SERV1844

November 2007

GLOBAL SERVICE LEARNING

INSTRUCTOR MATERIALS

PART OF GLOBAL SERVICE LEARNING MODULE SERV1844

24M MOTOR GRADER

INTRODUCTION

LAB EXERCISES AND POSTTEST ANSWERS

SERV1844 -2- Laboratory Exercises
11/07 Instructor Handout No. 1

Component Identification
Description
Identify the components of the 24M Motor Grader. Use the worksheets to take notes on the
types of input components. After locating the components on the schematic, locate the
components on the engine or machine.
Materials Needed
__ Electrical Schematic (for the machine being used)
__ Machine or engine with an electronic control system
SERV1844 -3- Laboratory Exercises
11/07 Instructor Handout No. 2

Lab A: Messenger Monitoring System

Machine Model_____________________________ Date___________________________

Serial Number______________________________ S.M.H.________________________
Directions: List the 4 Main Menu options in Messenger.

__________
Main Menu __________
__________
__________

Directions: Use messenger to find the following parameters.

1. Engine speed __________rpms

2. Engine coolant temperature __________

3. Fuel level__________

4. Lifetime total reverse distance traveled__________

5. Lifetime maximum fuel used__________

6. How many languages are offered__________

7. What is the top gear limit_________

8. Equipment number __________

9. Trans/Chassis ECM software part number__________

10. Machine hours__________

11. With the engine running at low idle, what is the boost pressure__________

12. With the engine running at low idle, what is the transmission output speed__________

13. With the engine running at low idle, what is the parking brake switch
status__________

14. With the engine running at low idle, what is the fuel temperature___________

15. With the engine running at low idle, what is the Power Train filter status__________
SERV1844 -4- Laboratory Exercises
11/07 Instructor Handout No. 3

Lab B: Messenger System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

B Service; Tattletale; Tattletale A. Menu that contains information on

Active Mode alternator status.

E Settings; Transmission B. Menu that contains information on

maximum recorded coolant temperature.

F Service; System Parameters; C. Menu that contains total fuel usage.

Engine

D Service; System Parameters; D. Menu that contains information on

Transmission transmission output speed.

A Service; System Parameters; E. Menu that contains maximum fwd

Monitoring System autoshift gear.

C Totals; Lifetime Totals F. Menu that contains information on inlet

air temperature.
SERV1844 -5- Laboratory Exercises
11/07 Instructor Handout No. 4

Lab C Worksheet
C18 ACERT™ Engine Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function
of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold and pilot systems.

_____ Engine ECM

Function: Electronic Control Module, governor, electronic fuel system control.
Location: Mounted on the engine, left side of engine compartment.

_____ Primary Fuel Filter

Function: 10 micron filter, removes large debris which could damage the injectors.
Location: Between the tank and the transfer pump, left side of engine.

_____ Fuel Transfer Pump

Function: Low pressure fuel pump.
Location: Near the balancer at the front of the engine.

_____ Electronic Priming Pump

Function: Primes fuel system from the tank through the filters to the injectors.
Location: Mounted on the primary filter housing.

_____ Secondary Fuel Filter

Function: Two micron filter, removes small debris which could damage the injectors.
Location: Downstream of the transfer pump, left side of the engine.

_____ Electronic Unit Injectors

Function: Controlled by the Engine ECM, delivers fuel to the cylinder.
Location: In the cylinder head below valve cover.

_____ Primary Speed Sensor

Function: Engine speed/timing measurement, TDC, and cylinder identification.
Location: At the lower right side of the timing gear cover.

_____ Secondary Speed Sensor

Function: Engine speed/timing measurement, TDC, and cylinder identification.
Location: On the rear of the timing gear housing.
SERV1844 -6- Laboratory Exercises
11/07 Instructor Handout No. 5

Lab C Worksheet
C18 ACERT™ Engine Component Identification Worksheet (continued)

_____ Engine Coolant Temperature Sensor

Function: Coolant temperature measurement for Engine ECM, instrument panel, temperature
warning.
Location: At the front of the engine on the water temperature regulator housing.

