Service Training MALAGA

B & C Bachoe Loaders

STUDENT QUIZZES

Sara JULY 1997

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Student Materials

Quiz: Machine Orientation

NOTE: Use the provided sales information brochures (specalogs) to answer the following questions. I. Directions Modified True / False: If question is false circle word or word that makes statement incorrect and replace with word(s) to make statement correct. 1. C Series and B Series Backhoes use the same engine. 2. The countershaft transmission used in B Series and C Series Backhoes features four speeds forward and four speeds reverse. 3. The IT front loader is standard on the 428C backhoe loader 4. The All Wheel Drive (AWD or 4-WD) front axle is equipped with brakes. 5. The C Series Backhoes use a hydraulic brake system. 6. The C Series Backhoes feature dry-type, radial seal air filters.. 7. The hydraulic system uses a fixed displacement pump with open center control valves. 8. All Wheel Steer provides three modes of operation. 9. The 438C operates at a higher system pressure than the 428C.

II. Directions: Circle the machine which best matches the statement. 1. The implement hydraulic pump is rated at 162 lpm (43 gpm). 2. On this machine the turbocharged engine is standard. 3. All Wheel Steer is an option for this machine. 4. The speed selector is on the steering column. 5. Which machines use the same size fuel tank? 6. Which machine has the slowest speed in fourth gear? Bonus question: 7. Which machines are built in Leicester England? 416C 426C 428C 436C 438C 428C 428C 428C 428C 428C 428C 438C 438C 438C 438C 438C 438C

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Student Materials

Quiz: Backhoe Engine and Fuel System

I. Directions: Match the component to its primary function. 1. Used to remove water from the fuel. 2. Controls the fuel pressure in the fuel injection pump. 3. Prevents filter damage during cold startups. 4. Allows air to escape 5. Limits maximum engine rpm. 6. Indicates engine oil level. 7. Provides engine "boost". 8. Indicates a plugged air filter 9. Triggers an alarm if engine oil pressure is low. 10. When it opens, it send coolant to the radiator top tank. 11. Prevents late fuel injection timing. 12. Used to crank the engine. 13. Controls the pressure at which the cooling system operates. A B C D E F G H I J K L M Radiator cap Oil pressure switch Water separator High idle stop Automatic advance mechanism Thermostat Engine oil dipstick Turbocharger Air filter indicator Fuel regulator valve Vent wire Starter Filter bypass valve

II. Directions Modified True / False: If question is false circle word or word that makes statement incorrect and replace with word(s) to make statement correct.

1. 2. 3. 4.

The Fuel Shut-off Solenoid on the C Series turns the fuel supply to the fuel filter on or off. Set-point is a critical specification that is easily checked and adjusted on all Cat backhoe loaders. The turbocharged engine also requires an engine oil cooler. The temperature in the bottom tank of the radiator should be higher than in the top tank.

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Student Materials

Quiz: Electrical System

I. Directions Electrical Schematic Interpretation: Using a electrical schematic for a 416C-438C Backhoe Loader, answer the following questions. 1. List the schematic grid locations and the machine silhouette number or letter for the transmission neutral switches? a. b. Bonus: c. grid location grid location machine location (silhouette) machine location (silhouette)

grid location

machine location (silhouette)

2. What is the part number of the neutral start switches? 3. Wires from the terminals of the XSMN neutral lock switch are plugged into 117898 connector at schematic location D-5. a. plug b. receptacle c. none of the above 4. Does the above part of the connector have a. pins only b. sockets only c. combination of pins and sockets d. none of the above 5. What does 604-Y22 OR-18 mean? a. A 22 gauge orange wire used for the stop lamp circuit. The wire is the number 18 wire of harness 9R9896. b. An 18 gauge yellow wire used for the stop lamp circuit. The wire is the number 604 wire of harness 9R9897. c. An 18 gauge orange wire used for the stop lamp circuit. The wire is the number 22 wire of harness 9R9896. d. none of the above of the

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6. Locate the lamp test relay on the schematic. List the schematic grid location, machine location letter or number, and the part number. grid location machine location (silhouette) part number 7. Locate the rear wiper switch on the schematic. List the schematic grid location, machine location letter or number, and the part number. grid location machine location (silhouette) part number 8. List the harness assembly part number that the rear wiper switch is plugged into?

9. What is the resistance of the Solenoid - A/C Clutch? 10. What is the part number of the converter sender? 11. The starter is grounded by: a. an internal electrical connection to the surface of the component b. having an external wire connected to vehicle structure 12. What two harnesses connect at schematic coordinates H-4?

