SERV1845-01

May 2008

GLOBAL SERVICE LEARNING

STUDENT MATERIALS

PART OF GLOBAL SERVICE LEARNING MODULE SERV1845-01

D11T TRACK-TYPE TRACTOR

WORKSHEETS WITH POSTTESTS
SERV1845-01 -2- Student Handout No. 1
05/08 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 -3- Student Handout No. 2
05/08 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 -4- Student Handout No. 3
05/08 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
____ Engine jacket water pump
____ AMOCS radiator cores
____ Water temperature regulator housing
____ Coolant shunt tank
____ Coolant fill tube and cap
____ Supplemental hydraulic demand fan
pump
____ Fan pump control valve
____ Fan pump pressure control solenoid
____ Fan pump discharge pressure sensor
____ 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 -5- Student Handout No. 4
05/08 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
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 ECM
____ Power train oil pump
____ Power train oil fill tube and dipstick
____ Power train lube distribution manifold
____ Torque converter scavenge screen
____ Torque converter outlet relief valve
____ Torque converter temp. sensor
____ Power train oil coolers
____ Transmission charging filter
____ Torque converter charging filter
____ Transmission system temp. plug
____ Transmission oil filter bypass switch
____ Torque converter oil filter bypass switch
____ Torque converter output speed sensor
____ Steering oil temp. sensor
____ Electronic steering/brake control valve
____ Service brake pedal position sensor
____ Parking brake switch
____ Left and right steering lever position
sensors (FTC control lever sensors)
-6- Student Handout No. 5
Laboratory Exercise
Power Train Pressure Test Ports
____ Torque converter outlet relief pressure
test port (N)
____ Power train system lube pressure (L1)
____ Lube distribution manifold pressure (L2)
____ Torque converter inlet relief (supply)
pressure test port (M)
____ Transmission charge pump pressure test
port (TP)
____ Power train oil S•O•S port
____ Brake and steering clutch pressure test ports
(B1/B2/C1/C2)
____ Torque converter filter S•O•S port
____ Transmission filter S•O•S port
____ Transmission speed clutch pressure test
port (P1)
____ Transmission directional clutch pressure
test port (P2)
____ Power train priority valve
____ Transmission control valve
____ Torque converter
____ Transmission
 05/08

Lab C: Power Train Hydraulic System Pressures Worksheet

Machine
Brakes ON Brakes OFF Brakes OFF LH Brakes RH Brakes Both Brakes Both Brakes
condition
ON ON ON ON
SERV1845-01

Actuating Parking Hand Hand Foot Foot

Control Brake Control Control Control Control (Stall)

Test
Location

Engine 700 ± 25 700 ± 25 1980 ± 80 1980 ± 80 1980 ± 80 1980 ± 80 1440 ± 40

Epeed rpm rpm rpm rpm rpm rpm rpm

Transmission
Gear Neutral Neutral Neutral Neutral Neutral Neutral Neutral

LH Clutch
Pressure
(C1)(1)
LH Brake
Pressure
(B1) (1)
RH Brake
Pressure
(B2) (1)
-7-

RH Clutch
Pressure
(C2) (1)
Trans Speed
Clutch (P1)
Pressure
Transmission
Direction (P2)
Clutch Press

Transmission
Pump (T)
Pressure

TC In (M)
Pressure

TC Out (N)
Pressure

System
Lube (L2)
Pressure
Transmission
Lube (L1)
Pressure

(1) The brake and clutch pressures are affected by the electronic brake clutch calibration procedure.
Student Handout No. 6
Laboratory Exercise
 05/08

Lab C: Power Train Hydraulic System Tests Worksheet

SPEED RANGE AND WHICH WHICH If E.T. os available, record

SERV1845-01

DIRECTION SOLENOIDS CLUTCHES the following information:

ARE ARE
ON? ENGAGED? SOLENOID CURRENT %
(Engine at LOW IDLE)

Third Speed Forward

Second Speed Forward

First Speed Forward

Neutral
-8-

First Speed Reverse

Second Speed Reverse

Third Speed Reverse

TRANSMISSION CLUTCH FILL CALIBRATION

YES NO

CALIBRATION
COMPLETED

FAULTS PRESENT
Student Handout No .7
Laboratory Exercise
SERV1845-01 -9- Student Handout No. 8
05/08 Posttest

POWER TRAIN 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 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
 POWER TRAIN HYDRAULIC OIL SYSTEM POSTTEST SCHEMATIC
05/08

D11T AND D11T CD CARRYDOZER

DIRECTIONS
SERV1845-01

I
COMPONENTS IDENTIFICATION: Write the letter of the Power
Train component or service point next to the name of the
component/service point listed in the right and left
hand bottom boxes.