_____ Engine Oil Pressure Sensor

Function: Oil pressure measurement for the Engine ECM, instrument panel, and low pressure
warning.
Location: On left side of engine in the oil gallery next to the Engine ECM.

_____ Intake Manifold Air Pressure Sensor

Function: Calculates the difference between atmospheric pressure and intake manifold air
pressure, referred to as "boost" pressure.
Location: Located on the left side of the engine compartment in the intake manifold.

_____ Intake Manifold Air Temperature Sensor

Function: Intake air temperature measurement for Engine ECM and temperature warning.
Location: Located on the left side of the engine compartment in the intake manifold.

_____ Turbo Inlet Pressure Sensor

Function: Measure air flow restriction from the air filter to the turbocharger.
Location: In the intake air tubing between the air filter housing and the turbocharger.

_____ Throttle Control Mode Switch

Function: Allows the operator to select the throttle control mode.
Location: On the panel to the right of the operator's seat.

_____ Throttle Resume/Decelerate Switch

Function: Allows the operator to resume the previous set engine rpm or decrease engine rpm
while the throttle lock is active.
Location: On the front of the right joystick.

_____ Throttle Set/Accelerate Switch

Function: Allows the operator the set the desired engine rpm or increase engine rpm while the
throttle lock is active.
Location: On the panel to the right of the operator's seat.

_____ Throttle Position Sensor

Function: Engine speed control.
Location: In the cab, on the throttle pedal assembly.
SERV1844 -7- Laboratory Exercises
11/07 Instructor Handout No. 6

Lab D: Engine System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

J Turbo inlet pressure sensor A. Receives sensor and switch inputs and
controls fan speed and engine rpm

G Engine derate B. A horsepower limiting event that limits

horsepower and continues to limit the
horsepower once the condition no longer
A Engine ECM exists

C. Final preparation of the fuel before the

D Fuel transfer pump fuel enters the fuel gallery

D. Supplies flow to the engine fuel system

H Atmospheric pressure sensor
E. An event that is based on atmospheric
pressure, intake manifold temperature,
K Differential fuel pressure switch and engine rpm

F. A horsepower limiting event that no

C Secondary fuel filter longer limits horsepower when the
condition no longer exists

I Timing calibration connector G. An event that limits the engine

horsepower

F Non-latching derate H. Engine ECM uses this sensor to calculate

all other pressure sensors on the engine

B Latching derate I. Used for timing the engine if the Engine

ECM or timing sensor is replaced

H Virtual exhaust derate J. Engine ECM uses this sensor to calculate

air filter restriction

K. Compares the difference between

incoming and outgoing fuel pressure
SERV1844 -8- Laboratory Exercises
11/07 Instructor Handout No. 7

Lab E Worksheet
Power Train Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function
of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold, and pilot systems.
_____ Transmission/Chassis ECM
Function: Electronic Control Module, transmission shifting, engine starting, and secondary
steering.
Location: Left side of the transmission.

_____ Transmission
Function: Provides speed and directional conversion of the available engine power.
Location: Mounted to the rear of the engine.

_____ Transmission Pump

Function: Supplies oil flow to the torque converter and transmission hydraulic system.
Location: Attached to the pump drive on the left side of the machine.

_____ Transmission Relief Valve

Function: Limits oil pressure to the transmission proportional solenoid valves.
Location: Mounted in the transmission control valve group.

_____ Transmission Filter

Function: Filters the oil from the transmission pump to the transmission hydraulic system.
Location: Mounted on the left side of the machine near the hydraulic tank.

_____ Transmission Modulating Valves

Function: Control oil flow and pressure to the speed and directional clutches.
Location: Mounted on top of the transmission below the top cover.

_____ Transmission Input Speed Sensor

Function: Measures transmission input speed.
Location: Mounted in the top of the transmission case.

