Series Ii, B & C Series Backhoe Loader Diagnostics: Service Training

Service Training STUDENT
Course Materials MATERIALS
SERIES II, B & C SERIES BACKHOE LOADER

DIAGNOSTICS
BUILDING CONSTRUCTION PRODUCTS
BCP BHL -2- Student Materials
5/1/98
STUDENT NOTES
5/1/98
TABLE OF CONTENTS
COURSE DESCRIPTION......................................................................................................4
PRE-COURSE/POST-COURSE ASSESSMENT..................................................................6
COURSE PLAN/OUTLINE...................................................................................................8
STUDENT LITERATURE CHECKLIST............................................................................11
MODULE: MACHINE ORIENTATION ............................................................................15
MODULE: ENGINE SYSTEMS .......................................................................................20
MODULE: ELECTRICAL SYSTEM ................................................................................32
MODULE: POWER TRAIN ..............................................................................................41
MODULE: AXLES AND BRAKES ..................................................................................63
MODULE: ENGINE, ELECTRICAL AND POWER TRAIN TROUBLESHOOTING...68
MODULE: STEERING AND IMPLEMENT HYDRAULIC SYSTEMS ........................78
MODULE: STEERING AND IMPLEMENT HYDRAULIC SYSTEMS

TROUBLESHOOTING......................................................................................................104
MODULE: ALL WHEEL STEERING ELECTRICAL & HYDRAULIC SYSTEMS ...110

5/1/98
COURSE DESCRIPTION
Backhoe Loader Diagnostics & C Series Introduction - Level III
Course Length: 5 Days
Course Ends: 4:00 P.M. Fifth Day
Class size: 8 students maximum
CONTENT WHO SHOULD ATTEND:

• Training Instructors
• Technical Communicators
• Product Support Engineers
• Service Technicians
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 will be challenged to answer
"what if" questions using the instructor's slides, service manual, system
schematics and will be tested to monitor their progress. All Wheel Steer
will be covered if a machine is available to perform diagnostics on. Note:
For field schools only, the class may be extended by 1/2 day to cover the
446 Backhoe Loader.
During lab exercises, the student will have an opportunity to operate the
machine to get a feel for the vehicle and to demonstrate their
understanding of systems operation by troubleshooting various "bugs"
installed for that purpose.
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 placed on the forward/reverse
shuttle control (electrical and mechanical). Students will disassemble
and assemble a control valve and locate the various pressure taps and
perform system tests as described in the service manual for the
transmission. The students will "bug" the transmission control valve to
demonstrate the effects of component malfunction.
5/1/98
• Brakes and Axles Lab- Students will perform proper brake

adjustment procedures 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 D&A the pump control valves
and implement control valves and explain the function of the piece
parts. They 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
• test and adjust the brake system
• 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
COURSE PRE-REQUISITES
SUGGESTED CACo. suggests 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.
• Basic ISO Pre-test SEBV0556
• Basic Hydraulic Pretest SEBV0557
• Basic Electrical Pretest SEBV0558
SUGGESTED CACo. suggests that students complete the following courses or
PREREQUISITE equilvalent courses prior to attending.
COURSES
• Multimedia Course "Fundamentals of Mobile Hydraulics"
TECD9001
• Multimedia Course "Fundamentals of Electricity"
TECD9002
• Multimedia Course "Fundamentals of Drive Trains"
TECD9004
5/1/98
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 B or C Series 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,
thermal start coil, radiator, water pump, 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..
5/1/98
7. 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.
❑ ❑ ❑ 8. Perform performance checks and/or adjust: max system pressure, low

pressure standby, and margin pressure.
❑ ❑ ❑ 9. Perform cycle time checks and signal system checks to identify

resolver or pump control problems per the provided handout.
❑ ❑ ❑ 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.
Post Course Assessment Only - Student should review the above

objective and palce checks in those boxes as appropriate. Student should
then sign his name below.
Student's Signature:
Instructor's Signature:
Date:
Instructor's comments:
5/1/98
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
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
- Identify valve components
5/1/98
MODULE: POWER TRAIN (cont'd)

- Lesson: Control Valve Operation
- Lesson: Power Train System Tests
- Case Study: Power Train
- Quiz: Power Train
- 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
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
BCP BHL - 10 - Student Materials
5/1/98
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
5/1/98
REQUIRED STUDENT STUDENT LITERATURE CHECKLIST

MATERIALS
❑ Description
Binder
Form No.
SENR2910
Fluid Power Graphic Symbols SEEV0529
Know Your Cooling System SEBD0518
❑ C Series
416C Thru 438C Lube and Maintenance Chart SELU6873
416C Specification Sheet AEHQ0428
3054 Diesel Engine - Systems Operation SENR5816
3054 Diesel Engine - Specifications SENR5815
C Series Transmission - Systems Operation. SENR1204
C Series Power Train - Systems Operation SENR1205
Hydraulic & Steering System -Systems Operation SENR1208
Hydraulic & Steering System -Test & Adjust SENR1272
C Series Hydraulic System Schematic SENR1213
416C, 426C, & 436C Series Electrical System
Schematic (for machines built before 1/1/98) SENR1212
416C, 426C, & 436C Series Electrical System
Schematic (for machines built after 1/1/98) SENR1276
❑ B Series
416B Thru 438B Lube and Maintenance Chart SELU6414
B Series Transmission - Systems Operation. SENR5806
B Series Hydraulic System Systems Operation SENR5808
B Series Hydraulic System Schematic SENR5810
416B, 426B, and 436B Electrical System Schematic SENR5814
❑ Series II
416 Thru 438 Lube & Maint. Chart SELU6232
4.236 Diesel Engine - Systems Operation. SENR3114
Series II BHL Differential, Rear Axle & Brakes -
Systems Operation SENR3157
416 BHL Hydraulic System - System Operation. SENR3195
5/1/98
STUDENT REFERENCE Reference Materials

