Service Training STUDENT

QUIZZES

C & D SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS
BCP BHL -2- Student Materials
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Quiz: Machine Orientation

NOTE: Use the provided sales information brochures (specalogs) to answer the following
questions.
I. Directions Modified True / False: If question is false circle word or word that makes statement
incorrect and replace with word(s) to make statement correct.

1. All D Series Backhoes are equipped with turbocharged engines.

2. The standard transmission used in D Series Backhoes features four speeds forward and four
speeds reverse.

3. The 420D, 430D, 432D and 442D are equipped with pilot controls for backhoe valve group.

4. The IT front loader is standard on the 416D and 424D backhoe loaders.

5. The All Wheel Drive (AWD) front axle is equipped with brakes.

6. The D Series Backhoes use a hydraulic brake system.

7. The D Series Backhoes feature dry-type, radial seal air filters.

8. The hydraulic system uses a fixed displacement pump with open center control valves.

9. All Wheel Steer provides three modes of operation.

10. Auto-up is an option on the 428D and 438D backhoes to raise the stabilizers.

11. The 430D operates at a higher system pressure than the 416D and 424D.

12. The speed selector is on the steering column on the standard transmission.

13. The implement hydraulic pump is rated at 162 lpm (43 gpm) on the 420D and 430D.

14. On machines equipped with RIDE CONTROL and the autoshift transmission, the Ride
Control switch has two positions.

15. The Auxililary Control ECM is used with all machines equipped with IT or parallel lift
linkage.
BCP BHL -3- Student Materials
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Quiz: Backhoe Engine and Fuel System

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

A Radiator cap
1. Used to remove water from the fuel.
B Oil pressure switch
2. Controls the fuel pressure in the fuel
injection pump. C Water separator

3. Prevents filter damage during cold startups. D High idle stop

4. Allows air to escape E Automatic advance mechanism

5. Limits maximum engine rpm. F Thermostat

6. Indicates engine oil level. G Engine oil dipstick

7. Provides engine "boost". H Turbocharger

8. Indicates a plugged air filter I Air filter indicator

9. Triggers an alarm if engine oil pressure is J Fuel regulator valve

low.
K Vent wire
10. When it opens, it send coolant to the radiator
L Starter
top tank.
M Filter bypass valve
11. Prevents late fuel injection timing.

12. Used to crank the engine.

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

1. A start aid coil is used instead of ether for cold weather starting.

2. The Fuel Shut-off Solenoid on the D Series turns the fuel supply to the fuel filter on or off.

3. A special tool is required to remove the top cover of the fuel pump on C backhoe loaders.

4. A cold start advance solenoid is used to reduce white smoke at startup.

5. Kerosene in the diesel fuel will not effect torque converter stall rpm.

6. The turbocharged engine also requires an engine oil cooler.

7. With the thermostat working correctly and the machine warmed up, the temperature in the
bottom tank of the radiator should be higher than in the top tank.
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Quiz: Electrical System

Directions Electrical Schematic Interpretation: Using SENR1276 electrical schematic for a 416C-
438C Backhoe Loader, answer the following questions.

1. List the schematic grid locations and the machine silhouette number or letter for the transmission
neutral switches ?
a. grid location machine location (silhouette) correct location
b. grid location machine location (silhouette) correct location
c. grid location machine location (silhouette) correct location

2. List the schematic grid locations and the machine silhouette number or letter for the loader neutral
switch?
grid location machine location (silhouette) correct location

3. What is the part number for all of the neutral start switches?

4. The 3E5175 connector at schematic coordinates E-8 which connects the harness to the shuttle
control is a:
a. plug
b. receptacle
c. none of the above

5. Does the above part of the connector have

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

6. What does 308 AF49YL-18 mean?

a. A 22 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 18 wire of
harness 149-0192.
b. A 18 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 308 wire
of harness 149-0192.
c. A 18 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 308 wire
of harness 9R9900.
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7. Locate the accessory relay on the schematic. List the schematic grid location, machine location
letter or number, and the part number.
grid location
machine location (silhouette)
part number