K
AA
DD
EE
H CC
LL A B C D E

JJ

FF BB
GG HH
C32
Engine
KK II
- 10 -

F G Fan Pump

Implement
Group

POWER TRAIN COMPONENTS

____ Torque Converter Charging Section

Power Train Oil Pump
____ Priority Valve

POWER TRAIN PRESSURE PORTS
____ Transmission Lube Pressure (L1)
____ System Lube Pressure (L2)
____ Right Brake Pressure (B2)
____ Right Clutch Pressure (C2)
____ Trans Speed Clutch Press. (P1)
____ Trans Direction Clutch Press. (P2)
____ Transmission Scavenge Section ____ Lube Distribution Manifold
Power Train Oil Pump
____ Left Clutch Pressure (C1)
____ Torque Converter Scavenge Section
____ Power Train Oil Coolers
____ T/C Inlet Pressure (M) Power Train Oil Pump
____ Steering Clutch And Brake Valve
____ Transmission Charging Section
____ T/C Outlet Relief Pressure (N)
Power Train Oil Pump
____ Torque Converter Charge Filter
____ Power Train Oil Sampling (S•O•S) ____ Brake Cooling Section
Power Train Oil Pump ____ Transmission Charge Filter
____ Transmission Pump Pressure (T)
____ Torque Converter Outlet Relief Valve ____ Transmission Control Valve
____ Left Brake Pressure (B1)
Student Handout No. 9
Posttest
SERV1845-01
05/08
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
____ Hydraulic oil tank
____ Hydraulic oil fill tube and sight glass
____ Lift/tilt implement pumps
____ Pressure reducing manifold
____ EH pilot manifold
____ Implement lockout solenoid valve
____ "Dead Electric" lower valve
____ Pilot oil filter
____ Dozer control valve
____ Ripper control valve
____ Lift pump pressure sensor
____ Tilt pump pressure sensor
____ Quick-drop valves
____ Dual tilt valve
____ Implement ECM
____ Hydraulic oil cooler and bypass valve
____ Hydraulic oil temperature sensor
____ Case drain return filter
____ Case drain return filter bypass switch
____ Main pump return filter
- 11- Student Handout No. 10
Laboratory Exercise
Implement Hydraulic Pressure Test Ports
____ Lift pump pressure test port (HPD1)
____ Tilt pump pressure test port (HPD2)
____ Hydraulic Pilot Pump Discharge pressure
test port (HFPD)
____ Pilot pressure test ports (9 ports, at EH
pilot manifold)
____ Pilot oil S•O•S (fluid sampling) port
____ Hydraulic Pilot Supply pressure test port
(HPS)
____ Resolver valve group
____ Ripper pin puller valve ( if equipped)
____ Pitch regenerate valve (Carrydozer only)
____ 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)
____ Ladder Ready control valve ( If equipped)
____ Ladder Ready directional motor (If
equipped)
 05/08

LAB D: PILOT, FAN, AND MAIN SYSTEM HYDRAULIC PRESSURE TEST

Spectification Actual Within Specification?

SERV1845-01

Pilot Supply Pressure (HPS)

@ HIGH IDLE

Pilot System Relief (HPSR)

@ 700 RPM

EH Pilot Manifold Ripper/Blade

Solenoid valve Pressures @ HIGH
IDLE
Blade / Ripper Main Relief
Pressure @ High Idle

Dozer Tilt Relief Pressure

- 12 -

@ High Idle

Lift Pump Pressure In Hold Position

@ 1800 RPM

Tilt Pump Pressure In Hold Position

@ 1800 RPM
Demand Fan Pump Maximum
Cutoff Pressure (HDFP) @ High Idle
with Fan at 100% and Engine @
60 Deg C (140 Deg F)
Demand fan Pump Standby
Pressure (HDFP) @ High Idle with
Fan at 0% and Engine @
60 Deg C (140 Deg F)
Fan Speed rpm
Student Handout No. 11
Laboratory Exercise
 05/08

LAB D: D11T HYDRAULIC CYLINDER CYCLE TIME TESTS

CYCLE TIME CHECK (SECONDS): LIFT CYLINDERS RAISE
1st Test 2nd Test 3rd Test Average
SERV1845-01

