Series Ii, B & C Series Backhoe Loader Diagnostics: Service Training
Series Ii, B & C Series Backhoe Loader Diagnostics: Service Training
Series Ii, B & C Series Backhoe Loader Diagnostics: Service Training
STUDENT NOTES
BCP BHL -3- Student Materials
5/1/98
TABLE OF CONTENTS
COURSE DESCRIPTION......................................................................................................4
PRE-COURSE/POST-COURSE ASSESSMENT..................................................................6
COURSE PLAN/OUTLINE...................................................................................................8
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
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)
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
❑ ❑ ❑ 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.
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.
❑ ❑ ❑ 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.
Instructor's Signature:
Date:
Instructor's comments:
BCP BHL -8- Student Materials
5/1/98
COURSE PLAN/OUTLINE
GET ACQUAINTED
COURSE WRAP-UP
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❑ 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
426C Specification Sheet AEHQ0429
436C Specification Sheet AEHQ0430
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
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❑ Parts Books
416C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2388
416C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2549
426C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2551
426C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2597
428C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2385
436C Backhoe Loader (w/ Single Tilt) Parts Manual SEBP2559
436C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2601
438C Backhoe Loader (w/ Parallel Lift) Parts Manual SEBP2387
416B Backhoe Loader Parts Book SEBP2357
428B Backhoe Loader Parts Book SEBP2360
416 Series II Parts Book SEBP1900
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❑ 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.
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❑ 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)
4-8T0859 Pressure Gauge (0 to 3600 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
OBJECTIVES
At the completion of this module you will be able to:
NOTE: For the following objectives, use the Operation and Maintenance
Guide as a reference during the lab activities.
❑ 4. Locate and read all machine warning labels for operating and
servicing the machine
BACKGROUND This lesson will help you gain familiarity with the correct machine
INFORMATION maintenance and operation guidelines, plus, machine features and
benefits.
Shop Lab
❑ • View introduction slide presentation
❑ • Remove floor plate and sheet metal (in preparation for later lab
exercises.)
Materials Needed
❑ Specalogs (for the machines used)
Operation and Maintenance Chart (if available)
Machine Walk-around Checklist
Operation and Maintenance Guide (for the machine used)
1-Mechanics Tool Box
Quiz
❑ • Complete "Quiz: Machine Orientation."
Materials Needed
❑ Student Quizzes handout
Specalogs (for the machines used)
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Place a check in the blank if the indicator, switch or control is working correctly.
Series II B Series C Series
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
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Place a check in the blank after locating each of the following controls
Series II B Series C Series
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
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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).
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
1-Mechanics Tool Box
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Directions: Use this sheet to take notes during the presentation. During the engine lab, use this sheet
as a checklist when identifying components.
REGULATOR VALVE
FUEL INLET
INLET SCREEN
TO FUEL
TRANSFER ADJUSTMENT
PUMP SCREW
SPRING
FROM FUEL
TRANSFER PISTON
PUMP
INLET
STROKE
ROTOR
ASSEMBLY
OUTLET
STROKE
FUEL
OUTLET
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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.
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
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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 service manual modules
Related engine specifications
1-6V3121 Multitach Group or 9U7400 Multitach II Group
1-1U5481 Pressure Gauge Group
1-1U5482 Pressure Hose and Adapter Group
1-6V4142 Nipple
1-8C7575 or 8C7576 adapter
1-Mechanics Tool Box
(Optional)
1-5P0957 Coolant and Battery Tester
1-4C6500 Digital Thermometer group
1-8T2700 Blowby/Air Flow Group
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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
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.
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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
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.
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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
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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
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OBJECTIVES
❑ 1. Use the electrical schematic and the provided handout to locate (on
the schematic and on the machine) and determine the part number of
the following electrical components: starter motor, alternator,
battery, fuse holder (use main fuse panel or keystart fuse), engine oil
pressure switch, coolant temperature switch, coolant temperature
sender, power train oil temperature sender (converter), fuel level
sender, engine shutdown solenoid, key start switch , start relay, start
aid switch, start aid coil
❑ 2. Using the provided service literature perform tests for the battery,
alternator, and starter on the machine using a voltmeter and clamp on
ammeter.
