914G Manual Del Estudiante PDF

Service Training STUDENT
Course Materials MATERIALS
914G WHEEL LOADERS &

IT14G INTEGRATED TOOLCARRIERS
BUILDING CONSTRUCTION PRODUCTS
BCP 914G/IT14G -2- Student Materials
12/1/98
STUDENT NOTES
12/1/98
TABLE OF CONTENTS
COURSE DESCRIPTION......................................................................................................4
COURSE OUTLINE/PLAN...................................................................................................8
STUDENT COURSE BOOK CHECKLIST ........................................................................10
LAB REQUIREMENTS.......................................................................................................12
MODULE: MACHINE ORIENTATION ............................................................................13
MODULE: ENGINE SYSTEMS .......................................................................................17
MODULE: ELECTRICAL SYSTEM ................................................................................24
MODULE: POWER TRAIN ..............................................................................................32
MODULE: HYTEC SYSTEM ............................................................................................57
MODULE: AXLES, BRAKES AND STEERING SYSTEMS...........................................63
MODULE: IMPLEMENT HYDRAULIC SYSTEMS .......................................................71

12/1/98
COURSE DESCRIPTION
BCP 914G/IT14G Hystat Machine - Level II
Course Length: 4 1/2 Days
Recommended Departure time: 12:30 P.M. Fifth Day
Course Code:
Fees: None
CONTENT Classroom work (approximately 50%) will cover machine orientation,

systems operation/testing and adjusting of the major vehicle systems, and
vehicle operation and maintenance. Students will be challenged to
demonstrate their understanding of course material and will be tested to
monitor their progress. Emphasis will be placed on the hydrostatic drive
transmission used in the 914G wheel loader and IT14G integrated
toolcarrier.
Various labs will be conducted to allow the students to become more
familiar with the iron and to put into practice those skills of testing and
adjusting learned in the classroom. Major systems to be considered and a
brief description of lab exercises are as follows:
• Machine Introduction - Students will perform a daily walk-around
inspection and operate the vehicle noting the characteristics of the:
steering, brakes, transmission, transmission controls, and implement
controls.
• Engine Labs - Students will identify engine components and
perform tests for high idle, low idle, and engine oil pressure.
• Electrical Labs - Students will demonstrate their ability to use
electrical schematics, locate components on the machine, and
determine if key electrical components are functioning properly.
Performance tests for the hystat transmission control system will be
performed.
• Power Train Labs - Students will locate the various service points
and perform the systems tests as described in the service manual for
for the hydrostatic drive transmission.
• Axle and Brake Systems Labs - Students will identify system
components and will perform system tests as described in the
service manual.
• Steering and Implement Hydraulic Systems Labs - Students will
D&A the implement control valves and explain the function of the
piece parts. They will perform hydraulic system tests as described
in the service manual.
12/1/98
Students will receive personnel copies of service manual modules

pertinent to the vehicles and systems being covered as well as related
handout materials used in the classroom.
Class size will be limited to 8 students maximum.
SKILLS TAUGHT
DIAGNOSTIC TESTS Upon completion of this course, the student will be able to perform the
following diagnostic tests:
• check engine high idle and low idle,
• test the hydrostatic transmission system
• test the hydraulic brake systems
• test and adjust the implement hydraulic systems
• test the electrical starting and charging systems
• test the hystat transmission control system
WHO SHOULD ATTEND/COURSE PRE-REQUISITES

This course is intended for Caterpillar servicemen.
Prerequisite tests should be administered at least one to two weeks before
students take the course.
PREREQUISITE TESTS Students should pass the following pretests with 90% or better.
• Successfully passed the Basic ISO Pre-test VEBV0556
• Successfully passed the Basic Hydraulic Pretest VEBV0557
• Successfully passed the Basic Electrical Pretest SEBV0558
Prerequisite courses should be completed prior to participating in this

course.
PREREQUISITE • Interactive Video Course "Fundamentals of Mobile Hydraulics"
COURSES TEVR9001
12/1/98
PRE-COURSE/POST-COURSE ASSESSMENT
Student can not do. Needs more

Student has demonstrated his
Student can perform task but

Use the following assessment to determine if a student either needs to
attend a course and what skills they need to improve. The assessment
needs more practice
then should be used at the completion of the course to measure the

student's progress.
competence
training
OBJECTIVES
❑ ❑ ❑ 1. Perform a 10 hour/daily machine inspection for a BCP wheel loader

or integrated tool carrier.
❑ ❑ ❑ 2. Using the handout provided and the related service manual modules
locate the following: fuel filter, fuel injection pump, fuel shutoff
solenoid, priming (lift) pump, water separator, oil filter, engine oil
dipstick, engine oil cooler, primary air filter, secondary air filter,
turbocharger, air filter indicator, start aid coil, radiator, water pump,
temperature regulator housing, high idle adjustment screw, low idle
adjustment screw, fuel injection pump lock bolt, and cold advance
device.
❑ ❑ ❑ 3. Using the handout provided and the related service manual modules,
perform engine tests for engine high idle, low idle, transfer pressure
and, engine oil pressure.
❑ ❑ ❑ 4. Using the provided service literature perform tests for the battery,
alternator, and starter on the machine using a voltmeter, clamp on
ammeter, and the battery analyzer.
❑ ❑ ❑ 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 hystat hydraulic oil system components and

service points on the machine: hystat pump, charge pump, motor(s),
filters, direction selector lever, speed selector switch or creeper lever,
hydraulic oil cooler, and motor displacement signal control valve
(high speed only).
❑ ❑ ❑ 7. Using the appropriate service manual module and the "Hydrostatic

System Testing" reference material handout. to perform Tests A-G (as
described in the reference material) on the machine to determine the
machine is set to specification. Pressures that will be checked and/or
adjusted include the following: AB - drive loop pressure, PG -
charge pressure, PS1 - pump signal pressure, PC - pump case
pressure, M1 - motor actuator pressure, M2 - motor actuator pressure
(high speed only), MS - motor signal pressure (high speed only), and
cooling loop pressure.
12/1/98
Student can not do. Needs more

Student has demonstrated his
Student can perform task but

needs more practice
competence
training
8. Using the appropriate service manual module, perform checks on the

❑ ❑ ❑ machine for the HYTEC system (if equipped) using the ECAP tool.,
Electronic Technician, and a jumper wire.
❑ ❑ ❑ 9. On the machine, locate the components the following components:

brake pedals, steering wheel, hydraulic tank, hydraulic oil filters,
hydraulic oil cooler, Hand Metering Unit (HMU), priority flow
control valve, steering and brake pump, brake reservoir, brake master
and boost cylinder, brake relief valve test port location, brake
pressure test location, steering pressure test port location, the
supplemental steering pump and motor (if equipped), parking brake
control, and brake disc inspection plugs. Record a check after
locating each component..
❑ ❑ ❑ 10. On the provided schematic of the steering and brake system identify
the following components: steering and brake pump, priority valve,
HMU, boost cylinder, power piston, and master cylinder.
❑ ❑ ❑ 11. On the machine, locate the following: hydraulic tank, oil filter,
hydraulic oil cooler, implement pump, pump supply pressure test
port, implement controls, implement valve group, main relief valve,
tilt control valve, lift control valve, auxiliary valve(s), pilot pressure
test port, pilot system accumulator, pilot shutoff valve, dead engine
lower valve, rotary shutoff valve (IT), and Ride Control accumulator
and solenoid.
❑ ❑ ❑ 12. Perform performance checks and/or adjust: maximum system
pressure and line relief settings.
Post-Course Assessment Only - Student should review the above
objective and place checks in those boxes as appropriate. Student
should then sign his name below.
Student's Signature:
Instructor's Signature:
Date:
Instructor's comments:
12/1/98
COURSE OUTLINE/PLAN
GET ACQUAINTED
MODULE: MACHINE ORIENTATION

- Lesson: Machine Orientation
- Slide presentation
- Shop Lab
- Machine Orientation Quiz
- Module Summary
MODULE: ENGINE SYSTEMS

- Lesson: Engine Systems
- Slide presentation on engine systems
- Shop lab
- Cooling system homework assignment
- Slide presentation on the fuel system
- Lesson: Engine Systems Tests
- Perform engine tests
- Review cooling system homework assignment
- Module Summary
MODULE: ELECTRICAL SYSTEM

- Lesson: Electrical Systems
- Electrical schematic discussion
- Identify electrical components
- Lesson: Electrical System Tests
- Starting and charging system components
- Quiz: Electrical System
- Module Summary
MODULE: POWER TRAIN

- Lesson: Power Train Component Identification
- Slide presentation on power train components
- Identify components on schematic and the machine
- Lesson: Hystat Pump and Motor Components Identification
- Identify pump and motor components using a parts book
- Lesson: Hystat Pump and Motor Component ID.(optional
- D&A and identify pump and motor components
- Lesson: Power Train System Tests
- Lesson: Hystat Problem Analysis
- Case Study: Power Train
- Quiz: Power Train
- Module Summary
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MODULE: HYTEC SYSTEM

- Lesson: HYTEC System Component Identification and Operation
- Slide presentation on the autoshift system
- Identify components
- Operate system
- Lesson: Autoshift System Tests
- Perform diagnostic tests
- Module Summary
MODULE: AXLES AND BRAKES

- 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
- Quiz: Axle and Brakes
- Module Summary
MODULE: IMPLEMENT HYDRAULIC SYSTEMS

- Lesson: Implement Hydraulic System Component Identification
and Tests
- Slide presentation on the hydraulic systems
- Identify hydraulic system components
- Lesson: Implement Control Valve Component Identification
(optional)
- Case Study: Implement Hydraulic System
- Quiz: Implement Hydraulic System
- Module Summary
COURSE WRAP-UP
BCP 914G/IT14G - 10 - Student Materials
12/1/98
REQUIRED STUDENT STUDENT COURSE BOOK CHECKLIST

MATERIALS
❑ Description Form No.
Binder SENR2910
Fluid Power Graphic Symbols SEEV0529
914G Specification Sheet AEHQ5047
IT14G Specification Sheet AEHQ5049
914G/IT14G Product Bulletin TEJB1057
Know Your Cooling System SEBD0518
3054 Engine System Operation, T&A SENR5815
Lucas Fuel System Supplement SENR6525
Power Train System Operation, T&A SENR6766
Electronic Transmission Control System SENR6767
Tool Operating Manual SEHS9343
Steering System Operation, T&A SENR6770
Brake System Operation, T&A SENR6772
Hydraulic System Operation, T&A SENR6774
Hydraulic System Schematic SENR6775
Electrical Schematic SENR6777
Optional
Power Train Specifications SENR6765
Steering System Specifications SENR6769
Brake System Schematic SENR6771
Hydraulic System Specifications SENR6733
12/1/98
STUDENT REFERENCE Reference Materials

MATERIALS
Operation and Maintenance Manuals - at least two copies of the
❑ following O&M Guides should be available until Lube and Maintenance
Charts are made available in order to expedite the first module.
914G SEBU6868
IT14G SEBU6869
❑ Service Manuals - the service manuals will provide answers to questions

on disassembly and assembly of components along with additional
specifications. Two copies should be available.
914G Wheel Loader – IT14G Integrated Toolcarrier SENR6760
❑ Parts Books
914G Wheel Loader SEBP2343
IT12G Integrated Toolcarrier SEBP2344
12/1/98
914G/IT14G LAB REQUIREMENTS
❑ Machine Requirements
1-914G/IT14G Speeder or High Speed Machine
1-914G/IT14G Standard Speed Machine
NOTE: If only the standard machine is available, the preference is that the
machine is equipped with an ECM.
❑ Tooling Requirements
1-6V3121 Multitach Group or 9U7400 Multitach II Group
1-1U5481 Pressure Gauge Group
1-1U5482 Pressure Hose and Adapter Group
1-Mechanic's Tool Box
2-6V7800 Multimeters or 9U7330 Fluke 87
1-8T0900 AC/DC Clamp- on Ammeter
1-127-8078 Battery Analyzer Group
5-6V3965 Nipples
5-3J1907 O-rings
3-8T2352 Tee
4-6V8397 O-ring
1-6V9508 Plug
2-6V3966 Test nipples
1-6V9829 Cap
1-8T8697 ECAP or ET
1-7X1700 Communications Adapter
1-7X1570 ECAP Cable - to machine
1-7X1851 ECAP Cable - between adapter and ECAP or
1-7X1420 ECAP Cable (original ECAP)
1-NEXG4523 Vehicle Functions Serv. Prog. Module for ECAP
1-NEXG4521 Serv. Prog. Module for Communication Adapter
1-8T0859 Pressure Gauge
1-8T0850 Pressure Gauge (for pilot system)
1-Stop Watch
1-Tape Measure
Optional
1-6V3000 Sure-seal Connector Kit
1-9U7246 Deutsch Connector Kit
1-1U5804 Crimp Tool (Deutsch connectors)
1-5P0957 Coolant and Battery Tester
1-4C6500 Digital Thermometer group
1-8T2700 Blowby/Air Flow Group
12/1/98
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.
MODULE 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.
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 wheel loader

or integrated tool carrier.
❑ 3. Identify the following BCP wheel loader or integrated tool carrier.

controls: Implement control levers, steering and brake controls,
governor controls, keystart switch, warning indicators, and accessory
switches and controls.
❑ 4. Locate machine warning labels for operating and servicing the

machine, on the ROPS, use of jumper cables, steering link, and
accumulators.
❑ 5. Demonstrate proper machine starting and stopping procedures for a

BCP wheel loader or integrated tool carrier.
❑ 6. Perform the provided machine operations and answer the questions

on the handout.
12/1/98
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
❑ • Perform a 10 hour/daily inspection before starting and or operating the
vehicle:
Check engine, drop box, brake, and power train/hydraulic system
oil levels.
Check cooling system fluid level. Check fuel level.
Identify service points.
Test for proper function of indicators and gauges.
Locate warning labels.
❑ • Identify the following machine controls: Implement control levers,

steering wheel, brake controls, governor controls, keystart switch,
warning indicators, and accessory switches and controls.
❑ • Perform startup and machine shutdown procedures. Operate the

machine - If feasible, move the vehicle, noting steering & brake
characteristics, power train operation, implement control function, etc.
Use the 914G/IT14G Vehicle Operation Worksheet.
❑ • 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.
Notice bucket leveler operation.
Back drag in FLOAT position.
❑ • Remove floor plate and sheet metal (in preparation for later lab
exercises.)
Materials Needed
❑ Specalogs (for the machines used)
914G/IT14G Machine Operation Worksheet
Operation and Maintenance Chart (for the machine used if
available)
Operation and Maintenance Guide (for the machine used)
Quiz
❑ • Complete "Quiz: Machine Orientation."
Student Quizzes handout
12/1/98
Machine Walk-around Checklist

Directions: Use this sheet when performing the machine orientation lab exercise. IT machines may be
substituted for the wheel loaders listed
Place a check in the blank if the fluid level is acceptable.
914G IT14G
Engine 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.

914G IT14G
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.
914G IT14G
Keystart switch
Turn signal
Tachometer
Engine coolant 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
12/1/98
Machine Walk-around Checklist - cont'd

Place a check in the blank after locating and reading the following warnings label on the machine..
914G IT14G
Before operating
Use of ether
Accumulators
Articulation area
Before roading
Loader arm brace
ROPS
Use of Jumpers
Place a check in the blank after locating each of the following controls
914G IT14G
Front governor pedal
Steering wheel
. Directional shifter
Speed selector
Directional or transmission neutral lock
Transmission neutralizer switche(s)
Brake pedals
Parking brake lever
Loader lift and tilt
Attachment lever
Attachment switch for IT machine
12/1/98
914G/IT14G Machine Operation Worksheet
Before starting the machine: FASTEN SEAT BELT.
1. Place the Speed Selector Switch in the High Speed mode. The parking brake should be ON.
Move the shift lever to FORWARD. Start the machine.
Did the machine start? Yes No
2. Move the shift lever to the NEUTRAL position. Start the machine.
Did the machine start? Yes No
3. With the parking brake ON, move the shift lever to FORWARD.
Did the machine move? Yes No
4. Release the parking brake with the shift lever still in FORWARD.
5. Move the shift lever to the NEUTRAL position (parking brake released) and then move the shift
lever to FORWARD.
Drive machine along test range:
6. When driving forward in HIGH SPEED (accelerator fully depressed), shift to the SLOW
SPEED mode.
Did the machine slow down? Yes No
7. When driving forward at maximum SLOW SPEED (accelerator fully depressed), shift to the
HIGH SPEED mode.
Did the machine speed up? Yes No
8. Remove your foot from the accelerator.

Did the machine continue moving? Yes No
9. Increase engine RPM (accelerator fully depressed) and engage the brakes.
Did the engine lug down? Yes No
12/1/98
10. Drive the machine in High Speed mode FORWARD, with the accelerator fully depressed.
Shift to REVERSE.
Does the machine move in REVERSE? Yes No
11. Drive the machine on to a slope or ramp, leave the machine in FORWARD with the machine
facing up the ramp or slope and remove your foot from the accelerator (parking and service
brakes released).
Does the machine move down the slope? Yes No
If the machine is equipped with a "creeper" control. Move the lever to different positions and note
machine performance.
12. With the accelerator fully depressed, gradually pull back on the "creeper lever."
Did the machine slow down? Yes No
Did the machine eventually stop? Yes No
With the machine in NEUTRAL, and the engine at high idle, operate the implements.
13. Put the pilot control into the loader "RAISE" detent and then operate the tilt circuit?
Which implement slows down? Lift Tilt Neither Both
14. Put the pilot control lever into the loader "FLOAT" detent and then pull up on the pilot shutoff
lever?
Does the implement stay in detent? Yes No
15. Return the pilot shutoff lever to the full open position. Raise the loader arms fully and rack the
bucket back. Turn off the machine. Now, operate the implements
Can the implements be lowered? Yes No
Return the machine to the lab starting point and shutoff the machine and engage the parking brake.
12/1/98
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.
MODULE OBJECTIVES
❑ 1. Using the handout provided and the related service manual modules
locate the following: fuel filter, fuel injection pump, fuel shutoff
solenoid, priming (lift) pump, water separator, oil filter, engine oil
dipstick, engine oil cooler, primary air filter, secondary air filter,
turbocharger, air filter indicator, start aid coil, radiator, water pump,
temperature regulator housing, high idle adjustment screw, low idle
adjustment screw, fuel injection pump lock bolt, and cold advance
device.
❑ 2. Using the handout provided and the related service manual modules
locate the following: engine oil pressure test port, plug for checking
engine boost, plugs for checking coolant temperatures.
❑ 3. Using the handout provided and the related service manual modules,
perform engine tests for engine high idle, low idle, transfer pressure
and, engine oil pressure. Optional additional checks may include fuel
injector testing, full load, injection timing, and cooling system tests.
❑ 4. As a homework assignment, read "Know Your Cooling System"

(form SEBD0518) and answer questions on the Cooling System
worksheet. The answers will be reviewed.
12/1/98
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.
Shop Lab
❑ • Use the Engine Systems Checklist to locate the engine components on
the machine. Put a check in the blank next to each engine component
located.
Classroom Lab
❑ • For homework, read "Know Your Cooling System" and review the
cooling system material in the O&M Guide to complete the Cooling
System Review Worksheet.
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
❑ Engine Systems Checklist
Governor Component Checklist
Cooling System Review Worksheet
O&M Guide for the machines
Related service manual modules
1-Mechanics Tool Box
OT Fishe
Optional
1-127-1069 Engine Timing Tool
914G/IT14G Student Reference Materials - Fuel System
Supplement
12/1/98
Engine Component Checklist

Directions: Use this sheet to take notes during the presentation. During a lab exercise, use this sheet as
a checklist when identifying and locating components.
Location & Description Location & Description

____ Fuel filter ____ Engine oil pressure test port
____ Fuel injection pump ____ Plug for checking engine boost
____ Fuel Shutoff Solenoid ____ Plugs for checking coolant
temperatures
____ Priming (lift) pump
____ Water separator
____ Oil filter
____ Engine oil dipstick
____ Engine oil pressure test port
____ Engine oil cooler
____ Primary air filter
____ Secondary air filter
____ Turbocharger
____ Air filter indicator
____ Start aid coil
____ Radiator
____ Water pump
____ Temperature regulator housing
____ High idle adjustment screw
____ Low idle adjustment screw
____ Fuel injection pump lock bolt
____ Cold advance device

12/1/98
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. When filling the cooling system, never fill faster than 5 gallons per minute.
8. An engine should never be operated with the temperature regulators removed.
9. When measuring the temperatures in the cooling system, the temperature in the radiator top
tank should be below the coolant boiling point.
10. The temperature of the water pump outlet must be approximately 8o to 20oF above the
temperature in the radiator top tank.
11. The most common cause of engine overcooling is temperature regulators stuck closed.
12. High sulfur fuel will cause increased engine wear during overcooling when the operating
temperature is below 175oF
13. Caterpillar Extended Life Coolant (ELC) or a commercial ELC that meets the Caterpillar
specification (EC-1) is the preferred antifreeze to use in Cat engines.
14. Commercial coolant/antifreeze that only meets the ASTM D3306 specification is acceptable
for use in Caterpillar engines.
15. The service life for the Caterpillar Extended Life Coolant (ELC) is for 5000 hours.
16. Caterpillar Extended Life Coolant (ELC) does not require a frequent addition of a
Supplemental Coolant Additive (SLC) only an extender needs to be added at 3000 hours or
every two years.
17. The effectiveness of the Caterpillar Extended Life Coolant (ELC) is reduced is it is mixed
with other types of antifreeze such as Caterpillar (DEAC)
12/1/98
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.
Materials Needed
❑ 3054 Engine In Chassis Test Sheet
Related service manual modules
Related engine specifications
NOTE: You may have to refer to the Power Train Systems Operation Testing
and Adjusting module for engine specifications.. The engine service
module shows specs for 3054 engines with a equipped with a
different fuel pump.
1-6V3121 Multitach Group or 9U7400 Multitach II Group

1-1U5481 Pressure Gauge Group
1-1U5482 Pressure Hose and Adapter Group
(Optional)
1-5P0957 Coolant and Battery Tester
1-4C6500 Digital Thermometer group
1-8T2700 Blowby/Air Flow Group
12/1/98
3054 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
Third Speed - Reverse
Inlet Manifold Pressure @ Full Load 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 pipe thread fitting and test nipple to check
engine oil pressure.
12/1/98
3054 Engine In Chassis Test Sheet

Name/Code Customer
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
Third Speed - Reverse
Inlet Manifold Pressure @ Full Load 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 pipe thread fitting and test nipple to check
engine oil pressure.
12/1/98
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,
batteries, fuse panel, engine oil pressure switch, coolant temperature
switch and sender, fuel level sender, fuel shutoff (shutdown)
solenoid, key start switch, starter relay, start aid switch, coil (start
aid), cold advance device , and hydraulic lockout detent override
switch.
❑ 2. Using the provided service literature perform tests for the battery,
alternator, and starter on the machine using a voltmeter, clamp on
ammeter, and the battery analyzer.
❑ 3. (Optional) Using the provided service literature, demonstrate the

function of the fuel shutoff solenoid and start aid.
❑ 4. 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.
❑ 5. Using the electrical schematic, complete a quiz related to information

found on the schematic and the shop labs.
12/1/98
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
❑ • Use the electrical schematic and to locate and identify the listed
electrical components on the Engine and 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 and circle the electrical component location letters recorded
previously.
Classroom Lab
❑ • Use the 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: The coil is called a "heater' on the schematic; however, since this is
the same component used on B series backhoes and there are more
of those produced, we will call it the same thing as the backhoes
which is a "coil."
Materials Needed
❑ Electrical System Checklist
Starting and Charging System Worksheet
Machine electrical schematic
12/1/98
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.
Location Part No. Coordinates & Description
Starter motor
Alternator
Batteries
Fuse panel (use a fuse part number from the fuse panel)
Engine oil pressure switch
Coolant temperature switch and sender
Fuel level sender
Fuel shutoff (shutdown) solenoid
Key start switch
Starter relay
Start aid switch
Coil (start aid - heater)
Cold advance device (no part number available)
Hydraulic lockout detent override switch

Starting and Charging System Worksheet
12/1/98
Directions: Use the machine electrical schematic to complete this schematic. Label the wires with the appropriate alpha-numerical codes.
NOTE: The "coil" is called a heater on the electrical schematic. Also, remember the alternator is not the "self-exciting" type..
BCP 914G/IT14G
ELECTRICAL STARTING AND CHARGING SYSTEM
SHIFT
HANDLE TO
NEUTRAL-START
RELAY
B+
ALT
ALTERNATOR
MAIN BREAKER
TO R
60 112-PU-10 ACCESSORIES
C OFF
MAIN POWER S ON
NEUTRAL-START B ST
RELAY 15 A RELAY
KEY START
SWITCH
AUX BREAKER
30 115-RD-10 10 A
- 29 -
ALT BREAKER
60
FUEL RESISTOR
SHUTOFF
SOLENOID
NEG POS NEG POS G S START AID
COOLANT SWITCH
MTR BAT
SWITCH
STARTER MOTOR
STARTER
DISCONNECT RELAY T°
SWITCH
(OPTIONAL) COLD
ADVANCE FROM
RD-0 DEVICE RESISTOR
LAMP
SWITCH
COIL
NOTE: The "coil" is called a heater on the electrical schematic.

Student Materials
Also, remember the alternator is not the "self-exciting" type.

12/1/98
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
Use the Electrical System Tests Worksheet to record results.

NOTE: On some machines, the ground for the starter or solenoid is through
its case to the engine, rather than a separate ground wire.
❑ • Demonstrate the function of the fuel shutoff solenoid. Disconnect wire

to the solenoid and try to start engine.
❑ • Perform optional checks as required by the instructor (i.e. - key start

switch, bucket kickouts). List the optional tests performed below:
Materials Needed
❑ Electrical System Tests Worksheet
12-V and 24-V Electrical Systems - Student Reference Materials
1-8T0900 AC/DC Clamp- on Ammeter
1-127-8078 Battery Analyzer Group
Optional
12/1/98
Electrical System Tests Worksheet
I. Battery Test: Reference - Batteries - SM 6/20/88
Voltage
II. Starter Tests: Reference - Starter - SM 5/28/90 - Enter test results in the charts provided.
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
. . . Yes - Go to Test B.
System
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 B-Maximum Allowable System
Chart A? Voltage Drops During Cranking
. . . Yes - Batteries and starter cables down to motor Absolute Maximum
are electrically within specifications. Go to Test C. Voltage Reading
Circuit 24V 12V
. . . No - Voltage drop (loss) between batteries and Batt. Pos. Post to Starter 0.5V 0.3V
starter is too great. Go to next step. Pos. Post (TP10 to TP6)
NOTE: For this exercise, assume your answer is Batt. Neg. Post to Starter 1.4V 0.7V
"NO" and then perform the next step. Enter results Neg. Post (TP7 to TP5)
in CHART B. Drop Across Only 1.0V .5V
Disconnect Switch
2. Measure voltage drops in cranking circuit per (TP8 to TP9)
Chart B. Are all voltages within specifications? Start Relay Contacts 0.8V 0.4V
(TP3 to TP6)
. . . Yes - Check engine. Go to Test C.
Solenoid Contacts 0.8V 0.4V
. . . No - Repair and/or replace faulty electrical (TP6 to TP4)
component .
III. Alternator Tests: Reference - Alternator - SM 5/4/87. Perform all steps in the article. Record
results below for the steps shown.
Initial Amperage (step 4)
Voltage (step 5)
Amperage (step 6)
12/1/98
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 five lessons, a case study and a quiz.
One of the lessons is optional.
OBJECTIVES
❑ 1. Locate the following hystat hydraulic oil system components and

service points on the machine: hystat pump, charge pump, motor(s),
filters, direction selector lever, speed selector switch or creeper lever,
hydraulic oil cooler, and motor displacement signal control valve
(high speed only).
❑ 2. On a schematic of the standard machine, identify the following hystat

hydraulic oil system components: charge pump, hystat piston pump,
filter group, crossover line relief and makeup valves, speed sensing
valve, Forward-Neutral-Reverse (FNR) valve, charge relief valve,
pressure override valve, Reverse solenoid, motor displacement
control valve, flushing valve, speed selector solenoid, piston motor,
and throttle pin.
❑ 3. On a schematic of the high speed machine, identify the following

hystat hydraulic oil system components: charge pump, hystat piston
pump, filter group, crossover line relief and makeup valves, speed
sensing valve, Forward-Neutral-Reverse (FNR) valve, charge relief
valve, pressure override valve, shuttle valve, motor displacement
control valves, flushing valve, speed selector solenoid, piston motors,
throttle pins, and motor displacement signal control valve.
❑ 4. Using the appropriate parts book and the provided checklists record
the correct part number and the parts book description for each
service manual component description.
12/1/98
❑ 5. Using the appropriate service manual module and the "Hydrostatic

adjusted include the following: AB - drive loop pressure, PG -
charge pressure, PS1 - pump signal pressure, PC - pump case
pressure, M1 - motor actuator pressure, M2 - motor actuator pressure
(high speed only), MS - motor signal pressure (high speed only), and
cooling loop pressure.
❑ 6. Using provided reference materials and handouts identify potential

system problems caused by malfunctioning components during a lab
exercise.
❑ 7. (Optional) D&A the hystat pump and motor, using the service
manual hystat D&A module.
❑ 8. On a quiz match the following hystat system component to its

function: speed sensing valve, charge pump relief valve, FNR valve,
motor displacement control valve, piston motor, motor displacement
signal control valve, pressure override valve, piston pump, charge
pump, and "creeper" valve.
❑ 9. On a quiz correctly identify specific machine operation characteristic

of the 914G and IT14G.
12/1/98
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
❑ • Identify the components on the Standard Power Train System
Components Checklist and the High Speed Power Train System
Components Checklist.
Shop Lab
❑ • Remove side panels as needed.
❑ • Locate power train oil system components listed on Hystat Components

Checklist. Record a check after locating each component.
❑ • Identify the pressure test locations: AB - drive loop pressure, PG -

charge pressure, PS1 - pump signal pressure, PC - pump case pressure,
M1 - motor actuator pressure, M2 - motor actuator pressure (high speed
only), and MS - motor signal pressure (high speed only). Record a
check after locating each test location.
❑
Materials Needed
Operation and Maintenance Guide
Service Manual
Parts Book
Hystat Components Checklist
Standard Pump Component Checklist
Standard Motor Component Checklist
High Speed Pump Component Checklist
High Speed Motors Component Checklist
Mechanic's Tool Box and hand tools
12/1/98
Hystat Components Checklist I

Directions: Use this sheet to take notes during the presentation (i.e. locations, functions). During a lab
exercise, use this sheet as a checklist when identifying components and pressure test locations.
Standard High Speed
Hystat pump
Charge pump
Motor(s)
Filters
Direction selector lever
Speed selector switch or creeper lever
Hydraulic oil cooler
N/A Motor displacement signal control valve (high speed only)
Pressure test locations
AB - Drive loop pressure
PG - Charge pressure
PS1 - Pump signal pressure
PC - Pump case pressure
M1 - Motor actuator pressure
N/A M2 - Motor actuator pressure (high speed only)
N/A MS - Motor signal pressure (high speed only)
Cooling loop pressure

Standard Power Train System
12/1/98
Components Checklist
Directions: Fill in the blanks next to
the numbers and letters with the
BCP 914G/IT14G
correct term.
CREEPER
VALVE
Identify Components STANDARD HYSTAT SYSTEM

HYSTAT BRAKE
VALVE
TO IMPLEMENT
PILOT SYSTEM
A _________________________ PUMP PS1 PG PC AB
B _________________________
X1
C _________________________ H MB
B
E K L
D _________________________ A TO
FLUSHING
BYPASS
BLOCK
X3
E _________________________ X4
G M
X2 MIN J
F _________________________
- 36 -
D TO TANK
RETURN CHECK
VALVE
G _________________________
I
MA
H _________________________
N
I__________________________
FWD
M1 MOTOR
J__________________________
F TO HYDRAULIC
C TANK
K _________________________
OIL
SAMPLING
L _________________________
M _________________________
N _________________________
Student Materials
High Speed Power Train
12/1/98
System Components Checklist

BCP 914G/IT14G
correct term.
HIGH SPEED HYSTAT SYSTEM LARGE MOTOR MS HYSTAT BRAKE/ CREEPER

Identify Components INCHING VALVE VALVE
M2
O
A _________________________ TO IMPLEMENT
PILOT SYSTEM
PUMP
PS1 PG PC AB M
B _________________________ K
MIN
N
X1
H MB
C _________________________ B
A E L
D _________________________
X3
X4
E _________________________ G
X2
- 37 -
F _________________________ D
M TO
FLUSHING
G _________________________ BYPASS
MA
J BLOCK
N
MIN
H _________________________
FWD TO TANK
RETURN CHECK
VALVE
I__________________________
F TO HYDRAULIC
TANK
C
J__________________________ I
M1
OIL
SAMPLING SMALL MOTOR
K _________________________
L _________________________
M _________________________
N _________________________
O _________________________
Student Materials
12/1/98
Lesson: Hystat Pump and Motor Components

Identification
BACKGROUND
INFORMATION
This lesson allows you to gain experience using the parts book to identify
with the hystat pump and motor components.
❑
Classroom Lab
• Use the checklist provided and a parts book to locate pump and motor
components
❑ • Write the correct part number next to the component description
Materials Needed
❑ Parts Book Hystat Components Checklists I & II
Parts Book
Student Notes
12/1/98
Parts Book Hystat Components Checklist I

Directions: During a lab exercise, use this sheet as a checklist when identifying components from the
parts book
Hystat Pump Components
Part No. Parts Book Description Service Manual Description
Hystat Pump
Speed Sensing Valve
Charge Relief Valve
Pressure Override Valve
FNR Valve
Pump Actuator
Cross-over relief and makeup
Standard Motor Components Machine Serial number prefix:
Standard Hystat Motor
Flushing Valve
Reverse Solenoid Valve
Speed Selector Solenoid Valve
Motor Displacement Control Valve
Throttle Pin
12/1/98
Parts Book Hystat Components Checklist II

Directions: During a lab exercise, use this sheet as a checklist when identifying components from the
parts book
Small Motor Components Machine Serial number prefix:
Small Motor
Shuttle Valve
Throttle Pin
Large Motor Components Machine Serial number prefix:
Large Motor
Flushing Valve
Throttle Pin
Motor Displacement Signal Control Valve

12/1/98
Lesson: Hystat Pump and Motor Component

Identification (Optional)
BACKGROUND
INFORMATION
This lesson allows you to gain hands on experience with the hystat pump
and motors.
Shop Lab
❑ • Disassemble the hystat pump. Lay out all components.
❑ • Assemble the hystat pump.
❑ • Disassemble the hystat motor(s). Lay out all components.
❑ • Assemble the hystat motor(s).
Materials Needed
❑ Service Manual
Parts Book
Mechanic's Tool Box with hand tools
Class notes
The following checklists can be used to assist in identifying components.

12/1/98
Directions: During a lab, use this sheet as a checklist when identifying components.
The pump group consists of the following components:
A variable displacement, overcenter piston pump provides flow to drive a bi-directional motor.
The actuator piston controls the angle of the pump swashplate.
The charge pump charges the system at start-up and provides makeup oil. Oil is directed by the
charge pump through the filter group, which cleans all the oil before entering the drive pump and
motor. The charge pump also provides the source for signal pressure to control the pump and
motor. The signal pressure will vary proportionally to the engine speed. The higher the engine
speed, the higher the signal pressure.
A speed sensing valve senses the charge flow and converts some of it to signal oil. The orifice in
the speed sensing valve creates a pressure differential which is proportional to engine speed. This
pressure differential is then multiplied by the speed sensing valve by a factor of approximately 7:1
and becomes signal oil. This signal is then used to control the pump and motor. The speed
sensing valve sends the signal to the FORWARD-NEUTRAL-REVERSE (FNR) valve and the
motor displacement control valve. The speed sensing valve sends oil not used for signal oil to the
remainder of the charge circuit.
An orifice in the signal line above the speed sensing valve allows the pressure override valve and
the hystat brake valve to function as designed. Without the orifice, the speed sensing valve would
compensate for flow loss through the hystat brake valve, thereby negating the braking capability
of the valve, or would decrease the ability of the pressure override valve to limit the maximum
drive loop pressure. A screen before the orifice reduces plugging of the orifice.
The combination crossover relief and makeup valves will open to protect the system by either
maintaining a minimum pressure or reducing pressure spikes in the drive loop. At machine start-
up, the valves open to direct oil to both sides of the pump and motor.
The charge pump relief valve limits the pressure of the oil not sent through the speed sensing
valve. The valve also limits the maximum hystat system pressure in NEUTRAL and the
maximum implement pilot system pressure.
The FORWARD-NEUTRAL-REVERSE (FNR) valve consists of a spool and two solenoids.
When one of the solenoids is energized by the electronic shift lever, the spool is shifted and sends
signal oil to actuate the pump to provide flow for the direction selected.
The pressure override valve limits the maximum drive loop pressure. A ball resolver senses the
highest drive loop pressure. When this pressure reaches a specified limit, the override valve will
open and send oil in the signal line to case drain, reducing the signal pressure and causing the
motor to upstroke and the pump to destroke. When the motor is upstroked or the pump is
destroked, machine speed is reduced.
A filter bypass valve and switch are part of the filter group. If the filter is plugged, the bypass
valve opens and the switch closes to turn on an indicator lamp in the operator's compartment. The
indicator lamp stays on as long as the valve is open. With cold oil, the bypass valve opens and the
indicator lamp lights temporarily. The lamp goes out when the oil reaches a specified
temperature.
12/1/98
The motor group consists of the following components:
A bi-directional, variable displacement, bent axis piston motor and actuator convert hydraulic
power into mechanical power. The power is transmitted into a gear box mounted to the the rear
axle. Power is also sent to the front axle by a drive shaft. The motor actuator piston controls the
motor displacement by changing the angle of the rotating group relative to its output shaft. The
higher the stroke or displacement, the higher the torque and lower the speed. The lower the
stroke, the lower the torque and higher the speed.
A throttle pin (orifice check valve) controls motor stroking time. The orifice slows the actuator
movement from minimum stroke to maximum stroke.
A motor displacement control valve senses the signal from the speed sensing valve. The valve
compares the signal with the drive loop pressure to control the motor actuator piston. When the
accelerator is depressed more, the signal pressure increases to destroke the motor. If the drive
pressure increases, the motor upstrokes.
A speed selector valve which, when energized, blocks the signal oil from reaching the motor
displacement valve. Since the motor stays fully stroked, machine speed is reduced to improve
loading performance. The speed selector valve is controlled by either the optional "creeper" valve
or a switch on the left side of the front console.
A reverse solenoid valve which, when energized, sends the REVERSE drive loop pressure to the
motor displacement control valve and actuator. In FORWARD, the reverse solenoid is de-
energized and the FORWARD drive loop pressure goes to the motor displacement control valve
and actuator. By stroking the motor with the higher drive loop pressure, hystat driving response is
improved and, during hydrostatic braking, system stability is maximized.
A flushing valve continuously drains some oil from the low pressure side of the drive loop
through the motor bearings to case drain. This action purges heat, debris and air from the drive
loop.
The hystat brake valve is controlled by the same pedal as the service brake. As the brake pedals
are depressed, the hystat brake valve allows signal oil to go to the tank, which causes the motor to
upstroke (if not already at maximum angle) and the pump to destroke. Engaging the brakes will
not reduce the engine speed, permitting faster implement speed due to higher flow from the
implement pump.
The optional "creeper" valve drains the signal oil from the speed sensing valve to the tank. This
action limits the machine speed and can also limit rimpull.
12/1/98
Directions: During a lab, use this sheet as a checklist when identifying components. NOTE: The high
speed machine pump is the same as the standard speed machine pump
The pump group consists of the following components:
A variable displacement, overcenter piston pump provides flow to drive a bi-directional motor.
The actuator piston controls the angle of the pump swashplate.
The charge pump charges the system at start-up and provides makeup oil. Oil is directed by the
charge pump through the filter group, which cleans all the oil before entering the drive pump and
motor. The charge pump also provides the source for signal pressure to control the pump and
small motor. The signal pressure will vary proportionally to the engine speed. The higher the
engine speed, the higher the signal pressure.
A speed sensing valve senses the charge flow and converts some of it to signal oil. The orifice in
the speed sensing valve creates a pressure differential which is proportional to engine speed. This
pressure differential is then multiplied by the speed sensing valve by a factor of approximately 7:1
and becomes signal oil. This signal is then used to control the pump and the small motor. The
large motor is controlled by the motor displacement signal control valve. The speed sensing valve
sends the signal to the FORWARD-NEUTRAL-REVERSE (FNR) valve and the small motor
displacement control valve. The speed sensing valve sends oil not used for signal oil to the
remainder of the charge circuit.
An orifice in the signal line above the speed sensing valve allows the pressure override valve and
the hystat brake valve to function as designed. Without the orifice, the speed sensing valve would
compensate for flow loss through the hystat brake valve, thereby negating the braking capability
of the valve, or would decrease the ability of the pressure override valve to limit the maximum
drive loop pressure. A screen before the orifice reduces plugging of the orifice.
The combination crossover relief and makeup valves will open to protect the system by either
maintaining a minimum pressure or reducing pressure spikes in the drive loop. At machine start-
up, the valves open to direct oil to both sides of the pump and motor.
The charge pump relief valve limits the pressure of the oil not sent through the speed sensing
valve. The valve also limits the maximum hystat system pressure in NEUTRAL and the
maximum implement pilot system pressure.
The FORWARD-NEUTRAL-REVERSE (FNR) valve consists of a spool and two solenoids.
When one of the solenoids is energized by the Electronic Control Module (ECM), the spool is
shifted and sends signal oil to actuate the pump to provide flow for the direction selected.
The pressure override valve limits the maximum drive loop pressure. A ball resolver senses the
highest drive loop pressure. When this pressure reaches a specified limit, the override valve will
open and send oil in the signal line to case drain, reducing the signal pressure and causing the
motor to upstroke and the pump to destroke. When the motor is upstroked or the pump is
destroked, machine speed is reduced.
12/1/98
High Speed Pump Component Checklist (continued)
A filter bypass valve and switch are part of the filter group. If the filter is plugged, the bypass
valve opens and the switch closes to turn on an indicator lamp in the operator's compartment. The
indicator lamp stays on as long as the valve is open. With cold oil, the bypass valve opens and the
indicator lamp lights temporarily. The lamp goes out when the oil reaches a specified
temperature.
The motor displacement signal control valve varies the signal to the large motor to control the
speed of the motor. In the HIGH speed range, the motor displacement signal control valve is
controlled by the Electronic Control Module (ECM). At approximately 500 rpm motor drive shaft
speed, the ECM causes the motor displacement signal control valve to start destroking the large
motor. At 2000 rpm, the large motor is fully destroked. In the LOW speed range, the motor
displacement signal control valve is not energized and the large motor stays upstroked to limit
vehicle speed so the higher engine speed can be used to improve implement performance. The
LOW speed range can be obtained by moving the optional "creeper" valve lever or by the speed
selector switch located in the right console (on machines without the "creeper" valve option).
Additional System Components:

The hystat brake valve is controlled by the same pedal as the service brake. As the brake pedals
are depressed, the hystat brake valve allows signal oil to go to the tank, which causes the motor to
upstroke (if not already at maximum angle) and the pump to destroke. Engaging the brakes will
not reduce the engine speed, permitting faster implement speed due to higher flow from the
implement pump.
The optional "creeper" valve drains the signal oil from the speed sensing valve to the tank. This
action limits the machine speed and can also limit rimpull.
12/1/98
The small motor group consists of the following components:
power into mechanical power. The motor actuator piston controls the motor displacement by
changing the angle of the rotating group relative to its output shaft. The higher the stroke or
displacement, the higher the torque and lower the speed. The lower the stroke, the lower the
torque and higher the speed.
A throttle pin with two orifice grooves controls motor stroking time. The larger orifice groove
slows the actuator movement from minimum stroke to maximum stroke. The smaller orifice
groove slows the actuator movement from maximum stroke to minimum stroke.
A motor displacement control valve senses the signal from the speed sensing valve. The valve
compares the signal with the drive loop pressure to control the motor actuator piston. When the
accelerator is depressed more, the signal pressure increases to destroke the motor. If the drive
pressure increases, the motor upstrokes.
A shuttle valve sends the active drive line pressure (either FORWARD or REVERSE) to the
motor displacement signal control valve valve and actuator. By stroking the motor with the higher
drive loop pressure, hystat driving response is improved and, during hydrostatic braking, system
stability is maximized.
High Speed Motors Component Checklist (continued)
The large motor group consists of the following components:
power into mechanical power. The motor actuator piston controls the motor displacement by
changing the angle of the rotating group relative to its output shaft.
A motor displacement control valve senses a variable signal from the motor displacement signal
control valve and meters the highest drive loop pressure to the motor actuator piston to destroke
the motor. When the accelerator is depressed more, the signal pressure increases to destroke the
motor. If the drive pressure increases, the motor upstrokes.
Two check valves sense the drive loop pressures. The highest drive loop pressure opens one
check valve and seats the other. The drive loop pressure then flows to the motor displacement
control valve. By stroking the motor with the higher drive loop pressure, hystat response is
improved during driving and braking.
A flushing valve continuously drains some oil from the low pressure side of the drive loop
through the motor bearings to case drain. This action purges heat, debris and air from the drive
loop.
A throttle pin (orifice check valve) controls motor stroking time. The orifice slows the actuator
movement from minimum stroke to maximum stroke.
12/1/98
Lesson: Power Train 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.
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
❑ • Using the appropriate service manual module and the "Hydrostatic
adjusted include the following: AB - drive loop pressure, PG - charge
pressure, PS1 - pump signal pressure, PC - pump case pressure, M1 -
motor actuator pressure, M2 - motor actuator pressure (high speed only),
❑ MS - motor signal pressure (high speed only), and cooling loop
pressure.
• Record pressure specifications from the service manual before going to

❑ the shop.
• Remove side panels and/or cab floor plates as needed.
Materials Needed
❑
Power Train Systems Operation Testing and Adjusting Service
Manual Module
"Hydrostatic System Testing" reference material handout
Tooling- refer to the Hydrostatici System Testing reference material
handout for needed tooling
12/1/98
Hystat System Tests
TEST A - Initial Test: The initial test checks the condition of the machine is easy to do. During this
test the charge pressure, pump signal pressure, and engine low idle can be readily adjusted in the field.
If low idle is below the mean, adjust it to slightly above the mean. If the speed sensing valve is
adjusted, pump signal pressure will never become greater than the charge pressure during at high idle.
Make sure the pump signal pressure is at least 600 kPa (90 psi) at low idle before doing the remaining
tests.
TEST B & C - Stall Tests: The Hydrostatic Stall Test and Implement Stall Test must be performed to
determine which system is causing a problem. Test B stalls the hystat system and the implement hydraulic
system independent of each other. The test can be used to identify low engine power problems, pressure override
valve, malfunctioning crossover reliefs, and brake misadjustments. To stall the implement system raise the loader
arms.
For the Hystat Stall Test, the parking brakes and service brakes are used to create a load against the hystat system.
The test MUST be done with the transmission neutralizer (parking brake switch) disabled and with the hystat
linkage disconnected. Machine is on the ground. Note how stalling the hystat system (if the hystat system is
good) has almost no effect on engine rpm. Caution: do not drive through the brakes for more than 15 seconds.
If machine is set correctly, the machine will not drive through the brakes.
Test C stalls the hystat system along with the implement hydraulics and is only required if the pump or motor has
been replaced. Make sure to use the actual high idle reading established during TEST A to compare with the
engine speed for the stall conditions.
TESTS D & E - Pump and Motor Displacement Control Checks
TEST D - Speed Sensing Valve Adjustment or "Start to Drive": can also be done with repeatable
results. If the numbers are off, redo TEST A. The test can be done in either speed mode and should get
the same results. The critical reading is the signal pressure (Note: the tighter signal pressure tolerance.
An optional test is the "Start to Move" test which can be done to accommodate the needs of the
customer.
TEST D- Pump Neutral Adjustment: can be done to make sure the pump is fully destroked. If the
pump is not destroked the machine could move in NEUTRAL.
TEST D - Maximum Runout - checks the maximum machine speed in both speed ranges is more
difficult to do since it is difficult to read all of the gages and ECAP or the multi-tach at the same time.
It may also be difficult to find a stretch of ground long enough for the machine to reach maximum speed
or before the machine begins to "lope" in the FAST MODE. If a slightly inclined slope is used,
maximum can be reached sooner; however, the drive loop pressure will be below the spec. Motor speed
or drive shaft speed is the critical specification. To get reliable results the machine should be off of the
ground. It is suggested that before removing putting the machine up in the air, to perform a "speed trap"
test first. If the speed trap results are acceptable there is no need to get the machine up in the air.
A quick check as to whether the motor is destroking for the FAST MODE is to run the machine at
maximum in the SLOW MODE and then switch into the FAST MODE. If the machine speeds up, then
the motor is destroking; however, the motor or motors may not be properly set to allow the machine to
reach maximum speed.
12/1/98
TEST E - Motor Displacement Actuator Control Test (M1): checks the motor displacement control
setting to make sure the motor destrokes correctly. Charge pressure is used instead of signal pressure to
get more reliable readings. A special tee must be used. Make sure you have the most current test
procedures available. NOTE: Do not attempt the optional test in the Service Manual if it is still shown,
it is a waste of time and you will not get satisfactory results.
TEST E - Parking Brake and Service Brake Capacity Tests: check the holding capabilities of the
parking brake and service brake against the hystat system.
TEST F - Hystat Brake Inching Valve Tests: Checks the relationship between the hystat
brake/inching valve and the service brakes and should be done; however, expect the stop test to end up
at about 600 kPa (90 psi) for pump signal when AB drive loop pressure is at 6000 kPa (900 psi).
When the service brake pressure reaches 500 kPa (75 psi), the AB - drive loop pressure is at 3000 kPa
(450 psi), the pump signal will be about 300 kPa (45 psi). NOTE: The tests results should show that
there is no overlap at mid-throttle. The hystat is fully braked before the brakes are applied. At higher
engine rpm there will be an overlap. The overlap at the higher rpm will, for instance, help prevent the
machine from rolling down a slope when loading the bucket.
TEST G - Overspeed or Motor Displacement Signal Control Valve Test: This test check to see if
the ECM will work correctly when the machine actually does overspeed. The best method is to use a
signal generator to demonstrate the correct operation of this valve. This test is for the High Speed
machines only
TEST E - Motor Displacement Actuator Control Test (M1): this test is done to determine if the
motor displacement valve is working correctly for the large motor. Once again a signal generator is
used to determine the shift point.
TEST G - Final Test: should be done with the machine off of ground in order to be able to read all of
the gauges. If TEST A, B, C, and D were good, then this test probably isn't required. Only do if a
pump or motor was replaced.
12/1/98
Lesson: Hystat Problem Analysis
BACKGROUND This lesson allows you to demonstrate your ability to identify components
INFORMATION which could cause the machine to not function correctly.
Classroom Lab ❑ • Analyze the problem and circle the appropriate responses. Record the
reasons for your selections.
Materials Needed
❑ Related service manual modules
Standard Hystat Reference Schematic
Standard Hystat System Problem Analysis Worksheet
High Speed Hystat Reference Schematic
High Speed Hystat System Problem Analysis Worksheet
Standard Hystat Reference Schematic
12/1/98
CREEPER
VALVE
914G/IT14G
STANDARD HYSTAT SYSTEM

FORWARD / HIGH
HYSTAT BRAKE
VALVE
TO IMPLEMENT
PILOT SYSTEM
PUMP PS1 PG PC AB SPEED SELECTOR
SOLENOID VALVE
X1 PRESSURE
OVERRIDE MB
VALVE
SPEED
SENSING FLUSHING
VALVE VALVE
TO
MOTOR DISPL FLUSHING
CONTROL BYPASS
VALVE BLOCK
X3
CHARGE RELIEF
VALVE
X4
X2 MIN
- 51 -
CROSSOVER
RELIEF AND
MAKEUP VALVES TO TANK
RETURN CHECK
VALVE
MA
REVERSE
THROTTLE SOLENOID
PIN VALVE
FWD
M1 MOTOR
FNR
VALVE
TO HYDRAULIC
TANK
OIL
SAMPLING
FILTER
BYPASS
SWITCH
Student Materials
914G/IT14G - 52 - Student Materials
12/1/98
Standard Hystat System Problem Analysis Worksheet
Directions: Circle the correct response(s) and then explain your reason(s). Use the Standard Hystat
Reference Schematic on the previous page.
1. In the Turtle mode, the Standard 914G is slow in both Reverse and Forward. Which of the
following may be at fault.
a. Speed sensing valve b. FNR valve
c. Creeper valve d. Pressure override valve
e. Motor displacement control valve f. Speed Selector valve
g. Reverse solenoid valve
Why?
2. In the Turtle mode, the Standard 914G is faster in Forward than in Reverse. Which of the
following component(s) may be at fault.
Why?
3. In the Rabbit mode, the Standard 914G is slow in both Reverse and Forward. Which of the
Why?
High Speed Hystat Reference Schematic
12/1/98
914G/IT14G
HIGH SPEED HYSTAT SYSTEM

FORWARD / LOW LARGE MOTOR CREEPER
MS HYSTAT BRAKE/
INCHING VALVE VALVE
MOTOR
DISPLACEMENT
M2
SIGNAL CONTROL
VALVE
TO IMPLEMENT
PILOT SYSTEM
THROTTLE
PUMP PS1 PG PC AB PIN
FLUSHING
VALVE
MIN
PRESSURE
X1 OVERRIDE MB
VALVE
SPEED MOTOR
SENSING DISPL
VALVE CONTROL
VALVE
X3
CHARGE RELIEF
VALVE
X4
X2
CROSSOVER
- 53 -
SHUTTLE
RELIEF AND
MAKEUP VALVES
THROTTLE
PIN
TO
FLUSHING
BYPASS
MA BLOCK
MIN
FWD TO TANK
RETURN CHECK
VALVE
FNR
VALVE
TO HYDRAULIC
TANK
MOTOR DISPLACEMENT
CONTROL VALVE
M1
OIL
SAMPLING SMALL MOTOR
FILTER
BYPASS
SWITCH
Student Materials
914G/IT14G - 54 - Student Materials
12/1/98
High Speed Hystat System Problem Analysis Worksheet
Directions: Circle the correct response(s) and then explain your reason(s). Use the High Speed Hystat
Reference Schematic on the previous page.
1. In the Turtle mode, the High Speed IT14G is slow in both Reverse and Forward. Which of the
c. Creeper valve d. Large motor displacement control valve
e. Small motor displacement control valve f. Motor displacement signal control valve
g. Small motor throttle pin h. Large motor throttle pin
Why?
2. In the Rabbit mode, the High Speed IT14G is faster in Forward than in Reverse. Which of the
following component(s) may be at fault.
c. Shuttle valve d. Large motor displacement control valve
e. Small motor displacement control valve f. Motor displacement signal control valve
g. Small motor throttle pin h. Large motor throttle pin
Why?
12/1/98
Case Study: Hystat Transmission
DIRECTIONS Use the provided service manual modules and notes to answer this case
study.
SITUATION The customer complained that his new IT14G Integrated Tool Carrier was
much slower than his 914G Wheel Loader while roading.
The service mechanic decided to perform the hystat tests to determine if

the motor was destroking correctly and if the pump would stroke fully.
The mechanic satisfactorily completed the pump tests but had some
difficulty with determining if the motor was destroking correctly. What
should he do now? Are additional tests needed, if so which one(s) and
what type of results would you expect if the test(s) identified a suspect
component or components?
List at least two other problems that could be preventing movement of the
machine. Describe the tests and the anticipated results. Use a Student
Troubleshooting Analysis to list and describe your actions.
12/1/98
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:
12/1/98
MODULE: HYTEC SYSTEM

The purpose of this module is to have you locate and identify Autoshift
system components and operate a machine to determine how the system
works. You will also perform system tests. The module is composed of
two lessons.
OBJECTIVES
❑ 1. Using the Standard and High Speed HYTEC Component Checklists

locate the components (if equipped) components and service points
on the machine.
❑ 2. Using the appropriate service manual module, perform checks on the

machine for the HYTEC system (if equipped) using the ECAP tool.
❑ 3. Using the appropriate service manual module, perform checks on the

machine for the HYTEC system (if equipped) using the Electronic
Transmission Control SENR5751, Electronic Technician, and a
jumper wire.
12/1/98
Lesson: HYTEC System Component Identification and

Operation
BACKGROUND This lesson allows you to become familiar with autoshift system
INFORMATION
components and how autoshift affects machine operation.
Shop Lab ❑ • Locate HYTEC components and test points - Use the "HYTEC System
Component Checklist" to locate components and identify test points on
the machine.
Materials Needed
❑ Related service manual modules and electrical schematic
Standard HYTEC System Components Checklist
High Speed HYTEC System Components Checklist
Standard HYTEC System Components Checklist
12/1/98
Directions: Record a check next to each component after locating it on the machine. Or if using
multiple machines, record th model number.
BCP 914G/IT14G
STANDARD HYSTAT TRANSMISSION CONTROL SYSTEM

SHIFT DIAGNOSTIC BUFFERED SPEEDOMETER
LEVER INDICATOR DRIVER
(ACTION LED)
RIDE CONTROL/ RIDE CONTROL/

LOAD CHECK SWITCH LOAD CHECK RELAY
PARKING BRAKE REVERSE MOTOR RELAY

SWITCH AND SOLENOID
KEY START SPEED SELECTOR

SWITCH SOLENOID
- 59 -
ELECTRONIC
HARNESS CODE REVERSE
CONNECTOR SOLENOID
CONTROL
MODULE
OPTIONS CODE FORWARD
CONNECTOR SOLENOID
MAIN STEERING SOLENOID COMMON

FLOW SWITCH INTERRUPT RELAY
CREEPER SWITCH OR SECONDARY SUPPLEMENTAL

SPEED SWITCH STEER RELAY
ENGINE SPEED SERVICE

SENSOR CONNECTOR
PRIMARY STEERING
DRIVE SHAFT FLOW LAMP
SPEED SENSOR
Student Materials
High Speed HYTEC System Components Checklist
12/1/98
Directions: Record a check next to each component after locating it on the machine. Or if using
multiple machines, record th model number.
BCP 914G/IT14G
HIGH SPEED HYSTAT TRANSMISSION CONTROL SYSTEM
SHIFT DIAGNOSTIC BUFFERED SPEEDOMETER

LEVER INDICATOR DRIVER
(ACTION LED)
RIDE CONTROL/ RIDE CONTROL/

LOAD CHECK SWITCH LOAD CHECK RELAY
PARKING BRAKE MOTOR DISPLACEMENT

SWITCH SIGNAL CONTROL SOLENOID
KEY START
SWITCH REVERSE
- 60 -
SOLENOID
ELECTRONIC
HARNESS CODE
CONNECTOR FORWARD
CONTROL SOLENOID
MODULE
OPTIONS CODE
CONNECTOR SOLENOID COMMON
INTERRUPT RELAY
MAIN STEERING
FLOW SWITCH SECONDARY SUPPLEMENTAL
STEER RELAY
CREEPER SWITCH OR
SPEED SWITCH SERVICE
CONNECTOR
ENGINE SPEED
SENSOR
PRIMARY STEERING
DRIVE SHAFT FLOW LAMP
SPEED SENSOR
Student Materials
12/1/98
Lesson: HYTEC System Tests
BACKGROUND This lesson allows you to become familiar with autoshift system tests and
INFORMATION the use of ECAP.
Shop Lab
❑ • Perform shift lever tests as per the service manual.
❑ • Use the ECAP tool to determine status of the control system, to scroll
active faults and inactive faults, and to clear inactive faults.
❑ • Use the Electronic Transmission Control SENR5751 and a jumper wire

to scroll active faults, to scroll inactive faults and to clear inactive faults.
NOTE: To easily create active and inactive faults, remove relays in panel on
right side of machne.
Related service manual modules and electrical schematic

Materials Needed
❑ 1-jumper wire (18 gauge with 2 male pins)
1-8T8697 ECAP or 1-Computer equipped with ET
1-7X1700 Communications Adapter
1-7X1570 ECAP Cable - to machine
1-7X1851 ECAP Cable - between adapter and ECAP or
1-7X1420 ECAP Cable (original ECAP)
1-NEXG4523 Vehicle Functions Serv. Prog. Module for ECAP
1-NEXG4521 Serv. Prog. Module for Communication Adapter
(Optional)
1-9U7400 Multitach II Group or 1-6V3121 Multitach Group
12/1/98
HARNESS CODE CONNECTOR
1 8 1 8 1 8
2 7 2 7 2 7
3 6 3 6 3 6
4 5 4 5 4 5
ACTIVE LOGGED ERASE

FAULT FAULT MODE
MODE MODE
• Identify codes without If the ECAP is not readily available, the harness code connector, a jumper
ECAP wire, and the diagnostic indicator LED can be used to identity active and
logged (inactive) faults. When a fault has been corrected, the fault can be
removed from the system's memory.
- Active faults mode To scroll for active faults, connect Pins 1 and 2. If more than one active
fault is present, removing the jumper wire will cause the led to flash and
hold on the last displayed code. If no active faults are present, the
diagnostic indicator LED will flash diagnostic code "11."
- Logged faults mode Connecting (jumping) Pins 2 and 5 of the connector will cause the
indicator LED to flash all inactive or logged system problems. Removing
the jumper wire will cause the LED to flash and hold the last displayed
code. If no logged faults are present, the indicator LED will flash
diagnostic code "12."
- Erase mode Jumping Pins 2 and 3 of the connector while the indicator LED is flashing
a held code will cause the code to be erased from memory.
12/1/98
MODULE: AXLES, BRAKE AND STEERING

SYSTEMS
The purpose of this module is to have you locate and identify axle, brake
and steering system components. You will also learn how the brake
control valves work and explain the function of their components.
System tests for the brake and steering systems will also be performed.
The module is composed of two lessons.
OBJECTIVES
❑ 1. On the machine, locate the components the following components:

hydraulic oil cooler, Hand Metering Unit (HMU), priority flow
control valve, steering and brake pump, brake reservoir, brake master
and boost cylinder, brake relief valve test port location, brake
pressure test location, steering pressure test port location, the
supplemental steering pump and motor (if equipped), parking brake
control, and brake disc inspection plugs. Record a check after
locating each component..
❑ 2. On the provided schematic of the steering and brake system identify

the following components: steering and brake pump, priority valve,
HMU, boost cylinder, power piston, and master cylinder.
❑ 3. On the provided schematic of the brake master cylinder identify the

following components: primary piston, plunger, power piston, servo
piston, secondary piston, load feedback piston, and relief valve.
❑ 4. Perform steering and brake hydraulic system checks as per the

service manual.
❑ 5. Perform brake mechanical checks and adjustments as per the service

manual module if required.
12/1/98
Lesson: Axle, Brake, and Steering Systems Component

Identification
INFORMATION components and service points.
Classroom Lab
❑ • On the Hydraulic Steering and Brake System Components Checklist
identify the following components: steering and brake pump, priority
valve, HMU, power cylinder, and master cylinder.
❑ • On the Brake Master Cylinder System Components Checklist identify

the following components: primary piston, plunger, power piston, servo
piston, secondary piston, load feedback piston, and relief valve.
Shop Lab
❑ • Remove side panels and/or cab floor plates as needed.
❑ • On the machine, locate the components the following components:

hydraulic oil cooler, Hand Metering Unit (HMU), priority flow control
valve, steering and brake pump, brake reservoir, brake master and boost
cylinder, brake relief valve test port location, brake pressure test
location, steering pressure test port location, the supplemental steering
pump and motor (if equipped), parking brake control, and brake disc
inspection plugs using the Axle, Brake and Steering System Component
Checklist.
❑ • 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, Brake and Steering System Component Checklist
Hydraulic Steering and Brake System Components Checklist
Brake Master Cylinder System Components Checklist
1-Mechanic's Tool Boxes and hand tools
12/1/98
Axle, Brake and Steering System Component Checklist

Directions: During a lab exercise, use this as a checklist when identifying components.
Brake pedals
Steering wheel
Hydraulic tank
Hydraulic oil filters
Hand Metering Unit (HMU)
Priority flow control valve
Steering and brake pump
Brake reservoir
Brake master and boost cylinder
Brake relief valve test port location
Brake pressure test location (either machine version)
Steering pressure test port location
Supplemental steering pump and motor (if equipped)
Parking brake control
Brake disc inspection plugs

Hydraulic Steering and Brake
12/1/98
System Components
the numbers and letters with the correct
BCP 914G/IT14G
term.
STEERING HIGH SPEED STEERING AND BRAKE SYSTEM
CYLINDERS
RIGHT TURN/BRAKES RELEASED
FROM HYSTAT
Identify Components SPEED SENSING
VALVE
C
A _________________________
D
B _________________________
C _________________________
E
D _________________________
E _________________________
- 66 -
F _________________________ B
G
G _________________________ A TO
IMPLEMENTS
F
FROM IMPLEMENT
PILOT SYSTEM
FRONT
BRAKES REAR
BRAKES
Student Materials
Brake Master Cylinder
12/1/98
System Components
Checklist
BCP 914G/IT14G
Directions: Fill in the blanks

next to the numbers and letters
with the correct term.
HIGH SPEED BRAKE MASTER AND BOOST CYLINDERS
Relief valve
FROM BRAKE
RESERVOIR
Plunger D E MASTER
C CYLINDER
High pressure piston B
I
Servo piston
A
J
- 67 -
Low pressure piston
Reaction piston TO BRAKE