_____ Transmission Output Speed Sensors

Function: Measures transmission output speed.
Location: Mounted on the output transfer gear on the left side of the machine.
SERV1844 -9- Laboratory Exercises
11/07 Instructor Handout No. 8

Lab E Worksheet
Power Train Component Identification Worksheet (continued)

_____ Transmission Oil Temperature Sensor

Function: Measures transmission oil temperature.
Location: Mounted on top of the transmission below the top cover.

_____ Magnetic Screen

Function: Removes metal particles from the supply oil.
Location: Mounted at the bottom left side of the transmission.

_____ Power Train Oil Cooler

Function: Cools the transmission hydraulic oil.
Location: Mounted on the right side of the engine.

_____ Engine Key Start Switch

Function: Signals the Trans/Chassis ECM when to energize the engine starter relay.
Location: Mounted in the front console of the operator's station.

_____ Engine Start Relay

Function: Activated by the Power Train ECM to energize the starter motor.
Location: Mounted inside of the left service center.

_____ Autoshift Switch (if equipped)

Function: Allows operator to select the desired shift mode; automatic or manual.
Location: In the service panel to the right of the operator's seat.

_____ Directional Switch

Function: Allows operator to select desired direction and speed.
Location: Mounted in the left steering/implement joystick.

_____ Upshift switch

Function: Allows the operator to manually upshift the transmission.
Location: Mounted in the left steering/implement joystick.

_____ Downshift switch

Function: Allows the operator to manually downshift the transmission.
Location: Mounted in the left steering/implement joystick.

_____ Differential Lock Switch

Function: Sends a signal to the Trans/Chassis ECM to energize or de-energize the differential
lock solenoid.
Location: In the service panel to the right of the operator's seat.
SERV1844 - 10 - Laboratory Exercises
11/07 Instructor Handout No. 9

Lab E Worksheet
Power Train Component Identification Worksheet (continued)

_____ Differential Lock Solenoid

Function: Controls oil flow to the differential lock.
Location: Mounted on the differential case.

_____ Differential
Function: To send power from the transmission out to the wheels.
Location: Mounted in the rear frame near the rear of the machine.

_____ Final Drives

Function: Provides a final gear reduction to provide the most torque during machine
operation.
Location: Mounted on the side of the differential case.

_____ Back-up Alarm

Function: Alerts surrounding area that the machine has been put into reverse.
Location: Mounted at the rear of the machine.
SERV1844 - 11 - Laboratory Exercises
11/07 Instructor Handout No. 10

Lab F: Power Train Hydraulic System Tests Worksheet

POWER TRAIN HYDRAULIC SYSTEM SPECIFICATION ACTUAL

Transmission Pump Pressure (kPa/psi)

Lubrication Pressure (kPa/psi)

Differential Lock Pressure (kPa/psi)

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

DIRECTION SOLENOIDS CLUTCHES the following information:
ARE ARE
Engine at LOW IDLE ON? ENGAGED? SOLENOID CURRENT %

Sixth Speed Forward

Fifth Speed Forward

Fourth Speed Forward

Third Speed Forward

Second Speed Forward

First Speed Forward

Neutral

First Speed Reverse

Second Speed Reverse

Third Speed Reverse

TRANSMISSION CLUTCH FILL CALIBRATION

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
SERV1844 - 12 - Laboratory Exercises
11/07 Instructor Handout No. 11

Lab G: Transmission Hydraulic System Components

and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

I Differential lock solenoid A. Provides speed and directional conversion

of the available engine power.

H Transmission oil cooler

B. Transmission oil supply stored in the
bottom of the differential case.
F Transmission relief valve
C. Removes metal particles from the supply
oil.
E Transmission pump
D. Filters the oil from the transmission pump
to the transmission hydraulic system.
D Transmission filter

E. Supplies oil flow to the transmission

G Transmission modulating valves hydraulic system.

F. Limits the oil pressure to the proportional

B Transmission oil reservoir
solenoid valves.

C Magnetic screen G. Controls oil flow and pressure to the

clutches.

A Transmission
H. Cools the transmission hydraulic oil.

I. Controls oil flow to the differential lock.

SERV1844 - 13 - Laboratory Exercises
11/07 Instructor Handout No. 12

Lab H: Transmission Electronic Control System Components

and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition

D Transmission/Chassis ECM A. Signals the ECM when to energize the

engine start relay.