8. What is the harness assembly part number and description of the accessory relay?
a. Part number b. Description

9. What is the flash code and CID-FMI for a Speed 3 Solenoid Short to Battery?
a. Flash Code b. CID-FMI

10. What is the resistance of the Solenoid - A/C Clutch?

11. What is the part number of the converter temp sender?

12. The starter is grounded by:

a. an internal electrical connection to the surface of the component
b. having an external wire connected to vehicle structure

13. What two harnesses connect at CONN 41?

14. What is the part number of the receptacle and the plug for CONN 41?
receptacle
plug

15. What does Y-C7 mean for CONN 41?

a. Connector number 7 of the 9R9896 harness assembly
b. Connector number 7 of the 9R9904 harness assembly
c. C7 of the 9R9896 harness assembly
d. none of the above
BCP BHL -6- Student Materials
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Quiz: Electrical System

Directions Electrical Schematic Interpretation: Using RENR3587 electrical schematic for a 416D-
442D Backhoe Loader, answer the following questions.

1. List the schematic grid locations and the machine silhouette number or letter for the transmission
neutralizer switch
grid location machine location (silhouette)
2. List the schematic grid locations and the machine silhouette number or letter for the loader neutral
switch?
grid location machine location (silhouette)

3. What is the part number for both switches?

4. Locate the attachment relay on the schematic. List the schematic grid location, machine location
letter or number, and the part number.
grid location machine location (silhouette)

5. The 3E3381 connector at schematic coordinates F-4 which is part of the front dash control is a:
a. plug
b. receptacle
c. none of the above

6. Does the above part of the connector have

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

7. What does 308 CR6 YL-18 mean?

a. A 22 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 6 wire of
harness 167-3702.
b. A 18 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 308 wire
of harness 183-4492.
c. A 18 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 6 wire of
harness 167-3702.
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8. For the fuse/relay block diagram at coordinates A4-A5 what is "K13"?

a. Part number b. Description

9. What is the flash code and CID-FMI for a Transmission Speed 3 Solenoid Short to Battery?
a. Flash Code b. CID-FMI

10. What is the resistance of the Solenoid - A/C Clutch?

11. The starter is grounded by:

a. an internal electrical connection to the surface of the component
b. having an external wire connected to vehicle structure

12. What two harnesses connect at CONN 46?

Letters: Part No.: Description:
Letters: Part No.: Description:

13. What is the part number of the receptacle and the plug for CONN 46?
receptacle
plug

14. What does MP-C4 represent for CONN 46?

a. Connector number 4 of the 179-9336 harness assembly
b. Connector number 4 of the 179-7998 harness assembly
c. C4 of the 179-9336 harness assembly
d. none of the above

14. What does MOM represent on the Dead Engine Lower Switch?
BCP BHL -8- Student Materials
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Quiz: Electrical System

Directions Starting System: Answer the following questions. Either circle the correct response or fill

START
TP1 RELAY TP2 START
SWITCH

C OFF

S ON
B ST

W X TP3
TP4
TP6 TP7

STARTER TP10 POS NEG

MOTOR

POS NEG
TP5 BATTERIES

1. When checking the battery voltage at TP10 and TP7, an acceptable reading for a good battery is:
a) 12.0 volts or above
b) 12.4 volts or above
c) 24 volts or above
d) 24.8 volts or above

2. When cranking, what is the maximum allowable voltage drop checked from TP10 to TP6:
a) .3 volt
b) .5 volt
c) 12.4 volts or above
d) none of the above

3. With the key start switch in the RUN position what is the maximum voltage drop from TP6 to TP4?

a) .4 volt
b) .8 volt
c) 12.4 volts or above
d) none of the above
BCP BHL -9- Student Materials
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Quiz: Transmission
I. Directions Modified True / False: If question is false, underline or circle the words or word that
make the statement incorrect and replace with word(s) to make statement correct. Questions are for
Series II and B Series backhoe loaders.