PISTONS
Power Piston
G H
Cup BOOST F
CYLINDER
Reservoir TO TANK
FROM STEERING
Bypass valve
Power piston
Student Materials
12/1/98
Lesson: Axle, Brake, and Steering Systems 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
❑ • Record pressure specifications from the service manual before going to
the shop.
❑ • Remove side panels and/or cab floor plates as needed.
❑ • Perform steering pressure checks as per the service manual.
❑ • Perform brake system checks as per the service manual.
❑ • Perform brake disc checks as per the service manual.
Materials Needed
❑ Axle, brake and steering service manual modules
Axle, Brakes, and Steering Test Sheet
1-1U5481 Pressure Test Gauge Group
1-1U5482 Hose and Fitting Group
1-8T2352 Tee
1-6V8397 O-ring
1-6V3966 Nipple
12/1/98

Name/Code Customer
Engine S/N Application
S.M.H. Date
Serviceman
Visuals Checks: Oil level OK Oil Type OK Oil Leaks

Air/Water in Oil Suction Screen Debris
Abrasives in Oil Oil Filter Examination
Brake and Steering System Tests:
914G/IT14G
PRESSURE TEST SPEC. ACTUAL
Steering Pressure Limiter
Brake Relief Valve
Brake System
Service Brake Disc Thickness Checks: Additional Checks:

Specification: ________ Steering Cycle Time:
Specification: ______
Actual:
Actual: ______
Front Right ________
Perform Operational Checks:
Front Left ________
Service Brake Test _____
Rear Right ________
Parking Brake Test _____
Rear Left ________ Transmission Neutralizer _____
BCP 914G/IT14G - 70 - Student
StudentMaterials
Materials
12/1/98

Name/Code Customer
Engine S/N Application
S.M.H. Date
Serviceman
Visuals Checks: Oil level OK Oil Type OK Oil Leaks

Air/Water in Oil Suction Screen Debris
Abrasives in Oil Oil Filter Examination
Brake and Steering System Tests:
914G/IT14G
PRESSURE TEST SPEC. ACTUAL
Steering Pressure Limiter
Brake Relief Valve
Brake System
Service Brake Disc Thickness Checks: Additional Checks:

Specification: ________ Steering Cycle Time:
Specification: ______
Actual:
Actual: ______
Front Right ________
Perform Operational Checks:
Front Left ________
Service Brake Test _____
Rear Right ________
Parking Brake Test _____
Rear Left ________ Transmission Neutralizer _____
12/1/98
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 electrical bucket
kickout system will also be tested. The module is composed of two
lessons, a case study and a quiz. One of the lessons is optional.
OBJECTIVES
❑ 1. Locate on the schematic the following: hydraulic tank, hydraulic

filter, pump, pump control valve, implement valve group, tilt control
valve, lift control valve, auxiliary control valve(s), pilot shut-off
valve, pilot valve, pilot system accumulator, main relief valve, line
relief and makeup valve, makeup valve, dead engine lower valve,
Ride Control components (accumulator and solenoid).
❑ 2. On the machine, locate the following: hydraulic tank, oil filter,

hydraulic oil cooler, implement pump, pump supply pressure test
port, implement controls, implement valve group, main relief valve,
tilt control valve, lift control valve, auxiliary valve(s), pilot pressure
test port, pilot system accumulator, pilot shutoff valve, dead engine
lower valve, rotary shutoff valve (IT), and Ride Control accumulator
and solenoid.
❑ 3. (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.
❑ 4. Perform performance checks and/or adjust: maximum system

pressure and line relief settings.
❑ 5. Perform cycle time checks and cylinder drift checks.
❑ 6. On a quiz identify ISO symbols to determine type, features and

number of valves and type of hydraulic tank.
❑ 7. Using provided reference materials and handouts identify potential

system problems caused by a improperly operating hydraulic system
during a case study.
12/1/98
Lesson: Implement Hydraulic System Component

Identification and System Tests
INFORMATION components and service points. This lesson will also allow you to gain
familiarity performing system checks, 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

which includes checking fluid levels as specified in the Operation
and Maintenance Guide. Remove side panels and/or cab floor plates
as needed.
Classroom Lab
❑ • Locate on the schematic the following: hydraulic tank, hydraulic filter,
pump, pump control valve, implement valve group, tilt control valve, lift
control valve, auxiliary control valve(s), pilot shut-off valve, pilot valve,
pilot system accumulator, main relief valve, line relief and makeup
valve, makeup valve, dead engine lower valve, Ride Control
components (accumulator and solenoid) using.Implement Hydraulic
System Component Checklist II.
Shop Lab
❑ • On the machine, locate the following: hydraulic tank, oil filter,
hydraulic oil cooler, implement pump, pump supply pressure test port,
implement controls, implement valve group, main relief valve, tilt
control valve, lift control valve, auxiliary valve(s), pilot pressure test
port, pilot system accumulator, pilot shutoff valve, dead engine lower
valve, rotary shutoff valve (IT), and Ride Control accumulator and
solenoid using Implement Hydraulic System Component Checklist I.
Record a check after locating each component..
❑ • Record pressure specifications from the service manual before going to

the shop on the Hydraulic System Test Sheet.
❑ • Install test nipples and perform system pressure tests as per the service
manual for maximum system pressure and pilot system pressure.
❑ • Use a stop watch to perform cycle time checks.
❑ • Use a stop watch and tape measure to perform cylinder drift checks.
12/1/98
Lesson: Implement Hydraulic System Component

Identification and System Tests (continued)
❑ Optional:
• Perform lift kickout and bucket positioner checks.
• Perform line relief pressure checks.
Materials Needed
❑ Hydraulic System Testing and Adjusting Service Manual Module
Implement Hydraulic System Component Checklists I, II, and III.
Hydraulic System Test Sheets
1-8T0859 Pressure Gauge
1-8T0850 Pressure Gauge (for pilot system)
1-1U5482 Hose and Fitting Group
1-Stop Watch
1-Tape Measure
12/1/98
Implement Hydraulic System Component Checklist I

Directions: Use this sheet to take notes during the presentation (i.e. locations, functions). During a lab
exercise, use this as a checklist when identifying components.
Implement controls
Hydraulic tank
Hydraulic oil filters
Implement pump
Implement valve group
Main relief valve
Tilt control valve
Lift control valve
Auxiliary control valve(s)
Pump supply pressure test port
Pilot system pressure test location
Pilot system accumulator
Pilot shutoff valve
Dead engine lower valve
Rotary shutoff valve (IT)
Ride Control accumulator and solenoid

Implement Hydraulic System
Components II
correct term.
IT14G IMPLEMENT HYDRAULIC SYSTEM

HOLD
Identify Components
C
A _________________________
K
B _________________________
C _________________________
B E H
D _________________________
D
E _________________________
- 75 -
F _________________________ INLET
MANIFOLD
A F G I J
G _________________________ STEERING
PUMP
H _________________________ FROM
N M
HYSTAT
CHARGE
PUMP
I__________________________
J__________________________ TO HYSTAT MOTOR
L
BEARING
FROM HYSTAT PUMP
CASE DRAIN
K _________________________
FROM HYSTAT MOTOR
CASE DRAIN
L _________________________
M _________________________
N _________________________
12/1/98
HYDRAULIC SYSTEM TEST SHEET

TESTS: SYSTEM PRESSURES
Pressure Spec. Actual
Maximum System Pressure
Pilot System Pressure
TESTS: IMPLEMENT CYCLE TIMES
CYCLE TIMES
1ST 2ND 3RD 4TH AVG. SPEC.
Implement 1
Implement 2
Implement 3
Implement 4
TESTS: IMPLEMENT DRIFT RATES

Enter the Times and Drift Specifications from the Service Manual. Enter the actual measurements for
each cylinder in the appropriate space.
Oil 38 to 48°C 49 to 64°C 65°C and Up

Temperature (100 to 119°F) (120 to 149°F) (150° F and Up)
Time
Drift Spec
Cyl. 1 -
Cyl. 2 -
Cyl. 3 -
Cyl. 4 -
Cyl. 5 -
Cyl. 6 -
Cyl. 7 -
12/1/98
HYDRAULIC SYSTEM TEST SHEET

TESTS: SYSTEM PRESSURES
Pressure Spec. Actual
Maximum System Pressure
Pilot System Pressure
TESTS: IMPLEMENT CYCLE TIMES
CYCLE TIMES
1ST 2ND 3RD 4TH AVG. SPEC.
Implement 1
Implement 2
Implement 3
Implement 4
TESTS: IMPLEMENT DRIFT RATES

Enter the Times and Drift Specifications from the Service Manual. Enter the actual measurements for
each cylinder in the appropriate space.
Oil 38 to 48°C 49 to 64°C 65°C and Up

Temperature (100 to 119°F) (120 to 149°F) (150° F and Up)
Time
Drift Spec
Cyl. 1 -
Cyl. 2 -
Cyl. 3 -
Cyl. 4 -
Cyl. 5 -
Cyl. 6 -
Cyl. 7 -
12/1/98
Lesson: Implement 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
❑ • Disassemble the implement control valve. Lay out all components.
❑ • Identify and state the purpose of the components using the Implement
Control Valve Component Checklist (Circle the component letter after
identifying each component.).
- makeup valve
- line relief valve
- check valve
❑ • Assemble the implement control valve.
Materials Needed
❑ Implement Control Valve Component Checklist
Service Manual
Parts Book
Implement control valve - for BCP wheel loaders or similar
Mechanic's Tool Box with hand tools
Class notes- control spool
Implement Control Valve
12/1/98
Components Checklist
Directions: Fill in the blanks next to the
numbers and letters with the correct term.
BCP 914G/IT14G
Identify Components 914G/IT14G LIFT VALVE

A _________________________
B ROD END HEAD END
B _________________________ D
A E
C _________________________
D _________________________
E _________________________
- 79 -
PARALLEL
C PASSAGE
SUPPLY PASSAGE TO TO TANK

PASSAGE NEXT VALVE SUPPLY
PASSAGE
TILT VALVE
BODY
Student Materials
12/1/98
Case Study: Hydraulic System
DIRECTIONS Use the provided service manual modules and notes to answer this case
study. A Student Analysis Sheet should be used to record your
conclusions.
SITUATION
The customer's 914G Wheel Loader has 704 service hours on it. The
operator says that the machine is not as productive as it was.
The mechanic performed cycle time tests and checked for maximum
system pressure for all implements. Maximum system pressure was
incorrect for the lift circuit only. He decided to adjust maximum system
pressure.
Did he make the correct decision?
Even if he did make the right decision, what else should be checked? List
at least two other problems that could be preventing movement of the
machine. Describe the tests and the anticipated results.
12/1/98
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:

Course Materials REFERENCE
MATERIALS

Course Materials REFERENCE
MATERIALS

Fuel System Supplement
12/1/98
FUEL HYDRAULIC SYSTEM
BOOST TRANSFER
WATER MAIN
PRESSURE PRESSURE
FUEL TANK SEPARATOR FILTER REGULATOR
BOOST FEED
CONTROLLER PUMP
SHUTOFF
SOLENOID
INJECTOR
FUEL RETURN TORQUE
CHECK VALVE VENT ORIFICE
TRIMMER
DELIVERY
VALVE
ROTOR
CAM
RING
ROLLERS TRANSFER
PUMP
METERING
VALVE
PLUNGERS
FLAT
AUTOMATIC HYDRAULIC
SCROLL PLATES
ADVANCE HEAD
MECHANISM COLD ADVANCE
DEVICE
ORIFICE
CHECK VALVE
LIGHT LOAD
ADVANCE VALVE LATCH
VALVE
19
• Identify fuel system FUEL SYSTEM

components and
functions The fuel system shown here is typical for the fuel injection pump used at
first production. The fuel system component functions are as follows:
The feed or lift pump is used to move fuel from the tank to a higher level
on the machine. The pump is also used to prime the system.
The water separator removes water from the fuel. Since the fuel
injection pump is lubricated by fuel, it is extremely important that water
does not enter the pump. Water will cause the pump to malfunction and
will lead to the rotor and plungers locking up. The water separator should
be serviced daily.
The transfer pump draws fuel from the tank and supplies fuel to the
injection pump.
➥
12/1/98
The hydraulic head is machined with bores and passages which allow
fuel to flow to and from a specific point. For example, fuel flows from
the transfer pump to the metering valve or from the metering valve to the
inlet passage to the rotor.
The rotor is located in the hydraulic head. The rotor distributes fuel to
the delivery valves. The rotor has four inlet passages and one outlet
passage. As the rotor turns, fuel enters the passages in the rotor and
forces the plungers in the drive end of the rotor outward. As the rotor
continues to turn, the inlet passage closes. As the plungers are forced
inward by the cam ring and rollers, the fuel pressure in the rotor increases.
At the same time, the outlet passage opens and fuel exits the rotor through
the delivery valves to the injectors.
The transfer pressure regulator controls the fuel transfer pressure within
the injection pump. Transfer pressure will increase as engine speed
increases. The regulator also permits the fuel to bypass the transfer pump
when the fuel system is being primed.
The shutoff solenoid allows fuel to enter the fuel injection pump when
the solenoid is energized. When the key start switch is moved to the OFF
position, the solenoid is de-energized and a spring moves the plunger in
the solenoid to block fuel flow.
The metering valve controls the amount of fuel to the hydraulic head or
rotor. The valve is connected to a mechanical governor and the throttle or
governor control lever. As the metering valve is rotated within the
hydraulic head, a delivery control groove in the valve precisely meters
fuel to the rotor.
A tapered flat on the metering valve works with the light load valve. The
flat is machined in line with the delivery control groove.
The light load valve and metering valve work with two control orifices in
the hydraulic head to override the normal speed advance system. During
low load conditions, the outward travel of the rollers and shoes is reduced
during the rotor filling cycle, which delays the point of roller contact with
the cam lobes resulting in retarded injection. The light load advance
compensates for this delay by advancing injection at reduced fuel levels.
Passageways are drilled within the hydraulic head body to connect the
metering valve "flat" with the pressure end of the advance device (through
a second control orifice) and the pump cambox.
➥
12/1/98
As the metering valve is rotated in the hydraulic head by the governor, a

larger or smaller flow path from the advance piston to the cambox is
created. The relationship between the "flat" with the delivery control
groove is arranged so that, as delivery is reduced, flow past the flat is also
reduced. Thus, the pressure signal applied to the advance piston is
increased to advance the timing.
The boost controller adjusts the maximum fuel delivery based on

variations in the boost pressure from the turbocharger. As boost pressure
increases, the scroll plates move and allow the plunger travel to increase.
This action permits an increase in fuel delivery resulting in more engine
horsepower.
The torque trimmer provides a means to regulate the volume of fuel

being delivered at full load. The torque trimmer provides the maximum
amount of fuel in the loadable range of the engine which can be burned
smoke free.
The delivery valves are check valves which open to allow fuel from the
pumping mechanism to the injectors. The valves rapidly reduce pressure
in the injector lines at the end of the injection cycle to ensure a rapid
closure of the injector nozzles and, in conjunction with the cam ring
profile, maintain a residual pressure in the fuel lines to the injectors.
The latch valve prevents transfer pressure from reaching the automatic
advance mechanism during cranking until the engine is started to prevent
premature advance timing.
The automatic advance mechanism progressively advances the start of

injection as engine speed increases. The automatic advance mechanism
causes the cam ring to rotate in the pump housing. The spring in the
mechanism moves the piston and cam ring to retard the timing, while
transfer pressure sensed on the left side of the piston works against the
spring to advance the timing.
The check valve prevents reverse fuel flow from the automatic advance
due to cam loading. The orifice permits fuel to vent from the automatic
advance when the engine rpm are reduced.
➥
12/1/98
The cold advance device is used to reduce white smoke by advancing the
engine timing to improve cold idling combustion capability. The cold
advance device is sometimes called a "wax motor" and is a relatively slow
response actuator. At start-up, a check valve prevents transfer pressure
from flowing to the right end of the automatic advance mechanism
preventing the sleeve from moving away from the start advance position.
This action prevents the spring from fully retarding the engine timing.
After the engine is started and allowed to warm up to a specified
temperature, a coolant switch closes and current is sent to the wax motor
causing the wax to melt. As the wax melts, it changes in volume and goes
from a solid to a liquid. After approximately 25 seconds or more, the pin
in the device moves to the left and unseats the check valve. Transfer
pressure then flows to the right end of the automatic advance mechanism
and moves the sleeve to the left against a stop to the normal automatic
advance operating mode.
The fuel return check valve maintains a slight pressure in the fuel
injection pump to ensure good lubrication. The fuel return check valve
also allows hot fuel to bleed from the injection pump to the tank for
cooling.
NOTE: The lift pump is used to assist in priming the fuel system;
however, because of the location of the fuel tank on these machines,
the pump is not as important as on other machines where the tank is
located below the level of the engine.
12/1/98
2 3
1 4
5
6
7
9
8
20
• Fuel pump A timing mark on the the mounting flange of the pump should align with
components: a corresponding timing mark on the timing cover.
1. Return check valve
Pump removal and installation procedures are similar to those used with
2. Boost controller
the Cat 3054 engine in other applications; however, refer to the service
3. Low idle stop manual to determine the correct procedures. Use the 127-1069 Engine
4. Fuel shutoff Timing Tool to time the engine to the injection pump as needed.
solenoid
5. Fuel transfer NOTE: If a new pump is installed on the engine, a locking bolt and a
pressure regulator two position spacer in the pump flange below the timing marks must
and inlet be loosened after installing the pump on the engine. In the locked
6. Torque trimmer position, the bolt prevents the pump drive shaft from turning. Move
the spacer to provide additional clearance between the bolt head and
7. Latch valve
the pump flange to unlock the pump drive shaft. If this procedure is
8. Automatic advance not performed, the fuel pump will be damaged if an attempt is made
mechanism and to start the engine.
cold advance
device
9. Delivery valve
12/1/98
FUEL INJECTION PUMP
LOW IDLE HIGH IDLE THROTTLE LEVER

STOP STOP
METERING VALVE
GOVERNOR
SPRING
FUEL SHUTOFF
SOLENOID
VENT ORIFICE
FUEL INLET
TRANSFER
PRESSURE
FUEL RETURN REGULATOR
CHECK VALVE
SCROLL LINK
PLATE SCREEN
DRIVE TRANSFER
SHAFT PUMP
SHIFTER AND PLUNGERS

SLEEVE
TO INJECTOR
GOVERNOR
FLYWEIGHTS SHOES
SCROLL PLATES
ROLLERS CAM RING AUTOMATIC ADVANCE ORIFICE

MECHANISM CHECK VALVE
21
• Identify components Shown here is a sectional view of the fuel injection pump.
and trace fuel flow
Fuel is drawn by the transfer pump through the pressure regulator and sent
to the metering valve when the solenoid is energized. The fuel also flows
through an annular groove around the rotor to the orifice check valve and
the automatic advance mechanism.
The metering valve controls the amount of fuel sent to the pumping
elements inside the rotor (plungers, cam ring, and shoes). As the rotor
turns, the cam ring forces the shoes and plungers in to increase the fuel
pressure. The pressurized fuel is then directed to the injectors.
NOTE TO THE INSTRUCTOR: The pump shown is not identical to

the pump used on the 914G/IT14G. The pump shown in this view is
not equipped with a boost controller.

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Service Training STUDENT

Course Materials MATERIALS

914G WHEEL LOADERS &

STUDENT COURSE BOOK CHECKLIST ........................................................................10

MODULE: MACHINE ORIENTATION ............................................................................13

MODULE: ENGINE SYSTEMS .......................................................................................17

MODULE: ELECTRICAL SYSTEM ................................................................................24

MODULE: POWER TRAIN ..............................................................................................32

MODULE: HYTEC SYSTEM ............................................................................................57

MODULE: AXLES, BRAKES AND STEERING SYSTEMS...........................................63

MODULE: IMPLEMENT HYDRAULIC SYSTEMS .......................................................71

CONTENT Classroom work (approximately 50%) will cover machine orientation,

Students will receive personnel copies of service manual modules

WHO SHOULD ATTEND/COURSE PRE-REQUISITES

Prerequisite courses should be completed prior to participating in this

Student can not do. Needs more

Student can perform task but

then should be used at the completion of the course to measure the

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

❑ ❑ ❑ 6. Locate the following hystat hydraulic oil system components and

❑ ❑ ❑ 7. Using the appropriate service manual module and the "Hydrostatic

Student can not do. Needs more

Student can perform task but

8. Using the appropriate service manual module, perform checks on the

❑ ❑ ❑ 9. On the machine, locate the components the following components:

MODULE: MACHINE ORIENTATION

MODULE: ENGINE SYSTEMS

MODULE: ELECTRICAL SYSTEM

MODULE: POWER TRAIN

MODULE: HYTEC SYSTEM

MODULE: AXLES AND BRAKES

MODULE: IMPLEMENT HYDRAULIC SYSTEMS

REQUIRED STUDENT STUDENT COURSE BOOK CHECKLIST

STUDENT REFERENCE Reference Materials

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

914G/IT14G LAB REQUIREMENTS

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 wheel loader

❑ 3. Identify the following BCP wheel loader or integrated tool carrier.

❑ 4. Locate machine warning labels for operating and servicing the

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

❑ 6. Perform the provided machine operations and answer the questions

Lesson: Machine Orientation

❑ • 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

914G/IT14G Machine Operation Worksheet

Before starting the machine: FASTEN SEAT BELT.

Did the machine move? Yes No

Drive machine along test range:

8. Remove your foot from the accelerator.

MODULE: ENGINE SYSTEMS

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

Lesson: Engine Systems

This lesson allows you to become familiar with identifying system

Engine Component Checklist

Location & Description Location & Description

____ Water separator

____ Oil filter