E Autoshift switch B. Allows the operator to manually

downshift the transmission.

B Downshift switch C. Measures input speed to the

transmission.

H Upshift switch D. Receives sensor and switch inputs and

controls transmission shifting and
engine starting.
C Transmission input speed sensor
E. Signals the ECM the shift mode in
which the operator wants to operate.
J Transmission modulating valves
F. Measures transmission output speed.

F Transmission output speed sensors G. Measures transmission oil temperature.

H. Allows the operator to manually

I Directional switch upshift the transmission.

I. Signals the ECM the direction the

G Transmission oil temperature sensor operator wants the machine to move.

J. Controls oil flow and pressure to the

A Engine key start switch clutches.
SERV1844 - 14 - Laboratory Exercises
11/07 Instructor Handout No. 13

Lab I Worksheet
Implement Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function
of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold, and pilot systems.
_____ Hydraulic Tank
Function: Stores the oil for the hydraulic systems on the machine.
Location: Behind the cab on the left side of the machine.

_____ Implement Control Valves

Function: To direct supply oil out to the machine's cylinders.
Location: Mounted to the left and right side of the frame below the cab.

_____ Implement and Steering Control Manifold

Function: Directs supply oil to the implement, steering, and pilot hydraulic systems.
Location: Mounted on a bracket attached to the transmission on the left side of the machine.

_____ Pilot Pressure Reducing Valve

Function: Reduces the pressure of the implement and steering supply oil to be used in the
implement control valves.
Location: Mounted in the implement and steering manifold.

_____ Main Relief Valve

Function: Protects the implement and steering systems from high pressure.
Location: Mounted in the implement and steering manifold.

_____ Implement and Steering Pressure Sensor

Function: Sends the Implement ECM indicating the pressure in the implement and steering
systems.
Location: Mounted above the implement/steering pump.

_____ Implement and Steering Pump

Function: Supplies oil flow to the implement and steering hydraulic systems.
Location: Mounted to the pump drive on the right side of the machine.

_____ Implement Pump

Function: Supplies oil to the implement system.
Location: Mounted to the implement/steering pump.

_____ Blade Lift Cylinders

Function: To raise and lower the blade.
Location: Mounted to the front frame and to the drawbar.
SERV1844 - 15 - Laboratory Exercises
11/07 Instructor Handout No. 14

Lab I Worksheet
Implement Component Identification Worksheet (continued)

_____ Blade Tip Cylinder

Function: Allows the operator to tilt the blade.
Location: Mounted to the blade and to the drawbar.

_____ Sideshift Cylinder

Function: Allows the operator to shift the blade from side to side.
Location: Mounted to the blade and to the drawbar.

_____ Centershift Cylinder

Function: Allows the operator to move the drawbar to the left or to the right.
Location: Mounted to the front frame and to the drawbar.

_____ Pilot Oil Filter

Function: Filters the pilot oil before the oil enters the implement control valves.
Location: Mounted on the right side of the machine near the hydraulic tank.

_____ Hydraulic Oil Filters

Function: Filter oil returning to the hydraulic tank.
Location: Mounted to the rear and to the right side of the tank.

_____ Case drain filter

Function: Filters oil from the pump case drains.
Location: On the left side of the hydraulic tank.

_____ Implement and Steering Joysticks

Function: Sends signals to the Implement ECMs based on operator input.
Location: On the left side and right side of the seat.

_____ Implement ECM

Function: Receives inputs and controls outputs of the implement hydraulic system.
Location: Rear of the operator's station behind the seat.

_____ Implement ECM (2)

Function: Receives inputs and controls outputs of the implement hydraulic system.
Location: Rear of the operator's station behind the seat.

_____ Hydraulic Lockout Switch

Function: Energizes or de-energizes the hydraulic lockout solenoid valve.
Location: In the service panel to the right of the operator's seat.