1. On the standard transmission, the control valve is used to control direction and speed.

2. If the FORWARD clutch pressure is within specification and the REVERSE clutch pressure
is too low and not within specification, check the relief valve spring.

3. The torque converter inlet relief valve controls the maximum oil pressure to the torque
converter.

4. The power shift transmission provides automatic shifting between 4th and 5th gear
FORWARD.

5. The standard transmission require the use of ET to troubleshoot the Power Shift
Transmission Control.

POWER TRAIN
HYDRAULIC SYSTEM R
All WHEEL DRIVE
5

6
D
F
F
G
E
7
2

C AWD

1
H I
B TRANSMISSION 3
A LUBE

4 J
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1. At pressure tap "3," can be checked.

A. Torque converter outlet pressure
B. Lube pressure
C. REVERSE clutch pressure
D. FORWARD clutch pressure
F. Pump supply pressure
E. Torque converter inlet pressure

2. Which pressure tap should be used to check FORWARD clutch pressure?

1
2
3
4
5
6

3. At pressure tap "1," can be checked.

A. Torque converter inlet pressure
B. Speed clutch pressure
C. Directional clutch pressure
D. Pump supply pressure
E. Lube pressure
F. None of the above

4. Pressure tap "4" is used to check

A. Torque converter outlet pressure.
B. Lube pressure.
C. Torque converter inlet pressure.
B. Directional clutch pressure
D. None of the above.

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

Directions: Answer the questions below with the best possible answer.

1. The only difference between an Autoshift transmission and the standard powershift transmission is?
a. The number of gears.
b. The number of solenoids.
c. The clutch pressures.
d. The ECM programming.

2. Which solenoids are energized for the following conditions:

a. Machine running in SECOND FORWARD:
b. Machine running in THIRD REVERSE:
c. Machine running in FIFTH FORWARD:
d. Machine running in FIRST REVERSE:
e. Machine running in SECOND REVERSE with neutralizer switch held down:
f. Machine running in SECOND FORWARD, FIRST gear disabled, downshift switch pressed:

4. In the Autoshift mode, the operator selects the _____________ the machine can go in.
a. the direction
b. the highest gear
c. the direction and the highest gear
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5. In the Autoshift mode, FIRST gear enabled, gear shift selector in THIRD FORWARD, without
operator input, which gears are available?

6. In the Autoshift mode, FIRST gear disabled, gear shift selector in FOURTH FORWARD, without
operator input, what gears are available?

7. In the manual mode, FIRST gear disabled, what gears are available?

8. With the Ride Control Switch in the automatic mode, the autoshift transmission ECM activates the
Ride Control.
a. True
a. False

9. What happens to the autoshift transmission if the speed sensor fails?

a. Returns to the machine to neutral
b. Downshifts over a period of time to FIRST gear.
c. Switches to MANUAL mode.
d. Leaves pieces of broken transmission on ground.
BCP BHL - 13 - Student Materials
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Quiz: Axle and Brakes

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

1. Can convert high RPM and low torque to low A Brakes

RPM and high torque mechanically.
B Inboard planetaries
2. Can convert high RPM and low torque to low
RPM and high torque hydraulically. C Front wheel drive clutch

3. Transfers power from the transmission to the

D Differential lock
front axle.

4. Causes both axles to rotate at the same rpm E Torque converter

when engaged
F Compensation valve
5. Can be engaged independently for sharper
turns

6. Permits pressure between the master cylinders

to equalize

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

1. D and C Series brakes are mechanically engaged.

2. D and C Series rear axles have brake inspection ports.

3. D and C Series brakes require pull rod (actuator rod) adjustments.

4. D and C Series feature a hydraulic brake reservoir.

5. D and C Series feature a mechanical drive line parking brake.

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Quiz: Implement Hydraulic System

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

1. Reduces pump flow to prevent the A Makeup valve

engine from stopping
B Pressure cut-off valve
2. Blocks return oil to help reduce
cylinder cavitation. C Pressure reducing valve

3. Senses the head end or rod end

D Secondary resolver
cylinder pressure.