MATERIALS
❑ Optional
Battery Test Procedures SEHS7633
428C Backhoe Loader Specifications HEHB2072
438C Backhoe Loader Specifications HEHB2073
Powershift Transmission - Systems Operation SENR1273
428C and 438C Electrical System Schematic
(European Cab for machines built before 1/1/98)) SENR1210
428C and 438C Electrical System Schematic
(European Cab for machines built after 1/1/98)) SENR1277
416B, 426B, 428B, 436B and 438B Electrical System
Schematic (European Cab) SENR5813
428 Series II Hydraulic System - Systems Operation SENR3472
428 Series II Hydraulic Schematic SENR3459
❑ 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
B Series Operation and Maintenance Guide SEBU6414
❑ 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
416, 426, 436, and 416 Series II, 426 Series II, 436 Series II
Backhoe Loader Service Manual SENR3160
❑ Parts Books
416C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2388
416C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2549
416B Backhoe Loader Parts Book SEBP2357
428B Backhoe Loader Parts Book SEBP2360
416 Series II Parts Book SEBP1900
5/1/98
❑ 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 Hydrualics" SEVN1837
"Introduction to Pressure Compensated Valves in
LS/PC Hydrualics" SEVN1900
"C-Series Walkaround" 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
2 - 416C/426C/436C backhoe loaders
1 - 416B/426B/436B backhoe loaders
1 - (Optional) 416 Series II/426 Series II/436 Series II backhoe
loaders
NOTE: Corresponding sideshift machines may also be used.
5/1/98
❑ 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
1-14C8054 fitting to check engine transfer pressure
1-127-8078 Battery Tester
8-6V3965 Nipples
8-3J1907 O-rings
2-8T0856 Pressure Gauge (0 to 870 psi)
1-1U5796 Differential Gauge Group
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)
To check transfer pressure on the Series II backhoes. Modify fitting

8T7861. A 6V6560 Seal is also required. About .100 in of thread
length needs to be removed for the fitting to work. If the threads
are not removed the fitting will block fuel flow in the pump.
1-4C8054 - Fitting to check fuel transfer pressure on the B & C
backhoes.
1-154-7151 - New tool for removing top cover to access fuel pump
solenoid
5/1/98
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:
❑ 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.
NOTE: For the following objectives, use the Operation and Maintenance
Guide as a reference during the lab activities.
❑ 2. Perform a 10 hour/daily machine inspection for a BCP backhoe

loader.
❑ 3. Identify the following BCP 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

BCP backhoe loader.
5/1/98
Lesson: Machine Orientation
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
❑ • Perform a 10 hour/daily inspection before starting and or operating the

vehicle using the Machine Walkaround 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 Walkaround 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.
❑ • 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)
5/1/98
5/1/98
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.
Series II B Series C Series
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 and precleaner if equipped
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
5/1/98
Machine Walk-around Checklist - cont'd

Place a check in the blank after locating and reading the following warnings label on the machine..
Before operating
Use of ether
Boom/swing area
Before roading
Start procedure for AWS
Loader arm brace
O&M connecting cable
ROPS
Use of Jumpers
Place a check in the blank after locating each of the following controls
Front governor pedal
Steering wheel
. Directional shifter
Speed selector
Directional or transmission neutral lock
Transmission neutralizer switches (both)
All wheel drive (AWD) switch (if equipped)
Differential lock pedal
Brake pedals
Parking brake lever (and release for C)
Loader lift and tilt
Attachment lever
N/A N/A Attachment switch for IT machine
Rear governor lever
Stabilizer controls
Boom lever
Swing lever or pedals
Stick lever
Bucket lever
E-stick/attachment lever
5/1/98
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.
OBJECTIVES
❑ 1. Using the handout provided and the related service manual modules
locate the following components on a Series II and B/C Series
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, ether start (mounting location - Series II), thermal
start coil (mounting location - B Series), radiator, water pump, low
idle adjustment screw, high idle adjustment screw, and temperature
regulator housing.
❑ 2. Identify on the provided handout the following components of the
Series II fuel injection pump: manual stop lever, fuel regulator valve,
fuel shutdown solenoid, rotor assembly, low idle adjustment, high
idle adjustment, auto advance mechanism, accelerator lever, fuel
return check valve, metering valve, transfer pump, flyweight
assembly, cam ring, rollers and governor spring.
❑ 3. Identify on the provided handout the following components of the
B Series 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
❑ 4. 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.
❑ 5. 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.
❑ 6. (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).
❑ 7. As a homework assignment, read "Know Your Cooling System"

(form SEBD0518) and answer questions on the Cooling System
worksheet. The answers will be reviewed.
❑ 6. Identify at least 10 different engine components by matching the
component to its function in a quiz.
5/1/98
Lesson: Engine Systems

BACKGROUND This lesson allows you to become familiar with identifying engine system
INFORMATION components.
This lesson allows you to become familiar with identifying system

components
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" 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
Comercially 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 Checklists I and II
Cooling System Review Worksheet
Related service manual modules
5/1/98
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.
........ ........ ........ Fuel filter
........ ........ ........ Fuel injection pump
........ ........ ........ Fuel Shutdown Solenoid
........ ........ ........ Priming (lift) pump )
........ ........ ........ Water separator (w/ fuel filter on C
........ ........ ........ Oil filter
........ ........ ........ Engine oil dipstick
........ ........ ........ Engine oil pressure test port
........ ........ ........ Engine oil cooler (turbocharged models only)
........ ........ ........ Primary air filter
........ ........ ........ Secondary air filter
........ ........ ........ Turbocharger (if equipped)
........ ........ ........ Air filter indicator
____ NA NA Ether Start (mounting location)
NA ____ ____ Start aid coil
........ ........ ........ Radiator
........ ........ ........ Water pump
........ ........ ........ Temperature regulator housing
........ ........ ........ High idle adjustment screw
........ ........ ........ Low idle adjustment screw

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5/1/98
Series II Fuel Pump Components
REGULATOR VALVE
FUEL INLET
INLET SCREEN
TO FUEL
TRANSFER ADJUSTMENT
PUMP SCREW
SPRING
FROM FUEL
TRANSFER PISTON
PUMP
ROTOR ASSEMBLY OPERATION

