Service Training

STUDENT
QUIZZES

"D" SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS

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Student Materials

Quiz: Machine Orientation

NOTE: Use the provided sales information brochures (specalogs) to answer the following
questions.
I. Directions Modified True / False: If question is false circle word or word that makes statement
incorrect and replace with word(s) to make statement correct.
1. All D Series Backhoes are equipped with turbocharged engines.
2. The standard transmission used in D Series Backhoes features four speeds forward and four
speeds reverse.
3. The 420D, 430D, 432D and 442D are equipped with pilot controls for the backhoe valve
group.
4. The IT front loader is standard on the 416D and 424D backhoe loaders.
5. The All Wheel Drive (AWD) front axle is equipped with brakes.
6. The D Series Backhoes use a hydraulic brake system.
7. The D Series Backhoes feature dry-type, radial seal air filters.
8. The hydraulic system uses a fixed displacement pump with open center control valves.
9. All Wheel Steer provides three modes of operation.
10. Auto-up is an option on the 428D and 438D backhoes to raise the stabilizers.
11. The 430D operates at a higher system pressure than the 416D and 424D.
12. The speed selector is on the steering column on the standard transmission.
13. The implement hydraulic pump is rated at 162 lpm (43 gpm) on the 420D and 430D.
14. On machines equipped with RIDE CONTROL and the autoshift transmission, the Ride
Control switch has two positions.
15. The Auxililary Control ECM is used with all machines equipped with IT or parallel lift
linkage.

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Student Materials

Quiz: D Backhoe Engine and Fuel System

I. Directions: Match the component to its primary function.
1. Used to remove water from the fuel.

Radiator cap

2. Controls the fuel pressure in the fuel

injection pump.

Oil pressure switch

Water separator

3. Prevents filter damage during cold startups.

High idle stop

4. Also called a "wax" motor

Automatic advance mechanism

5. Limits maximum engine rpm.

Thermostat

6. Indicates engine oil level.

Engine oil dipstick

7. Provides engine "boost".

Turbocharger

8. Indicates a plugged air filter

Air filter indicator

9. Triggers an alarm if engine oil pressure is

low.

Fuel regulator valve

Cold start advance solenoid

Starter

Filter bypass valve

10. When it opens, it send coolant to the radiator

top tank.
11. Prevents late fuel injection timing.
12. Used to crank the engine.
13. Controls the pressure at which the cooling
system operates.

II. Directions Modified True / False: If question is false circle word or word that makes statement
incorrect and replace with word(s) to make statement correct.
1. A start aid coil (thermal starting aid/air inlet heater)is used instead of ether for cold weather
starting.
2. The Fuel Shut-off Solenoid on the D Series turns the fuel supply to the internal transfer
pump on or off.
3. A cold start advance solenoid is used to reduce white smoke at startup.
4. Kerosene in the diesel fuel will not effect torque converter stall rpm.
5. The turbocharged engine also requires an engine oil cooler.
6. With the thermostat working correctly and the machine warmed up, the temperature in the
bottom tank of the radiator should be higher than in the top tank.

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Student Materials

Quiz: Electrical System

Directions Electrical Schematic Interpretation: Using RENR3587 electrical schematic for a 416D442D Backhoe Loader, answer the following questions. RENR2869 "Power Train Electronic Control
System" is required for question 9.
1. List the schematic grid locations and the machine silhouette number or letter for the transmission
neutralizer switch.
grid location

machine location (silhouette)

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

machine location (silhouette)

3. What is the part number for both switches?

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

machine location (silhouette)

part number

5. The 3E3382 connector at schematic coordinates F-4 which is part of the front dash control is a:
a. plug
b. receptacle
c. none of the above
6. Tthe above part of the connector has:
a. pins only
b. sockets only
c. a combination of pins and sockets
d. none of the above
7. What does 308 CR6 YL-18 mean?
a. A 22 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 6 wire of
harness 167-3702.
b. A 18 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 308 wire
of harness 183-4492.
c. A 18 gauge yellow wire used for the Key Switch Run circuit. The wire is the number 6 wire of
harness 167-3702.

