SERV1833-01 July 2008
GLOBAL GLO BAL SER SERVIC VICE E LE LEARN ARNING ING TECHNICAL PRESENT PRESENTA ATION
"C" SERIES SKID STEER LOADERS 246C/256C/262C/272C MULTI TERRAIN LOADERS 277C/287C/297C COMPACT COMP ACT TRAC TRACK K LOADERS LOADERS 279C/289C/299C
Service Servi ce Train raining ing Meeting Guide Guide (STMG)
"C" SERIES SKID STEER LOADERS 246C/256C/262C/272C MULTI TERRAIN LOADERS 277C/287C/297C COMPACT COMP ACT TRACK LOADERS 279C/289C/299C AUDIENCE Level II - Service personnel who understand the principles of machine system operation, diagnostic equipment, and procedures for testing and adjusting.
CONTENT This presentation provides an overview of the "C" Series Skid Steer Loaders and Multi-Terrain Loaders Field Follow Machines. This presentation may be used for self-paced and self-directed training. OBJECTIVES
After learning the information in this meeting guide, the serviceman will be able to: 1. identify identify the new service and maintenance maintenance features features on the "C" Series Skid Steer Steer Loaders and Multi-Terrain Loaders; 2. operat operatee the machine using the new controls controls for machine machine travel and work tool functions functions;; 3. operat operatee the instrument instrument cluster cluster screen in the operator operator mode and service mode; mode; 4. locate and identif identify y the new components components on the "C" Series Series Skid Steer Steer Loaders and and Multi-Terrain Multi-T errain Loaders; 5. explai explain n the basic basic operation operation of the new machine machine systems. systems. 6. identi identify fy the new new Cat ET scree screens ns used to to diagnose diagnose the machine machine system systems. s. REFERENCES
STMG "B" Series Skid Steer Loaders and Multi-Terrain Loaders Machine Systems Operation Salles Sa esg gram - Extreme Duty Power erttrain (XDP) for C - Series SS SSL L's: 3044 and 3046 Engines for Caterpillar Built Machines System Operation/Testing and Adjusting Distributor Type Fuel Pump for 3044 & 3046 Tier 2 Engines
Estimated Time: 8 Hours Visuals: 81 Handouts: 8 Form: SERV1833-01 Date: 07/08 © 2008 Caterpillar
SERV1783 TEKQ0590 90--01 SENR6457 SERV1777
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TABLE OF CONTE CONTENTS NTS INTRODUCTION ................................................... ....................................................... .....................................................................5 ..............5 Similarities and Differences ....................................................... ...................................................................................................8 ............................................8 OPERATOR'S OPERA TOR'S ST STA ATION.............................................................. ................................................9 ENGINE......................................................................................................................................34 ELECTRICAL SYSTEM ................................................ ........................................................ ...........................................................39 ...39 Interlock Strategy..................................................................................................................47 POWER TRAIN ..................................................... ............................................................................................................. ....................................................................49 ............49 WORK TOOL HYDRAULIC SYSTEM ..................................................... ...................................................................................66 ..............................66 CTL UPDA UPDATE.................... TE........................................................................... .........................................................................................................82 ..................................................82 TIER 3 UPDA UPDATE TE .................................................... ............................................................................................................ ....................................................................84 ............84 CONCLUSION...........................................................................................................................85 VISUAL LIST ........................................................ ................................................................................................................ ....................................................................86 ............86 HYDRAULIC SCHEMATIC COLOR CODE...........................................................................87 HANDOUTS...............................................................................................................................88
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NOTES Changes made to Visuals, 2, 11, 12, and 53.
Text changes made to pages, 5, 7, 15, 26, 28, 29, 36, 37, 39, 53, 62, and 63
July 08 changes: Text changes made to pages, 1 thru 9, 14 - 15, 30,- 31, 41, 53 - 55, 80 - 86, 92.
Visuals: 31, 58, 74 thru 76 thru 79
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"C" Series SKID STEER LOADERS 246C/256C/262C/272C MULTI TERRAIN LOADERS L OADERS 277C/287C/297C 277C/287C/297C COMPACT COMP ACT TRACK TRA CK LOA LOADERS DERS 279C/289C/299C 279C/289C/299C
© 2008 Caterpillar
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INTRODUCTION
The 246C/256C/262C/272C Skid Steer Loaders, the 277C/287C/297C Multi Terrain Loaders and the 279C/289C/299C Compact Terrain Loaders are the latest generation of Caterpillar Skid Steer Loaders and Multi-Terrain Loaders retaining many of the proven features of the "B" Series machines along with additional performance and many design improvements. The hydrostatic drive system and work tool hydraulic system are electronically controlled by the Machine Electronic Control Module (ECM). The Machine ECM controls all the functions that the Operator Interlock ECM and Auxiliary Hydraulic ECM controlled on the "B" Series machines. The Machine ECM controls additional functions in the "C" Series machines. The high flow XPS hydraulic system is is now optional on all 246C/256C/262C/272C Skid Steer Steer Loaders, 277C/287C/297C Multi Terrain Loaders and 279C/289C/299C Compact Terrain Loaders. Ride Control has been added as an option on all "C" Series SSL machines. This presentation discusses the new components and features of the 246C/256C/262C/272C Skid Steer Loaders, the 277C/287C/297C Multi Terrain Loaders and the 279C/289C/299C Compact Terrain Loaders. The "C" Series product line brings significant improvements in performance, operator comfort, controllability,, versatility controllability ve rsatility,, and styling.
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KEY NEW FEATURES FEATURES - Operator's Station - Electronically Controlled Hydrostatic Drive System - Electronically Controlled Work Tool Hydraulic System - Improved Electrical System - Ride Control System (SSL only) - High Flow Hydraulic XPS System Optional on all Machines Machines - Creeper Control - Two-speed Option - Tough Guard
Hoses
- Undercarriage with Optional Dual Level Suspension S uspension 2
The "C" Series Skid Steer Loaders, Multi Terrain Loaders and Compact Terrain Loaders are equipped with several new features as shown in this illustration. The operator's station has been redesigned with several new controls and an Advanced Machine Information and Control System (AMICS) digital display panel that can display machine information, along with three operator modes and seven service modes. The hydrostatic drive system is now electronically controlled by the Machine ECM. The joysticks in the cab ca b send signals to the Machine ECM, which sends corresponding signals to the pump control solenoids to control pump output. The work tool hydraulic system is also electronically controlled by the Machine ECM. The joysticks in the cab ca b send signals to the Machine ECM, which sends corresponding signals to the work tool lift, tilt, tilt, and auxiliary solenoids. The solenoids control the work tool directional directional spools, which control oil to the lift and tilt cylinders and the auxiliary circuit. The electrical system includes a new single Machine ECM, which controls many more machine functions than the "B" Series machines.
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Ride Control has been added as an option on the Skid Steer Steer Loaders only. only. The Ride Control System operates similarly to current Caterpillar wheel loaders. The optional high flow XPS hydraulic system is now optional on all "C" Series machines. A creeper control function has been added, which allows the operator to select a maximum machine travel speed at full joystick movement. The two-speed function is optional on all machines. Cat ToughGuard™ hydraulic hoses provide excellent abrasion resistance, which exceeds the capabilities of standard hydraulic hoses. The MTL undercarriage has been redesigned with greater serviceability serviceability in mind, and when fitted, the optional Dual Level Suspension utilizes eight independently pivoting bogie axles for smoother travel.
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SIMILARITIES AND DIFFERENCES FEATURES
DIFFERENT
SIMILAR
SAME
X
Machine Appearance X
Operator's Station
X
Engine Electrical
X
Hydrostatic Drive System
X
Work Tool Hydraulic System
X
Undercarriage
X X
Maintenance Items
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Similarities and Differences
The chart above shows the similarities and differences between the new 246C/256C/262C/272C Skid Steer Loaders, the 277C/287C/297C Multi Terrain Loaders and the 279C/289C/299C Compact Track Loader and the current "B" Series machines.
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OPERATOR'S STA STATION TION
The new Skid Steer Loader cab provides optimal space. Machines equipped with the optional enclosed cab (as shown in this illustration), a new door provides the operator with greater visibility to the work tool. The new cab is sealed and has a positive positive pressure. The cab comes radio ready and the dead engine lower function is now performed from the cab. A Rollover Protective Protective Structure Structure (ROPS) cab is standard. A Falling Object Protective Structure Structure II (FOPS II) cab is available as an option. The FOPS II cab can be used for applications that that require protection from large, heavy, falling objects. The top window is bonded and cannot be removed, which improves reliability against leaks and dust entering the cab.
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The cab can be raised by removing two bolts at the front of the cab, which allows easy access to components. The bolt (arrow) on the right right side of the machine is shown in this illustration. illustration. The cab rotates up as a complete unit.
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The top illustrations show show the air conditioning ducting. Air flows into the machine through the fresh air inlet (1). (1). Air flows into the evaporator compartment (2) through a duct (3) below the cab. The air passes over the evaporator (4) and is cooled. The cooled air is routed into the cab through a duct (5) on the bottom of the cab. The bottom right illustration shows the evaporator housing (6) removed from the machine.
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This cab is equipped with a mechanical suspension seat. There are two armrests (1) in the "C" Series machines, which rotate rotate from side-to-side. In this illustration the armrests are shown shown in the UP position. The seat can be moved back and forth with the seat lever (2) below the left side of the seat. The knob (3) located below the center of the seat cab be turned to adjust the seat suspension.
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In this illustration the armrests (1) are shown in the DOWN position. This cab is equipped with an optional air suspension seat. The seat can be moved back and forth with the seat lever (2) (2) below the left side of the seat. The knob (3) located below the center of the seat can be pulled in or out to adjust the seat suspension by operating an internal pump to inflate the seat bladder.
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The left and right joysticks are are adjustable fore / aft independently from from the seat. The joystick adjustment lever (1) is located to the rear of the joystick. Additionally the joystick pods are seat mounted, which provides for greater controllability over rough terrain. In the standard control lever pattern, the left joystick (2) provides directional control and has the same function as previous models. The switches on the left joystick joystick are: - ho horn rn (3 (3)) - auxili auxiliary ary electrical electrical control control "C1" (4) - auxili auxiliary ary electrical electrical control control "C2" (5) - contin continuous uous flow flow control control (6) The trigger switch (not visible) located on the front side of joystick is used to control the two-speed function or the auxiliary electrical electrical function "AUX 7." The multifunction switch on the left overhead console determines the functionality of the trigger switch.
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The right joystick adjustment lever (1) is located to the rear of the joystick. In the standard control lever pattern, the right joystick (2) provides work tool control and functions the same as previous models. The thumb switch (3) controls the proportional auxiliary hydraulics or the high flow auxiliary hydraulics if the auxiliary hydraulic mode switch switch is in the HIGH FLOW position. The switches to the right of the thumb switch operate the work tool control circuit found on high flow machines. The top switch switch (4) activates the C+ C+ function. The bottom switch (5) activates the C-function. A trigger switch switch (not visible) visible) on the front of the joystick controls the FLOAT FLOAT function. As the implement control is now electro-hydraulic, there is no detent position. Therefore to operate the FLOAT FLOAT function, depress the switch and move the the lever forward or move the lever forward forward and depress the switch.
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AUXILIARY FUNCTIONS STANDARD CONFIGURATION C1
C2 C D E
A2
B A H G
A1
Work Tool Electrical Connector
F
Electrical Connector Pin Arrangement
Auxiliary Hydraulic Connections
C1 Aux 6
Thumb Switch (A1/A2 Aux)
C2 Aux 5 Right Joystick
Left Joystick
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This illustration shows the joystick controls and the auxiliary hydraulic and electrical connections on machines with a standard hydraulic configuration. The thumbswitch on the right joystick controls proportional hydraulic oil flow to the loader arms through the A1 and A2 connectors. The C1 switch on the left joystick provides electrical power to some work tools through pin C on the work tool electrical connector. connector. The C2 switch on the left joystick joystick provides electrical power to some work tools through pin D on the work tool electrical connector.
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Work Tool Electrical Connector
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Return
AUXILIARY FUNCTIONS HIGH FLOW CONFIGURATION
C+
C-
High Flow (A1)
High Flow (A2)
Standard (A1)
C1
Standard (A2)
C2
C D E
Aux 7
B A H G
F
Electrical Connector Pin Arrangement Auxiliary Hydraulic Connections C+ Aux 4 C1 Aux 6
Thumb Switch (A1 / A2 Aux)
Aux 7 Trigger Switch C- Aux 3
C2 Aux 5 Right Joystick
Left Joystick
12
This illustration shows the joystick controls and the auxiliary hydraulic and electrical connections on machines equipped with a high flow hydraulic configuration. The thumbswitch on the right joystick controls proportional hydraulic oil flow to the loader arms through the A1 and A2 A2 connectors. For standard work tools, oil is provided through the standard A1 and A2 hydraulic connectors. For high flow work tools, oil oil is provided through the high flow A1 and A2 hydraulic connectors. The C+ and C- switches on the right joystick control ON/OFF hydraulic oil flow to the loader arms through the C+ and C- connectors. The C1 switch on the left joystick provides electrical power to some work tools through pin C on the work tool electrical connector. connector. The C2 switch on the left joystick joystick provides electrical power to some work tools through pin D on the work tool electrical connector. The trigger switch provides electrical power to some work tools through pin B on the work tool electrical connector when the multifunction switch on the left overhead console is in the AUX 7 position.
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CONTROL L EVER PATTERNS PATTERNS Standard
Bucket Lower
Foward
Left Turn
Optional
Right Turn
Tilt Backward
Tilt Forward
Reverse
Bucket Raise
LH Forward
RH Forw Forw ard
Bucket Raise
Bucket Lower
Tilt Backward
LH Reverse
Tilt Forward
RH Reverse
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Two control patterns are available for for the "C" Series machines. The control patterns are software enabled attachments. The Standard pattern is the the same pattern used on the former machines. The optional pattern provides an alternative control pattern with the convenient control and feel of dual control lever steering and work tool controls. Films in the operator's compartment identify the installation of the optional pattern on a machine.
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The fuse panel (1), the document compartment (2), the recirculation filter (3), and the radio (4) are all located at the rear of the cab. NOTE:
All machines are equipped with radio wiring and a radio r adio mounting location. However,, the radio However rad io is a dealer installed component.
The armrest switch (5) is located below the left armrest. armrest. The armrest must be down to activate activate the hydraulic controls. The fuse panel includes fuses (6) and 10 relays (7). The fuse panel cover (8) includes a decal. A lanyar lanyard d is attached attached to the fuse fuse panel and and cover. cover. The Cat ET connect connector or (9) is located located above above the fuse panel. A pleated automotive style cab recirculation filter filter (10) replaces the foam recirculation recirculation filter used on the "B" Series machines.
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The cab fresh air filter is located on the left side at the rear of cab. Remove the filter cover (arrow) to service the filter element.
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Lifting hooks (arrows) can be attached to optional mounts on the top of the cab for lifting the machine. A four-point lifting kit is optional.
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The governor control lever (1) is shown in the top illustration and the accelerator pedal (2) is shown in the bottom illustration. A new throttle position sensor (not shown) is located on the accelerator pedal assembly. assembly.
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The throttle position sensor (1) (1) is located at the base of the accelerator pedal assembly (2). The throttle position sensor sends a signal to the Machine ECM indicating the accelerator pedal position. The throttle position signal is used by the Machine ECM to control machine underspeed conditions.
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This illustration shows the relocated windshield washer reservoir (arrow).
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A dead engine lower handle (arrow) has been installed installed in the cab to allow the lift lift arms to be lowered from inside the cab in the event of a dead engine and no electrical power or in the event of an uncharged accumulator.
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In a situation where the operator is unable to lower the lift arms, there is an unlocking mechanism built into the door. To remove the door, the top handle (2) must be pulled up and the bottom handle (3) pulled down. Then, the gas strut (1) must be removed. A decal (4) is located on the door post that shows the door removal procedure. NOTE:
For the complete door removal procedure, refer to the "C" Series Operation and Maintenance Manual.
Also visible in the bottom illustration is the windshield washer switch (5) and the door switch (6). The door switch switch prevents lift lift arm movement while the the door is open. Inadvertent lift arm movement could damage the door.
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The left overhead console includes the following switches: -Auxiliary hydraulic pressure release (1) -Hydraulic lockout and interlock override (2) -Rear work lights (3) -Front work lights (4) -Auxiliary 7/two-speed selection switch (5) -Auxiliary electrical control (6) -Automatic level control (7) -Work tool coupler control (8)
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The left overhead display includes the key start switch (1), the 12-volt receptacle (2), the parking brake switch (3), and the joystick control pattern switch (4, if equipped). If the pattern switch is installed, either the standard pattern 1, or the optional pattern 2, must be selected to release the parking brake. Indicator Lamps (5) and (6) will blink until a selection is made. The parking brake will not be able ab le to be released until a selection is made. Once a pattern pa ttern is selected, the appropriate lamp will stay illuminated. A digital display panel (7) includes the the warning indicators (8), the fuel level gauge (9), and the service hour meter (10). The bottom illustration shows the warning indicators illuminated. illuminated. There are three warning levels. With a Level 1 warning, the alert indicator is ON continuously. continuously. With a Level 2 warning, the alert indicator flashes. flashes. With a Level 3 warning, the alert indicator flashes flashes and a warning alarm sounds.
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The heating and air conditioning controls have been moved to the right overhead console. The switches include the fan speed control switch (1), the air conditioning control switch (2), and the temperature control switch (3). To the left of the heating and air conditioning controls are the creeper switch (4), and the optional ride control switch (5). (5). The creeper control switch allows the the operator to select a maximum machine travel speed at full joystick movement.
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The optional Advanced Machine Information and Control System (AMICS) display panel includes a digital display panel (1) with a coolant temperature gauge (2) and a hydraulic oil temperature gauge (3). (3). A digital display window (4) is used to display machine information. The switches below the digital display panel include the beacon switch (5), the hazard flashers (6), the optional roading lights (7), and the optional turn signals (8). The bottom illustration shows all the available icons that can be displayed on the digital display window. NOTE: Not
all icons displayed above are currently available for use. us e.
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The optional Advanced Machine Information and Control System (AMICS) display panel will show various machine information in three Operator Modes and eight Service Modes. The function selector key (1) is used to toggle between available modes. The scroll up key (2) and scroll down key (3) are used to toggle between screens or settings within a mode. The three Operator Modes are: - Mode 1 (Display Screen): displays basic machine information including engine speed (default start-up mode shown in the top right illustration), system voltage, and job clock. - Mode 2 (Implement (Implement Control): displays the current lift and tilt function response setting (bottom left illustration). illustration). The three implement response settings settings are Fine Control, Medium Control, and Coarse Control. Fine control is one bar, bar, medium control is two bars, and coarse coa rse control is three bars. The default setting is medium. Fine control provides a more precise implement response. - Mode 3 (Creeper Control): displays the current creeper control setting setting (bottom right illustration). There are 10 creeper settings, which allow the maximum machine travel travel speed to be set between 5% and 100% of full speed.
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These illustrations show the display panel in the Service Mode. To display the Service Mode press and hold the function select key (1) and the scroll up key (2) for at least three seconds. The function select key allows navigation between modes and the arrows keys allow navigation within each mode.The eight Service Modes are: - Mode 0 (Active Diagnostics): Diagnostics): displays the active diagnostic codes. If no active faults are present the display will show "0 - 0" (top illustration). The bottom illustration shows an an active diagnostic code. - Mode 1 (Logged Diagnostics): Diagnostics): displays the logged diagnostic diagnostic codes. - Mode 2 (Active Events): displays the active active event codes.
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- Mode 3 (Logged (Logged Events): Events): displ displays ays the logged event event codes. codes. - Mode 4 (Software P/N Machine): displays the currently installed installed Machine ECM software part number numbe r. - Mode 5 (Machine Parameters): displays the engine coolant temperature, the hydraulic oil temperature, and the left and right drive motor speed and direction. - Mode 6 (Component Status): displays the status of the throttle position, the joystick position, the parking brake switch, the backup alarm relay, the stop lamp relay, and the ride control status. - Mode 7 (Units): (Units): allows the units to be set to to Metric or English.
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34 ENGINE
The 3044C engine is similar to the "B" Series machines. The engine ratings have been increased and an ATAAC has been added to the 272C and 297C machines to increase power. The bottom views show the front front of the engine with the engine cover removed. The following components have new locations in the engine compartment: - Hydrau Hydraulic lic oil filt filter er (1) - Maint Maintenance enance and lubrication lubrication points points decal (2) - Engine coolant coolant reservoi reservoirr (3) - Fuel filter filter and priming priming pump pump (4) - Jump start start receptac receptacle le (5) - Oil filler cap - (relocated from the front timing timing cover to the valve cover, cover, (6) - Air cleaner cleaner decal (7): (7): A decal has been been added to the the air filter filter housing housing to ensure ensure proper proper installation. The dust ejector must also be checked daily to to ensure it is not plugged.
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- Fuel tank tank and filler filler cap cap (8) - Engine oil dipsti dipstick ck (9) - Air conditioning compressor (10): (10): The compressor has been moved into the engine compartment and is now driven by a belt. - Engine oil oil filter filter (11) (11)
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The oil filter (1) is is now mounted vertically for improved improved serviceability. serviceability. The "C" Series engine is equipped with an open breather system(2).
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An Air to air aftercooler (ATAAC) (1) has been added to the 272C Skid Steer Loader and the 297C Multi-Terrain Multi-Terrain Loader. The AT ATAAC housing (2) and hydraulic drive motor (3) for the ATAAC fan are located at the back of the engine compartment behind the cab. The AT ATAAC motor is driven by oil from the ATAAC pump (not shown) which is mounted to the charge pump. The ATAAC fan forces air through the aftercooler and out the top of the engine compartment. Debris can be cleaned from the ATAAC by opening a panel (4) behind the cab. Also located on the side of the ATAAC housing is the air conditioning condenser (where fitted).
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In cold weather, the glow plugs are powered by the Machine ECM through the cold start relay when the key start switch is turned to the ON position. The glow plug indicator (arrow) on the left overhead console will illuminate when the key start switch is turned on and go out when the engine is ready to start. The ECM will monitor both the engine coolant temperature and the hydraulic oil temperature. If either temperature is below the preset value, the glow plugs will be activated.
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ELECTRICAL ELECTR ICAL SYSTEM
The battery (arrowed) has been relocated under the cab from from the engine compartment. A remote jump start receptacle is located in the engine compartment as previously described.
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The single Machine ECM (1) is located at the back of the cab. Two power relay modules (2) and six fuses (not visible) visible) are also located behind the cab. The fuses are accessed by removing the fuse covers (3). The Machine ECM is an A4:M1 ECM with two 70-pin connectors. The Machine ECM on the "C" Series machines replaces the Operator Interlock ECM and Auxiliary Hydraulic ECM on the "B" Series machines.
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MACHINE ECM INPUTS AND OUTPUTS Key Start Switch
Two Speed Solenoid
Engine Speed Sensor Engine Coolant Temperature Sensor
Left Hystat Pump Forward Solenoid Left Hystat Pump Reverse Solenoid
Hydraulic Oil Temperature Sensor Fuel Level Sensor
Right Hystat Pump Forward Solenoid
Armrest Switch
Right Hystat Pump Reverse Solenoid
Continuous Flow Switch
Auxiliary Valve Solenoid 1
Auxiliary Hydraulic Pressure Release Switch Battery
Auxiliary Valve Solenoid 2 Demand Fan Solenoid
High Pressure Tool Detent Switch Engine Oil Pressure Switch
Tilt Up Implement Solenoid
Hydraulic Lockout Switch Creeper Control Switch Alternator R Terminal
Tilt Down Implement Solenoid Lift Implement Solenoid Lower Implement Solenoid
Air Cleaner Indicator Switch
Pilot ON / OFF Solenoid
Throttle Level Position Sensor Aux 1 / Aux 2 RLR or Aux 2 Switch
Machine ECM
Ride Control Switch
Load Sense Relief Valve Solenoid (XPS) Implement Pilot Solenoid Start Relay
Aux 1 Switch
Cold Start Relay
Door Switch
Stop Lamp Relay
RH Joystick Trigger Switch
Back-up Alarm Relay
RH Joystick C+ Switch
Fuel Pump Relay
LH Joystick Fore / Aft Switch
Ride Control Self Level Relay
LH Joystick Side / Side Switch
Cold Start Advance Relay
Left Motor Speed Sensor Right Motor Speed Sensor Hydraulic Filter Bypass Switch
CAT Data Link
CAT ET Product Link
RH Joystick Fore / Aft Switch CAN Data Link
RH Joystick Side / Side Switch Pattern Change Switch
(If Equipped)
Two Speed Switch
Instrument
Park Brake Switch
Clusters
Interlock Override Switch Seat Switch
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This illustration shows shows the Machine ECM inputs and outputs. There are several more machine functions that are controlled by the Machine ECM in the "C" Series machines. The Machine ECM controls the following hydrostatic drive features: -two-speed control - Creepe Creeperr contro controll -Joystick steering and speed control -Neutral interlock -Underspeed control -Power management control -Fault management control -Uncommanded track movement detection
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The Machine ECM controls the following work tool hydraulic system features: -Auxiliary bleed off control -Auxiliary tool control -Bucket tilt control -Lift arm raise/lower control -Continuous flow control -Interlock override control -Joystick pattern changer - Ride control control The Machine ECM controls the following machine system features: -Engine start interlock -Glow plug start control -Hydraulic demand fan control
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Cat ET can be used for configuring and diagnosing the "C" Series machines. This screen shows the Machine status screen. Several status screen are available to aid in troubleshooting Machine ECM controlled controlled functions. The screens are: - Ma Mach chin inee - Int Interl erlock ock - En Engi gine ne - Hys Hystat tat input inputss - Hys Hystat tat outpu outputs ts - Hys Hystat tat contr control ol - Imple Implement ment contr control ol - Auxili Auxiliary ary hydraul hydraulics ics - Hi High gh flo flow w - Jo Joys ysti tick ck
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This illustration illustration shows the machine Configuration screen. Several "C" Series machine features can be installed using the Configuration screen.
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The following components can be calibrated using Cat ET: - Throt Throttle tle position position sensor sensor - Joyst Joystick ick control control levers levers - Work tool hydraulic system solenoids - Hysta Hystatt pump solen solenoids oids - Demand fan soleno solenoid id
Text Reference
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Text Reference
45
The Machine ECM, left console display, and right console display can all be flashed using the Cat ET Wi WinFlas nFlash h program. program.
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Text Reference
MACHINE ECM INPUTS AND OUTPUTS Key Start Switch
Two Speed Solenoid
Engine Speed Sensor
Left Hystat Pump Forward Solenoid
Engine Coolant Temperature Sensor
Left Hystat Pump Reverse Solenoid
Hydraulic Oil Temperature Sensor
Right Hystat Pump Forward Solenoid
Fuel Level Sensor
Right Hystat Pump Reverse Solenoid
Armrest Switch Continuous Flow Switch
Auxiliary Valve Solenoid 1
Auxiliary Hydraulic Pressure Release Switch
Auxiliary Valve Solenoid 2 Demand Fan Solenoid
Battery
Tilt Up Implement Solenoid
High Pressure Tool Detent Switch Engine Oil Pressure Switch
Tilt Down Implement Solenoid
Hydraulic Lockout Switch
Lift Implement Solenoid
Creeper Control Swi tch
Lower Implement Solenoid
Alternator R Terminal
Pilot ON / OFF Solenoid
Air Cleaner Indicator Switch Throttle Level Position Sensor Aux 1 / Aux 2 RLR or Aux 2 Switch
Load Sense Relief Valve Solenoid (XPS) Machine ECM ECM
Ride Control Switch
Implement Pilot Solenoid Start Relay Cold Start Relay
Aux 1 Switch
Stop Lamp Relay
Door Switch
Back-up Alarm Relay
RH Joystick Trigger Switch RH Joystick C+ Switch
Fuel Pump Relay
LH Joystick Fore / Aft Switch
Ride Control Self Level Relay
LH Joystick Side / Side Switch
Cold Start Advance Relay
Left Motor Speed Sensor Right Motor Speed Sensor
CAT Data Link
CAT ET
Hydraulic Filter Bypass Switch
Product Link
RH Joystick Fore / Aft Switch
CAN Data Link
(If Equipped)
RH Joystick Side / Side Switch Hydraulic Lockout Lamp
Pattern Change Switch Two Speed Switch
Park Brake Lamp
Park Brake Switch
Armrest / Seat Lamp
Interlock Override Switch Seat Switch
46
Interlock Strategy
The interlock strategy is similar to the "B" Series machines, but is now controlled by the Machine ECM. This illustration shows the input and output components (red) used to control the interlock function. The Machine ECM prohibits the engine from starting starting and de-energizes the pilot ON/OFF solenoid valve and the implement pilot shutoff solenoid valve until certain conditions are met. The Machine ECM disables the work tool hydraulic system until the operator is seated with the armrest down, the door closed, the hydraulic lockout switch off, and the park brake released. The Machine ECM reads the input signals from various switches on the machine. The armrest switch is a normally open switch switch located at the hinge point for the the left armrest. The armrest switch closes when the left armrest is lowered. The seat switch is a normally open switch that is located below the operator's seat. seat. The seat switch closes when the the operator is seated in the seat. The door switch is a normally open switch switch located on the inside inside of the door. door. The door switch closes when the door is closed.
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Text Reference
The Machine ECM determines operator requests from from input signals from the key start switch, the park brake switch, and the hydraulic lockout switch. The Machine ECM controls engagement of the starter starter motor. motor. The start relay is powered by the Machine ECM when the following inputs are are seen: the key start switch, the armrest armrest switch, and the seat switch. An open circuit on the key start switch input disables disables machine starting. A short to ground on the key switch input input blows a fuse, fuse, disabling machine starting. starting. A short to battery battery on the key start switch input causes the start relay to be continuously energized as long as the armrest switch and seat switch remain in the closed position. An open circuit or short to ground to the start relay disables disables machine starting. Shorts to battery in the start relay circuit cause the start relay to be continuously energized, resulting in starter motor damage. The implement pilot shutoff solenoid and park brake solenoid are energized by the Machine ECM when the park brake switch is depressed. Once energized, the implement pilot shutoff shutoff solenoid will not be disabled with the park brake switch. NOTE:
If the selectable s electable pattern switch is installed, a pattern (1 or 2) must be chosen ch osen before the park brake can be released.
The work tool hydraulic system can be disabled independently of the travel system by depressing the optional hydraulic lockout switch or by opening the operator's compartment door. The implement pilot shutoff solenoid remains energized as long as the hydraulic lockout switch and the door switch remain closed to ground. Opening either of the switches causes the ECM to disable the solenoids. The implement pilot shutoff shutoff solenoid is re-energized re-energized when the hydraulic lockout switch and the door switch are closed to ground.
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Text Reference
HYDROSTATIC HYDROSTATIC DRIVE SYSTEM Left Motor Speed Sensor Left Motor
Parking Brake Pump Control Solenoid Valves (Left Motor)
Right Motor Speed Sensor Right Motor
Parking Brake
Machine ECM
Pump Control Solenoid Valves (Right Motor)
Work Tool Pump
Pilot ON/OFF Solenoid
Engine
Engine Speed Sensor Throttle Lever Position Sensor Joystick Position Signals Park Brake Switch Creeper Control Switch
Charge Pump
Demand Fan Motor
Hydrostatic Drive Pump
Hydraulic Oil Filter
47
POWER TRAIN
The hydrostatic drive system is now electronically controlled by the Machine ECM through four pump control solenoids. The joysticks send a signal to the the ECM when moved by the operator. The ECM sends corresponding signals to to the pump control solenoid valves, which control pump output flow to the travel motors. Each motor includes a speed sensor for the feedback signal to Machine ECM. The ECM also receives input from the engine speed sensor and the throttle lever position sensor to control the underspeed function. The speed sensing sensing valve has been eliminated. The travel pilot solenoid and park brake solenoid have been eliminated and replaced by the travel pilot ON/OFF solenoid valve located located on the hydrostatic pump. The park brake switch sends a signal to the ECM to control the park brake function. The creeper switch sends a signal to the Machine ECM, which allows the operator to select a maximum machine travel speed at full joystick movement. A two-speed valve is also located on the pump if the machine is equipped with the optional optional two-speed motors.
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1
Text Reference
3 8
6
4
2
11
12
7
9
5 10
48
This illustration shows shows the right side of the the hydrostatic pump. From this side of the the pump the following components are visible: - Left motor motor reverse reverse pump solenoid solenoid (1) - Left motor motor servo pressure pressure port port (2) - Right motor motor servo pressur pressuree port (3) - Right motor motor reverse reverse pump solenoid solenoid (4) - Right reverse crossover relief and makeup valve (5) - Pilot ON/OFF ON/OFF solenoid solenoid valve valve (6) - Charge oil to to implement pilot shutoff valve (7) - Char Charge ge relief relief valve valve (8) - Case drain port (9) - Left reverse crossover relief and makeup valve (10) (10) - Left forward crossover crossover relief and makeup valve (11) - Right forward crossover relief and makeup valve (12)
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Text Reference
3
2
5
6
4
1 7
8 15
10
9
14
13 11 12
49
This illust illustratio ration n shows the the left side side of the hydrostat hydrostatic ic pump. From this side of the the pump the following components are visible: - Right forward forward pump pump solenoid solenoid (1) - Right forward forward drive drive loop port (MC) (MC) (2) - Brake supply supply port port (3) (3) - Left forward forward drive drive loop port (MB) (MB) (4) - Char Charge ge pressure pressure tap (5) (5) - Left forward forward pump pump solenoid solenoid (6) - Left motor motor servo pressure pressure port port (7) - Right motor motor servo pressur pressuree port (8) - Case drain port (9)
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- Charg Chargee oil inlet inlet port (10) (10) - Left forward forward travel drive drive loop port (11) (11) - Left reverse reverse travel travel drive loop loop port (12) - Right reverse reverse travel travel drive loop loop port (13) - Right forward forward travel travel drive loop port (14) - Case drain drain port (15)
Text Reference
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Text Reference
1
50
The SSL travel drive motors are radial radial piston motors with a similar type of design as the "B" Series machines. The brakes are spring engaged and hydraulically released. The MTL drive motors are axial piston motors Each hydrostatic drive motor contains a flushing valve. The flushing valve maintains maintains a minimum system pressure as it drains some oil from the low pressure side of the drive loop. The pump crossover relief valves helps supply the makeup oil that the flushing valve drains. As the oil flows to the case drain, heat and any contamination is purged from the drive loop. The "C" Series travel motors each contain a speed sensor (1) that send a speed signal to the Machine ECM indicating motor speed and direction. A two-s two-speed peed travel travel system system is optional optional on all machines machines.. The SSL two-s two-speed peed travel travel motor contains additional spools and passages which forces the motor to spin faster for the same flow rate to control flow from the pump. The MTL two-speed travel motors utilize utilize a swashplate to control the flow to achieve the same end result. A two-speed solenoid is mounted below the hydrostatic drive drive pump. The two-speed solenoid valve is used to shift the travel motor control spool.
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Text Reference
HYDROSTATIC DRIVE SYSTEM PARK BRAKE APPLIED To Pilot Shutoff Solenoid
From Manual Lowering Valve From Pilot Shutoff Solenoid
Cooler
Travel Motor
Travel Motor
Flushing Valve
Flushing Valve
From Work Tool Valve Group
To / From Work Tool Coupler Valve Return Manifold
Hydraulic System Filter
Demand Fan Motor Park Brake
Pilot On/Off Solenoid
Park Brake Right Pump Solenoid Valve
Left Pump Solenoid Valve Hydrostatic Drive Pump
To Work Tool Valve Group
ATAAC Fan Motor
Actuator Piston
M Actuator Piston
Crossover Relief Valves
Crossover Relief Valves
Work Tool Charge ATAAC Pump Pump Pump
Charge Relief Valve
51
This illustration shows the "C" Series machines hydrostatic drive hydraulic system in the HOLD position. The charge pump sends oil through the demand fan motor and hydraulic oil filter to the charge pump relief valve, the crossover relief and makeup valves, the park brake solenoid valve, the two-speed solenoid valve (if equipped), and the implement pilot shutoff valve. When the engine is started, the pilot pilot ON/OFF solenoid is de-energized. de-energized. The solenoid valve directs oil to drain and the the park brakes are engaged by spring force. When the operator depresses the park brake switch, a signal is sent to the Machine Machine ECM. The ECM energizes the Pilot ON/OFF solenoid. The solenoid valve directs oil to the the park brake piston and the pump control solenoid valves. Charge oil acts against spring spring force to release the park brakes. The pump solenoid valves control charge oil to the actuator pistons upon command of the Machine ECM. The actuator pistons pistons control the swashplates. The angle of the swashplates control the amount of oil and the direction of oil flow from the pump to the motors.
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Text Reference
In HOLD, the speed and direction control lever lever is centered. No signal is sent from from the control lever to the Machine ECM. The pump control valves are held in the center position position by spring force and no pressure oil is directed to the actuator pistons. With no signal signal pressure oil to either end of the actuator pistons, the pistons stay in the centered or neutral position. The centering springs for the actuator pistons hold the swashplates at zero angle. With the the swashplates in this position, the hydrostatic drive pump group does not produce oil flow. Without output from the hydrostatic drive pump group to turn the drive motors, the machine does not move. The crossover relief and makeup valves protect the system by either maintaining a minimum drive loop pressure or reducing pressure pressure spikes in the drive loops. At machine start-up, the makeup valves open to direct charge oil to to both sides of the pump and motor. motor. The oil in both lines to the drive motors are approximately at charge pressure. The main purpose of the travel motor flushing valve is to drain used hot oil from the low pressure side of the drive loop to case drain, which purges heat and contamination from the drive loop. The relief valve in the flushing valve also also controls the minimum pressure pressure in the low pressure side drive loop when the machine moves.
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Text Reference
HYDROSTATIC DRIVE SYSTEM FORWARD To Pilot Shutoff Solenoid
From Manual Lowering Valve From Pilot Shutoff Solenoid
Cooler
Travel Motor
Travel Motor
Flushing Valve
Flushing Valve
From Work Tool Valve Group Group
To / From Work Tool Coupler Valve Return Manifold
Hydraulic System Filter
Demand Fan Motor Park Brake
Pilot On/Off Solenoid
Park Brake Right Pump Solenoid Valve
Left Pump Solenoid Valve Hydrostatic Drive Pump
To Work Tool Valve Group Group
FWD ATAAC Fan Motor
Actuator Piston
M Actuator Piston
Crossover Relief Valves
Crossover Relief Valves
Work Tool Charge ATAAC Pump Pump Pump
Charge Relief Valve
52
This illustration shows the conditions that are present when the speed and direction lever is moved to the FORWARD position. As the speed and direction lever is moved forward, a signal is sent to the Machine ECM. The ECM sends corresponding signals to to the right and left pump forward forward solenoids. The pump solenoid valves direct signal pressure to the actuator pistons. The Machine ECM receives feedback signals from the travel motor speeds sensors. sensors. The ECM processes the speed signals and sends the appropriate signals to the right and left pump forward solenoids to precisely control machine ground speed. For FORWARD, FORWARD, the oil flows to the end of both actuator pistons. The magnitude of the Machine ECM signal to the right and left pump forward solenoids determines the signal pressure oil at the actuator piston and how far the actuator pistons move.
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Text Reference
The signal pressure oil at the actuator pistons moves the swashplates to the forward position. As the swashplates move, pump output flow flow increases and is sent to to the drive motors. The oil from the pump also flows to the top of the flushing valve and moves it down. With the flushing valve moved, oil from the low pressure side of the drive motors flows through the flushing valve and the relief valve back to the return manifold. With no restrictions in the drive motor loop, the oil flow causes the drive motors to rotate, and the machine moves FORWARD.
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Text Reference
TWO-SPEED SSL SS L HYDROSTATIC HYDROSTATIC DRIVE SYSTEM RABBIT MODE / FORWARD Two-speed Valve To Drain Manifold
To Pilot Shutoff Solenoid
Travel Motor
Two-speed Selector Spool
Flushing Valve
Flushing Valve
Two-speed Selector Spool
Travel Motor
Park Brake
Park Brake
Left Pump Solenoid Valve
Right Pump Solenoid Valve
Crossover Relief Valve
M
Actuator Piston
Crossover Relief Valve
Pilot On/Off Solenoid
Actuator Piston M
Crossover Relief Valve
Crossover Relief Valve
From Charge Pump
Charge Pressure Relief Valve
Hydrostatic Drive Pump
53
This illustration shows shows the "C" Series SSL machines hydrostatic drive pump and motors with the two-speed option in the Forward/Rabbit Mode position. The two-speed solenoid valve is used to direct charge oil to shift the two-speed selector spool, which controls oil flow from the hydrostatic pump to half of the travel motor pistons. NOTE:
The schematic shows two motor symbols in each motor. motor. Each motor symbol represents half of the pistons in the motor.
The travel motor is a radial-piston type motor. motor. Two sets of passages direct flow to and from the hydrostatic pump to the motor pistons. pistons. On the "C" Series Skid Steer Loaders half of the oil flow passages are blocked. In Turtle Mode, pump operation is identical to the standard hydrostatic drive system and the two-speed travel motor operates the the same as the standard travel motor. motor. The two-speed solenoid is de-energized and oil flows past the two-speed selector spool.
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Text Reference
TWO-SPEED MTL HYDROSTATIC DRIVE SYSTEM RABBIT MODE / FORWARD To Drain Manifold
To Pilot Shutoff Solenoid
Two-speed Valve
Travel Motor
Parking Brake
Parking Brake Flashing Valve
Final Drive
Final Drive
Two-speed Selector Spool
Left Pump Solenoid Valve
Right Pump Solenoid Valve
Pilot On/Off Solenoid
M
Actuator Piston
Crossover Relief Valve
Crossover Relief Valve
Actuator Piston M
Crossover Relief Valve
Crossover Relief Valve
From Charge Pump
Charge Pressure Relief Valve
Hydrostatic Drive Pump
54
To activate Rabbit Mode, the operator must select Rabbit Mode on the multifunction switch located on the left overhead console and then press the left joystick trigger switch on the front of the speed and direction lever. lever. The multifunction switch and trigger trigger switch signal the Machine ECM, which energizes the two-speed solenoid. The two-speed solenoid valve directs charge charge oil to shift the two-speed two-speed selector spool. The two-speed selector spool blocks oil flow from the hydrostatic pump to half of the travel motor oil flow passages.. The travel motor speed increases due to to the decreased displacement of the travel motor. motor. The charge oil keeps the pistons seated, avoiding wear. wear. The default state for the two-speed two-speed travel system is Turtle Mode. The Machine ECM returns the machine to Turtle Mode whenever the machine is is turned off. off. The MTL drive motor is an axial piston motor motor design utilizing a planetary final drive. With the two-speed option enabled, a two-speeed valve shifts a two-speed selector spool which varies the angle of the swashplate, therefore increasing motor speed accordingly.
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Text Reference
ELECTRONIC CONTROL SYSTEM ENGINE UNDERSPEED FUNCTION
Left Forward Pump Solenoid
Engine Speed Sensor
Throttle Position Sensor
Left Reverse Pump Solenoid
Machine ECM ECM
Right Forward Pump Solenoid
Right Reverse Pump Solenoid
54
This illustration shows the components used to control the machine underspeed function. The underspeed function of the Machine ECM senses the increase and decrease in the engine speed caused by the total total load on the machine. The underspeed function distributes distributes the available engine power between the requirements of the hydrostatic drive system and implement hydraulic system. system. When the underspeed function is needed, the Machine ECM will automatically signal the appropriate pump control solenoids to decrease or increase the hydrostatic pump displacement. The Machine ECM uses the engine speed sensor and the throttle lever position sensor to perform the underspeed function. The Machine ECM determines desired engine eng ine speed by reading the signal from the throttle throttle position sensor. sensor. The ECM determines actual engine speed by reading the signal from the engine speed sensor. If the engine speed is too low, the Machine ECM decreases the the hydrostatic pump displacement as necessary to reduce the power demand and keep the engine from stalling.
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Text Reference
When a travel mode is selected and the engine speed is increased, the Machine ECM increases the signal to the pump control solenoid solenoid valves. This action results in higher higher speed once the speed and direction lever is moved. When the machine decelerates, the travel motor speed sensors send a signal to the ECM indicating a decrease in ground speed. The ECM sends a corresponding signal to to de-energize the pump control solenoids. Also, the charge pump sends less less oil flow to the pump control solenoid valves. With a decreased Machine ECM signal to the pump control solenoid solenoid valves and less charge pump oil flow to the solenoid valves, the hydrostatic pump begins to destroke. This action also prevents engine lug.
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Text Reference
9
3
2
7 4 56
1
10
5
5
6
8
1
4
7
10 57
10
5
6
5
Two types of undercarriages are available on the "C" Series Multi-Terrain Multi-Terrain Loaders. The top illustration shows the the Dual Level Suspension (DLS). The bottom illustration shows the Single Level Suspension (SLS). The Dual Level Suspension uses flexible torsional axles with pivoting bogie wheels, which allows each undercarriage roller assembly to flex independently for smoother travel. Each undercarriage assembly consists of a hydrostatic axial piston motor (1) which has the drive sprocket assembly (2) attached attached to it. The sprocket assembly can be removed as a unit to service the roller sleeves or rings (3).
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Text Reference
The hydrostatic motor requires an oil change after the first 250 service hours and every subsequent 500 service hours. The roller frame assembly (4) supports the front and rear idler wheels (5) and the bogie wheels (6). The tensioner (7) allows adjustment adjustment of the track tension. As the hydrostatic piston motor support structure (drive table) (8) rotates, the drive sprocket group rotates engaging the triple row of lugs on the track (9). An extra (third) row of drive lugs and an extra (third) row of rollers has been added to the sprocket assembly on the "C" Series machines. Also, a extra (fourth) row row of bogie wheels has been added to the "C" Series machines Grease fittings (10) (2 front/2 rear) are located on the front and rear torsion axle tubes of the undercarriage. Note:
Grease fittings are located at the front and at the rear of both the DLS and SLS undercarriage. Not all grease grease fittings are are visible in the illustrations.
The undercarriage area is more open which aids cleaning and does not retain dirt and debris
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Text Reference
1
4 3
2
58
The fan (1) and fan motor (2) are located in the rear compartment. The fan provides cooling air for the radiator and hydraulic oil cooler. cooler. The fan motor receives oil flow flow from the charge pump to drive the fan. The "C" Series machines are equipped with a demand fan, which is standard on all machines. Fan speed is controlled by the Machine ECM through through a solenoid (3) on the fan motor. motor. The demand fan solenoid regulates the amount of oil flow supplied to the fan motor and also acts as a relief valve for the fan circuit at high engine speeds. The Machine ECM controls the fan speed based on signals from the coolant temperature sensor and the hydraulic oil temperature sensor. The hydraulic oil sampling port (4) is located on the fan motor.
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Text Reference
DEMAND FAN CIRCUIT To Work Tool Coupler
MAXIMUM FAN SPEED
S O S Tap
To Hydrostatic Drive Pump
Demand Fan Motor Charge Pump
Machine ECM
Hydraulic Oil Temperature Sensor Coolant Temperature Sensor
Demand Fan Solenoid Valve
59
Oil from the charge charge pump flows to the demand fan motor. motor. The demand fan solenoid regulates the amount of oil flow supplied to the fan motor and also acts as a relief valve for the fan circuit at high engine speeds. Oil from the fan motor flows through the hydraulic oil filter filter to the hydrostatic drive pump.. The machine ECM will send a proportional current signal to the solenoid valve to inrease or decrease fan speed based on signals from the hydraulic oil temperature sensor and coolant temperature sensor. sensor. If the machine ECM senses that either of the input signals are absent, it will then close the valve fully, allowing the cooling fan to run at maximum speed.
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Text Reference
WORK TOOL HYDRAULIC SYSTEM
Diverter Valve
Ride Control
Lift
Lift Pilot Solenoids
Work Tool Control Valve
Aux ili ary
Tilt
Aux Pi lot Solenoids
Tilt Pilot Solenoids
Pilot Supply Solenoid Continuous Flow Switch Auxi liar y Hydr auli c Pres sur e Release Sw itc h Hydraulic Lockout Switch Ride Control Switch Aux ili ary 1 Sw itc h Joystick Position Signals and Switches
Machine ECM
Engine
Hydrostatic Drive Pump
Work Tool Pump
Charge Pump
ATAAC Pump
Demand Fan Motor
ATAAC Fan Motor
Hydraulic Oil Filter
60
WORK TOOL TOOL HYDRA HYDRAULIC ULIC SYSTEM
The work tool hydraulic system is now electronically controlled by the Machine ECM through the lift, tilt, and auxiliary auxiliary solenoid valves. The joysticks send a signal to the the ECM when moved by the operator ope rator.. The ECM sends corresponding signals to the solenoid valves, which control the position of the lift, tilt, and auxiliary directional spools. The work tool control valve internal hydraulic components are very similar to the "B" Series machines. A pilot shutoff solenoid solenoid valve replaces the work tool pilot solenoid. solenoid. The electronically controlled auxiliary function is the same as the "B" Series machine. The ride control system is new to the "C" Series machines and operates similar to Caterpillar wheel loaders. The work tool self level option is the same as the "B" Series machines. The XPS High Flow Hydraulic System is now optional on all "C" Series machines.
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Text Reference
1
61
2 62
The hydraulic tank includes a new breather (1) at the top of tank that is serviceable. The tank will have a hydraulic oil level sight glass (2) on the side of tank that is more visible from the right side of the machine.
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Text Reference
4 1 3
2
63
The radiator (1) and hydraulic oil cooler (2) are more accessible in the "C" Series machines because the grill raises to a higher angle than the "B" Series machines. An oil fill access (3) has been added to the oil cooler to allow hydraulic oil to be added to the hydraulic system without having to raise the cab to access the hydraulic tank. Also visible in this illustration is the radiator cap (4).
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Text Reference
1 3 2 64
4
65
5
The top illustration shows the standard work tool gear pump (1) for a machine without the High Flow option. Also shown is the AT ATAAC pump (2) mounted to the charge pump (3). The bottom illustration shows the variable displacement piston pump (4) for machines with the High Flow option. The pumps have not changed but the pump control valve (5) is now located on the bottom of the pump.
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Text Reference
1
2
66
1 2 67
The work tool control valve (1) and diverter (self-leveling) valve (2) are located above the right frame rail. The self-leveling option has the same functionality functionality as the "B" Series machines. A removable panel (not visible) allows easy access to the components located below the right side of the cab. The diverter valve can be easily accessed to allow installation in the field.
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Text Reference
1
12 1 2
2
13 4
3 5 3
6
7
4
8
5
9
9
6
10
10
7
8
11
13
11 14
14
68
These illustrations show the work tool control valve on a High Flow machine in different positions. The top left illustration shows the work tool control valve in the same position as it would be installed above the right frame rail in the machine. The components visible are: - Auxili Auxiliary ary line relief relief valve valve (1)
- Auxil Auxiliary iary return return solenoid valve valve (8)
- Til Tiltt head end line relief relief valve (2)
- Ti Tilt lt back solenoid solenoid valve valve (9)
- Lift line line relief relief valve (3) (3)
- Lower solenoi solenoid d valve (10) (10)
- Auxili Auxiliary ary supply supply solenoid solenoid valve (4)
- C- solenoid solenoid valve valve (11) (11)
- Til Tiltt forward forward solenoid solenoid valve (5)
- Pilot press pressure ure port port (12)
- Raise solenoi solenoid d valve (6) (6)
- Ti Tilt lt rod end line relief relief valve (13) (13)
- C+ solenoid solenoid valve (7)
- Load sense sense relief valve valve (14) (14)
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Text Reference
2
69
1
4
3 70
Travel at high speeds speeds over rough terrain causes work tool movement. The optional Ride Control System acts as a shock absorber by absorbing work tool forces, which stabilize the machine. The new ride control valve (1) is located next to the diverter valve (2) above the right frame rail. The ride control accumulator (3) is located near the bottom of the right frame rail. The accumulator precharge valve (not shown) is is mounted next to the accumulator. accumulator. The ride control valve contains two solenoids (4). The Ride Control System is controlled controlled by the Machine ECM. The Machine ECM receives a signal from the ride control switch to operate the ride control system. The ECM sends a signal to the ride control relay, relay, which energizes the ride control control solenoids. The Ride Control System is speed sensitive. The system activates at 8 km/h (5 (5 mph) and deactivates at 6 km/h (3.7 mph).
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Text Reference
RIDE CONTROL SYSTEM ON
Lift Cylinders
Ride Control Valve To / From Work Tool Lift Valve
Ride Control Accumulator
Accumulator Precharge Valve
Ride Control Relay
Machine ECM
Ride Control Switch
From Charge Pump
71
This illustration shows shows a hydraulic schematic of the Ride Control Control System. With the the Ride Control System ON and the lift control valve in HOLD, oil is blocked at both the rod and head ends of the lift cylinders. When the ride control switch is is activated, a signal is sent sent to the Machine ECM. When the ground speed activation threshhold is reached, the ECM sends a corresponding signal to the ride control relay. relay. The ride control relay energizes the ride control solenoids and the precharge precharge solenoid and oil from the head end of the lift cylinders flows through the left ride control solenoid which connects the head end of the lift cylinders to the ride control accumulator. Oil from the rod end of the lift cylinders is open to the tank through the right ride control solenoid. The accumulator precharge solenoid isolates the accumulator from the charge pump oil. With the Ride Control System OFF, OFF, the ride control solenoids are de-energized. Oil from the rod end of the lift cylinders is blocked from flowing to the tank through the right ride control solenoid. Charge oil flows through through the precharge valve to charge the ride ride control accumulator. accumulator. When the ride control relay is energized by the Machine ECM, the relay sends an override voltage signal to the self-level diverter solenoid regardless of the self-level switch position. The self-level diverter solenoid decouples the lift and tilt cylinders while the Ride Control System is active.
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Text Reference
1 72
3 1
73
2
The implement pilot shutoff valve (1) is located on the right frame rail to the rear of the right travel motor. motor. The pilot shutoff solenoid solenoid (2) blocks oil to the work tool control valve solenoids when the hydraulic lockout switch in the cab is activated. The pilot accumulator (3) provides tilt, dump, and work tool auxiliary lowering capabilities for a limited time after the engine has been shut down.
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Text Reference
74
Cat ToughGuard™ ToughGuard™ hydraulic hoses are used on the "C" Series machines. ToughGuard™ hoses provide abrasion resistance, which exceeds the capabilities of standard hydraulic hoses. The ToughGuard™ hoses include a polyethylene exterior cover, which eliminates the need for nylon, or plastic add-on protection in most applications.
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Text Reference
WORK TOOL HYDRAULIC SYSTEM HOLD Lift Cylinders
Work Tool Valve Group
Diverter Valve
Ride Control Valve
Dump Solenoid Valve
Raise Solenoid Valve
Tilt Cylinders
Line Relief Valves
Auxiliary Tools
Line Relief Valve
Line Relief Valve
Aux Solenoid Valve
Main Relief Valve
Ball Valve (Dead Engine Lower) Ride Control Accumulator
Tilt Control Valve
Lift Control Valve Accumulator Precharge Valve
Rack Back Solenoid Valve
Lower Solenoid Valve
Auxiliary Control Valve
Aux Solenoid Valve
Pilot Supply Solenoid
Cooler Coupler Cylinders Return Manifold
Hydraulic System Filter
Coupler Valve Demand Fan Motor
Hydrostatic Drive Pump Group
Work Tool Pump
Charge Pump
ATAAC Pump
ATAAC Fan Motor
75
This illustration shows the work tool hydraulic system in the HOLD position. The "C" Series machines are equipped with an open-center work tool hydraulic system the same as the "B" Series machines. However, the lift, lift, tilt, and auxiliary functions are now electro-hydraulically controlled, the same as the auxiliary functions were on the "B" Series machines. The work tool hydraulic system consists of a tank, a fixed displacement pump, a control valve group, two lift cylinders, two two tilt cylinders, and an auxiliary work tool. The work tool control valves are in parallel as to pump flow. flow. The work tool hydraulic system shares a hydraulic tank, an oil filter, and an oil cooler with the hydrostatic drive system. The lift, tilt, and auxiliary valve spools are each controlled by two solenoid valves located in the work tool control valve group. The hydrostatic drive system charge charge pump provides pilot oil to the solenoid valves. The charge relief valve in the hydrostatic hydrostatic pump group limits the maximum pilot system pressure. An accumulator provides tilt, dump, and work tool auxiliary lowering capabilities for a limited time after the engine has been shut down.
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Text Reference
The optional automatic level control uses a diverter valve to maintain the work tool in a level position during the raising of the loader load er arms. At machine start-up with the work tool control lever in HOLD, the charge pump sends oil through the fan motor and the oil filter to the hydrostatic drive pump group. From the hydrostatic drive pump group, charge oil is sent to the pilot shutoff valve solenoid and to the lift, tilt, and auxiliary solenoids in the work tool tool control valve group. The energized pilot shutoff valve solenoid enables pilot oil to be available at the work tool solenoid valves. The pilot shutoff valve solenoid and the work tool solenoid valves are energized by the Machine ECM. When the auxiliary thumbswitch on the work tool joystick is activated or the work tool control lever is moved from the HOLD position, a signal is sent sent to the Machine ECM. The Machine ECM sends a corresponding signal to energize a solenoid, which directs pilot oil to the appropriate control valve spool in the control valve group. The more the thumbswitch or work tool control lever is moved, the higher the pilot oil flow that is directed to the work tool control valve spool. The amount of pilot oil to the work tool control valve group determines the distance the spool in the control valve shifts and the amount of hydraulic oil directed to the cylinders from the pump. The tilt circuit is equipped with line relief valves for the rod and head ends of the cylinder. cylinder. The lift circuit is equipped with a line relief valve and a manual lowering valve on the head end of the lift cylinder circuit. The auxiliary circuit is equipped with a line relief valve for the two auxiliary lines. With all the control valve group valves in HOLD (shown), the pump supply oil flows through the center passage of each valve before returning to the tank. When in HOLD, a centering spring keeps the control spool centered. Pump supply oil enters the supply supply passages, flows around the control spool, and flows to the next valve. Supply oil also flows to the the load check valve.
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Text Reference
WORK TOOL HYDRAULIC SYSTEM RAISE Lift Cylinders
Work Tool Valve Group
Diverter Valve
Ride Control Valve
Line Relief Valves
Dump Solenoid Valve
Raise Solenoid Valve
Tilt Cylinders Line Relief Valve
Auxiliary Tools Line Relief Valve
Aux Solenoid Valve
Main Relief Valve
Ball Valve (Dead Engine Lower) Ride Control Accumulator
Tilt Control Valve
Lift Control Valve Accumulator Precharge Valve
Rack Back Solenoid Valve
Lower Solenoid Valve
Auxiliary Control Valve
Aux Solenoid Valve
Pilot Supply Solenoid
Cooler Coupler Cylinders Return Manifold
Hydraulic System Filter
Coupler Valve Demand Fan Motor
Hydrostatic Drive Pump Group
Work Tool Pump
Charge Pump
ATAAC Pump
ATAAC Fan Motor
76
When the operator moves the work tool control lever to the RAISE position, a signal is sent to the Machine ECM. The Machine ECM sends a corresponding signal to energize the raise solenoid valve, which directs pilot oil to the top of the lift valve spool in the control valve group. The lift valve spool is shifted shifted down by pilot oil which blocks the oil flow through the center of the valve to the next valve. The return oil from the rod end flows through an internal passage in the lift control valve spool. The oil flowing through the internal passage is restricted creating pressure which is less than system pressure. After flowing through the internal passage the return oil can become supply oil for the tilt control valve or auxiliary control.
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Text Reference
If the work tool control lever is only partially shifted, some pump supply oil is metered through the center of the lift valve to the next circuit and then to the tank (unless one of the other control valves is fully shifted). If the lift circuit is stalled in either direction, no oil returns from the lift cylinders to become supply oil for the tilt circuit. If the lift control spool is fully shifted, there will also also be no oil metered to the tilt circuit. circuit. The tilt circuit will not function until the pilot valve for for the lift circuit is moved from the fully shifted position. NOTE:
Supply oil to the tilt and auxiliary circuits are shown in pink and red stripes to reflect that the lift control valve is of a series flow design.
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Text Reference
OPTIONAL HIGH FLOW XPS HYDRAULIC SYSTEM HOLD
Tilt Cylinders
Work Tool
Lift Cylinders
Auxiliary Tools
Line Relief Valves Auxiliary Solenoid Valve A2
C+ Solenoid Valve Load Sensing Signal Rail Diverter Valve
Raise Solenoid Valve
Aux Pump Rail
Dump Solenoid Valve
Ride Control Valve
Ride Control Accumulator
Work Compensator Tool
Accumulator Precharge Valve
CSolenoid Valve
Pilot Shutoff Solenoid
Lift
Flow Control Orifice
Lower Solenoid Valve
Tilt Rack Back Solenoid Valve
Aux. Auxiliary Solenoid Valve A1
Cooler
Coupler Cylinders Return Manifold
Coupler Valve
Demand Fan Motor
Hydraulic System Filter
Hydrostatic Drive Pump Group Work Tool Pump
Charge Pump
ATAAC Pump
ATAAC Fan Motor
77
This illustration shows the optional High Flow XPS Hydraulic System. The High Flow XPS system features a load sensing, pressure compensated, variable displacement piston pump and closed-center control valves used in a Proportional Priority Pressure Compensated (PPPC) hydraulic system. The PPPC hydraulic system divides the oil flow between each operating circuit in the system. system. The amount of oil directed to a particular circuit is proportional to the position of the compensator control spool. Because the valves are pressure compensated, cylinder speeds will not change as the load varies as long as the pump can meet system system flow needs. When the flow demands of the system system exceed the total flow available from the pump, the flow is divided proportionally between all activated circuits; however, the work tools will all move slower due to the reduced amount of flow available. The "A1" solenoid and "A2" solenoid provide pilot oil to shift the control spool for the auxiliary functions. These solenoids are proportionally controlled by the Machine ECM.
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Text Reference
The operation of the valve is identical to that of the B Series valve, however the high flow selector switch has been removed. The High Flow operation is now contolled by the presence of a High Flow enabled worktool being detected across pins F and G on the worktool electrical connector. The high flow operation functions similar similar to the "standard flow" circuit, circuit, except that the Machine ECM directs more current to the A1 or A2 solenoid valves, allowing the auxiliary control spool to shift farther farther.. When the thumbswitch is in the High Flow mode (maximum UP or DOWN position), higher current current is sent to the auxiliary auxiliary solenoid. This will allow more hydraulic oil flow to the auxiliary hydraulic circuit. A dual stage load sensing sensing relief valve is used to maintain system system pressure. The system pressure is increased during high flow operation through the "A1" or "A2" solenoid. When only the high flow circuit is active, the Machine ECM will energize the XPS control solenoid for the dual stage load sensing sensing relief valve. The pressure cut-off spool within the Pump Control Valve will now limit the maximum pressure. The "C+" solenoid and "C-" solenoid provide pilot oil to shift the control spool for suppling oil to the secondary auxiliary lines on the work work tool lift arm. The "C+" and "C-" solenoids are ON/OFF and controlled by switches on the work work tool joystick Operation of these circuits will will cause the XPS control solenoid valve to de-energise, (should pins F and G be shorted together) therefore reducing the max max system pressure to the “standard” value. Upon releasing the buttons, the ECM will re-energise the XPS control solenoid valve. NOTE:
Although the outer o uter two envelopes enve lopes on each e ach end of the auxiliary/high flow spool are identical on the schematic, more flow is allowed through the outermost envelopes.
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Text Reference
78
Compactt Track Compac Track Loader Update
The CTL range consists of three machines, the the the 279C, 289C and the 299C. These machines are built on the current MTL chassis and Tier Tier 3 engine configurations, but are equipped with a CAT CA T designed and manufactured suspended CTL style undercarriage. This undercarriage design utilizes a steel embedded MHE style track, a large external drive sprocket, a grease tensioner with Spring recoil system and all steel sprockets, rollers and idlers. The undercarriage is mounted to the chassis by four fully indpendant torsional axles. The machine is two speed as standard, with a max runout speed of 8.5 mph. The drive motors are of a similar similar design to that of the MTL drive motors, both are axial piston piston drive motors, with planetary outboard final drives, for information on the operation of the two speed system, please refer to page 59 for more detailed information.
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Text Reference
3
1
6
4
2 7
5
79
The undercarriage design comprises of the following main components: - Frame assembly (1) - Recoil / grease tensioner and front idler assembly (2) - Drive motor and planetary final drive (3) - Rear idler (4) - Roller wheels (5) - Torsion axles (6) - Track (7) The sprockets, idlers and roller wheels are high strength cast iron, oil filled for life, with duocone metal face seals and machined steel backed bronze bearings. The track has steel steel embeds to provide a metal on metal interface with the drive sprocket. The recoil / tensioner provides for ease of service, undercarriage frontal shock absorbtion and to prevent debris from damaging the track
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Text Reference
80
Tier 3 UPDA UPDATE TE From February 2008, the 3044C DIT Tier 2 engine was replaced by the C3.4 Turbochaged Turbochaged Tier 3 engine, with the horsepower ratings for each machine remaining the same as Tier 2.
The C3.4 Tier 3 engine has been redesigned to include the following features: ..Denso Fuel Injection Pump has been replaced by a Bosch unit. ..Sound suppression material fitted as standard. ..Open Circuit Breather system. The 69kW 272C, 297C and 299C machines have a Boost Control Device (BCD) fitted fitted to the Bosch Fuel Pump, this device limits the free acceleration smoke by limiting the boost pressure, instead of the boost going to maxium, the BCD ramps up the pressure, thus reducing the amount of free acceleration smoke created.
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Text Reference
81
CONCLUSION
This presentation has provided information on the "C" Series Skid Steer Loaders, Multi Terrain Loaders and Compact Terrain Loaders. Key service features, new components, and component locations were identified and discussed. This presentation supports the service manual. For service repairs, repairs, adjustments, and maintenance, always refer to the Operation and Maintenance Manual, Service Manuals, and other related service publications.
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Visual List
VISUAL VIS UAL LIS LIST T
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.. 11 12. 13. 14.. 14 15.. 15 16.. 16 17. 18. 19. 20. 21. 22. 23. 24.. 24 25. 26. 27. 28. 29. 30. 31.. 31 32. 33. 34.. 34 35.. 35 36. 37. 38.. 38 39.. 39 40.. 40 41. 42.
Mod odel el vi view ew Key Ke y new new feat featur ures es Simila Sim ilarit rities ies and and differ difference encess Oper Op erat ator or's 's stat statio ion n Right Ri ght si side de of cab Air cond conditi itioni oning ng duct ducting ing Mechani Mec hanical cal sus suspen pensio sion n seat seat Armres Arm rests ts in down down pos positi ition on Joysti Joy stick ck adju adjustm stment ent leve lever r Right Rig ht joysti joystick ck adjust adjustment ment lever lever Auxili Aux iliary ary funct function ionss - standard standard configuration Auxili Aux iliary ary func functio tions ns - high high flow flow configuration Contro Con troll lever lever patt pattern ernss Fuse Fu se pa pane nell Cab Ca b fres fresh h air fi filt lter er Lift Li ftin ing g hook hookss Govern Gov ernor or cont control rol lev lever er Thrott Thr ottle le posi positio tion n senso sensor r Thrott Thr ottle le posi positio tion n senso sensor r Wind indshi shield eld washe washerr reservo reservoir ir Dead Dea d engi engine ne low lower er knob Doorr unlo Doo unlocki cking ng mech mechanis anism m Doorr removi Doo removing ng proced procedure ure decal decal Left Le ft over overhe head ad cons consol olee Leftt over Lef overhea head d dis displa play y Warning indicat indicators ors illum illuminated inated Heating Heati ng and and air air condit conditioning ioning contro controls ls Creepe Cre eperr cont control rol swi switch tch Right Rig ht over overhead head dis displa play y panel panel Digita Dig itall disp display lay win window dow Oper Op erat ator or mo modes des Displa Dis play y panel panel in ser servic vicee mode mode Select Sel ect key and and scro scroll ll up up key 3044 30 44C C eng engin inee Oill filt Oi filter er Air to to air after aftercooler cooler (A (AT TAAC) Panel Pan el openi opening ng for for clea cleanin ning g Glow Gl ow plug plug indi indica cato tor r Elect El ectri rica call syste system m Mach Ma chin inee EC ECM M Machin Mac hinee ECM input inputss and outp outputs uts Machin Mac hinee stat status us scr screen een
43. 44. 45. 46. 47. 48. 49. 50. 51 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78.. 78 79. 80. 81.. 81
Machinee configu Machin configurat ration ion scre screen en Compone Com ponent nt calibr calibrati ation on using using ET Catt ET Ca ET Win infl flas ash h pro progr gram am Machin Mac hinee ECM inpu inputs ts and and output outputss interlock strategy Hydrost Hydr ostati aticc drive drive sys system tem Leftt side Lef side of hydr hydrost ostati aticc pump pump Right Rig ht side side of hydro hydrosta static tic pump pump Trave Tr avell drive drive motors motors speed speed senso sensor r Hydrost Hydr ostati aticc drive drive sys system tem - Part Part brak brakee applied Hydrost Hydr ostati aticc drive drive system system - Forward Forward SSL hyd hydro ro drive drive sys sys - Rabbi Rabbitt mode/f mode/forw orward ard MTL MT L hy hydr dros os dri drive ve sys systt - Rabb Rabbit it mode/forward Electr Ele ctroni onicc control control system system - engine engine underspeed function Dual Leve Levell Suspens Suspension ion (DL (DLS) S) Single Sin gle Leve Levell Suspens Suspension ion (SLS (SLS)) Fan and fa fan n mot motor or Demand Dem and fan fan circui circuitt - Maximu Maximum m speed speed Work tool tool hydra hydrauli ulicc system system Hydraul Hydr aulic ic tan tank k brea breathe ther r Hydraul Hydr aulic ic oil oil level level sight sight glass glass Radiato Radi atorr and hydra hydrauli ulicc oil cool cooler er Work too tooll gear gear pum pump p Variabl ariablee displace displacement ment pisto piston n pump pump Work tool tool control control valve valve and and diverter diverter valve valve Work tool tool control control valve valve and and diverter diverter valve valve Work tool contr control ol valve valve posit positions ions Ride Ri de con contr trol ol val valve ve Ridee contr Rid control ol accu accumul mulato ator r Ridee contr Rid control ol syst system em - On Implem Imp lement ent pilot pilot shut shutof offf valve valve Pilot Pil ot acc accumul umulato atorr valv valvee Tough oughGua Guard™ rd™ hydra hydrauli ulicc hoses hoses Work tool tool hydrauli hydraulicc system system - Hold Work tool tool hydrauli hydraulicc system system - Raise High Hig h flow flow hydrau hydraulic lic syst system em - Hold Hold CTL CT L Mo Mode dell vi view ew CTL CT L und under erca carr rria iage ge cal calll out out C3.4 C3 .4 eng engin inee vi view ew Conc Co nclu lusi sion on
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Text Reference
HYDRAULIC SCHEMATIC COLOR CODE Black - Mechanical connection . Seal Seal
Red - High pressu re oil
Dark Gray - Cutaway Cutaway secti on
Red/White Red/White Stripes Stripes - 1st pressure reducti reducti on
Light Gray - Surface colo r
Red Crosshatch - 2nd reduction in pressure
White - Atmosph ere or Air (No pr ess ur e)
Pink - 3rd reduction reduction i n pressure
Purple - Pneumatic pressure
Red/Pink Stripes - Secondary source oil pressure
Yellow - Moving or activated components
Orange - Pilot, charge, or Torque Converter oil
Cat Yellow Yellow - (Restr (Restr icted u sage) Identification Identification of components within a moving group
Orange / White White Stri pes Reduced pilot, charge, or TC oil pressure
Brown - Lubricating oil
Orange Crosshatch - 2nd reduction in pilot, charge, or TC oil pressure.