INLET
PASSAGE FUEL
INLET DISTRIBUTOR
PLUNGERS PASSAGE
INLET
STROKE
ROTOR
ASSEMBLY
OUTLET
STROKE
FUEL
OUTLET
5/1/98
5/1/98
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. Always use both supplemental coolant additive and a coolant conditioner element at the
same time.
8. When filling the cooling system, never fill faster than 5 gallons per minute.
9. An engine should never be operated with the temperature regulators removed.
10. An 8T2700 Blowby/Air Flow Indicator Group should be used to check air velocity.
11. When measuring the temperatures in the cooling system, the temperature in the radiator top
tank should be below the coolant boiling point.
12. The temperature of the water pump outlet must be approximately 8o to 20oF above the
temperature in the radiator top tank.
13. The most common cause of engine overcooling is temperature regulators stuck closed.
14. High sulfur fuel will cause increased engine wear during overcooling when the operating
temperature is below 175oF
5/1/98
Lesson: Engine System Tests

BACKGROUND This lesson allows you to become familiar with typical engine system
INFORMATION tests
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.
• 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 Bachoe 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 engine specifications
1-1U5481 Pressure Gauge Group
1-1U5482 Pressure Hose and Adapter Group
1-6V4142 Nipple
1-8C7575 or 8C7576 adapter
(Optional)
1-5P0957 Coolant and Battery Tester
1-4C6500 Digital Thermometer group
1-8T2700 Blowby/Air Flow Group
5/1/98
4.236 Perkins Engine In Chassis Test Sheet
Machine Model Dealer
Name/Code Customer
Machine PIN (S/N) Job
Transmission S/N Application
Engine S/N Date
S.M.H. Serviceman
VISUAL CHECKS: Fuel Level Engine Oil level

Coolant level Power Train Oil level
Oil/Coolant/Fuel Leaks Air Filters and Precleaner Inspection
TEST SPECS ACTUAL COMMENTS

Engine rpm: 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 -13ºC to -6ºC (8° 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 Alternator Output Voltage
Starter Cold Cranking Amps
Note: Remove the engine oil pressure switch and install a 6V3965 test nipple to check engine oil
pressure. This is the typical test nipple used for most hydraulic system tests.
To check transfer pressure on the Series II backhoes. Modify fitting 8T7861. A 6V6560 Seal is also
required. About .100 in of thread length needs to be removed for the fitting to work. If the threads are
not removed the fitting will block fuel flow in the pump.
5/1/98
Name/Code Customer
Engine S/N Date
S.M.H. Serviceman


Low Idle


[Should be 4.5ºC to 11ºC (8°F to 20°F) less than Top Tank Temperature]

Idle

5/1/98
3054 Engine In Chassis Test Sheet

Name/Code Customer
Engine S/N Date
S.M.H. Serviceman


Low Idle



Idle

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
5/1/98

Name/Code Customer
Engine S/N Date
S.M.H. Serviceman


Low Idle

Fourth Speed Speed - Reverse


Idle

5/1/98
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.
5/1/98
Lesson: Electrical 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
❑ B or C Series Electrical System Checklist
B or C Series Starting and Charging System Sheet
B or C Series Machine electrical schematic
B Series Backhoe Loaders - Electrical and Transmission - Student
Reference Materials
5/1/98
"B" 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.
Electrical Components
Machine Schematic
Location Part No. Location Description
Starter motor
Alternator
Battery
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
Thermostart (Start aid) coil

5/1/98
"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.
Electrical Components
Machine Schematic
Location Part No. Location Description
Starter motor
Alternator
Battery
Keystart fuse
Engine oil pressure switch
Coolant temperature switch and sender
Power train oil temperature sender (converter)
Fuel level sender
Engine shutdown solenoid
Key start switch
Start relay
Start aid switch
Thermostart (Start aid) coil

5/1/98
5/1/98
5/1/98
Lesson: Electrical System Tests
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
❑ • 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
1-127-8078 Battery Tester
Optional
5/1/98
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. Chart A-Typical System Voltage During
Do not 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 Voltage Reading
are 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
Pos. Post (TP10 to TP6)
starter is too great. Go to next step.
Batt. Neg. Post to Starter 1.4V 0.7V
NOTE: For this exercise, assume your answer is Neg. Post (TP7 to TP5)
"NO" and then perform the next step. Enter results Drop Across Only 1.0V .5V
in CHART B. Disconnect Switch
(TP8 to TP9)
2. Measure voltage drops in cranking circuit per Start Relay Contacts 0.8V 0.4V
Chart B. 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 .
III. Alternator Tests: Reference - Alternator - SM 5/4/87
Initial Amperage (step 4.)
Voltage (step 5)
Amperage (step 6)
5/1/98
Voltage
NOTE: Use the posts representing 12 or 24 Volts. Chart A-Typical System Voltage During
Do not 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)
Record Voltage ___________ System
. . . Yes - Go to Test B. 12 Volt 6V to 8V 7V to 9V 8V to 10V
System
1. Is voltage equal to or greater than that shown in
Chart A? Chart B-Maximum Allowable System
Record Voltage ___________
Absolute Maximum
. . . Yes - Batteries and starter cables down to motor Voltage Reading
are 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 is too great. Go to next step.
Batt. Neg. Post to Starter 1.4V 0.7V
NOTE: For this exercise, assume your answer is Neg. Post (TP7 to TP5)
"NO" and then perform the next step. Enter results Drop Across Only 1.0V .5V
in CHART B. Disconnect Switch
(TP8 to TP9)
2. Measure voltage drops in cranking circuit per Start Relay Contacts 0.8V 0.4V
. . . 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)
5/1/98
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 and the steering control valves work 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 Series II and B Series machines, identify the

following power train hydraulic oil system components: filter,
suction screen, torque converter, transmission pump, main 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 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
❑ 3. 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.
❑ 4. 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..
❑ 5. (Optional for Series II and B Series) D&A the transmission control

valve and identify the following: rotary selector spool, relief valve,
load piston (if equipped), check valve (if equipped), orifice ( if
equipped), solenoid & neutralizer spool, flow control valve ,
transmission neutralizer switch, and torque converter inlet relief
valve.
5/1/98
❑ 6. Using the appropriate service materials, identify and record on the

provided test sheet the specifications for the following power train
❑ 7. Using the appropriate service manual module, locate the test location
and perform checks on the machine for the following power train
❑ 8. On a quiz identify the function of the following transmission control

valve components: rotary selector spool, relief valve, load piston ,
check valve, orifice, solenoid & neutralizer spool, flow control valve,
transmission neutralizer switch, and torque converter inlet relief
valve.
❑ 9. Using provided reference materials and handouts identify potential

system problems caused by malfunctioning components during a
classroom lab exercise. Record your results.
5/1/98
Lesson: Power Train Hydraulic Component Identification

