GLOBAL SERVICE LEARNING STUDENT MATERIALS MATERIALS
PART OF GLOBAL SERVICE LEARNING MODULE SERV1845-01
D11T D11T TRACK-TYPE TRACK-TY PE TRACTOR WORKSHEETS WITH POSTTESTS
SERV1845-01 05/08
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Student Handout No. 1 Laboratory Exercise
Lab A: Engine System Components Identification Directions: Use this sheet to take notes during the presentation. During the lab exercise, use this sheet as a checklist when locating and identifying the components. Engine Components
____ Primary and Secondary fuel filters
____ Alternator
____ Electric fuel priming pump and switch
____ Ether injection control solenoid
____ Fuel transfer pump
____ Intake manifold air pressure sensors (2)
____ Engine oil fill tube and dipstick
____ Atmospheric air pressure sensor
____ Engine oil filters
____ Intake manifold air temperature sensor
____ Engine oil S•O•S test port
____ Fuel temperature sensor
____ Engine oil pressure test port
____ Fuel pressure sensor
____ Engine oil pressure sensor
____ Fuel filter differential pressure switch
____ Engine pre-lube motor and pump
____ Turbo inlet pressure sensor
____ Air filters
____ "Crank-without-Inject" connector/plug
____ Turbochargers
____ Primary (crank) speed/timing sensor
____ Main electrical disconnect switch
____ Secondary (cam) speed/timing sensor
____ Starter Disconnect switch
____ Starter
____ A4 Engine ECM
____ Auxiliary start receptacle ____ ORS metering valve ____ ORS make-up tank ____ ORS make-up tank level sensor
SERV1845-01 05/08
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Student Handout No. 2 Posttest
ENGINE SYSTEM POSTTEST
Using any of the provided classroom materials, demonstrate your knowledge of the various machine systems by circling the BEST ANSWER for each of following questions.
1. The atmospheric pressure sensor is used: A. to calculate boost pressure and air filter restriction B. to determine ambient air pressure and as a reference for all other engine pressure sensors C. to calculate gauge pressure for engine oil and fuel D. all of the above answers (A, B, and C) E. answers A and C 2. The intake manifold air pressure sensor is used to: A. calculate boost pressure B. determine air filter restriction C. determine ATAAC restriction D. all of the above 3. The turbo inlet air pressure sensor is used to: A. calculate boost pressure B. determine air filter restriction C. determine turbocharger failure D. answers A and B 4. The fuel transfer pump: A. draws fuel from the secondary fuel filter B. draws fuel from the primary fuel filter C. maintains fuel system pressure D. provides fuel flow through the entire fuel system E. answers A, C, and D F. answers B and D 5. The fuel pressure regulator: A. maintains fuel system pressure B. is positioned between the fuel injectors and the fuel tank C. is positioned between the fuel injectors and the fuel transfer pump D. answers A and B E. answers A and C 6. The primary (crank) speed/timing sensor: A. provides engine speed information to the Engine ECM B. provides engine speed information to the Power Train ECM C. is used to calculate the AutoShift mode strategy D. all of the above answers (A, B, and C) E. answers A and B
SERV1845-01 05/08
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Student Handout No. 3 Laboratory Exercise
Lab B: Cooling System and Demand Fan System Components Identification Directions: Use this sheet to take notes during the presentation. During a lab exercise, use this sheet as a checklist when locating and identifying the components. Cooling System Components
Demand Fan System Components
____ Engine oil cooler
____ Main hydraulic demand fan pump
____ Power train oil coolers
____ Supplemental hydraulic demand fan pump
____ Engine jacket water pump ____ AMOCS radiator cores ____ Water temperature regulator housing ____ Coolant shunt tank
____ Fan pump control valve ____ Fan pump pressure control solenoid ____ Fan pump discharge pressure sensor
____ Coolant fill tube and cap
____ Hydraulic Fan Pump Discharge pressure test port (HDFP)
____ Coolant level sight glass
____ Fan motor
____ Cooling system drain valve
____ Fan return filter
____ ATAAC cores
____ Fan return filter bypass switch
____ Hydraulic Pilot Pump Discharge pressure test port (HFPD) ____ Coolant temperature sensor ____ Coolant flow switch ____ AMOCS radiator and shunt tank ____ Engine coolant S•O•S test port ____ Temperature regulator housing
SERV1845-01 05/08
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Student Handout No. 4 Posttest
DEMAND FAN SYSTEM POSTTEST
Using any of the provided classroom materials, demonstrate your knowledge of the various machine systems by circling the BEST ANSWER for each of following questions.