Green Green - Tank, sump, or r eturn oi l
Blue - Trapped oil
Green Green / White Stri pes Scavenge Oil or Hydraulic Void
HYDRAULIC SCHEMATIC SCHEMATIC COLOR CODE
This illustration identifies the meanings of the colors used in the hydraulic schematics and cross-sectional views shown throughout this presentation.
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E D O C R O L O C C I T A M E H C S C I L U A R D Y H
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l i o e r u s s e r p h g i H d e R
l a e S . n o i t c e n n o c l a c i n a h c e M k c a l B
n o i t c u d e r e r u s s e r p t s 1 s e p i r t S e t i h W / d e R
n o i t c e s y a w a t u C y a r G k r a D
e r u s s e r p n i n o i t c u d e r d n 2 h c t a h s s o r C d e R
r o l o c e c a f r u S y a r G t h g i L
e r u s s e r p n i n o i t c u d e r d r 3 k n i P
) e r r u o s e s r e e r h p p o s N o ( r m t i A A e t i h W
Handout No. 1
e r u s s e r p l i o e c r u o s y r a d n o c e S s e p i r t S k n i P / d e R
l i o r e t r e v n o C e u q r o T r o , e g r a h c , t o l i P e g n a r O
e r u s s e r p l i o C T r - o , s e e g p r i r a t h S c e , t i t o h l i W p / d e e c g u n d a e r O R
n i n o i . t e c r u u d s e s r e d r n p 2 l - i o h C c T t a r h o s , s e o g r r C a e h g c , n t a o r l i O p
l i o d e p p a r T e u l B
e r u s s e r p c i t a m u e n P e l p r u P
s t n e n o p m o c d e t a v i t c a r o g n i v o M w o l l e Y
s t n e n o p p u m r o ) o e c g g f g a n s o i u n v o o l i d t e a m i o t c a c i g i r f i n n t t i t i s n h a e e t i i c d R ( I w r b u w L o l l n e Y w t o r a B C
l i o n r u t e r r o , p m u s , k n a T n e e r G
d i o V c i l - u a s r e d p y i r t H S r o e l i t i h O W e / g n n e e v e a r c G S
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Handout No. 2
Machine Walk-around Checklist Directions: Use this sheet when performing a machine orientation lab exercise.
Place a check in the blank after locating each of the following controls: Key start switch Armrests Governor lever Accelerator pedal Left joystick Horn Continuous flow switch Auxiliary electrical controls (C1/C2, if equipped) Auxiliary electrical control for pin "B" on loader arm (if equipped) Two-speed switch Multifunction switch Right joystick Thumbswitch for A1/A2 auxiliary control Secondary auxiliary control switches (C+/C-, if equipped) Park brake switch Creeper switch Ride control switch (if equipped) Pattern changer switch (if equipped) HVAC controls (if equipped) Dead engine lower knob Place a check in the blank if the fluid level is acceptable: Engine oil level Hydraulic system oil level Cooling system fluid level Fuel level
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Handout No. 3
Machine Walk-around Checklist (continued) Place a check in the blank after locating each of the following components: Cab hold-down bolts Fuse panel Cab recirculation filter Cab fresh air filter Hydraulic oil filter Engine oil fill cap Engine oil filter Fuel filter and water separator Air filter indicator Fuel tank and filler cap Engine jump start receptacle Battery Machine ECM Power relay modules ATAAC housing and ATAAC motor (if equipped) Hydraulic fill cap (top off)
Place a check in the blank after locating each of the following gauges and indicators: Fuel level gauge Service hour meter Coolant temperature gauge (if equipped) Hydraulic oil temperature gauge Digital display window (if equipped)
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Handout No. 4
Left Overhead Overhead Display Display - Indic Indicator ator Iden Identifica tification tion
List the name of each indicator shown above: 1) ____________________
9) ____________________
2) ____________________
10) ____________________
3) ____________________
11) ____________________ (if equipped)
4) ____________________
12) ____________________ (if equipped)
5) ____________________ (if equipped)
13) ____________________
6) ____________________
14) ____________________ (if equipped)
7) ____________________
15) ____________________ (if equipped)
8) ____________________
16) ____________________ (if equipped)
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Handout No. 5
Optional AMICS AMICS Display - Mode Identification Display each operator mode and service mode on the digital display window. window. Describe the function of each mode. Operato Oper atorr Mod Modes es
Mode 1: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 2: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 3: ______________________________________________________________ Service Modes
Mode 0: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 1: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 2: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 3: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 4: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 5: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 6: ___________________________ _______________________________________________________ ___________________________________ _______ Mode 7: ___________________________ _______________________________________________________ ___________________________________ _______
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Machine Systems Component Identification Place a check in the blank after locating each of the following components: ATAAC pump ATAAC motor Charge pump Work tool pump Hydrostatic drive pump Hydrostatic drive pump control solenoids Pilot ON/OFF solenoid valve Two-sp wo-speed eed solenoid valve (if equipped) Travel motor speed sensors Engine speed sensor Throttle lever position sensor Pilot shutoff valve solenoid and accumulator Diverter valve Work tool control valve Load sense relief valve (High Flow System, if equipped) Ride control valve (if equipped) Ride control accumulator (if equipped) Work tool coupler solenoid valve Oil cooler Hydraulic oil tank breather
Handout No. 6
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- 94 l o p o T u o k r r o G W e v l m a o r V F
Handout No. 7
m e t s y r S e t c i i l l u F a r d y H
E
D C e v l l m o a o V o r T r F k e / r l o o p T W u o C l d n r f o u i t n e a R M
E l p o u o T o r k r G o e v l W o a T V
l e v a l u a n V a g M n i r m e o r w o F L
F G
J f f o t u h i d S o t n o e l i l P o S m o r F
r o t o M l e v a r T
A
I
H
K
B
L
f f d O i / n o n O e t l o o l S i P
f f o t u d h i S o n t l o e l i o P S o T r o t o M l e v a r T
A
B I
M
H
M
m e t s y S e v i r D c i t a t s o r d y H
o t t x e n s k n a l b e h t n i l l i F
: s n o i t c e r i D
A
B
C
D
E
F
G
H
I
J
K
L
M
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E C
D
B
H I
Handout No. 8
F
m e t s y r S e t c i i l l F u a r d y H
G
r o t o M n a F d n a m e D
r e l o o C
A
J K
L
s r e d n i l y C r e l p u o C
M
. m r e t t c e r r o c e h t h t i w s r e t t e l e h t o t t x e n s k n a l b e h t n i l l i F
m e t s y S c i l u a r d y H l o : o s n T i o t k r c e o i r W D
C
D
E
p u o r G p m u P e v i r D c i t a t s o r d y H
P
O
B
Q
d l n r f o u i t n e a R M
N
A
r e e l v p l u a o V C
F
G
H
I
J
K
L
M
N
O
P
Q
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Posttest
Posttest 1. The left left and and right right joysti joysticks: cks: A. B. C. D.
are not are not ad adju just stab able le move mo ve only only wit with h the the seat seat adju adjust stme ment nt are adju adjusta stable ble indep independe endentl ntly y from from the the seat seat are adjus adjusted ted using using a pushb pushbutt utton on below below the the joystic joystick k
2. Which of the following following filters filters has been relocated relocated on the "C" Series machines? machines? A. B. C. D.
Engine Engi ne ai air fil filtter Reci Re circ rcul ulat atio ion n filt filter er Fres Fr esh h ai air fil filte ter r None No ne of th thee abo above ve
3. The optional digital digital display panel includes a digital display window and which of the following gauges? A. B. C. D.
Hydraul Hydr aulic ic oil oil tempe tempera ratu ture re gauge gauge Coola Coo lant nt te temp mper erat atur uree gau gauge ge Engin Eng inee oi oill pr pres essu sure re ga gauge uge Both A and B
4. How many operator operator modes modes are available available on the digital digital display? display? A. B. C. D.
1 2 3 4
5. The ATAAC fan is hydraulically driven by the: A. B. C. D.
ATAAC pu pump hydr hy dros osta tati ticc driv drivee pump pump charge pump work to tool pu pump
6. Which of the following switches is an input to to the Machine ECM for the interlock interlock control? A. B. C. D.
Seat sw switch Armr Ar mres estt swi witc tch h Door switch Alll of the ab Al abov ovee
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Posttest
7. Which of the following following components components has been eliminated eliminated from from the hydrostatic hydrostatic drive system on the "C" Series machines? A. B. C. D.
Motorr flu Moto flush shin ing g valv valvee Spee Sp eed d se sens nsin ing g va valv lvee Char Ch arge ge re reli lief ef va valv lvee Cros Cr osso sover ver re reli lief ef val valve ve
8. The functions of the travel pilot valve solenoid and the pilot on/off solenoid are now controlled by the: A. B. C. D.
pump con pump contr trol ol sol solen enoi oid d trave tr avell pil pilot ot va valv lvee sol solen enoi oid d pilo pi lott shut shutof offf sole soleno noid id park pa rk br brak akee sol solen enoi oid d
9. The tilt tilt and lift functio functions ns are controlle controlled d by the: A. B. C. D.
Machine EC ECM work wo rk to tool ol pi pilo lott val valve vess work to tool re relay mech me chan anic ical al li link nkag agee
10. Which of the following following components components is new to the work tool hydraulic hydraulic system? system? A. B. C. D.
Wor ork k too tooll pil pilot ot val valve vess Auxi Au xili liar ary y so sole lenoi noid d va valv lvee Pilo Pi lott shu shuto tofff val valve ve Flow Fl ow con contr trol ol or orif ific icee
SERV1833-01
Posttes Pos ttestt Answer Answer Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
C B D C A D B D A C
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Posttest Answers