BACKGROUND This lesson will help you gain familiarity with the machine and locate
INFORMATION 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
❑ • View a slide presentation on power train components
• On Power Train Checklists II and III, identify the following power train
❑ hydraulic oil system components: filter, suction screen, torque
converter, transmission pump, cold start relief valve, torque converter
inlet relief valve, transmission control valve, and transmission oil cooler
❑ • 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.
Shop Lab
❑ • 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.
Wiht 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
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" NOTE: Also,
never remove the torque converter inlet relief valve from the adapter
plate with the control valve mounted to the transmission.
❑
Materials Needed Operation and Maintenance Guide
Service Manual
Parts Book
Power Train Component Checklists
B Series Power Train Component Checklist
C Series Power Train Component Checklists I & II
B Series Backhoe Loaders - Electrical and Transmission - Student
Reference Materials
Mechanic's Tool Box and hand tools
5/1/98
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.

Fill tube
Filter
Suction screen
Torque converter housing
Transmission directional control selector lever
N/A N/A Relief valve
Cold start relief valve (if equipped)
Torque converter inlet relief valve
Transmission control valve
AWD solenoid valve (if equipped)
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)

5/1/98
C -Series Power Train Component Checklist I

Directions: During a lab, use this sheet as a checklist when identifying components and pressure test
locations.
B
E C
F
D
J
H
G
Identify Components and Test Ports
Filter
Main Relief Valve
Cold Start Relief Valve
Torque Converter Inlet Relief Valve
Transmission Control Valve
AWD Solenoid
Pump Supply Pressure Por

Forward Clutch Pressure Port
Reverse Clutch Pressure Port
Torque Converter Inlet Pressure Port
Torque Converter Outlet Pressure Port
5/1/98
5/1/98
5/1/98
Lab: Transmission Control Valve Component

Identification (Optional)
BACKGROUND This lesson allows you to gain hands on experience with the control valve
INFORMATION and its components.
Shop Lab
❑ • View a slide presentation on power train components and label
components on the Transmission Control Valve Component Checklist II.
❑ • Disassemble the transmission control valve. Lay out all components.
❑ • Identify and state the purpose of the following components using the
Control Valve Component Reference Checklists (Circle the component
letter after identifying each component.):
- rotary selector spool
- relief valve
- load piston (if equipped)
- check valve (if equipped)
- orifice ( if equipped)
- solenoid & neutralizer spool
- transmission neutralizer switch
- flow control valve
- torque converter inlet relief valve
❑ • Assemble the control valve.
❑ • Disassemble and assemble additional components (if available): pump,

clutch assembly, the current transmission control valve, etc.
Materials Needed
❑ Service Manual
Parts Book
Transmission control valve 9N4506
Mechanic's Tool Box with hand tools
Transmission Control Valve Component Checklists I, II, and III
Class notes
5/1/98
Transmission Control Valve Component Checklist I
Directions: Use this sheet to take notes during the presentation. During a lab exercise, use this sheet as
a checklist when identifying components.
____ Rotary selector spool - directs oil to and from the two directional clutches
____ Relief valve - controls maximum clutch pressure. When open, the relief valve directs oil to the
tank. In older machines the valve works with a load piston.
____ Load piston (if equipped) - controls maximum directional clutch pressure.
____ Check valve (if equipped) - allows the load piston chamber to drain rapidly during a shift.
____ Orifice - (next to the check valve if equipped) controls flow to the load piston. By controlling
the rate of oil to the load piston, the rate of clutch pressure increase is controlled.
____ Solenoid & Neutralizer spool - drains clutch pressure between shifts to provide smoother shifts
and to provide "on the go" shifting.
____ Flow control valve - provides priority oil flow to transmission control valve. Flow not needed
is sent to the torque convertor. The flow control valve cannot handle all of the excess flow, so
a bypass orifice is required.
____ Torque convertor inlet relief valve - protects the torque converter from high pressures (cold
start-ups). The valve is located in an adapter plate below the transmission control valve on
older machines.
5/1/98
Transmission Control Valve Component Checklist II

III. Directions: Match the components with the associated letter.
TRANSMISSION CONTROL VALVE
A
D
TO REVERSE BALL
CLUTCH DETENT
TO DRAIN TO FORWARD
CLUTCH
PUMP
SUPPLY
E
B
F
H G
TO TORQUE
CONVERTER
I
Rotary Selector Spool Neutralizer Valve Spool
Load Piston Relief Valve
Check Valve Flow Control Valve
Torque Converter Inlet Relief Valve Orifice

5/1/98
Transmission Control Valve Component Checklist III

III. Directions: Match the components with the associated letter.
C
B
TO TORQUE
CONVERTER D
R F
E
PUMP
SUPPLY
A
F
Rotary Selector Spool
Torque Converter Inlet Relief Valve
Solenoid
Neutralizer Valve Spool
Relief Valve
Flow Control Valve

5/1/98
Lesson: Control Valve Operation
BACKGROUND This lab allows you to explain the operation of the control valve
INFORMATION components during a shift from NEUTRAL into REVERSE.
Classroom Lab
❑ For the "Control Valve Operation Worksheet" enter "T" for true and "F"
for false in the blanks to describe the given shift condition.
The instructor will review the answers with you.
Materials Needed ❑ Control Valve Operation Worksheet

5/1/98
Control Valve Operation Worksheet
TRANSMISSION CONTROL VALVE

FORWARD-NEUTRALIZED
PASSAGES TO
DRAIN
TO REVERSE
CLUTCH
TO FORWARD
CLUTCH
PUMP
SUPPLY
TO TORQUE
CONVERTER
Directions: Underline or circle the word or phrase that describes the valve conditions when
FORWARD is neutralized. Refer to the schematic for FORWARD-NEUTRALIZED.
The operator is making a speed shift and presses the neutralizer switch to allow an "on the go" shift.....
1. The solenoid is (energized)(de-energized).
2. Clutch pressure (is drained)(increases).
3. The load piston chamber (is drained) (full of oil).
4. The neutralizer solenoid and spool drains (pump supply oil only)(pump supply oil and clutch oil).
5. Clutch modulation (is)(is not) occurring.

