Service Training

Course Materials

STUDENT MATERIALS

C-SERIES TRACK-TYPE TRACTORS AND 933/939 TRACK-TYPE LOADERS

BUILDING CONSTRUCTION PRODUCTS

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Student Materials

STUDENT NOTES

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Student Materials

TABLE OF CONTENTS

COURSE CONTENTS...........................................................................................................? STUDENT COURSE BOOK CHECKLIST ..........................................................................? MODULE: MACHINE ORIENTATION...............................................................................? MODULE: IMPLEMENT HYDRAULIC SYSTEMS .........................................................?

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Student Materials

COURSE CONTENTS
MODULE: IMPLEMENT HYDRAULIC SYSTEM - Lesson: Implement Hydraulic System Component Identification and System Tests - Slide presentation on the hydraulic system - Shop lab on implement hydraulic system - identify hydraulic system components - perform hydraulic system tests - Lesson: Implement Control Valve Component Identification (optional) - Identify valve components lab - Case Study: Implement Hydraulic System - Quiz: Implement Hydraulic System - Module Summary

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STUDENT COURSE BOOK CHECKLIST

DESCRIPTION Binder Fluid Power Graphic Symbols

FORM NO. SENR2910 SEEV0529

D3C/D4C/D5C Series III Hyd. System Operation, Test and Adjust SENR5339

Reference Materials D3C/D4C/D5C Series III Track-Type Tractor Hyd.Sys. Schematic SENR5340 933/939 Hyd. System Operation, Test and Adjust 933/939 Track-Type Loader Hyd.Sys. Schematic D3C Series III Spec Sheet D5C Series III Spec Sheet 933 Spec Sheet D3C/D4C/D5C Series III O&M Manual 933/939 Operation and Maintenance Manual D3C Series III Track-type Tractor Parts Book D4C Series III Track-type Tractor Parts Book D5C Series III Track-type Tractor Parts Book 933/939 Track-type Loader Parts Book D3C/D4C/D5C Series III Service Manual 933/939 Service Manual SENR5353 SENR5354 AEHQ3866 AEHQ3851 AEHQ3869 SEBU6731 SEBU6732 SEBP2241 SEBP2242 SEBP2243 SEBP2244 SENR5330 SENR5345

Videos "D3C/D4C/D5C Series III and 933/939 Sales and Service Walk-around" TEVN2576

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Student Materials

MODULE: IMPLEMENT HYDRAULIC SYSTEMS

The purpose of this module is to have you locate and identify hydraulic system components. You will also learn how the implement control valves work and explain the function of their components. System tests for the hydraulic system will also be performed by you. The electrical bucket kickout system will also be tested. The module is composed of two lessons, a case study and a quiz. One of the lessons is optional.

MODULE OBJECTIVES

1. Locate on the schematic the following: hydraulic tank, hydraulic filter, pump, pump control valve, implement valve group, tilt control valve, lift control valve, additional control valves (if equipped) inlet manifold, all system pressure test ports, ripper cylinder, and blade/bucket cylinders. 2. On the machine, locate the following: hydraulic tank, hydraulic filter, pump, pump control valve, implement valve group, tilt control valve, lift control valve, additional control valves (if equipped), inlet manifold, all system pressure test port locations, and implement controls. 3. (Optional) D&A an implement control valve and demonstrate verbally to the instructor that the student understands the functions of all components (if components are available). These components may include line reliefs, makeup valves, check valves, and main control spools. 4. Perform performance checks and/or adjust: maximum system pressure and line relief settings. 5. Perform cycle time checks and cylinder drift checks 6. On a quiz identify ISO symbols to determine type, features and number of valves and type of hydraulic tank. 7. Using provided reference materials and handouts identify potential system problems caused by a improperly operating hydraulic system during a case study.

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Student Materials

Lesson: Implement Hydraulic System Identification and System Tests

BACKGROUND INFORMATION

This lesson will help you gain familiarity with the machine and locate components and service points. This lesson will also allow you to gain familiarity performing system checks, using the Service Manual, and determining if the machine is operating to specifications.
NOTE: Before operating the machine, perform a 10 hour or daily inspection which includes checking fluid levels as specified in the Operation and Maintenance Guide. Remove side panels and/or cab floor plates as needed.