_____ Hydraulic Lockout Solenoid Valve

Function: Controls pilot oil flow to the electrohydraulic pilot control valves.
Location: On the steering and implement manifold.
SERV1844 - 16 - Laboratory Exercises
11/07 Instructor Handout No. 15

Lab I Worksheet
Implement Component Identification Worksheet (continued)

_____ Blade Cushion Switch (if equipped)

Function: To activate or deactivate the blade cushion.
Location: In the service panel to the right of the operator's seat.

_____ Blade Cushion Accumulators (if equipped)

Function: Provides a cushion for the blade lift cylinders in case the blade contacts an
immovable object.
Location: Mounted on the front frame by the blade lift cylinders.

_____ Ripper Control

Function: Sends a signal to the Implement ECM to raise/lower the ripper.
Location: To the right of the operator's seat.

_____ Ripper Cylinders

Function: To raise and lower the ripper.
Location: Mounted to the rear of the machine.
SERV1844 - 17 - Laboratory Exercises
11/07 Instructor Handout No. 16

Lab J: Implement Hydraulic System Tests Worksheet

PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS
Specification Actual Within Specification?
Pilot Pressure

Margin Pressure

Pump Cutoff Pressure

Signal Relief Valve

Main Relief Valve

COMPENSATOR VALVE PRESSURE AND FLOW ADJUSTMENT
Does the flow compensation 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 needs adjustment?
_____________________________________________________________________________

CYCLE TIME 1st Test 2nd Test 3rd Test Average

CHECK

Blade Lift
Blade Tip
Centershift
Sideshift
Blade Circle

Ripper
Oil Temp ____°F

Cycle times within specifications? Yes No

IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
Lab K: Implement Hydraulic System Identification
11/07

Directions: Fill in the blanks next to the letters with the correct term.
SERV1844

A. Main Relief Valve

B. Pilot Pressure Reducing Valve

C. Pilot Shutoff Valve

D. Pilot Oil Filter

E. Resolver
O
F. Articulation Cylinders P
L M
G. Line Relief Valve H I F
N
H. Blade Accumulator G
- 18 -

I. Blade Lift Cylinder

K
J. Electrohydraulic Solenoid Valve

K. Signal Relief Valve J

Steering
Control
Valve
L. Wheel Lean Cylinder E

Hydraulic Tank
M. Circle Drive Motor B C

N. Center Shift Cylinder A

D
Return
Filter
O. Side Shift Cylinder
Case
Return Drain
Filter Filter

P. Swivel
Instructor Handout No. 17
Laboratory Exercises
SERV1844 - 19 - Laboratory Exercises
11/07 Instructor Handout No. 18

Lab L: Implement System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

E Implement and steering joysticks A. Controls pilot oil to the implement control
spools.

B Implement ECM B. Controls the electrohydraulic pilot control

valve.

A Electrohydraulic pilot control C. Reduces the pressure of the Implement and

valves Steering System to the pressure setting for
the pilot system.

F Implement control valves D. Signals the ECM that the operator wants
the implement hydraulics disabled.

H Signal relief valve E. An input to the Implement ECM

controlling implement functions.

C Pilot pressure reducing valve F. Controls oil flow to the implement

cylinders.

I Implement and steering pump G. Used to connect the blade accumulators to

the blade cylinders.

D Hydraulic lockout switch H. Limits the maximum load signal that is sent
to the Implement and Steering Pump.

G Blade cushion solenoid valve I. Supplies oil for the implement and steering
systems.
SERV1844 - 20 - Laboratory Exercises
11/07 Instructor Handout No. 19

Lab M Worksheet
Steering Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function
of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold, and pilot systems.
_____ Hydraulic Tank
Function: Stores the oil for the hydraulic systems on the machine.
Location: Behind the cab on the left side of the machine.

_____ Implement and Steering Pump

Function: Supplies oil flow to the implement and steering hydraulic systems.
Location: Mounted to the pump drive on the right side of the machine.

_____ Implement and Steering Control Manifold

Function: Directs supply oil to the implement, steering, and pilot hydraulic systems.
Location: Mounted on a bracket attached to the transmission on the left side of the machine.

_____ Main Relief Valve

Function: Protects the implement and steering systems from high pressure.
Location: Mounted in the implement and steering manifold.

_____ Implement and Steering Pump Pressure Sensor

Function: Sends the Implement ECM a signal indicating the pressure in the implement and
steering systems..
Location: Mounted above the implement and steering pump.

_____ Steering Control Valve

Function: Directs oil to the steering cylinders to turn the machine.
Location: Mounted to the left side of the frame below the cab.

_____ Implement and Steering Joysticks

Function: Sends signals to the Implement ECMs based on operator input.
Location: On the left side and right side of the seat.

_____ Steering Cylinders

Function: To turn the front wheels to the left or to the right.
Location: Front of the machine.

_____ Steering Cylinder Position Sensors

Function: To send a signal to the Implement ECM indicating steering cylinder position.
Location: Inside of the steering cylinders.
SERV1844 - 21 - Laboratory Exercises
11/07 Instructor Handout No. 20

Lab M Worksheet
Steering Component Identification Worksheet (continued)

_____ Secondary Steering Pump

Function: Supplies steering system flow if the primary steering system or engine failure occurs.
Location: Mounted to the bottom of the output transfer gear.

_____ Secondary Steering Solenoid Valves

Function: Allows the operator to steer the machine when the primary solenoid valves have
failed.
Location: Mounted to the left side of the frame below the cab and above the steering control
valve.

_____ Primary Steering Indicator

Function: Alerts the operator of a failure of the primary steering system.
Location: On the right side of the dash.

_____ Secondary Steering Indicator

Function: Alerts the operator that the secondary steering system is activated.
Location: On the right side of the dash.

_____ Secondary Steering System Test Switch

Function: Manually activates the secondary steering system for test purposes.
Location: Front console in operator's station.

_____ Articulation Cylinders

Function: To articulate the machine to the left or to the right.
Location: Mounted to the front and rear frames.

_____ Articulation Position Sensors

Function: Sends a signal to the Implement ECM indicating how far the machine has been
articulated.
Location: On top of the articulation pins in the articulation hitch.

_____ Articulation Auto Recenter Switch

Function: To automatically recenter the front and rear frames.
Location: In the left implement and steering joystick.

_____ Wheel Lean Cylinder

Function: To lean the front wheels to the left or to the right.
Location: On the front of the machine.

_____ Wheel Lean Switches

Function: Allows the operator to lean the front wheels to the left or right.
Location: In the left implement and steering joystick.
SERV1844 - 22 - Laboratory Exercises
11/07 Instructor Handout No. 21

Lab N: Steering System Tests

STEERING SYSTEM PRESSURE TESTS

Specification Actual Within Specification?
Margin Pressure

Pump Cutoff Pressure

Signal Relief Valve

Main Relief Valve

ARTICULATION SOLENOIDS CALIBRATION

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED

ARTICULATION POSITION SENSORS CALIBRATION

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED

STEERING CYLINDER POSITION SENSOR CALIBRATION

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
SERV1844 - 23 - Laboratory Exercises
11/07 Instructor Handout No. 22

Lab O: Steering System Components and

Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

I Hydraulic tank A. Supplies steering system flow if the

primary steering system or engine failure
occurs.

H Implement and steering pump B. Directs oil to the spools in the steering
control valve for secondary steering
operation.

B Secondary steering solenoid valves C. An input to the Implement ECM

communicating the articulation angle of the
machine.

F Implement and steering pump D. An input to the Implement ECM to control

control valve steering functions.

C Articulation position sensors E. Alerts the operator of a failure of the

primary steering system.

J Steering control valve F. Controls pump flow and pressure.

E Primary steering indicator G. Alerts operator that the secondary steering

system is activated.

A Secondary steering motor and pump H. Supplies oil to the steering system when
the engine is running.

D Implement and steering joystick I. Stores the oil for the hydraulic systems on
the machine.

G Secondary steering indicator J. Directs oil to the steering cylinders to turn

the machine.
SERV1844 - 24 - Laboratory Exercises
11/07 Instructor Handout No. 23

Lab P Worksheet
Brake Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function
of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold, and pilot systems.
_____ Hydraulic Tank
Function: Stores the oil for the hydraulic systems on the machine.
Location: Behind the cab on the left side of the machine.

_____ Brake and Fan Pump

Function: Supplies oil flow to the brake and fan hydraulic systems.
Location: Mounted to the transmission pump on the left side of the machine.

_____ Accumulator Charging Valve

Function: Gives the brake system priority over the fan system and maintains accumulator
pressure.
Location: Left side of the machine near the articulation hitch.

_____ Brake Accumulators

Function: Supplies oil to the brake system.
Location: Mounted on the rear of the operator's station.

_____ Service Brake Valve

Function: Controls oil flow and pressure to the service brakes.
Location: Connected to the brake pedal and mounted on the front of the operator's station.

_____ Service Brake Pressure Sensor

Function: Sends the Trans/Chassis ECM a signal indicating the pressure in the brake
accumulators.
Location: Mounted on the accumulator charging valve.

_____ Service Brakes

Function: Primary brakes for stopping the machine.
Location: In the wheel stations of the tandem housing.

_____ Parking Brake Solenoid

Function: Controls oil flow to the parking brake.
Location: Mounted below the rear of the cab.
SERV1844 - 25 - Laboratory Exercises
11/07 Instructor Handout No. 24

Lab P Worksheet
Brake Component Identification Worksheet (continued)

_____ Parking Brake Pressure Switch

Function: Send the Trans/Chassis ECM a signal when the parking brake is released.
Location: On the parking brake valve.

_____ Parking Brake

Function: Prevents movement of the machine when engaged.
Location: In the wheel stations of the tandem housing.
SERV1844 - 26 - Laboratory Exercises
11/07 Instructor Handout No. 25

Lab Q: Brake System Tests Worksheet

ACCUMULATOR PRESSURE TEST

SPECIFICATION ACTUAL
Charging Valve Cut-in Pressure
Charging Valve Cut-out Pressure

BRAKE SYSTEM PRESSURE TEST

SPECIFICATION ACTUAL
Right Service Brake Control Valve Pressure

Left Service Brake Control Valve Pressure

SERVICE BRAKE TEST

Did the service brakes keep the machine from moving in Fifth Speed Forward at HIGH IDLE?

If the machine moves during the test, what is the next course of action?

PARKING BRAKE TEST

Did the parking brake keep the machine from moving in Fifth Speed Forward at HIGH IDLE?

If the machine moves during the test, what is the next course of action?
SERV1844 - 27 - Laboratory Exercises
11/07 Instructor Handout No. 26

Lab R: Brake System Components and

Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

C Hydraulic tank A. Primary brakes for stopping the machine.

F Parking brake B. Supplies oil to the brake and fan systems.

B Brake and fan pump C. Stores the oil for the hydraulic systems on
the machine.

A Service brakes D. Supply oil to the brake system when the

engine is OFF.

I Service brake pressure sensor E. Controls oil flow and pressure to the service
brakes.

J Parking brake valve F. Prevents movement of the machine when

engaged.

E Service brake valve G. Maintains accumulator pressure between

4485 kPa (2100 psi) CUT-OUT and
11725 kPa (1700 psi) CUT-IN.

H Parking brake pressure switch H. Sends parking brake oil pressure signal to
the Power Train ECM.

D Brake accumulators I. An input to the Trans/Chassis ECM

communicating the pressure in the brake
system.

G Accumulator charging valve J. Controls oil flow to release parking brake.

SERV1844 - 28 - Laboratory Exercises
11/07 Instructor Handout No. 27

Lab S Worksheet
Fan Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function
of each component is explained.
Example: _____Pilot Pump
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold, and pilot systems.
_____ Hydraulic Tank
Function: Stores the oil for the hydraulic systems on the machine.
Location: Behind the cab on the left side of the machine.

_____ Brake and Fan Pump

Function: Supplies oil flow to the brake and fan hydraulic systems.
Location: Mounted to the transmission pump on the left side of the machine.

