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994K WHLLDR Course en STU
994K WHLLDR Course en STU
CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2015 Caterpillar Inc. All Rights Reserved.
Caterpillar: Confidential Yellow
SERV2070 - 10/15 -2- Course PARTICIPANT MATERIALS
Table Of Contents
Course Preparation
• Course Agenda............................................................................................................................. 5
• Course Description..................................................................................................................... 10
• Learning Outcomes.....................................................................................................................11
• Course Pre-Work........................................................................................................................ 12
Course Preparation
PARTICIPANT MATERIALS
Estimated
Day Topic Activity Content Actual
time
Lab 1 Participants will locate and identify the 30 minutes
implement hydraulic system components on
the Lab 1 Worksheets.
Estimated
Day Topic Activity Content Actual
time
Visual Review fan system learning outcomes. 10 minutes
Presentation
Estimated
Day Topic Activity Content Actual
time
Lab 1 Participants will locate and identify the brake 30 minutes
system components on the Lab 1 Worksheets.
Axle Oil Visual Classroom visual presentation of the axle oil 60 minutes
Cooling System Presentation cooling system; participants take notes on
Components component location and functionality using the
and Operation Lab 1 Worksheets.
Estimated
Day Topic Activity Content Actual
time
4 Introduction Safety briefing, engine and support systems 10 minutes
to Engine learning outcomes
and Support
Systems
Module
Engine and Visual Classroom visual presentation of the engine 60 minutes
Support Presentation and support systems; participants take notes
Systems on component location and functionality using
Components the Lab 1 Worksheets.
and Operation
Lab 1 Participants will locate and identify the engine 30 minutes
and support systems components on the Lab
1 Worksheets.
Course Description
• Course purpose/reason This training is designed for participants to locate and identify components, quickly
and accurately diagnose problems, test and properly adjust components, and gain
knowledge of the strategies used in all of the major systems of the 994K Wheel
Loader. Lab exercises will be used for skill development and knowledge check.
• Competency Statement At the completion of this course, you will be able to accurately locate and identify
machine and systems components, diagnose problems, and test and properly
adjust components during lab exercises and classroom knowledge checks with at
least 80% accuracy.
Specalog
Learning Outcomes
• Course learning outcomes Upon completion of this 994K Wheel Loader course, you will be able to:
• Locate and identify major machine components.
• Test and properly adjust machine systems and components.
• Describe systems and component operations.
11
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Power Train module of
the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Test and adjust the Power Train System.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Power Train Component Identification
• Lab 2 Power Train System Tests
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
Function:
2. Torque Converter
Function:
Function:
Function:
Function:
Function:
7. Transmission
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Participants will follow the procedures in the service manuals to test and properly
adjust the pressures for the power train system to within specifications.
• Materials needed ❏❏ 994K Wheel Loader
❏❏ Lab 2 Worksheet
❏❏ Operation and Maintenance - 994K Wheel Loader (SEBU9196)
❏❏ Specifications - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR4903)
❏❏ Systems Operation, Testing and Adjusting - Power Train, Steering, Braking,
Hydraulic Machine Systems (UENR4904)
❏❏ Troubleshooting - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR5475)
• Lab preparation Prior to conducting a lab exercise, perform the following steps:
❏❏ Prepare a safety briefing for the lab to be conducted.
❏❏ Select the machine to be used in the lab exercise.
❏❏ Review the lab exercise to ensure participants can demonstrate their ability to
accomplish the objectives.
• Participant instructions Participants are to divide into groups of two. Assign each group to a machine. Use
the service information and the Lab 2 Worksheet to complete the activity.
Neutral
Knowledge Check
25
1 2 3 5
4
6
2 3
10
7
1 5 4
8
11
9
12
P3 13
P1
14 15
3
16
2
1
P2 5 17
23
4
18
24 19
22
21
20 19
Module 1 Knowledge Check Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
15. 21.
16. 22.
17. 23.
18. 24.
19. 25.
20.
21
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Implement System
module of the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Test and adjust the Implement System.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Implement System Component Identification
• Lab 2 Implement System Tests
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
1. Hydraulic Tank
Function:
2. Implement Pumps
Function:
Function:
4. Lift Cylinder
Function:
5. Tilt Cylinder
Function:
6. Implement ECM
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Participants will follow the procedures in the service manuals to test and properly
adjust the pressures for the implement system to within specifications.