1. The sensors (inputs) used to control the hydraulic demand fan are: A. intake manifold air temperature, coolant temperature, and fan pump discharge pressure B. intake air temperature and fan pump discharge pressure C. coolant temperature and fan pump discharge pressure D. hydraulic oil temperature, intake air temperature, coolant temperature, and fan pump discharge pressure 2. When controlling the hydraulic demand fan, the Engine ECM: A. sends maximum current to the fan pump control solenoid to produce minimum speed B. sends minimum current to the fan pump control solenoid to produce maximum speed C. sends maximum current to the fan pump control solenoid to produce maximum speed D. sends minimum current to the fan pump control solenoid to produce minimum speed E. answers A and B F. answers C and D 3. The hydraulic demand fan may be shut OFF by: A. disconnecting the fan pump control solenoid B. using the Cat Advisor Configuration screen to turn fan control OFF C. using the Cat ET Configuration screen to turn fan control OFF D. answers B and C E. answers A and C F. none of the above 4. Maximum fan speed (high pressure cutoff) can be attained by: A. disconnecting the fan pump control solenoid B. using the Cat Advisor Configuration screen to turn fan control OFF C. using the Cat ET Configuration screen to turn fan control OFF D. answers A and B E. answers A and C F. none of the above
SERV1845-01 05/08
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Student Handout No. 5 Laboratory Exercise
Lab C: Power Train Components Identification Directions: Use this sheet to take notes during the presentation. During a lab exercise, use this sheet as a checklist when locating and identifying the components. Power Train Components
Power Train Pressure Test Ports
____ Power Train ECM
____ Torque converter outlet relief pressure test port (N)
____ Power train oil pump ____ Power train system lube pressure (L1) ____ Power train oil fill tube and dipstick ____ Lube distribution manifold pressure (L2) ____ Power train lube distribution manifold ____ Torque converter scavenge screen ____ Torque converter outlet relief valve
____ Torque converter inlet relief (supply) pressure test port (M) ____ Transmission charge pump pressure test port (TP)
____ Torque converter temp. sensor ____ Power train oil S•O•S port ____ Power train oil coolers ____ Transmission charging filter
____ Brake and steering clutch pressure test ports (B1/B2/C1/C2)
____ Torque converter charging filter
____ Torque converter filter S•O•S port
____ Transmission system temp. plug
____ Transmission filter S•O•S port
____ Transmission oil filter bypass switch
____ Transmission speed clutch pressure test port (P1)
Using any of the provided classroom materials, demonstrate your knowledge of the various machine systems by circling the BEST ANSWER for each of following questions. 1. The Torque Converter Inlet Relief Valve: A. limits the maximum oil pressure to the torque converter B. limits the maximum oil pressure in the torque converter C. protects the components in the torque converter when the oil is cold D. answers A and C E. answers B and C 2. The Power Train Priority Valve ensures that: A. the power train lube manifold receives supply oil before the steering clutch and brake control valve B. the transmission control receives supply oil before the steering clutch and brake control valve control valve C. the steering clutch and brake control valve receives supply oil before the transmission control valve 3. Which components of the transmission control valve work together to control the clutch engagement time and to limit the maximum clutch pressure: A. the load piston and speed selector spool B. the ratio valve and load piston C. the solenoid valve and the modulating valve D. the modulating valve and load piston 4. The steering clutches are: A. spring applied and hydraulically released B. hydraulically applied and spring released C. hydraulically applied and hydraulically released 5. The brakes are: A. spring applied and hydraulically released B. hydraulically applied and spring