5/1/98
Lesson: Power Train System Tests

This lesson will allow you gain familiarity performing system checks,
BACKGROUND
using the Service Manual, and determining if the machine is operating to
INFORMATION
specifications.
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
❑ • Record pressure specifications from the service manual before going to
the shop.
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 be
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
❑ • 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
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
1-1U5482 Hose and Fitting Group
5-6V3965 Nipples
5-3J1907 O-rings
1-6V3121 Multi-tach Group or 9U7400 Multitach Group
5/1/98
Backhoe Loader Transmission Test Sheet

Machine Model _______________________ Dealer __________________________________
Name/Code ________________________ Customer _______________________________
Mach. S/N (PIN) _____________________ Job ____________________________________
Trans. S/N _________________________ Application ______________________________
Engine S/N _________________________ Date ___________________________________
S.M.U. ______________________________ Serviceman ______________________________
VISUAL CHECKS
Oil Level _______ Suction Screen _______

Oil Type _______ Oil Filter _______
Oil Leaks _______ Abrasives in Oil _______
Air/H2O in Oil _______ Debris in Pan _______
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
PRESSURE TEST SHIFT ENGINE SPEED

LEVER SPEC ACTUAL
T. C. Outlet (T. C. stall) 4th/FWD

T. C. Outlet (T. C. stall) 4th/REV
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.
5/1/98

Mach. S/N (PIN) _____________________ Job ____________________________________
Engine S/N _________________________ Date ___________________________________
S.M.U. ______________________________ Serviceman ______________________________
VISUAL CHECKS

PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX

LEVER SPEC ACTUAL

both speed ranges.
5/1/98

Mach. S/N (PIN) _____________________ Job ____________________________________
Engine S/N _________________________ Date ___________________________________
S.M.U. ______________________________ Serviceman ______________________________
VISUAL CHECKS

PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX

LEVER SPEC ACTUAL

both speed ranges.
5/1/98
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.
5/1/98
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.
5/1/98
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.
5/1/98
Transmission Case Study
DIRECTIONS Students may use the provided service manual modules and their notes to
answer the case study. The second page of the case study should be
distributed during the class room discussion.
SITUATION The customer's AWD 416B Backhoe Loader with 1239 service hours will
not move when the transmission is shifted to either FORWARD or
REVERSE.
After checking fluid levels, the field mechanic checked both FORWARD
and REVERSE clutch pressure and found the clutch pressures to be very
low and out of specification. After discussing the problem with his
technical communicator, they decided the machine should be sent to the
shop due to either a bad pump or damaged clutch seals.
Did they made the correct decision?
Even if they did or did not make the right decision, what else should be
checked before bringing the machine back to the shop? List at least two
other problems that could be preventing movement of the machine.
Describe the tests and the anticipated results.
5/1/98
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:
5/1/98
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. (Optional) Perform B an C Series brake system checks as per the

service manual.
❑ 3. (Optional) Perform differential lock system checks as per the

provided handout.
❑ 4. (Optional) Perform Series II brake system checks as per the service

manual.
5/1/98
Lesson: Axle and Brake Component Identification

Shop Lab
❑ • View slide presentation on the axle and brake system
❑ • Locate components listed on the Axle and Brake Component Checklist.

Record a check after locating each component.
❑ • D&A available components. Refer to the parts book or related materials

to identify components. Confirm identification with the instructor.
Materials Needed
❑ Operation & Maintenance Guide
Service Manual
Parts Book
Axle and Brake Component Checklist
B and C Series Brake Schematic
5/1/98
Axle and Brake System Component Checklist

Directions: During a lab exercise, use this as a checklist when identifying components.
Series II B and C Series
Brake pedals Brake pedals
Parking brake control Parking brake control
Differential lock pedal Parking brake disc and pads
Brake adjusting bolt Differential lock pedal
Differential fill plug Brake disc inspection plugs
Differential drain plug Brake bleed screws
Front AWD Differential fill plug Reservoir
Front AWD Differential drain plug Brake lamp
AWD solenoid Differential fill plug
AWD control switch Differential drain plug
Front AWD Differential fill plug
Front AWD Differential drain plug
AWD solenoid
AWD control switch

5/1/98
B And C Series Brake Schematic
BRAKE MASTER CYLINDERS

FROM
RESERVOIR SUPPLY PORT
VALVE STEM PLUNGER
RIGHT BRAKE
RELEASED
TO BRAKE COMPENSATION PUSH

PISTON VALVE ROD
PLUNGER
BRIDGE PIPE
LEFT BRAKE
ENGAGED
PUSH ROD
TO BRAKE
PISTON
5/1/98
Lesson: Axle and Brake System Tests

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
❑ • Test Brakes (rear wheels off of ground), First Forward at low idle.
Depressing either pedal fully, left or right, will stop respective brake.
Depressing both pedals simultaneously will stop both wheels at the
same rate. If wheel speeds are not equal while applying both brakes
gradually until fully stopped, check adjustment.
Series II -Reference Service Magazine 10/17/88.
On Series II machines, mis-adjust service brakes to reduce brake
performance. Have students perform proper brake adjustment
procedures.
❑ • 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.
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.
Materials Needed
❑ Axle, brake and steering service manual modules
5/1/98
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.
5/1/98
Lesson: Engine, Electrical, and Power Train

Troubleshooting
INFORMATION 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.
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.
❑ • 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.
Materials Needed
❑ Related service manual modules
Student Troubleshooting Analysis worksheets
12-V and 24-V Electrical Systems - Student Reference Materials
2-1U5481 Pressure Test Gauge Group
10-6V3965 Nipples
5-3J1907 O-rings
Optional
5/1/98
Name/Code Customer
Engine S/N Date
S.M.H. Serviceman