• Materials needed ❏❏ 994K Wheel Loader
❏❏ Lab 2 Worksheets
❏❏ Operation and Maintenance - 994K Wheel Loader (SEBU9196)
❏❏ Specifications - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR4903)
❏❏ Systems Operation, Testing and Adjusting - Power Train, Steering, Braking,
Hydraulic Machine Systems (UENR4904)
❏❏ Troubleshooting - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR5475)
❏❏ Schematic - Hydraulic System (UENR5398)
• Lab preparation Prior to conducting a lab exercise, perform the following steps:
❏❏ Prepare a safety briefing for the lab to be conducted.
❏❏ Select the machine to be used in the lab exercise.
❏❏ Review the lab exercise to ensure participants can demonstrate their ability to
accomplish the objectives.
• Participant instructions Participants are to divide into groups of two. Assign each group to a machine. Use
the service information and the Lab 2 Worksheets to complete the activity.
Calibration Complete
Implement Electronic System
Yes No
Lever Sensor Calibration (VIMS)
Lever Sensor Calibration (ET)
Linkage Sensor Calibration (VIMS)
Linkage Sensor Calibration (ET)
Pump Solenoid Calibration (VIMS)
Pump Solenoid Calibration (ET)
Valve Solenoid Calibration (VIMS)
Valve Solenoid Calibration (ET)
Knowledge Check
994K
IMPLEMENT CONTROL VALVES
HOLD
25 25
26 26
11 21
6 8
10 7
9 8
7 10
5 9 13
19 13 19
4
14 27
3 27 20
17 15
15 17
14 16
2 16 12
12 18
1 18
22
22
23 24
30
Module 2 Knowledge Check Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
15. 22.
16. 23.
17. 24.
18. 25.
19. 26.
20. 27.
21.
32
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Fan System module of
the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Test and adjust the Fan System.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Fan System Component Identification
• Lab 2 Fan System Tests
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
1. Fan Pump
Function:
Function:
Function:
Function:
5. Bypass Valve
Function:
Function:
Participants will follow the procedures in the service manuals to test and properly
adjust the pressures for the fan system to within specifications.
• Materials needed ❏❏ 994K Wheel Loader
❏❏ Lab 2 Worksheet
❏❏ Operation and Maintenance - 994K Wheel Loader (SEBU9196)
❏❏ Specifications - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR4903)
❏❏ Systems Operation, Testing and Adjusting - Power Train, Steering, Braking,
Hydraulic Machine Systems (UENR4904)
❏❏ Troubleshooting - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR5475)
• Lab preparation Prior to conducting a lab exercise, perform the following steps:
❏❏ Prepare a safety briefing for the lab to be conducted.
❏❏ Select the machine to be used in the lab exercise.
❏❏ Review the lab exercise to ensure participants can demonstrate their ability to
accomplish the objectives.
• Participant instructions Participants are to divide into groups of two. Assign each group to a machine. Use
the service information and the Lab 2 Worksheet to complete the activity.
Knowledge Check
8
4
5
3
9 2
6 10
7
1
38
Module 3 Knowledge Check Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
39
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Steering System module
of the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Test and adjust the Steering System.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Steering System Component Identification
• Lab 2 Steering System Tests
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
1. Steering Pumps
Function:
Function:
3. Diverter Valve
Function:
Function:
5. Steering Cylinders
Function:
Function:
Function:
Function:
9. Neutralizer Valves
Function:
Participants will follow the procedures in the service manuals to test and properly
adjust the pressures for the steering system to within specifications.
• Materials needed ❏❏ 994K Wheel Loader
❏❏ Lab 2 Worksheet
❏❏ Operation and Maintenance - 994K Wheel Loader (SEBU9196)
❏❏ Specifications - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR4903)
❏❏ Systems Operation, Testing and Adjusting - Power Train, Steering, Braking,
Hydraulic Machine Systems (UENR4904)
❏❏ Troubleshooting - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR5475)
• Lab preparation Prior to conducting a lab exercise, perform the following steps:
❏❏ Prepare a safety briefing for the lab to be conducted.
❏❏ Select the machine to be used in the lab exercise.
