Service Training

MALAGA

B & C Backhoe Loaders

ANSWERS TO
STUDENT
QUIZZES

Sara
JULY 1997
BCP BHL -2- Instructor Materials
7/1/97

ADMINISTER QUIZ Quiz: Machine Orientation

Approx. time: 25 min.

Have students complete the quiz. Explain how to complete the quiz and
what reference materials can be used.
• Review - the quiz answers with the students and explain why an answer
is more appropriate than theirs. Take notes if suggestions come up to
make any of the questions better.

Answers:

I. True/False
1. T
2. T
3. T
4. F, is not
5. T
6. T
7. F, variable and closed
8. F, four : IRM, Front Wheels only, Crab and Circle Steer
9. F, the same

II. Circle the machine which best matches the statement.

1. 438C
2. 438C
3. 438C
4. None
5. 428C 438C
6. 428C

BONUS
7. 428C 438C. If needed, Leicester canl produce the other machines
if to help meet the demand. Leicester is primarily responsible for just the
sideshift models.
BCP BHL -3- Instructor Materials
7/1/97

ADMINISTER QUIZ Quiz: Backhoe Engine and Fuel System

Approx. time: 30 min. Have students complete the quiz. Explain how to complete the quiz and
what reference materials can be used.
• Review - the quiz answers with the students and explain why an answer
is more appropriate than theirs. Take notes if suggestions come up to
make any of the questions better.

Answers:

I. Match the component to its primary function

1. C
2. J
3. M
4. K
5. D
6. G
7. H
8. I
9. B
10. F
11. E
12. L
13. A

II. Directions Modified True / False:

T 1.
F 2. Set-point is a critical specification that is easily checked and
adjusted NOT CRITICAL AND NOT EASILY
CHECKED OR ADJUSTED
T 3.
F 4. The temperature in the bottom tank of the radiator should be
higher LOWER than in the top tank.
 7/1/97
BCP BHL
416C - 438C STARTING AND CHARGING SYSTEM
TO DIODE BLOCK 309-GY
ASSEMBLY ALTERNATOR
L
G S
101-RD B+ P 450-YL
IG
MTR BAT E
RD-00 TAC
MOTOR POS NEG POS NEG
STARTER

15 A 105-RD
KEY S
A SWI
303-BR
202-BK
R
308-YL

25A 103-RD 101-RD C

-4-
XSMN LOCK OFF
START RELAY ACC
XSMN GROUND S ON
BK UP ALARM B ST
ACCESSORY RELAY PK BRK SW
BK UP ALARM
REV SOLENOID
FWD SOLENOID
START
FWD SOL RTN AID SW STAR
XSMN B+
REV SOL RTN
CO
KEY SW 307-OR 310-PU
10A 112-PU 101-RD SHIFT
CONTROL
MAIN
RELAY
308-YL 306-GN
308-YL
101-RD

Instructor Materials
START
RELAY 308-YL
15A 194-GN E
304-WH SH
SO
NOTE: If SENR5813 orCAB SENR RELAY 308-YL
5814 is used for the exercise, the student may need to add a resistor before the
diode, change the alternator ground, and the 101-RD wire to the alternator should be labeled 109-OR. The
schematic shown here is more current than the published schematic.
 7/1/97
BCP BHL
416C - 438C STARTING AND CHARGING SYSTEM
TO DIODE BLOCK 309-GY
ASSEMBLY ALTERNATOR
L
G S
101-RD B+ P 450-YL
IG
MTR BAT E
RD-00
TACH
MOTOR POS NEG POS NEG
STARTER

15 A 105-RD
KEY START
A SWITCH
303-BR
202-BK
R
308-YL

-5-
25A 103-RD 101-RD XSMN LOCK C OFF
START RELAY ACC
XSMN GROUND S ON
BK UP ALARM B ST
ACCESSORY RELAY PK BRK SW
BK UP ALARM
REV SOLENOID
FWD SOLENOID
START
FWD SOL RTN AID SW START AID
XSMN B+
REV SOL RTN
COIL
KEY SW 307-OR 310-PU
10A 112-PU 101-RD SHIFT
CONTROL
MAIN
RELAY
308-YL 306-GN
308-YL
101-RD START

Instructor Materials
RELAY 308-YL
15A 194-GN ENGINE
304-WH SHUTDOWN
SOLENOID
CAB RELAY 308-YL
BCP BHL -6- Instructor Materials
7/1/97

ADMINISTER QUIZ Quiz: Electrical System

Approx. Time: 45 min Have students complete Electrical Schematic Interpretation and Starting
System pages in the Student Quizzes handout. Explain how to complete
the quiz and what reference materials can be used. NOTE: The quiz
may be used as a homework assignment.
• Review- Review the quiz answers with the students and explain why an
answer is more appropriate than theirs.