13. What is the part number of the receptacle and the plug at H4? receptacle plug 14. What does N-C3 mean by the connector at schematic coordinates H-4? a. Connector number 3 of the 130-6256 harness assembly b. Connector number 3 of the 130-6257 harness assembly c. C3 of the 130-6256 harness assembly d. none of the above

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Student Materials

II. Directions Starting System: Answer the following questions. Either circle the correct response or fill in the blanks. You may use your notes and reference materials.
START RELAY

TP1

TP2

START SWITCH
R C S B
OFF ON ST

W TP4

TP3 TP6 TP7 STARTER MOTOR TP5 TP10

POS NEG POS NEG

TP8

BATTERIES DISCONNECT SWITCH TP9

1. When checking the battery voltage at TP10 and TP7, an acceptable reading for a good battery is: a) 12.0 volts or above b) 12.4 volts or above c) 24 volts or above d) 24.8 volts or above 2. When cranking, what is the maximum allowable voltage drop checked from TP10 to TP6: a) .3 volt b) .5 volt c) 12.4 volts or above d) none of the above 3. With the key start switch in the RUN position what is the maximum voltage drop from TP6 to TP4? a) .4 volt b) .8 volt c) 12.4 volts or above d) none of the above

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Student Materials

Quiz: Transmission
I. Directions: Match the component to its primary function. Refer to the control valve schematic on the next page for a B Series backhoe transmission. 1. Maintains flow in the control valve 2. Controls the rate of modulation 3. Directs oil to the clutches 4. Drains oil in the control valve to allow "on the go" shifting 5. Drains excess oil in the control valve to maintain pressure 6. With the relief valve, it works to control maximum clutch pressure 7. Helps drain the load piston chamber rapidly when a shift is made A Load Piston B Check Valve C Flow Control Valve D Relief Valve

E Rotary Selector Spool F Orifice G Neutralizer Spool and Solenoid

II. Directions Modified True / False: If question is false, underline or circle the words or word that make the statement incorrect and replace with word(s) to make statement correct. Questions are for B Series backhoe loaders. 1. This transmission control valve is used to control direction and speed. 2. If the FORWARD clutch pressure is within specification and the REVERSE clutch pressure is too low and not within specification, check the load piston springs (or relief valve spring). 3. The torque converter inlet relief valve controls the maximum oil pressure to the torque converter. 4. The load piston springs (or relief valve spring) are shim adjustable if the clutch pressures are too low. 5. One of the main reasons for using a solenoid and neutralizer spool is to provide smoother directional shifts.

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Student Materials

III. Control Valve Operation Directions: Underline or circle the word or phrase that describes the valve conditions when the machine is in FORWARD.

TRANSMISSION CONTROL VALVE

FORWARD

TO REVERSE CLUTCH

TO DRAIN TO FORWARD CLUTCH

PUMP SUPPLY

ORIFICE

TO TORQUE CONVERTER

1. The solenoid is (energized)(de-energized). 2. FORWARD clutch pressure is (drained)(at maximum). 3. The load piston chamber is (vented)(full of oil). 4. The relief valve (is) (is not) metering oil to drain. 5. Clutch modulation (is just beginning)(has ended).

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Student Materials

IV. Directions: Circle the correct response.

POWER TRAIN HYDRAULIC SYSTEM

SOLENOID

R F

BYPASS ORIFICE FILTER TORQUE CONVERTER INLET RELIEF VALVE

TORQUE CONVERTER PUMP TRANSMISSION LUBE SUCTION SCREEN AND MAGNET LUBE OIL COOLER TORQUE CONVERTER OUTLET

1. At pressure tap "2," A. B. C. D. F. E.

can be checked.

Torque converter outlet pressure Lube pressure REVERSE clutch pressure FORWARD clutch pressure Pump supply pressure Torque converter inlet pressure

2. Which pressure tap should be used to check FORWARD clutch pressure? 1 2 3 4 5 6

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Student Materials

3. At pressure tap "1," A. B. C. D. E.

can be checked.

Torque converter inlet pressure Speed clutch pressure Directional clutch pressure Lube pressure None of the above

4. Pressure tap "3" is used to check A. B. C. D. Torque converter outlet pressure. Lube pressure. Torque converter inlet pressure. None of the above.

5. If pressures are checked at points 5 and 6, which pressure should be higher with the machine in REVERSE? 5 6

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Student Materials

V. Directions: Circle the correct response.

POWER TRAIN HYDRAULIC SYSTEM

All WHEEL DRIVE
RELIEF VALVE

R
7 6

FILTER

F
RELIEF VALVE (COLD START) AWD SOLENOID VALVE

DIRECTIONAL SELECTOR SOLENOID VALVE

AWD

PUMP SUPPLY PUMP TRANSMISSION LUBE LUBE

TORQUE CONVERTER INLET RELIEF VALVE

TORQUE CONVERTER

3
OIL COOLER

TORQUE CONVERTER OUTLET

SUCTION SCREEN

4 1. At pressure tap "3," A. B. C. D. F. can be checked.

Torque converter outlet pressure Lube pressure REVERSE clutch pressure FORWARD clutch pressure Pump supply pressure

E. Torque converter inlet pressure 2. Which pressure tap should be used to check FORWARD clutch pressure? 1 2 3 4 5 6

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Student Materials

3. At pressure tap "1," A. B. C. D. E. F.

can be checked.