❏❏ Review the lab exercise to ensure participants can demonstrate their ability to
accomplish the objectives.
• Participant instructions Participants are to divide into groups of two. Assign each group to a machine. Use
the service information and the Lab 2 Worksheet to complete the activity.
Does the flow compensator valve need adjustment? _______ Yes _______ No
Does the pressure compensator valve need adjustment? _______ Yes _______ No
Which tests indicate if the flow compensator or the pressure compensator need adjustment?
_____________________________________________________________________________________
_____________________________________________________________________________________
Knowledge Check
21
4 10
20 7 19
5
18 17 16
11
14 15
3
13
1
12 9 9
8 8
2
46
Module 4 Knowledge Check Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
15. 19.
16. 20.
17. 21.
18.
48
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Brake System module of
the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Test and adjust the Brake System.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Brake System Component Identification
• Lab 2 Brake System Tests
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
Function:
2. Brake Pump
Function:
3. Relief Valve
Function:
4. Brake Accumulators
Function:
Function:
6. Service Brakes
Function:
Function:
Function:
9. Parking Brake
Function:
Function:
Function:
Participants will follow the procedures in the service manuals to test and properly
adjust the pressures for the brake system to within specifications.
• Materials needed ❏❏ 994K Wheel Loader
❏❏ Lab 2 Worksheet
❏❏ Operation and Maintenance - 994K Wheel Loader (SEBU9196)
❏❏ Specifications - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR4903)
❏❏ Systems Operation, Testing and Adjusting - Power Train, Steering, Braking,
Hydraulic Machine Systems (UENR4904)
❏❏ Troubleshooting - Power Train, Steering, Braking, Hydraulic Machine Systems
(UENR5475)
• Lab preparation Prior to conducting a lab exercise, perform the following steps:
❏❏ Prepare a safety briefing for the lab to be conducted.
❏❏ Select the machine to be used in the lab exercise.
❏❏ Review the lab exercise to ensure participants can demonstrate their ability to
accomplish the objectives.
• Participant instructions Participants are to divide into groups of two. Assign each group to a machine. Use
the service information and the Lab 2 Worksheet to complete the activity.
Did the service brakes keep the machine from moving in Third Speed Reverse at HIGH IDLE? _______ Yes _______ No
If the machine moves during the test, what is the next course of action? ______________________________________
_________________________________________________________________________________________________
Did the parking brake keep the machine from moving in Second Speed Forward at HIGH IDLE? _______ Yes _______ No
If the machine moves during the test, what is the next course of action? _______________________________________
__________________________________________________________________________________________________
Knowledge Check
16
1
11
14
9
12 15
13 10
8
4 5
7 6
3
2
17 19
18
55
Module 5 Knowledge Check Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
15. 18.
16. 19.
17.
57
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Axle Oil Cooling System
module of the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Axle Oil Cooling System Component Identification
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Knowledge Check
11
11
12
13
10
12 19
8 8
12
7 9
18
7 12
9
5
6
4
14
6
3
17 15
16
2
1
62
Module 6 Knowledge Check Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 8.
2. 9.
3. 10.
4. 11.
5. 12.
6. 13.
7. 14.
15. 18.
16. 19.
17.
64
Learning Outcomes
• Module learning outcomes You will meet the following learning outcomes during this Engine and Support
System module of the 994K Wheel Loader course:
• Locate, identify, and describe the function of all major components and service
points of the 994K Wheel Loader.
• Module Competency Statement At the completion of this module, you will be able to successfully complete the
following exercises:
• Lab 1 Engine and Support System Component Identification
• Knowledge Check
Instructions: During the lab exercise, use this sheet as a checklist when identifying components and their functions and fill in
the component function in the space provided .
1. Engine ECM
Function:
Function:
Function:
Function:
Function:
6. Fuel Injectors
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Function:
Knowledge Check
5
6
4
70
Module 7 Knowledge Check WORKSHEET 1 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 4.
2. 5.
3. 6.
FUEL SYSTEM
9
8 7
2
6
4
3
1
71
Module 7 Knowledge Check WORKSHEET 2 Name: Date
Directions: Fill in the blanks next to the numbers with the correct component name.
1. 6.
2. 7.
3. 8.
4. 9.
5.