Low Idle



Idle

5/1/98

Name/Code Customer
Engine S/N Date
S.M.H. Serviceman


Low Idle



Idle

5/1/98
Voltage
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.
System
1. Is voltage equal to or greater than that shown in Chart A?
Record Voltage ___________ Chart B-Maximum Allowable System
. . . Yes - Batteries and starter cables down to motor
Absolute Maximum
are electrically within specifications. Go to Test C.
Voltage Reading
. . . No - Voltage drop (loss) between batteries and Circuit 24V 12V
starter is too great. Go to next step. Batt. Pos. Post to Starter 0.5V 0.3V
NOTE: For this exercise, assume your answer is
"NO" and then perform the next step. Enter results Batt. Neg. Post to Starter 1.4V 0.7V
in CHART B. Neg. Post (TP7 to TP5)
Drop Across Only 1.0V .5V
2. Measure voltage drops in cranking circuit per Disconnect Switch
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)
5/1/98

Mach. S/N (PIN) _____________________ Job ____________________________________
Engine S/N _________________________ Date ___________________________________
S.M.U. ______________________________ Serviceman ______________________________
VISUAL CHECKS

PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX

LEVER SPEC ACTUAL

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.
5/1/98

Mach. S/N (PIN) _____________________ Job ____________________________________
Engine S/N _________________________ Date ___________________________________
S.M.U. ______________________________ Serviceman ______________________________
VISUAL CHECKS

PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX

LEVER SPEC ACTUAL

both speed ranges.
5/1/98


1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
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1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
5/1/98


1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
5/1/98
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.
5/1/98
❑ 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.
5/1/98
Lesson: Load Sensing/Pressure Compensated Hydraulics

BACKGROUND This lesson will help you gain familiarity with Load Sensing/Pressure
INFORMATION
Compensated Hydraulics. LS/PC systems typically used closed center
implement control valves.
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
5/1/98
Lesson: Implement Hydraulic System Component

Identification
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
C Series Hydraulic System Component Checklist
5/1/98
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.
Hydraulic tank
Hydraulic oil filter(s)
Pump
Pump control valve
Loader valve group
Backhoe valve group
Implement controls
Pump supply pressure test port
Signal pressure test port
NA Torque Limiter
5/1/98
5/1/98
5/1/98
5/1/98
Lesson: Hydraulic Pump and Pump Control Valve

Component Identification (Optional)
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.).
❑ • Assemble the hydraulic pump and pump control valve.
Materials Needed
❑ Backhoe Hydraulic Component Checklist
Series II Hydraulic Pump Component Checklist
B Series Hydraulic Pump Component Checklist
C Series Hydraulic Pump Component Checklist
Torque Limiters - Student Reference Materials
Parts Book
Hydraulic pump and pump control valve - for BCP backhoe loaders
or similar
Class notes
5/1/98
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.
Series II B Series C Series Pump Control Valve
Margin spool
Check valve
Pressure cut-off
NA 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
5/1/98
Series II Hydraulic Pump Components Checklist

Directions: Fill in the blanks with the correct response. Use this sheet to take notes during the
presentation.
PUMP OFF
NO SIGNAL
PUMP OUTPUT
A
B
D
H
G
E
H
5/1/98
B Series Hydraulic Pump Components Checklist

presentation.
416B-438B HYDRAULIC PUMP

LOW PRESSURE STANDBY
PUMP
NO SIGNAL OUTPUT
B G
A C
E D
G
5/1/98
C Series Hydraulic Pump Components Checklist

Directions: Fill in the blanks next to the letters with the correct term. Use this sheet to take notes
during the slide presentation.
IMPLEMENT AND STEERING PUMP

LOW PRESSURE STANDBY
PUMP
SIGNAL
B OUTPUT
C
D
A
F
E
F
5/1/98
Lesson: Implement Control Valve Component

Identification (Optional)
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.).
❑ • 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:
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)
Class notes
5/1/98
Implement Control Valve Components Checklist

presentation.
FROM CLOSED CENTER CONTROL VALVE
PREVIOUS HOLD
VALVE
HEAD ROD
B END END
E
A
TO TANK
TO TANK
D
FROM
C PUMP
TO NEXT
VALVE
F
5/1/98
Lesson: Implement Hydraulic System Tests
INFORMATION using the Service Manual, and determining if the machine is operating to
specifications.
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.
❑ • Perform Margin Pressure, Low Pressure Standby, and Maximum System

pressure checks as per classroom discussion and service manual.
❑ • 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
❑ • 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
❑ • Check line reliefs as per service manual. Adjust bucket positioner cam
and switch as per service manual.
Materials Needed
❑ Backhoe Hydraulic System Tests sheets
416 Series II BackHoe loader Hydraulic System Lab Sheet
B & C Series Backhoe Loader Hydraulic System Lab Sheet
Backhoe System Testing
Troubleshooting the Resolver Network on Series II, B & C Series
Backhoe Loaders
2-8T0859 Pressure Gauge (0 to 3600 psi) or 1-1U5796
Differential Gauge Group
1-Stop Watch
1-Tape Measure
5/1/98
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.
2. Activate any implement slowly and watch the gauges.
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: Due to the signal pressure limiter, the steering circuit is commonly used to check margin
pressure because the steering circuit pressure is below maximum system pressure. When steering is
stalled, a signal of approximately 14000 kPa (2050 psi) is sent to the pump. The pump increases flow
due to oil being sent to tank through the signal pressure limiter. Pump supply pressure increases. The
difference between the pump supply pressure and the steering signal is margin pressure.
5/1/98
416 Series II 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
• 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 Margin Pressure to 140 psi. Record cycle times for loader lift below:
Average Cycle time
• Adjust Margin Pressure to 350 psi. Record cycle times for loader lift below:
Average Cycle time
• Reset Low Pressure Standby to 250 psi. Recheck cycle times and margin pressure.
Average Cycle time
Margin Pressure
Describe your conclusions:

5/1/98
B & C Series 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
• Invert front bucket fully and lower to the ground. Record cycle times for loader lift below:
Loader lift cycle time specification
Average Cycle time
• Adjust Low Pressure Standby to 150 psi. Record cycle times for loader lift below:
Average Cycle time
• Adjust Low Pressure Standby to 450 psi. Record cycle times for loader lift below:
Average Cycle time
• Reset Low Pressure Standby to 320 psi. for the B series and 350 psi for the C series. Recheck cycle
times and margin pressure.
Average Cycle time
Margin Pressure
Describe your conclusions:

5/1/98
BACKHOE LOADER HYDRAULIC TESTS
DATE _______________________________ DEALER _______________________________

MACHINE MODEL ___________________ CUSTOMER ______________________________
NAME/CODE ________________________ JOB ______________________________________
MACH S/N (PIN) _____________________ APPLICATION ____________________________
S.M.U. _______________________________ SERVICEMAN ___________________________
LOW PRESSURE STANDBY ___________________

RUN ALL TESTS AT MAX.
MARGIN PRESSURE ___________________
RPM
MAXIMUM SYSTEM PRESSURE _________________
MACHINE AT NORMAL
ENGINE LOW IDLE SPEED ___________________ OPERATING
TORQUE LIMITER ENGINE SPEED ___________________ TEMPERATURES
CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L (Leveler Off)
O Tilt Back
A (Leveler Off)
D Raise
E (Leveler Off)
R Raise (Leveler On,
Full Bucker Dump))
Bucket Dump
Bucket Load
Stick In
Stick Out
Swing
B (Stop to Stop)
A Swing
C (Stop to Snubber)
K
E-Stick Extend
H
O
E E-Stick Retract
Left Stab. - Raise
Left Stab. - Lower
Right Stab. - Raise
Right Stab. - Lower
Boom Pause
Auxiliary 1
Auxiliary 2
5/1/98
DATE _______________________________ DEALER _______________________________

NAME/CODE ________________________ JOB ______________________________________
S.M.U. _______________________________ SERVICEMAN ___________________________

MARGIN PRESSURE ___________________ RPM
MACHINE AT NORMAL
CYCLE TIMES
TEST
Bucket Dump
L (Leveler Off)
O Tilt Back
A (Leveler Off)
D Raise
E (Leveler Off)
Full Bucker Dump))
Bucket Dump
Bucket Load
Stick In
Stick Out
Swing
B (Stop to Stop)
A Swing
C (Stop to Snubber)
K
E-Stick Extend
H
O
E E-Stick Retract
Left Stab. - Raise
Left Stab. - Lower
Right Stab. - Raise
Right Stab. - Lower
Boom Pause
Auxiliary 1
Auxiliary 2
5/1/98
Troubleshooting the Resolver Network on Series II, B & C 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 (Series II machines ):
1. Auxiliary - 8th valve (if equipped).
2. Left Stabilizer (as when positioned to operate the backhoe).
3. Boom
4. Swing
5. Backhoe bucket
6. Stick
7. Right Stabilizer
8. Extendable stick (if equipped)
9. Loader bucket tilt.
10. Loader lift
11. Multi-purpose bucket (if equipped)
12. Steering
NOTE: The above valve order is different on B and C Series 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.
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).
5/1/98
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.
The above procedures can be applied to other LS/PC systems including those with valve sections with
an axial drilled hole with cross drilled holes which sense signal pressure. These can be considered as
serving the same function as primary resolvers. These are found in the D6H-D8N TTT, Challenger 65,
G-Series Motor Graders and 916-936 Wheel Loaders.
5/1/98
5/1/98
Hydraulic Case Study
DIRECTIONS Use the provided service manual modules and notes to answer this case
study.
SITUATION 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. He decided that since all the implements
were slow it must be a flow problem caused by a bad pump.
What else would you do before installing a new pump?
List at least two other problems that could be causing the machine not
move. Describe tests and your anticipated results?
5/1/98
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT

5/1/98
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.
5/1/98
Lesson: Steering and Implement Hydraulic System

Troubleshooting
INFORMATION 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.
Shop Lab
❑ • 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.
Materials Needed
❑ Related service manual modules and reference materials
Backhoe Hydraulic System Tests sheets
2-8T0859 Pressure Gauge (0 to 3600 psi) or 1-1U5796 Differential
Gauge Group
1-Stop Watch
1-Tape Measure
5/1/98
DATE _______________________________ DEALER _______________________________

NAME/CODE ________________________ JOB ______________________________________
S.M.U. _______________________________ SERVICEMAN ___________________________

RPM
MACHINE AT NORMAL
CYCLE TIMES
TEST
Bucket Dump
L (Leveler Off)
O Tilt Back
A (Leveler Off)
D Raise
E (Leveler Off)
Full Bucker Dump))
Bucket Dump
Bucket Load
Stick In
Stick Out
Swing
B (Stop to Stop)
A Swing
C (Stop to Snubber)
K
E-Stick Extend
H
O
E E-Stick Retract
Left Stab. - Raise
Left Stab. - Lower
Right Stab. - Raise
Right Stab. - Lower
Boom Pause
Auxiliary 1
Auxiliary 2
5/1/98
DATE _______________________________ DEALER _______________________________

NAME/CODE ________________________ JOB ______________________________________
S.M.U. _______________________________ SERVICEMAN ___________________________

RPM
MACHINE AT NORMAL
CYCLE TIMES
TEST
Bucket Dump
L (Leveler Off)
O Tilt Back
A (Leveler Off)
D Raise
E (Leveler Off)
Full Bucker Dump))
Bucket Dump
Bucket Load
Stick In
Stick Out
Swing
B (Stop to Stop)
A Swing
C (Stop to Snubber)
K
E-Stick Extend
H
O
E E-Stick Retract
Left Stab. - Raise
Left Stab. - Lower
Right Stab. - Raise
Right Stab. - Lower
Boom Pause
Auxiliary 1
Auxiliary 2
5/1/98
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT

5/1/98
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT

5/1/98
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
5/1/98
Lesson: All Wheel Steer System Component Identification

Classroom 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.
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 and II , plus the AWS Electrical Schematic. Record a check
after locating each component..
Materials Needed ❑ AWS System Checklist I and II
B Series AWS Electrical Schematic.
C Series AWS Electrical Schematic.
Related service manual module

5/1/98
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.
B Series C Series
All Wheel Steer Control Valve Group
Rear Axle Position Gage
Rear Position Micro-switch
Pressure Switch
Rear Axle Position Sender
AWS Select Switch