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Student Materials

8. For the fuse/relay block diagram at coordinates A4-A5 what is "K13"?

a. Part number

b. Description

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

b. CID-FMI

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

11. The starter is grounded by:
a. an internal electrical connection to the surface of the component
b. having an external wire connected to vehicle structure
12. What two harnesses connect at CONN 46?
Letters:

Part No.:

Description:

Letters:

Part No.:

Description:

13. What is the part number of the receptacle and the plug for CONN 46?
receptacle
plug
14. What does MP-C4 represent for CONN 46?
a. Connector number 4 of the 179-9336 harness assembly
b. Connector number 4 of the 179-7998 harness assembly
c. C4 of the 179-9336 harness assembly
d. none of the above
14. What does MOM represent on the Dead Engine Lower Switch?

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Student Materials

Quiz: Electrical System

Directions Starting System: Answer the following questions. Either circle the correct response or fill
in the blanks. You may use your notes and reference materials.
START
RELAY

TP1

TP2

START
SWITCH
R
C
S
B

OFF
ON
ST

TP3

TP4

TP7

TP6

STARTER
MOTOR

TP10

POS NEG

POS NEG

TP5

BATTERIES

1. When checking the battery voltage at TP10 and TP7, an acceptable reading for a good battery is:
a) 12.0 volts or above
b) 12.4 volts or above
c) 24 volts or above
d) 24.8 volts or above
2. When cranking, what is the maximum allowable voltage drop checked from TP10 to TP6:
a) .3 volt
b) .5 volt
c) 12.4 volts or above
d) none of the above
3. With the key start switch in the RUN position what is the maximum voltage drop from TP6 to TP4?
a) .4 volt
b) .8 volt
c) 12.4 volts or above
d) none of the above

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Student Materials

Quiz: Transmission
I. Directions Modified True / False: If question is false, underline or circle the words or word that
make the statement incorrect and replace with word(s) to make statement correct.
1. On the standard transmission, the control valve is used to control direction and speed.
2. If the FORWARD clutch pressure is within specification and the REVERSE clutch
pressure is too low and not within specification, check the relief valve spring.
3. The torque converter inlet relief valve controls the maximum oil pressure to the torque
converter.
4. The autoshift transmission provides automatic shifting between 4th and 5th gear
FORWARD in the Manual Mode.
5. The standard transmission requires the use of ET for troubleshooting.

V. Directions: Circle the correct response.

5
C

F
D

7
AWD

1
B

G
A

TRANSMISSION
LUBE

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1. At pressure tap "3,"

A.
B.
C.
D.
F.
E.

Student Materials

can be checked.

Torque converter outlet pressure

Lube pressure
REVERSE clutch pressure
FORWARD clutch pressure
Pump supply pressure
Torque converter inlet pressure

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

1
2
3
4
5
6
3. At pressure tap "1,"

can be checked.

A.
B.
C.
D.
E.

Torque converter inlet pressure

Speed clutch pressure
Directional clutch pressure
Pump supply pressure
Lube pressure

F.

None of the above

4. Pressure tap "4" is used to check

A.
B.
C.
B.
D.

Torque converter outlet pressure.

Lube pressure.
Torque converter inlet pressure.
Directional clutch pressure
None of the above.

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

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Student Materials

BACKHOE LOADER AUTOSHIFT TRANSMISSION QUIZ

Directions: Answer the questions below with the best possible answer.
1. The only difference between an Autoshift transmission and the standard powershift transmission
is?
a. The number of gears.
b. The number of solenoids.
c. The clutch pressures.
d. The ECM programming.
2. Which solenoids are energized for the following conditions:
a. Machine running in SECOND FORWARD:
b. Machine running in THIRD REVERSE:
c. Machine running in FIFTH FORWARD:
d. Machine running in FIRST REVERSE:
e. Machine running in SECOND REVERSE with neutralizer switch held down:
f. Machine running in SECOND FORWARD, FIRST gear disabled, downshift switch pressed:

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

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

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Student Materials

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

7. With the Ride Control Switch in the automatic mode, the autoshift transmission ECM activates the
Ride Control.
a. True
a. False
8. What happens to the autoshift transmission if the speed sensor fails?
a. Returns to the machine to neutral
b. Downshifts over a period of time to FIRST gear.
c. Switches to MANUAL mode.
d. Leaves pieces of broken transmission on ground.