Torque converter inlet pressure Speed clutch pressure Directional clutch pressure Pump supply pressure Lube pressure None of the above

4. Pressure tap "4" is used to check A. B. C. B. D. Torque converter outlet pressure. Lube pressure. Torque converter inlet pressure. Directional clutch pressure None of the above.

5. If pressures are checked at points 3 and 6, which pressure should be higher with the machine in FORWARD? 3 6

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Student Materials

Quiz: Axle and Brakes

I. Directions: Match the component to its primary function. 1. Can convert high RPM and low torque to low RPM and high torque mechanically. 2. Can convert high RPM and low torque to low RPM and high torque hydraulically. 3. Transfers power from the transmission to the front axle. 4. Causes both axles to rotate at the same rpm when engaged 5. Can be engaged independently for sharper turns 6. Permits pressure between the master cylinders to equalize A Brakes B Inboard planetaries C Front wheel drive clutch D Differential lock E Torque converter F Compensation valve

II. Modified True / False. If question is false circle word or word that makes statement incorrect and replace with word(s) to make statement correct. 1. B and C Series brakes are mechanically engaged. 2. B and C Series rear axles have brake inspection ports. 3. B and C Series brakes require pull rod (actuator rod) adjustments. 4. B and C Series feature a hydraulic brake reservoir. 5. B and C Series feature a mechanical drive line parking brake.

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Student Materials

Quiz: Implement Hydraulic System

I. Directions: Match the component to its primary function. 1. Reduces pump flow to prevent the engine from stopping 2. Blocks return oil to help reduce cylinder cavitation. 3. Senses the head end or rod end cylinder pressure. 4. Compares the signal pressures between valve bodies. 5. Opens when the cylinder is voiding. 6. Opens when cylinder pressures go too high. 7. Depending on its angle, the pump will increase or decrease flow. 8. Acts as the main relief. 9. Helps control the swashplate. 10. Compares the highest cylinder pressure to pump output pressure. A B C D E F G H I J K Makeup valve Pressure cut-off valve Restrictor valve Secondary resolver Swashplate Bias piston Flow compensator/margin spool Line relief valve Primary resolver Torque limiter Pressure reducing valve

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Student Materials

II. 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. The difference in pressure between pump supply pressure and signal pressure is called margin pressure. 2. Margin Pressure is usually higher than Low Pressure Standby. 3. The special orifice in the tilt circuit is required to check margin pressure. 4. To check maximum system pressure the engine should be at low idle. 5. If an implement is in stall there is no flow available for another implement. 6. All implement control valves with a pressure reducing valve in them limit the pressure drop across the directional control spool to the value of the pressure reducing valve spring. 7. If margin pressure is 300 psi and the implement sends a signal of 1000 psi the resultant pump supply pressure is 1300 psi. 8. When operating 2 implements at the same time, the implement with the higher work port pressure will have its flow needs met first if the pump cannot meet total system flow needs 9. If margin pressure is set too low machine cycle times will be slower. 10. The steering circuit has flow priority over the loader lift circuit. 11. If margin pressure is changed low pressure standby will also be changed.

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Student Materials

III. Multiple choice. Select the best answer. 1. If the pump is at Low Pressure Standby: a. There is a signal being sent from the implements. b. The pump will signal itself by way of the signal network. c. There is no signal being sent from the implements. d. None of the above 2. Adjusting the flow compensator screw effects: a. Margin pressure and maximum system pressure. b. Margin pressure and low pressure standby. c. Margin pressure only. d. None of the above 3. Adjusting the pressure cut-off screw will effect: a. Maximum system pressure. b. Low pressure standby. c. Margin pressure. d. None of the above 4. The variable displacement pump in a backhoe will upstroke (Note: Treat engine speed as remaining constant): a. If there is an increase in work port pressure but the flow requirements do not change. b. If the flow requirements increase but the highest work port pressure decreases. c. If the flow requirements do not change and the work port pressure stays the same. d. None of the above 5. While an implement is activated and the operator maintains a constant lever displacement, a drop in engine RPM will cause the pump: a. To Upstroke b. To Destroke c. To remain unchanged d. None of the above

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Student Materials

6. If no implements are being operated the pump is at: a. High Pressure Stall and minimum flow. b. Low Pressure Standby and minimum flow. c. High Pressure Stall and maximum flow. d. Low Pressure Standby and maximum flow. e. None of the above 7. If the operator stalls one circuit and then operates another implement: a. The pump will destroke to decrease flow. b. Flow remains the same. c. The pump will go to Low Pressure Standby. d. The pump will upstroke to increase flow. e. None of the above 8. If the operator maintains a fixed lever position and the engine rpm are increased: a. The pump will upstroke to maintain flow. b. The pump will destroke to maintain flow. c. The pump swashplate angle remains unchanged. e. None of the above 9. If the torque limiter spring setting is increased from the present setting: a. The pump will upstroke sooner b. The pump will upstroke later c. The pump will destroke sooner d. The pump will destroke later e. None of the above