4. Compares the signal pressures E Swashplate

between valve bodies.
F Bias piston
5. Opens when the cylinder is voiding.
G Flow compensator/margin spool
6. Opens when cylinder pressures go too
high.
H Line relief valve

7. Depending on its angle, the pump will

I Primary resolver
increase or decrease flow.

8. Acts as the main relief. J Torque limiter

9. Helps control the swashplate.

10. Compares the highest cylinder

pressure to pump output pressure.
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II. Directions: The following are true or false. Enter T for true and F for false. If false, circle the
word or words that make the statement false and replace with a word or words that make the statement
correct.

1. The difference in pressure between pump supply pressure and signal pressure is called
margin pressure.

2. Margin Pressure is usually higher than Low Pressure Standby.

3. The special orifice in the tilt circuit is required to check margin pressure.

4. To check maximum system pressure the engine should be at low idle.

5. If an implement is in stall there is no flow available for another implement.

6. All implement control valves with a pressure reducing valve in them limit the pressure
drop across the directional control spool to the value of the pressure reducing valve spring.

7. If margin pressure is 300 psi and the implement sends a signal of 1000 psi the resultant
pump supply pressure is 1300 psi.

8. When operating 2 implements at the same time, the implement with the higher work port
pressure will have its flow needs met first if the pump cannot meet total system flow needs

9. If margin pressure is set too low machine cycle times will be slower.

10. The steering circuit has flow priority over the loader lift circuit.

11. If margin pressure is changed low pressure standby will also be changed.
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III. Multiple choice. Select the best answer.

1. If the pump is at Low Pressure Standby:

a. There is a signal being sent from the implements.
b. The pump will signal itself by way of the signal network.
c. There is no signal being sent from the implements.
d. None of the above

2. Adjusting the flow compensator screw effects:

a. Margin pressure and maximum system pressure.
b. Margin pressure and low pressure standby.
c. Margin pressure only.
d. None of the above

3. Adjusting the pressure cut-off screw will effect:

a. Maximum system pressure.
b. Low pressure standby.
c. Margin pressure.
d. None of the above

4. The variable displacement pump in a backhoe will upstroke (Note: Treat engine speed as remaining
constant):
a. If there is an increase in work port pressure but the flow requirements do not change.
b. If the flow requirements increase but the highest work port pressure decreases.
c. If the flow requirements do not change and the work port pressure stays the same.
d. None of the above

5. While an implement is activated and the operator maintains a constant lever displacement, a drop in
engine RPM will cause the pump:
a. To Upstroke
b. To Destroke
c. To remain unchanged
d. None of the above
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6. If no implements are being operated the pump is at:

a. High Pressure Stall and minimum flow.
b. Low Pressure Standby and minimum flow.
c. High Pressure Stall and maximum flow.
d. Low Pressure Standby and maximum flow.
e. None of the above

7. If the operator stalls one circuit and then operates another implement:
a. The pump will destroke to decrease flow.
b. Flow remains the same.
c. The pump will go to Low Pressure Standby.
d. The pump will upstroke to increase flow.
e. None of the above

8. If the operator maintains a fixed lever position and the engine rpm are increased:
a. The pump will upstroke to maintain flow.
b. The pump will destroke to maintain flow.
c. The pump swashplate angle remains unchanged.
e. None of the above

9. If the torque limiter spring setting is increased from the present setting:
a. The pump will upstroke sooner
b. The pump will upstroke later
c. The pump will destroke sooner
d. The pump will destroke later
e. None of the above
BCP BHL Student Materials
8/15/01
KNOW YOUR COOLING SYSTEM QUIZ (Answers)

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.

F 1. When the engine is cold, the temperature regulators direct PREVENTS the flow of coolant
to the radiator and prevents DIRECTS the flow of coolant back to the water pump.