❑ 3. Using the electrical schematic and the provided handout. Draw and
numerically code the wires to correctly connect the components of
the starting and charging system.
BACKGROUND This lesson allows you to become familiar with locating electrical system
INFORMATION components on the machine and in using the machine electrical
schematic.
Classroom Lab
❑ • View a slide presentation on the starting and charging system.
• Use the electrical schematic and to locate and identify the listed
electrical components on the Electrical System Checklist. Record the
schematic coordinates, part number and machine location in the
provided blanks.
NOTE: The instructor will discuss how to use the electrical schematic
for troubleshooting (color coding, switch specification chart), and how
to locate components on the machine.
Shop Lab
❑ • Use the checklist to locate the engine and electrical components on the
machine. Put a check in the blank next to each engine component
located or circle the electrical component location letters recorded
previously.
Classroom Lab
❑ • Use the provided electrical schematic and the Starting and Charging
System Worksheet. Draw and numerically code the wires to correctly
connect the components of the starting and charging system.
NOTE: Depending on which electrical schematic is used, a resistor may have
to be added to the schematic and the alternator ground modified.
Materials Needed
❑ 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
1-Mechanics Tool Box
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Electrical Components
Machine Schematic
Location Part No. Location Description
Starter motor
Alternator
Battery
Keystart fuse
Start relay
Electrical Components
Machine Schematic
Location Part No. Location Description
Starter motor
Alternator
Battery
Keystart fuse
Start relay
BACKGROUND This lesson allows you to become familiar with typical on the machine
INFORMATION electrical system tests using a voltmeter and ammeter.
Shop Lab
❑ • Perform the following electrical system test on the machine using a
voltmeter, clamp on ammeter, and battery analyzer:
batteries
alternator
starter
Refer to service magazine articles below which are in the 12-V and 24V
Electrical Systems handout for procedures.
a) Batteries - SM 6/20/88
b) Alternator - SM 5/4/87
c) Starter - SM 5/28/90
Materials Needed
❑ 12-V and 24-V Electrical Systems - Student Reference Materials
Electrical System Tests Worksheet
1-6V7800 Multimeters or 9U7330 Fluke 87
1-8T0900 AC/DC Clamp- on Ammeter
1-127-8078 Battery Tester
1-Mechanics Tool Box
Optional
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
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Voltage
Test A. Check battery voltage at the battery posts while cranking, or attempting to crank.
NOTE: Use the posts representing 12 or 24 Volts. 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 .
Voltage (step 5)
Amperage (step 6)
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Voltage
Test A. Check battery voltage at the battery posts while cranking, or attempting to crank.
NOTE: Use the posts representing 12 or 24 Volts. 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 .
Voltage (step 5)
Amperage (step 6)
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OBJECTIVES
❑ 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.
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
❑
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
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Filter
Suction screen
Test Locations:
Lube pressure
E C
F
D
J
H
G
Filter
Main Relief Valve
Cold Start Relief Valve
Torque Converter Inlet Relief Valve
Transmission Control Valve
AWD Solenoid
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.
❑ • 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
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
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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.
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A
D
TO REVERSE BALL
CLUTCH DETENT
TO DRAIN TO FORWARD
CLUTCH
PUMP
SUPPLY
E
B
F
H G
TO TORQUE
CONVERTER
I
C
B
TO TORQUE
CONVERTER D
R F
E
PUMP
SUPPLY
A
F
Solenoid
Relief Valve
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.
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.....
4. The neutralizer solenoid and spool drains (pump supply oil only)(pump supply oil and clutch oil).
Shop Lab
❑ • Record pressure specifications from the service manual before going to
the shop.
Suggested reference articles:
SM 5/11/87 - SMCS 3000 "New Transmission Group; New
Transmission Relief Valve Adapter." Note: This is the only article
that has complete and understandable transmission pressure for all
backhoes up to the C-Series. On 4WD machines, you may see pump
supply pressure of 250 ± 15 psi. The service manuals tend to 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
❑ • 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
2-Mechanic's Tool Boxes and hand tools
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VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
NOTE: Depending on which service publication is used, specifications may not always be provided for
both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As
the machine attempts to drive through the brakes, the machine will not move.
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VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
NOTE: Depending on which service publication is used, specifications may not always be provided for
both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As
the machine attempts to drive through the brakes, the machine will not move.
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VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
NOTE: Depending on which service publication is used, specifications may not always be provided for
both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As
the machine attempts to drive through the brakes, the machine will not move.
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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.
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.
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.
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.
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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:
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OBJECTIVES
❑ 1. On the machine, locate the components listed on the Axle and Brake
System Component Checklist for a backhoe loader..
Shop Lab
❑ • View slide presentation on the axle and brake system
Materials Needed
❑ Operation & Maintenance Guide
Service Manual
Parts Book
Axle and Brake Component Checklist
B and C Series Brake Schematic
1-Mechanic's Tool Boxes and hand tools
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AWD solenoid
RIGHT BRAKE
RELEASED
PLUNGER
BRIDGE PIPE
LEFT BRAKE
ENGAGED
PUSH ROD
TO BRAKE
PISTON
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Shop Lab
❑ • Remove side panels and/or cab floor plates as needed.
❑ • 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
Materials Needed
❑ Axle, brake and steering service manual modules
1-Mechanic's Tool Boxes and hand tools
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OBJECTIVES
Shop Lab
❑ • Split into Two Groups with One Machine per Group.
Materials Needed
❑ Related service manual modules
3054 Engine In Chassis Test Sheet
Electrical System Tests Worksheet
Backhoe Loader Transmission Test Sheet
Student Troubleshooting Analysis worksheets
12-V and 24-V Electrical Systems - Student Reference Materials
2-6V3121 Multitach Group or 9U7400 Multitach II Group
2-1U5481 Pressure Test Gauge Group
2-1U5482 Hose and Fitting Group
10-6V3965 Nipples
5-3J1907 O-rings
2-6V7800 Multimeters or 9U7330 Fluke 87
2-8T0900 AC/DC Clamp- on Ammeter
2-Mechanic's Tool Boxes and hand tools
Optional
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
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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
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.
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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
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Voltage
Test A. Check battery voltage at the battery posts while cranking, or attempting to crank.
NOTE: Use the posts representing 12 or 24 Volts.
Do not check voltage on the cable post clamps. Chart A-Typical System Voltage During
Cranking Versus Ambient Temperature
1. Is voltage equal to or greater than what is shown in
-23°C To-7°C -7°C To 10°C 10°C To 27°C
Chart A?
Temp. (-10°F To 20°F) (20°F to 50°F) (50°F To 80°F)
Record Voltage ___________ 24 Volt 12V to 16V 14V to 18V 16V to 20V
System
. . . Yes - Go to Test B.
12 Volt 6V to 8V 7V to 9V 8V to 10V
System
Test B. Measure starter motor voltage from TP4 to TP5 while cranking, or attempting to crank.
1. Is voltage equal to or greater than that shown in Chart A?
Record Voltage ___________ Chart B-Maximum Allowable System
Voltage Drops During Cranking
. . . Yes - Batteries and starter cables down to motor
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
Pos. Post (TP10 to TP6)
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
Chart B. Are all voltages within specifications? (TP8 to TP9)
Start Relay Contacts 0.8V 0.4V
. . . Yes - Check engine. Go to Test C. (TP3 to TP6)
. . . No - Repair and/or replace faulty electrical Solenoid Contacts 0.8V 0.4V
component . (TP6 to TP4)
Voltage (step 5)
Amperage (step 6)
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VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
NOTE: Depending on which service publication is used, specifications may not always be provided for
both speed ranges.
Hint: Raise the rear wheels off of the ground using the stabilizers to check transmission pressures to
reduce the chance of driving through the brakes during a test.
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VISUAL CHECKS
PRESSURE TESTS
PARKING BRAKE - ON
SHIFT PRESSURES
PRESSURE TEST LEVER LOW IDLE HIGH IDLE
SPEC ACTUAL SPEC ACTUAL
Pump Supply N XXXX
Forward Clutch F
Reverse Clutch R
Lube N
T. C. Inlet N XXXX
T. C. Outlet (T.C. Stall) 4th/Fwd XXXX XXXX
AWD Clutch Pressure N
NOTE: Depending on which service publication is used, specifications may not always be provided for
both speed ranges.
When testing the transmission pressures, use the stabilizers to raise the rear wheels off the ground. As
the machine attempts to drive through the brakes, the machine will not move.
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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:
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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:
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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:
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OBJECTIVES
❑ 10. On a quiz, match state of pump (i.e. upstroke, destroke, low pressure
standby, stall) to operational condition.
Quiz
❑ • Complete the quiz at the back of the LS/PC Student Handout after
participating in the classroom review
NOTE: Remove side panels and/or cab floor plates as needed.
Materials Needed
❑ LS/PC Student Handout with Quiz
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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
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Hydraulic tank
Pump
Implement controls
NA Torque Limiter
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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.).
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
Related service manual modules
Parts Book
Hydraulic pump and pump control valve - for BCP backhoe loaders
or similar
Mechanic's Tool Box with hand tools
Class notes
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Margin spool
Check valve
Pressure cut-off
NA Torque Limiter
Hydraulic Pump
Large actuator
Swash plate
Drive shaft
Primary resolver
Secondary resolver
Makeup valve
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D
H
G
E
H
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PUMP
NO SIGNAL OUTPUT
B G
A C
E D
G
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A
F
E
F
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BACKGROUND This lesson allows you to gain hands on experience with the implement
INFORMATION control valve and its components.
Shop Lab
❑ • Disassemble the implement control valve. Lay out all components.
❑ • Identify and state the purpose of the components using the Backhoe
Hydraulic Component Checklist and the Implement Control Valve
Component Checklist . (Circle the component letter after identifying
each component.).
Materials Needed
❑ Backhoe Hydraulic Component Checklist
Implement Control Valve Component Checklist
Service Manual
Parts Book
Implement control valve - for BCP backhoe loaders or similar
Additional hydraulic components (optional)
Mechanic's Tool Box with hand tools
Class notes
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HEAD ROD
B END END
E
A
TO TANK
TO TANK
D
FROM
C PUMP
TO NEXT
VALVE
F
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BACKGROUND This lesson will allow you gain familiarity performing system checks,
INFORMATION using the Service Manual, and determining if the machine is operating to
specifications.
Shop Lab
❑ • Record pressure specifications from the service manual before going to
the shop.on the Hydraulic System Test Sheet
Optional
❑ • Check line reliefs as per service manual. Adjust bucket positioner cam
and switch as per service manual.
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
Related service manual modules
2-8T0856 Pressure Gauge (0 to 870 psi)
2-8T0859 Pressure Gauge (0 to 3600 psi) or 1-1U5796
Differential Gauge Group
1-1U5482 Hose and Fitting Group
1-Stop Watch
1-Tape Measure
2-Mechanic's Tool Boxes and hand tools
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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:
If margin pressure needs to be adjusted, the following method is quicker and safer for the mechanic:
2. Mentally add to or subtract from low pressure standby about the same amount required to set
margin pressure to specification. Since both pressures are adjusted by the same screw, an
adjustment to one also affects the other. This relationship, however, is not linear.
3. Make this adjustment to the flow compensator (margin spool) while the machine is in low
pressure standby.
NOTE: 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.