_____ Fan Solenoid Valve

Function: Sends a load signal to the brake and fan pump to upstroke or destroke the brake and
fan pump.
Location: In the accumulator charging valve on the left side of the machine near the
articulation hitch.

_____ Fan Motor

Function: Converts hydraulic energy into mechanical motion.
Location: At the rear of the machine.

_____ Oil Cooler

Function: To cool oil returning to the hydraulic tank from the fan motor.
Location: At the rear of the machine.

_____ Engine ECM

Function: Electronic Control Module, governor, electronic fuel system control.
Location: Mounted on the engine, left side of engine.

_____ Engine Coolant Temperature Sensor

Function: Coolant temperature measurement for Engine ECM, instrument panel, temperature
warning.
Location: At the front of the engine on the water temperature regulator housing.

_____ Intake Manifold Temperature Sensor

Function: Intake air temperature measurement for Engine ECM and temperature warning.
Location: Located on the left side of the engine compartment in the intake manifold.
SERV1844 - 29 - Laboratory Exercise
11/07 Instructor Handout No. 28

Lab S Worksheet
Fan Component Identification Worksheet (continued)

_____ Hydraulic Oil Temperature Sensor

Function: Hydraulic oil temperature measurement for the Implement ECM and temperature
warning.
Location: At the rear of the machine by the fan oil cooler.
SERV1844 - 30 - Laboratory Exercises
11/07 Instructor Handout No. 29

Lab T: Fan System Tests Worksheet

FAN SYSTEM TEST

Specification Actual Within Specification?
Margin Pressure

High Pressure Cutoff

Minimum Fan Speed

Maximum Fan Speed

COMPENSATOR VALVE PRESSURE AND FLOW ADJUSTMENT
Does the flow compensation 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 needs adjustment?
_____________________________________________________________________________

FAN SYSTEM TEST

Where any faults present during the calibration (Yes or No)?

If faults were present, list the faults:
SERV1844 - 31 - Laboratory Exercises
11/07 Instructor Handout No. 30

Lab U: Fan System Components and

Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

H Hydraulic tank A. Coolant temperature measurement for

Engine ECM, instrument panel, temperature
warning.

B Fan solenoid valve B. Sends a load signal to the brake and fan
pump to upstroke or destroke the brake and
fan pump.

D Brake and fan pump C. Hydraulic oil temperature measurement for

the Implement ECM and temperature
warning.

F Fan motor D. Supplies oil to the brake and fan systems.

C Hydraulic oil temperature sensor E. Intake air temperature measurement for

Engine ECM and temperature warning.

G Engine ECM F. Converts hydraulic energy into mechanical

motion.

E Intake manifold temperature sensor G. Electronic Control Module, governor,

electronic fuel system control.

A Engine coolant temperature sensor H. Stores the oil for the hydraulic systems on
the machine.
SERV1844 - 32 - Instructor Handout No. 31
11/07

HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical Connection. Seal Red - High Pressure Oil

Dark Gray - Cutaway Section Red / White Stripes - 1st Pressure Reduction

Light Gray - Surface Color Red Crosshatch - 2nd Reduction in Pressure

White - Atmosphere or Air (No Pressure) Pink - 3rd Reduction in Pressure

Purple - Pneumatic Pressure Red / Pink Stripes - Secondary Source Oil Pressure

Yellow - Moving or Activated Components Orange - Pilot, Charge or Torque Converter Oil

Cat Yellow - (Restricted Usage) Orange / White Stripes - Reduced Pilot, Charge, or
Identification of Components TC Oil Pressure
within a Moving Group
Orange / Crosshatch - 2nd Reduction in Pilot,
Brown - Lubricating Oil Charge, or TC Oil Pressure

Green - Tank, Sump, or Return Oil Blue - Trapped Oil

Green / White Stripes -

Scavenge / Suction Oil or Hydraulic Void

HYDRAULIC SCHEMATIC COLOR CODE

This illustration identifies the meanings of the colors used in the hydraulic schematics and
cross-sectional views shown throughout this presentation.