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Student Materials

Quiz: Axle and Brakes

I. Directions: Match the component to its primary function.
1. Can convert high RPM and low torque to low RPM
and high torque mechanically.
2. Can convert high RPM and low torque to low RPM
and high torque hydraulically.

A Brakes
B Inboard planetaries
C Front wheel drive clutch

3. Transfers power from the transmission to the front

axle.

D Differential lock

4. Causes both axles to rotate at the same rpm when

engaged

E Torque converter

5. Can be engaged independently for sharper turns

F Compensation valve

6. Permits pressure between the master cylinders to

equalize

II. Modified True / False. If question is false circle word or word that makes statement incorrect and
replace with word(s) to make statement correct.
1. D Series brakes are mechanically engaged.
2. D Series rear axles have brake inspection ports.
3. D Series brakes require pull rod (actuator rod) adjustments.
4. D Series feature a hydraulic brake reservoir.
5. D Series feature a mechanical drive line parking brake.

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Student Materials

Quiz: Implement Hydraulic System

I. Directions: Match the component to its primary function.
1. Reduces pump flow to prevent the engine
from stopping

Makeup valve

Pressure cut-off valve

Pressure reducing valve

Secondary resolver

Swashplate

Bias piston

6. Opens when cylinder pressures go too high.

Flow compensator/margin spool

7. Depending on its angle, the pump will

increase or decrease flow.

Line relief valve

Primary resolver

Torque limiter

Backflow check valve

2. Blocks return oil to help reduce cylinder

cavitation.
3. Senses the head end or rod end cylinder
pressure.
4. Compares the signal pressures between valve
bodies.
5. Opens when the cylinder is voiding.

8. Acts as the main relief.

9. Helps control the swashplate.
10. Compares the highest cylinder pressure to
pump output pressure.

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Student Materials

II. Directions: The following are true or false. Enter T for true and F for false. If false, circle the
word or words that make the statement false and replace with a word or words that make the statement
correct.
1. The difference in pressure between pump supply pressure and signal pressure is called
margin pressure.
2. Margin Pressure is usually higher than Low Pressure Standby.
3. On "D" Series machines maximum system pressure is checked at the signal pressure tap.
4. To check low pressure standby the engine should be at low idle.
5. With dynamic bleed steering, if pressure is checked at the signal line tap, the gage should
read 0 kPa (0 psi).
6. All implement control valves with a pressure reducing valve in them limit the pressure
drop across the directional control spool to the value of the pressure reducing valve
spring.
7. If margin pressure is 2280 kPa (330 psi) and the implement sends a signal of 6900 kPa
(1000 psi) the pressure reading on the pump supply pressure tap should be 9180 kPa
(1330 psi).
8. When operating 2 implements at the same time, the implement with the higher work port
pressure will have its flow needs met first if the pump cannot meet total system flow
needs
9. If margin pressure is set too low machine cycle times will be slower.
10. The steering circuit has flow priority over the loader lift circuit.
11. The torque limiter requires two separate pressure adjustments in order to provide the dual
settings.

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Student Materials

III. Multiple choice. Select the best answer.

1. If the pump is at Low Pressure Standby:
a. There is a dynamic bleed signal being sent from the implements.
b. The pump will signal itself by way of the signal network.
c. There is no signal being sent from the implements.
d. None of the above
2. Adjusting the flow compensator screw effects:
a. Margin pressure and maximum system pressure.
b. Margin pressure and low pressure standby.
c. Margin pressure only.
d. None of the above
3. Adjusting the pressure cut-off screw will effect:
a. Maximum system pressure.
b. Low pressure standby.
c. Margin pressure.
d. None of the above
4. The variable displacement pump in a backhoe will upstroke (Note: Treat engine speed as remaining
constant):
a. If there is an increase in work port pressure but the flow requirements do not change.
b. If the flow requirements increase but the highest work port pressure decreases.
c. If the flow requirements do not change and the work port pressure stays the same.
d. None of the above
5. While an implement is activated and the operator maintains a constant lever displacement, a drop in
engine RPM will cause the pump:
a. To Upstroke
b. To Destroke
c. To remain unchanged
d. None of the above

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6. If no implements are being operated the pump is at:

a. High Pressure Stall and minimum flow.
b. Low Pressure Standby and minimum flow.
c. High Pressure Stall and maximum flow.
d. Low Pressure Standby and maximum flow.
e. None of the above
7. If the operator stalls one circuit and then operates another implement:
a. The pump will destroke to decrease flow.
b. Flow remains the same.
c. The pump will go to Low Pressure Standby.
d. The pump will upstroke to increase flow.
e. None of the above
8. If the operator maintains a fixed lever position and the engine rpm are increased:
a. The pump will upstroke to maintain flow.
b. The pump will destroke to maintain flow.
c. The pump swashplate angle remains unchanged.
e. None of the above
9. If the torque limiter spring setting is increased from the present setting:
a. The pump will upstroke sooner
b. The pump will upstroke later
c. The pump will destroke sooner
d. The pump will destroke later
e. None of the above
10. The pressure compensated flow regulator makes sure:
a. The pump will not upstroke too much
b. The pump will not destroke too much
c. The pump will destroke sooner
d. The pump will destroke later
e. None of the above

Student Materials

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Student Materials

KNOW YOUR COOLING SYSTEM QUIZ (Answers)

The following are true or false. Enter T for true and F for false. If false, circle the word or words that
make the statement false and replace with a word or words that make the statement correct.
F

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

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

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

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

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

6. A 40% concentration of antifreeze in water will protect the cooling system to

approximately -40o -12o Fahrenheit.

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

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

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

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

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

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

13. Caterpillar Extended Life Coolant (ELC) or a commercial ELC that meets the Caterpillar
specification (EC-1) is the preferred antifreeze to use in Cat engines.

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

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

16. Caterpillar Extended Life Coolant (ELC) does not require a frequent addition of a
Supplemental Coolant Additive (SLC) only an extender needs to be added at 3000 hours or
every two years.

17. The effectiveness of the Caterpillar Extended Life Coolant (ELC) is reduced is it is mixed
with other types of antifreeze such as Caterpillar (DEAC)

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Student Materials

BACKHOE LOADER AUTOSHIFT TRANSMISSION QUIZ ANSWERS

1. The only difference between an Autoshift transmission and the standard powershift transmission
is?
a. The number of gears.
b. The number of solenoids.
c. The clutch pressures.
d. The ECM programming.
2. Which solenoids are energized for the following conditions:
a. Machine running in SECOND FORWARD:
b. Machine running in THIRD REVERSE:
c. Machine running in FIFTH FORWARD:
d. Machine running in FIRST REVERSE:

1 and 4
2 and 6
1 and 6
2 and 4

e. Machine running in SECOND REVERSE with neutralizer switch held down:

f. Machine running in SECOND FORWARD, FIRST gear disabled, downshift switch pressed:
3 and 4
3. In the Autoshift mode, the operator selects the _____________ the machine can go in.
a. the direction
b. the highest gear
c. the direction and the highest gear
4. In the Autoshift mode, FIRST gear enabled, gear shift selector in THIRD FORWARD, without
operator input, which gears are available?
FIRST, SECOND, THIRD, FOURTH, FIFTH
5. In the Autoshift mode, FIRST gear disabled, gear shift selector in FOURTH FORWARD, without
operator input, what gears are available?
SECOND, THIRD, FOURTH, FIFTH

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Student Materials

6. In the manual mode, FIRST gear disabled, what gears are available?
FIRST, SECOND, THIRD, FOURTH
7. With the Ride Control Switch in the automatic mode, the autoshift transmission ECM activates the
Ride Control. True or False
8. What happens to the autoshift transmission if the speed sensor fails?
a. Returns to the machine to neutral
b. Downshifts over a period of time to FIRST gear.
c. Switches to MANUAL mode.
d. Leaves pieces of broken transmission on ground.

Service Training

STUDENT
REFERENCE
MATERIALS

ENGINE

D SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS

Service Training

STUDENT
REFERENCE
MATERIALS

POWER TRAIN

D SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS

Service Training

STUDENT
REFERENCE
MATERIALS

ELECTRICAL SYSTEM

D SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS

Service Training

STUDENT
REFERENCE
MATERIALS

STEERING AND IMPLEMENT HYDRAULIC SYSTEM

D SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS

Service Training

STUDENT
REFERENCE
MATERIALS

MISCELLANEOUS

D SERIES BACKHOE LOADER DIAGNOSTICS

BUILDING CONSTRUCTION PRODUCTS