Classroom Lab

Locate on the schematic the following: hydraulic tank, hydraulic filter, pump, pump control valve, implement valve group, tilt control valve, lift control valve, additional control valves (if equipped) inlet manifold, all system pressure test ports, ripper cylinder, and blade/bucket cylinders using the Track-type Tractor Hydraulic System Checklist and theTracktype Loader Hydraulic System Checklist On the machine, locate the following: hydraulic tank, hydraulic filter, pump, pump control valve, implement valve group, tilt control valve, lift control valve, inlet manifold, all system pressure test ports, implement controls using the Implement Hydraulic System Component Checklist. Record a check after locating each component.. Remove side panels and/or cab floor plates as needed. Record pressure specifications from the service manual before going to the shop on the Hydraulic System Test Sheet Install test nipples and perform system pressure tests as per the service manual for maximum system pressure Use a stop watch to perform cycle time checks Use a stop watch and tape measure to perform cylinder drift checks

Shop Lab

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Lesson: Implement Hydraulic System Component Identification and System Tests (continued)

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Materials Needed

Optional Perform lift kickout and bucket positioner checks

Perform line relief pressure checks

Hydraulic System Testing and Adjusting Service Manual Module Hydraulic System Test Sheets 1-8T0859 Pressure Gauge 1-1U5482 Hose and Fitting Group 1-6V4142 Nipples 1-8C7575 or 8C7576 adapters 1-6V7800 Multimeters or 9U7330 Fluke 87 1-Stop Watch 1-Tape Measure 2-Mechanic's Tool Boxes and hand tools

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Student Materials

Implement Hydraulic System Component Checklist

Directions: Use this sheet to take notes during the presentation (i.e. location, functions). During a lab exercise, use this as a checklist when identifying components. Hydraulic tank

Hydraulic oil filter

Pump

Inlet manifold with main relief valve

Ripper valve if equipped

Tilt control valve

Lift control valve

Angle control valve (TTT)

Multipurpose control valve (TTL - if equipped)

Implement controls

System pressure test location

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HYDRAULIC SYSTEM TEST SHEET

TEST: MAXIMUM SYSTEM PRESSURE Pressure Maximum System Pressure CYCLE TIMES 3RD 4TH Spec. Actual

1ST Implement 1 Implement 2 Implement 3 Implement 4

2ND

AVG.

SPEC.

TESTS: IMPLEMENT DRIFT RATES Enter the Times and Drift Specifications from the Service Manual. Enter the actual measurements for each cylinder in the appropriate space. Oil Temperature Time Drift Spec Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6 Cyl. 7 38 to 48C (100 to 119F) 49 to 64C (120 to 149F) 65C and Up (150 F and Up)

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Student Materials

HYDRAULIC SYSTEM TEST SHEET

TEST: MAXIMUM SYSTEM PRESSURE Pressure Maximum System Pressure CYCLE TIMES 3RD 4TH Spec. Actual

1ST Implement 1 Implement 2 Implement 3 Implement 4

2ND

AVG.

SPEC.

TESTS: IMPLEMENT DRIFT RATES Enter the Times and Drift Specifications from the Service Manual. Enter the actual measurements for each cylinder in the appropriate space. Oil Temperature Time Drift Spec Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6 Cyl. 7 38 to 48C (100 to 119F) 49 to 64C (120 to 149F) 65C and Up (150 F and Up)

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Student Materials

Lesson: Implement Control Valve Component Identification (Optional)

BACKGROUND INFORMATION

This lesson allows you to gain hands on experience with the control valve and its components.

Shop Lab

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Disassemble the implement control valve. Lay out all components. Identify and state the purpose of the following components using the Implement Control Valve Component Checklist (Circle the component letter after identifying each component.): - control spool - makeup valve - line relief valve - check valve

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Materials Needed

Assemble the control valve

Service Manual Parts Book Implement control valve - for C track-type tractors or similar Mechanic's Tool Box with hand tools Implement Control Valve Component Checklist Class notes

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Student Materials

Implement Control Valve Component Checklist

Directions: Match the components to the associated letter. Use this sheet to take notes during the presentation. During the D&A Lab use this sheet as a checklist when identifying components.

HEAD END

ROD END

D C
____ Control spool

____ Check valve

____ Makeup valve

____ Line relief valve

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Student Materials

Case Study: Implement Hydraulic System

DIRECTIONS

Use the provided service manual modules and notes to answer this case study.

SITUATION

The customer's 939 Track-type Loader has 781 service hours. When the bucket is rapidly lowered to the ground there is no initial downward force. The bucket pauses for 4-6 seconds before downward force is created. After checking fluid levels, the field mechanic checks pump supply pressure and performs cycle time checks. Supply pressure is good and cycle times are within specification. What else should be checked? List at least two problems that could be causing the hesitation. Describe tests and your anticipated results?

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Student Materials

Student Troubleshooting Analysis

STEP 1 - MAKE SURE PROBLEM EXISTS: STEP 2 - STATE THE PROBLEM:

STEP 3 - VISUAL INSPECTION: STEP 4 - LIST ALL POSSIBLE CAUSES: 1. 2. 3. 4. 5. STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA: 1. RESULT 2. RESULT 3. RESULT 4. RESULT 5. RESULT STEP 6 - ISOLATE AND ELIMINATE: STEP 7 - REPAIR MACHINE: STEP 8 - VERIFY FIX:

Service Training
Course Materials

REFERENCE MATERIALS

C-SERIES TRACK-TYPE TRACTORS AND 933/939 TRACK-TYPE LOADERS

BUILDING CONSTRUCTION PRODUCTS