released C. hydraulically applied and hydraulically released 6. When the service brakes are FULLY APPLIED (ENGAGED) using the service brake pedal: A. the proportional brake valve solenoids are DE-ENERGIZED and the secondary brake valve solenoid is ENERGIZED B. the proportional brake valve solenoids are ENERGIZED and the secondary brake valve solenoid is DE-ENERGIZED C. the proportional brake valve solenoids are DE-ENERGIZED and the secondary brake valve solenoid is DE-ENERGIZED D. the proportional brake valve solenoids are ENERGIZED and the secondary brake valve solenoid is ENERGIZED E. none of the above answers
Lab D: Hydraulic System Components Identification Directions: Use this sheet to take notes during the presentation. During a lab exercise, use this sheet as a checklist when locating and identifying the components. Implement Hydraulic Components
Implement Hydraulic Pressure Test Ports
____ Hydraulic oil tank
____ Lift pump pressure test port (HPD1)
____ Hydraulic oil fill tube and sight glass
____ Tilt pump pressure test port (HPD2)
____ Lift/tilt implement pumps
____ Hydraulic Pilot Pump Discharge pressure test port (HFPD)
____ Pressure reducing manifold ____ EH pilot manifold
____ Pilot pressure test ports (9 ports, at EH pilot manifold)
____ Implement lockout solenoid valve
____ Pilot oil S•O•S (fluid sampling) port
____ "Dead Electric" lower valve
____ Hydraulic Pilot Supply pressure test port (HPS)
____ Pilot oil filter ____ Resolver valve group ____ Dozer control valve ____ Ripper pin puller valve ( if equipped) ____ Ripper control valve ____ Pitch regenerate valve (Carrydozer only) ____ Lift pump pressure sensor ____ Tilt pump pressure sensor ____ Quick-drop valves
____ Dynamic inclination sensor (If equipped with AutoCarry) ____ Ground speed radar ( If equipped with AutoCarry)
____ Diverter valve ( If equipped with AutoCarry) ____ Lift cylinder position sensor ( If equipped with AutoCarry or on a Carrydozer)
____ Hydraulic oil temperature sensor ____ Ladder Ready control valve ( If equipped) ____ Case drain return filter ____ Case drain return filter bypass switch ____ Main pump return filter
Using any of the provided classroom materials, demonstrate your knowledge of the implement system by entering the letter of the BEST ANSWER for each of the implement system components listed at the left.
Hydraulic oil tank Implement pump Pressure reducing manifold Implement lockout solenoid valve Pilot oil filter Dozer and ripper control valves Lift dump valve Tilt dump valve Shuttle valve
A. Direct the flow of high pressure pump supply oil to the implement cylinders. B. Ensures that clean oil is delivered to the solenoid controlled pilot valves. C. Opens to bypass the cooler when the hydraulic oil is cold and closes when the hydraulic oil is warm to direct oil through the cooler. D. Provides oil flow through the entire hydraulic system for the operation of the implements. E. ENERGIZED by the Implement ECM to direct pilot pressure oil to move an implement control valve spool. F. Receives signals from implement control lever sensors and sends corresponding currents to the appropriate solenoid controlled pilot valves.
Solenoid controlled pilot valve
G. Blocks the flow of pilot pressure oil to the EH pilot manifold when DE-ENERGIZED.
Quick-drop valve Implement ECM
H. Directs rod-end oil from the blade lift cylinders into the head-ends when the blade falls rapidly to the ground.
Resolver valve group
I.
Hydraulic oil cooler bypass valve
J. Is closed by high pressure supply oil to shut off oil flow to tank when a blade lift or a ripper function is active.
Serves as a reservoir for the hydraulic oil.
K. Contains the pressure reducing valve and the Dead Electric Lower valve. L. Directs high pressure supply oil to the lift dump valve and the lift relief valve when a blade lift function is active. M. Is closed by high pressure supply oil to shut off oil flow to tank when a blade tilt function is active. N. Supplies pilot oil to the pressure reducing valve for lowering the implements with the implement controls during a dead engine situation