Answers: Electrical Schematic Interpretation

1. a. C-3, F b. I-5, F 8. 105-5159
BONUS: c. A-5, F 9. 3.5 ± .15
2. 8Y7237 10. 4W9972
3. b. receptacle 11. a. an internal electrical....
4. a. pins only 12. 130-6257, 130-6256
5. c. 13. 9G3673 receptacle
6. D-12, A, 3E9362 9G3667 plug
7. C-10, D, 1180366 14. a. Conn.# 3 of 130-6256

Note: For question 1, the "Component Location Chart" is mistaken. Both

transmisssion neutralizer switches are on ithe nside tof he cab. One
is in the speed shift handle and the other is in the loader control
lever. Also, one of the switch locations does show up on the chart
due to a misspelling on the schematic at coordinates A-5.

Answers: Starting System

1. b. 12.4 volts or above
2. a. .3 volt
3. c. system voltage
BCP BHL -7- Instructor Materials
7/1/97

Lesson: Control Valve Operation

FACILITATE
CLASSROOM LAB
Have students complete the quiz. Explain how to complete the quiz and
Approx. Time: 10 min.
what reference materials can be used.
• Review - the quiz answers with the students and explain why an answer
is more appropriate than theirs. Take notes if suggestions come up to
make any of the questions better.

Answers:
1. (energized)
2. (is drained)
3. (is drained)
4. (pump supply oil and clutch oil).
5. (is not)
BCP BHL -8- Instructor Materials
7/1/97

ADMINISTER CASE Case Study: Power Train

STUDY

Explain how to complete the case study. Students should be broken up in

Approx. Time: 30 min.
to groups. Notes and reference materials should be used. Some potential
problems, tests, and results are listed below:

POSSIBLE SOLUTIONS • Thepump is actually bad. Check pump supply pressure. If it is within
specification, then the pump is not the cause of the problem.
• Thecold start relief valve is open. Remove from block and check for
debris
• TheAWD clutch is leaking. De-energize the AWD solenoid and re-
check pressures.
• The load piston springs (if equipped) are broken or the load piston is
stuck, so pressure cannot increase and oil goes over the relief valve.
Check to see if springs are not broken or missing and check for burrs on
the load piston.
• The relief valve springs (if equipped) are broken or the relief valve is
stuck, so pressure cannot increase and oil goes over the relief valve.
Check to see if springs are not broken or missing and check for burrs on
the valve.
• Thelinkage between the selector lever and control valve is suspect.
Check for broken, loose, or disconnected linkage. Probably not the
cause of the problem.
• Orifice
(if equipped) to load piston chamber is plugged. Disassemble
components to check for a plugged orifice.
• The wrong power train oil or lack of oil Check oil level and type of oil
• The neutralizer spool is stuck open, has a broken spring or the solenoid
will not allow the spool to close. Check to see if the solenoid is
energized. If not, remove the solenoid, neutralizer spool and spring.
Check for suspect components.

ACTUAL SOLUTION The above problem is based on an actual field problem. Checking out the
solenoid and neutralizer spool would have identified the problem.
It was discovered that the pin (rod) on the solenoid, which forces the
neutralizer spool open when the solenoid is energized, had loosened.
The pin would not allow the neutralizer spring to close off the drain
passages below the neutralizer spool. With the drain passages open,
supply oil and clutch oil was going directly to the tank.
BCP BHL -9- Instructor Materials
7/1/97

ADMINISTER QUIZ Quiz: Power Train

Approx. Time: 30 min
Have students complete power train quiz pages in the Student Quizzes
handout. Explain how to complete the quiz and what reference materials
can be used. NOTE: The quiz may be used as a homework assignment.
• Review - Review the quiz answers with the students.

Answers:

I. Match the component to its primary function.

C 1. Flow Control Valve
F 2. Orifice
E 3. Rotary Selector valve
G 4. Neutralizer Spool and Solenoid
D 5. Relief Valve
A 6. Load Piston
B 7. Check Valve

II. Modified True / False.

F 1. and speed. direction only
F 2. the load piston springs (or relief valve spring).
REVERSE clutch seals
T 3.
F 4. are shim adjustable if the clutch pressures are too low. are
not
F 5. directional shifts. speed

III. Control Valve Operation Directions:

1. The solenoid is (energized)(de-energized).
2. FORWARD clutch pressure is (drained)(at maximum).
3. The load piston chamber is (vented)(full of oil).
4. The relief valve (is) (is not) metering oil to drain.
5. Clutch modulation (is just beginning)(has ended).
BCP BHL - 10 - Instructor Materials
7/1/97

IV Multiple Choice:
1. C. REVERSE clutch pressure
2. 5
3. D. Lube pressure
4. A Torque converter outlet pressure
5. 6

V. Multiple Choice:
1. A. Torque converter outlet pressure
2. 6
3. D Pump Supply pressure
4. B Lube pressure
5. 6
BCP BHL - 11 - Instructor Materials
7/1/97

BEGIN LESSON Quiz: Axle and Brake System

Approx. Time: 5 min.

Have students complete power train quiz pages in the Student Quizzes
ADMINISTER QUIZ handout. Explain how to complete the quiz and what reference materials
can be used. NOTE: The quiz may be used as a homework assignment.
Approx. Time: 20 min.

• Review - Review the quiz answers with the students.

I. Directions: Match the component to its primary function.

B 1. Inboard Planetaries.
E 2. Torque converter
C 3. Front wheel drive clutch
D 4. Differential lock
A 5. Brakes
F 6. Compensation valve

II. Modified True / False.

F 1. B and C Series brakes are mechanically . hydraulically
T 2.
F 3. require pull rod (actuator rod) adjustments. do not require
T 4. .
T 5
BCP BHL - 12 - Instructor Materials
7/1/97

Case Study: Implement Hydraulic System

DIRECTIONS Explain how to complete the case study. Students should be broken up in
to groups. Notes and reference materials should be used
Approx. Time: 30 min.

SITUATION Some potential problems, tests, and results are listed below:

• Margin pressure may be set to low or the margin spool is broken.

Check margin pressure and adjust to specification. If it can't be
adjusted disassemble valve.

• The pressure compensator may be set to low or the spring is broken

Check maximum system pressure and adjust if necessary. It may
have to be disassembled.

•A secondary resolver in the steering valve may have a seal problem or

debris in it preventing a good signal from reaching the pump.
Work the tilt and lift together and see if the implements respond. The
resolver or a seal may have to be replaced.

ACTUAL SOLUTION The above problem is based on an actual field problem.

The secondary resolver in the steering valve had a bad seat and was
allowing signal oil to go to the tank through it. This caused the pump
not to produce enough flow.
BCP BHL - 13 - Instructor Materials
7/1/97

ADMINISTER QUIZ Quiz: Implement Hydraulic System

Approx. Time: 30 min
Have students complete implement hydraulic system pages in the Student
Quizzes handout. Explain how to complete the quiz and what reference
materials can be used.
• Review - Review the quiz answers with the students.

Answers:

I. Directions: Match the component to its primary function.

1. J Torque limiter
2. C Restrictor valve
3. I Primary resolver
4. D Secondary resolver
5. A Makeup valve
6. H Line relief valve
7. E Swashplate
8. B Pressure cut-off valve
9. F Bias piston
10. G Flow compensator/margin spool

II. Directions: The following are true or false.

T 1.
F 2. Margin Pressure is usually higher.... LOWER
F 3. The special orifice in the tilt circuit is.... IS NOT
F 4. engine should be at low idle. HIGH
F 5. If an implement is in stall there is no flow.... IS
T 6.
T 7. .
F 8. the higher work port pressure.... LOWER
T 9.
T 10.
T 11.
BCP BHL - 14 - Instructor Materials
7/1/97

III. Multiple choice. Select the best answer.

1. c. There is no signal being sent from the implements.
2. b. Margin pressure and low pressure standby.
3. a. Maximum system pressure.
4. b. If the flow requirements increase but the highest work port pressure
decreases.
5. a. To Upstroke
6. b. Low Pressure Standby and minimum flow.
7. d. The pump will upstroke to increase flow.
8. b. The pump will destroke to maintain flow.
9. d. The pump will destroke later