for parallel lift)
D
E Float
R Raise
Bucket Dump
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
E-Stick Extend
B
A E-Stick Retract
C
K Left Stabilizer Up
H
O Left Stabilizer Down
E
Right Stabilizer Up
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
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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 - 110 - Student Materials
8/02/02
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 - 111 - Student Materials
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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 - 112 - Student Materials
8/02/02
PUMP
LOADER LOADER LOADER CONTROL
AUX. TILT LIFT HMU VALVE
ORIFICE
RESOLVER
TORQUE
LOADER SECTION STEERING LIMITER
RESOLVER
CONNECTED TO
SWASHPLATE
PUMP
LOADER LOADER LOADER CONTROL
AUX. TILT LIFT HMU VALVE
ORIFICE
RESOLVER
TORQUE
LOADER SECTION STEERING LIMITER
RESOLVER
CONNECTED TO
SWASHPLATE
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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.
The customer's 416D 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.
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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 When troubleshooting always perform a visual inspection first. Look for
Inspection 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:
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8/02/02
LIST POSSIBLE The next step in the process is to list all of the possible causes of the
FAULTS 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 Now, create a list of tests should be performed and describe what the
determine root cause 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 - 116 - Student Materials
8/02/02
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.
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
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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.
OBJECTIVES
Shop Lab
❑ • Split into Two Groups with One Machine per Group.
Materials Needed
❑ 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 - 120 - Student Materials
CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L
O Tilt Back
A Regenerative Dump
(for parallel lift)
D
E Float
R Raise
Bucket Dump
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
E-Stick Extend
B
A E-Stick Retract
C
K Left Stabilizer Up
H
O Left Stabilizer Down
E
Right Stabilizer Up
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
BCP BHL - 121 - Student Materials
CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L
O Tilt Back
A Regenerative Dump
(for parallel lift)
D
E Float
R Raise
Bucket Dump
Stick In
Stick Out
Swing
(Stop to Stop)
Swing
(Stop to Snubber)
E-Stick Extend
B
A E-Stick Retract
C
K Left Stabilizer Up
H
O Left Stabilizer Down
E
Right Stabilizer Up
Boom Lower
Boom Pause
Boom Raise
(to snubber)
Boom Raise
(to stop)
Auxiliary 1
Auxiliary 2
BCP BHL - 122 - Student Materials
8/02/02
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
OBJECTIVES
Shop Lab
❑ • 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, plus the 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
C D Model
Pressure Switch
TST 1 TST 2
BCP BHL
THERMAL
ALL WHEEL STEER SYSTEM
IRM RELIEF HOLD
LEFT VALVE
VALVE
IRM PILOT
RIGHT POPPET
VALVE VALVES
LOCK
VALVE
PILOT
RESOLVER POPPET
VALVES
REAR
AXLE
- 127 -
LOADER TILT
VALVE
GROUP LIFT
SIGNAL
TO STABILIZER
VALVE GROUP
STEERING
PRIORITY
VALVE
TORQUE LIMITERS
BACKHOE LOADERS
BUILDING CONSTRUCTION PRODUCTS
BCP BHL -2- Student Materials
8/02/02
TORQUE
LIMITER
PUMP
SIGNAL OUTPUT
FLOW PRESSURE
COMPENSATOR COMPENSATOR
The C Series and D 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 -3- Student Materials
8/02/02
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.
MARGIN TORQUE
SPOOL LIMITER
SMALL ACTUATOR
PASSAGE TO AND BIAS SPRING
TANK
- Destrokes pump as The torque limiter monitors the pump swashplate angle and the pump
pressure increases 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
- Spring force varies allowable pump displacement is inversely proportional to the pump
with swashplate discharge pressure. The higher the pressure, the less pump flow is
angle
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 -5- Student Materials
8/02/02
TORQUE LIMITER
NORMAL
ADJUSTMENT
SCREW
SIGNAL ACTUATOR
SPRING PISTON
SLEEVE SLOT SPOOL
REDUCED
FLOW
PASSAGE TO
TANK
SIGNAL
• Maintains input torque The torque limiter will maintain control over the swashplate as long as
setting 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.
TORQUE LIMITER
SETTING
S
Y 3000 PSI A
S
TORQUE LIMITER
T CONTROL RANGE
E
M
B B
P
R
E
S
S
U
R
E
A
43 GPM
FLOW RATE
BCP BHL -7- Student Materials
8/02/02
Adjustments to the torque limiter can be made, but are not usually
required.
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.
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.
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.
3) If the engine still stalls. Back out the torque limiter to reduce the
spring setting.
5) Restart machine. Repeat step 2. If the engine does not stall the
torque limiter has been adjusted correctly.
For dual tilt cylinder machines, follow the same steps, except stall the
bucket in the dump position, instead of racking back.
For more precise adjustment of the torque limiter follow the procedures
in the service manual. A torque converter stall test should also be done
before adjusting the torque limiter. The engine may not be performing
correctly.