5/1/98
5/1/98
5/1/98
Service Training COURSE REFERENCE

DIAGNOSTICS
Service Training COURSE REFERENCE
TORQUE LIMITERS

DIAGNOSTICS
5/1/98
IMPLEMENT AND STEERING PUMP

TORQUE LIMITER REDUCES FLOW
PUMP
SIGNAL OUTPUT
LARGE ACTUATOR
MARGIN TORQUE
SPOOL LIMITER
SMALL ACTUATOR
PASSAGE TO AND BIAS SPRING
TANK
416-438C Torque Limiter

• Torque limiter The torque limiter monitors the pump swashplate angle and the pump
operation 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
- Destrokes pump as
allowable pump displacement is inversely proportional to the pump
pressure increases
discharge pressure. The higher the pressure, the less pump flow is
- Spring force varies available.
with swashplate
angle 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.
5/1/98
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 the
setting 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.
5/1/98
416B - 438B HYDRAULIC PUMP

TORQUE LIMITER - OPEN
TORQUE
LIMITER
PUMP
SIGNAL OUTPUT
FLOW
COMPENSATOR
PRESSURE
COMPENSATOR
416B-438B Torque Limiter

• Maintains input torque If the pump is at maximum flow and the signal pressure increases above
setting 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 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.
5/1/98
ENGINE RPM VS. THE TORQUE

LIMITER SETTING E
N
Engine RPM and the torque limiter setting
are directly proportional to one another.
G
I
At points A and B the input torque is the
same; However, at the higher low idle engine N
speed for point B, the torque limiter setting E
can be set higher. B
R A
P
M
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 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
5/1/98
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.
416B-438B Torque Limiter Adjustments
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 no longer causes the engine to die, no further adjustment
is required.
3) If the engine still dies. 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 dies. 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 die the torque limiter has been adjusted
correctly.
5/1/98
416C-438C Torque Limiter Adjustments
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. The engine
rpm should drop about 100 to 140 rpm from the low idle setting. If this
occurs, then no further adjustment is required.
3) If the engine rpm drops lower than 100 to 140 rpm. Back out the
torque limiter to reduce the spring setting until engine lug falls between
100 to 140 rpm less than low idle.
4) If engine rpm lug is less than a 100 rpm, the torque limiter setting
should be increased.

Series Ii, B & C Series Backhoe Loader Diagnostics: Service Training

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Series Ii, B & C Series Backhoe Loader Diagnostics: Service Training

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Service Training STUDENT

Course Materials MATERIALS

SERIES II, B & C SERIES BACKHOE LOADER

STUDENT LITERATURE CHECKLIST............................................................................11

MODULE: MACHINE ORIENTATION ............................................................................15

MODULE: ENGINE SYSTEMS .......................................................................................20

MODULE: ELECTRICAL SYSTEM ................................................................................32

MODULE: POWER TRAIN ..............................................................................................41

MODULE: AXLES AND BRAKES ..................................................................................63

MODULE: ENGINE, ELECTRICAL AND POWER TRAIN TROUBLESHOOTING...68

MODULE: STEERING AND IMPLEMENT HYDRAULIC SYSTEMS ........................78

MODULE: STEERING AND IMPLEMENT HYDRAULIC SYSTEMS

MODULE: ALL WHEEL STEERING ELECTRICAL & HYDRAULIC SYSTEMS ...110

CONTENT WHO SHOULD ATTEND:

Classroom work (approximately 30%) will consist of a product

• Brakes and Axles Lab- Students will perform proper brake

KEY DIAGNOSTIC TOOLS USED IN CLASS

❑ ❑ ❑ 1. Perform a 10 hour/daily machine inspection for a BCP backhoe

❑ ❑ ❑ 6. Locate the following power train hydraulic oil system components

❑ ❑ ❑ 8. Perform performance checks and/or adjust: max system pressure, low

❑ ❑ ❑ 9. Perform cycle time checks and signal system checks to identify

Post Course Assessment Only - Student should review the above

MODULE: MACHINE ORIENTATION

MODULE: ENGINE SYSTEMS

MODULE: ELECTRICAL SYSTEM

MODULE: POWER TRAIN

MODULE: POWER TRAIN (cont'd)

MODULE: AXLES AND BRAKES

MODULE: ENGINE, ELECTRICAL, AND POWER TRAIN

MODULE: STEERING AND IMPLEMENT HYDRAULIC

MODULE: STEERING AND IMPLEMENT HYDRAULIC

MODULE: ALL WHEEL STEERING ELECTRICAL &

REQUIRED STUDENT STUDENT LITERATURE CHECKLIST

STUDENT REFERENCE Reference Materials

❑ Operation and Maintenance Manuals - at least two copies of the

❑ Service Manuals - the service manuals will provide answers to questions

Should have access to the following to repair wiring

To check transfer pressure on the Series II backhoes. Modify fitting

MODULE: MACHINE ORIENTATION

❑ 1. Using the appropriate specalogs, identify machine features on a quiz

❑ 2. Perform a 10 hour/daily machine inspection for a BCP backhoe

❑ 3. Identify the following BCP backhoe loader controls: Steering and

❑ 5. Demonstrate proper machine starting and stopping procedures for a

Lesson: Machine Orientation

❑ • Perform a 10 hour/daily inspection before starting and or operating the

❑ • Identify the following machine controls: Implement control levers,

❑ • Perform startup and machine shutdown procedures. Operate the

❑ • Operate the implements (optional) - note the operation of the different

Machine Walk-around Checklist

Place a check in the blank if acceptable or after task was performed.

Machine Walk-around Checklist - cont'd

MODULE: ENGINE SYSTEMS

❑ 7. As a homework assignment, read "Know Your Cooling System"

Lesson: Engine Systems

This lesson allows you to become familiar with identifying system

Backhoe Loader Engine Checklist

Series II B Series C Series

........ ........ ........ Fuel filter

........ ........ ........ Fuel injection pump

........ ........ ........ Fuel Shutdown Solenoid

........ ........ ........ Priming (lift) pump )

........ ........ ........ Water separator (w/ fuel filter on C

........ ........ ........ Oil filter

NA Start aid coil