Oil Temp 158-176°F

Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): DUAL TILT LEFT

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): DUAL TILT RIGHT

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
- 13 -

Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): RIPPER CYLINDER RAISE

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): RIPPER CYLINDER SHANK IN

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No
Student Handout No. 12
Laboratory Exercise
 05/08

LAB D: D11T CD HYDRAULIC CYLINDER CYCLE TIME TESTS

CYCLE TIME CHECK (SECONDS): LIFT CYLINDERS RAISE
SERV1845-01

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): DUAL TILT LEFT

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): DUAL TILT RIGHT

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
- 14 -

Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): RIPPER CYLINDER RAISE

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No

CYCLE TIME CHECK (SECONDS): RIPPER CYLINDER SHANK IN

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No
Student Handout No. 13
Laboratory Exercise
 05/08
SERV1845-01

LAB D: D11T CD HYDRAULIC CYLINDER CYCLE TIME TESTS

CYCLE TIME CHECK (SECONDS): PITCH FORWARD
Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No
- 15 -

CYCLE TIME CHECK (SECONDS): RACK BACK

Oil Temp 158-176°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Specification Within Specification? ____ Yes ____ No
Student Handout No. 14
Laboratory Exercise
SERV1845-01 - 16 - Student Handout No. 15
05/08 Posttest

HYDRAULIC SYSTEM POSTTEST

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 A. Direct the flow of high pressure pump supply oil
to the implement cylinders.
Implement pump
B. Ensures that clean oil is delivered to the solenoid
controlled pilot valves.
Pressure reducing manifold
C. Opens to bypass the cooler when the hydraulic
Implement lockout solenoid valve oil is cold and closes when the hydraulic oil is
warm to direct oil through the cooler.
Pilot oil filter
D. Provides oil flow through the entire hydraulic
system for the operation of the implements.
Dozer and ripper control valves
E. ENERGIZED by the Implement ECM to direct
Lift dump valve pilot pressure oil to move an implement control
valve spool.
Tilt dump valve F. Receives signals from implement control lever
sensors and sends corresponding currents to the
Shuttle valve 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 H. Directs rod-end oil from the blade lift cylinders
into the head-ends when the blade falls rapidly
Implement ECM to the ground.

Resolver valve group I. Serves as a reservoir for the hydraulic oil.

J. Is closed by high pressure supply oil to shut
Hydraulic oil cooler bypass valve off oil flow to tank when a blade lift or a ripper
function is active.
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
 DIRECTIONS
COMPONENTS IDENTIFICATION: Write the letter of the hydraulic
05/08

D11T IMPLEMENT HYDRAULIC SYSTEM POSTTEST SCHEMATIC component or service point next to the name of the
BLADE RAISE component/service point listed in the right and left hand bottom
boxes.

Typical
for Blade
SERV1845-01

RE
B HE

Lift and Tilt

Cylinders To Ladder
Attachment
F
Drain from
Ladder Attachment
To Case Drain

G
C

CC BB

N
GG

R
T

S
I

V EE
- 17 -

Q
M

AA HH
U

DD

FF H
J

P
L E

Case
A Drain
O
Vacuum D
Valve Case
Group Drain

HYDRAULIC SYSTEM COMPONENTS

____ Dual Tilt Valve ____ Fan Pump HYDRAULIC SYSTEM PRESSURE PORTS
____ Dump Valve ____ Lift Relief Valve
____ Dead Electric Lower Valve ____ Pilot Pump ____ Lift Pump Pressure (HPD1) ____ Ripper Lower Pilot Pressure (HPRL)
____ Ripper Warming Valve ____ Shuttle Valve
____ Tilt Pump Pressure (HPD2) ____ Ripper Shank Out Pilot Pressure
____ Ripper Lift Spool ____ Blade Lift Spool ____ Pilot Pressure Reducing Manifold ____ AutoCarry Diverter Valve (HPSO)
____ Pilot Pump Pressure (HPS)
____ Ripper Tip Spool ____ Blade Tilt Spool ____ Lift Pump ____ EH Pilot Manifold ____ Blade Raise Pilot Pressure (HPDR)
Student Handout No. 16
Posttest

____ PCO Valve Pressure (HPRV) ____ Blade Tilt Right Pilot Pressure (HPTR)
____ Tilt Relief Valve ____ Resolver Valve Group ____ Tilt Pump