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• Invert front bucket fully and lower to the ground. Record cycle times for loader lift below:
Loader lift cycle time specification
Test One Test Two Test Three
Average Cycle time
• Adjust Margin Pressure to 140 psi. Record cycle times for loader lift below:
Test One Test Two Test Three
Average Cycle time
• Adjust Margin Pressure to 350 psi. Record cycle times for loader lift below:
Test One Test Two Test Three
Average Cycle time
• Reset Low Pressure Standby to 250 psi. Recheck cycle times and margin pressure.
Test One Test Two Test Three
Average Cycle time
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 Low Pressure Standby to 150 psi. Record cycle times for loader lift below:
Test One Test Two Test Three
Average Cycle time
• Adjust Low Pressure Standby to 450 psi. Record cycle times for loader lift below:
Test One Test Two Test Three
Average Cycle time
• Reset Low Pressure Standby to 320 psi. for the B series and 350 psi for the C series. Recheck cycle
times and margin pressure.
Test One Test Two Test Three
Average Cycle time
Margin Pressure
CYCLE TIMES
TEST
1ST 2ND 3RD 4TH AVG. SPEC
Bucket Dump
L (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
Boom Pause
Auxiliary 1
Auxiliary 2
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BACKHOE LOADER HYDRAULIC TESTS
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
Boom Pause
Auxiliary 1
Auxiliary 2
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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.
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).
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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.
BCP BHL - 101 - Student Materials
5/1/98
BCP BHL - 102 - Student Materials
5/1/98
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.
List at least two other problems that could be causing the machine not
move. Describe tests and your anticipated results?
BCP BHL - 103 - Student Materials
5/1/98
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
OBJECTIVES
Shop Lab
❑ • Split into Two Groups with One Machine per Group.
Materials Needed
❑ Related service manual modules and reference materials
Backhoe Hydraulic System Tests sheets
2-8T0856 Pressure Gauge (0 to 870 psi)
2-8T0859 Pressure Gauge (0 to 3600 psi) or 1-1U5796 Differential
Gauge Group
1-1U5482 Hose and Fitting Group
1-Stop Watch
1-Tape Measure
2-Mechanic's Tool Boxes and hand tools
BCP BHL - 106 - Student Materials
5/1/98
BACKHOE LOADER HYDRAULIC TESTS
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
Boom Pause
Auxiliary 1
Auxiliary 2
BCP BHL - 107 - Student Materials
5/1/98
BACKHOE LOADER HYDRAULIC TESTS
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
Boom Pause
Auxiliary 1
Auxiliary 2
BCP BHL - 108 - Student Materials
5/1/98
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
1.
2.
3.
4.
5.
1.
RESULT
2.
RESULT
3.
RESULT
4.
RESULT
5.
RESULT
OBJECTIVES
❑ 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.
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..
NOTE: Remove side panels and/or cab floor plates as needed.
B Series C Series
Pressure Switch
TORQUE LIMITERS
MARGIN TORQUE
SPOOL LIMITER
SMALL ACTUATOR
PASSAGE TO AND BIAS SPRING
TANK
If the pump is at maximum flow and the signal pressure increases above
the torque limiter setting, the torque limiter opens and directs some of the
signal oil to the tank through a slot in the torque limiter spool. A pressure
drop occurs across the orifice in the signal line which results in a slight
loss of the actual signal pressure. The margin spool then moves up and
allows supply oil to the large actuator piston. The pump will then
destroke.
BCP BHL -3- Student Materials
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.
TORQUE
LIMITER
PUMP
SIGNAL OUTPUT
FLOW
COMPENSATOR
PRESSURE
COMPENSATOR
The reduced pump flow will be at a sufficient level to maintain the input
torque setting. If the cylinder pressure continues to increase, the torque
limiter will again open and destroke the pump more.
TORQUE LIMITER
SETTING
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
BCP BHL -6- Student Materials
5/1/98
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.
BCP BHL -7- Student Materials
5/1/98
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.