F 2. An increase in cooling system pressure will lower RAISE the boiling point of the coolant.

T 3 Rate of heat transfer is measured by the specific heat properties of a given liquid.

F 4. Water with a high chloride concentration DISTILLED WATER is best for cooling system
usage.

F 5. Coolant conditioner is not IS necessary in cooling systems that use distilled water.

F 6. A 40% concentration of antifreeze in water will protect the cooling system to approximately
-40o -12o Fahrenheit.

T 7. When filling the cooling system, never fill faster than 5 gallons per minute.

T 8. An engine should never be operated with the temperature regulators removed.

T 9. When measuring the temperatures in the cooling system, the temperature in the radiator top
tank should be below the coolant boiling point.

F 10. The temperature of the water pump outlet must be approximately 8o to 20oF above
BELOW the temperature in the radiator top tank.

F 11. The most common cause of engine overcooling is temperature regulators stuck
closed.OPEN

T 12. High sulfur fuel will cause increased engine wear during overcooling when the operating
temperature is below 175oF

T 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.

F 14. Commercial coolant/antifreeze that only meets the ASTM D3306 specification is NOT
acceptable for use in Caterpillar engines.

F 15. The service life for the Caterpillar Extended Life Coolant (ELC) is for 5000 6000 hours.

T 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.
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BACKHOE LOADER AUTOSHIFT TRANSMISSION QUIZ ANSWERS

1. The only difference between an Autoshift transmission and the standard powershift transmission is?
a. The number of gears.
b. The number of solenoids.
c. The clutch pressures.
d. The ECM programming.

2. What type of speed sensor is used with the Autoshift transmission? What type of input wave does it
form?
a. hall effect, square wave
b. magnetic, ac sine wave
c. variable voltage, DC wave

3. Which solenoids are energized for the following conditions:

a. Machine running in SECOND FORWARD: 1 and 4

b. Machine running in THIRD REVERSE: 2 and 6
c. Machine running in FIFTH FORWARD: 1 and 6
d. Machine running in FIRST REVERSE: 2 and 4
e. Machine running in SECOND REVERSE with neutralizer switch held down: 6
f. Machine running in SECOND FORWARD, FIRST gear disabled, downshift switch pressed:
3 and 4

4. In the Autoshift mode, the operator selects the _____________ the machine can go in.
a. the direction
b. the highest gear
c. the direction and the highest gear

5. In the Autoshift mode, FIRST gear enabled, gear shift selector in THIRD FORWARD, without
operator input, which gears are available?

FIRST, SECOND, THIRD, FOURTH, FIFTH

6. In the Autoshift mode, FIRST gear disabled, gear shift selector in FOURTH FORWARD, without
operator input, what gears are available?

SECOND, THIRD, FOURTH, FIFTH

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7. In the manual mode, FIRST gear disabled, what gears are available?

FIRST, SECOND, THIRD, FOURTH

8. With the Ride Control Switch in the automatic mode, the autoshift transmission ECM activates the
Ride Control. True or False

9. What happens to the autoshift transmission if the speed sensor fails?

a. Returns to the machine to neutral
b. Downshifts over a period of time to FIRST gear.
c. Switches to MANUAL mode.
d. Leaves pieces of broken transmission on ground.

10. On 446B, the autoshift mode provides shift protection by limiting the maximum speed in each gear
to allow a shift from FORWARD to REVERSE or vice versa? True or False.
Service Training STUDENT
REFERENCE
MATERIALS

ENGINE

C SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS
Service Training STUDENT
REFERENCE
MATERIALS

POWER TRAIN

C SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS
Service Training STUDENT
REFERENCE

ELECTRICAL SYSTEM

C SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS
Service Training STUDENT
REFERENCE
MATERIALS

STEERING AND IMPLEMENT HYDRAULIC SYSTEM

C SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS
Service Training STUDENT
REFERENCE
MATERIALS

MISCELLANEOUS

C SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS