SERV1844

November 2007

GLOBAL SERVICE LEARNING

INSTRUCTOR MATERIALS

PART OF GLOBAL SERVICE LEARNING MODULE SERV1844

24M MOTOR GRADER

INTRODUCTION

LAB EXERCISES AND POSTTEST ANSWERS

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Laboratory Exercises
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

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Laboratory Exercises
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__________

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Laboratory Exercises
Instructor Handout No. 3

Lab B: Messenger System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component

Function Definition

Service; Tattletale; Tattletale

Active Mode

A. Menu that contains information on

alternator status.

Settings; Transmission

B. Menu that contains information on

maximum recorded coolant temperature.

Service; System Parameters;

Engine

C. Menu that contains total fuel usage.

Service; System Parameters;

Transmission

D. Menu that contains information on

transmission output speed.

Service; System Parameters;

Monitoring System

E. Menu that contains maximum fwd

autoshift gear.

Totals; Lifetime Totals

F. Menu that contains information on inlet

air temperature.

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
Instructor Handout No. 6

Lab D: Engine System Components and Functions Posttest

Directions: Match each component to the correct function.
Function Component

Function Definition

Turbo inlet pressure sensor

A. Receives sensor and switch inputs and

controls fan speed and engine rpm

Engine derate

Engine ECM

B. A horsepower limiting event that limits

horsepower and continues to limit the
horsepower once the condition no longer
exists

Fuel transfer pump

C. Final preparation of the fuel before the

fuel enters the fuel gallery

Atmospheric pressure sensor

D. Supplies flow to the engine fuel system

Differential fuel pressure switch

E. An event that is based on atmospheric

pressure, intake manifold temperature,
and engine rpm
F. A horsepower limiting event that no
longer limits horsepower when the
condition no longer exists

Secondary fuel filter

Timing calibration connector

G. An event that limits the engine

horsepower

Non-latching derate

H. Engine ECM uses this sensor to calculate

all other pressure sensors on the engine

Latching derate

I. Used for timing the engine if the Engine

ECM or timing sensor is replaced

Virtual exhaust derate

J. Engine ECM uses this sensor to calculate

air filter restriction
K. Compares the difference between
incoming and outgoing fuel pressure

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
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

DIRECTION
Engine at LOW IDLE

WHICH
SOLENOIDS
ARE
ON?

If E.T. is available, record

WHICH
CLUTCHES the following information:
ARE
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
CALIBRATION
COMPLETED

NO

FAULTS PRESENT

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Laboratory Exercises
Instructor Handout No. 11

Lab G: Transmission Hydraulic System Components

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

Differential lock solenoid

Transmission oil cooler

Transmission relief valve

Function Definition
A. Provides speed and directional conversion
of the available engine power.
B. Transmission oil supply stored in the
bottom of the differential case.
C. Removes metal particles from the supply
oil.

Transmission pump

Transmission filter

Transmission modulating valves

Transmission oil reservoir

Magnetic screen

Transmission

D. Filters the oil from the transmission pump

to the transmission hydraulic system.
E. Supplies oil flow to the transmission
hydraulic system.
F. Limits the oil pressure to the proportional
solenoid valves.
G. Controls oil flow and pressure to the
clutches.
H. Cools the transmission hydraulic oil.
I. Controls oil flow to the differential lock.

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Laboratory Exercises
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

Transmission/Chassis ECM

A. Signals the ECM when to energize the

engine start relay.

Autoshift switch

B. Allows the operator to manually

downshift the transmission.

Downshift switch

C. Measures input speed to the

transmission.

Upshift switch

D. Receives sensor and switch inputs and

controls transmission shifting and
engine starting.

Transmission input speed sensor

E. Signals the ECM the shift mode in
which the operator wants to operate.

Transmission modulating valves

F. Measures transmission output speed.

Transmission output speed sensors

G. Measures transmission oil temperature.

Directional switch

H. Allows the operator to manually

upshift the transmission.

Transmission oil temperature sensor

I. Signals the ECM the direction the

operator wants the machine to move.

Engine key start switch

J. Controls oil flow and pressure to the

clutches.

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
Instructor Handout No. 16

Lab J: Implement Hydraulic System Tests Worksheet

PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS
Actual
Within Specification?
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?
Does the pressure compensator valve need adjustment?

YES
YES

NO
/

NO

Which tests indicate if the flow compensator or the pressure compensator needs adjustment?
_____________________________________________________________________________

CYCLE TIME
CHECK

1st Test

2nd Test

3rd Test

Average

Blade Lift
Blade Tip
Centershift
Sideshift
Blade Circle
Ripper
Oil Temp ____F
Cycle times within specifications?

Yes

No

IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS

YES
CALIBRATION
COMPLETED

NO

FAULTS PRESENT

P. Swivel

O. Side Shift Cylinder

N. Center Shift Cylinder

Return
Filter

Return
Filter
Case
Drain
Filter

Hydraulic Tank

M
F

Steering
Control
Valve

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M. Circle Drive Motor

L. Wheel Lean Cylinder

K. Signal Relief Valve

J. Electrohydraulic Solenoid Valve

I. Blade Lift Cylinder

H. Blade Accumulator

G. Line Relief Valve

F. Articulation Cylinders

E. Resolver

D. Pilot Oil Filter

C. Pilot Shutoff Valve

B. Pilot Pressure Reducing Valve

A. Main Relief Valve

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

Lab K: Implement Hydraulic System Identification

SERV1844
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Laboratory Exercises
Instructor Handout No. 17

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Laboratory Exercises
Instructor Handout No. 18

Lab L: Implement System Components and Functions Posttest

Directions: Match each component to the correct function.
Function Component

Function Definition

Implement and steering joysticks

A. Controls pilot oil to the implement control

spools.

Implement ECM

B. Controls the electrohydraulic pilot control

valve.

Electrohydraulic pilot control

valves

C. Reduces the pressure of the Implement and

Steering System to the pressure setting for
the pilot system.

Implement control valves

D. Signals the ECM that the operator wants

the implement hydraulics disabled.

Signal relief valve

E. An input to the Implement ECM

controlling implement functions.

Pilot pressure reducing valve

F. Controls oil flow to the implement

cylinders.

Implement and steering pump

G. Used to connect the blade accumulators to

the blade cylinders.

Hydraulic lockout switch

H. Limits the maximum load signal that is sent

to the Implement and Steering Pump.

Blade cushion solenoid valve

I. Supplies oil for the implement and steering

systems.

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
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
CALIBRATION
COMPLETED

NO

FAULTS PRESENT

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Laboratory Exercises
Instructor Handout No. 22

Lab O: Steering System Components and

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

Function Definition

Hydraulic tank

A. Supplies steering system flow if the

primary steering system or engine failure
occurs.

Implement and steering pump

B. Directs oil to the spools in the steering

control valve for secondary steering
operation.

Secondary steering solenoid valves

C. An input to the Implement ECM

communicating the articulation angle of the
machine.

Implement and steering pump

control valve

D. An input to the Implement ECM to control

steering functions.

Articulation position sensors

E. Alerts the operator of a failure of the

primary steering system.

Steering control valve

F. Controls pump flow and pressure.

Primary steering indicator

G. Alerts operator that the secondary steering

system is activated.

Secondary steering motor and pump

H. Supplies oil to the steering system when

the engine is running.

Implement and steering joystick

I. Stores the oil for the hydraulic systems on

the machine.

Secondary steering indicator

J. Directs oil to the steering cylinders to turn

the machine.

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Laboratory Exercises
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.

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Laboratory Exercises
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.

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Laboratory Exercises
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
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Laboratory Exercises
Instructor Handout No. 26

Lab R: Brake System Components and

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

Component

Function Definition

Hydraulic tank

A. Primary brakes for stopping the machine.

Parking brake

B. Supplies oil to the brake and fan systems.

Brake and fan pump

C. Stores the oil for the hydraulic systems on

the machine.

Service brakes

D. Supply oil to the brake system when the

engine is OFF.

Service brake pressure sensor

E. Controls oil flow and pressure to the service

brakes.

Parking brake valve

F. Prevents movement of the machine when

engaged.

Service brake valve

G. Maintains accumulator pressure between

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

Parking brake pressure switch

H. Sends parking brake oil pressure signal to

the Power Train ECM.

Brake accumulators

I. An input to the Trans/Chassis ECM

communicating the pressure in the brake
system.

Accumulator charging valve

J. Controls oil flow to release parking brake.

SERV1844
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Laboratory Exercises
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
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Laboratory Exercise
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
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Laboratory Exercises
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?
Does the pressure compensator valve need adjustment?

YES
YES

NO
/

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
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Laboratory Exercises
Instructor Handout No. 30

Lab U: Fan System Components and

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

Component

Function Definition

Hydraulic tank

A. Coolant temperature measurement for

Engine ECM, instrument panel, temperature
warning.

Fan solenoid valve

B. Sends a load signal to the brake and fan

pump to upstroke or destroke the brake and
fan pump.

Brake and fan pump

C. Hydraulic oil temperature measurement for

the Implement ECM and temperature
warning.

Fan motor

D. Supplies oil to the brake and fan systems.

Hydraulic oil temperature sensor

E. Intake air temperature measurement for

Engine ECM and temperature warning.

Engine ECM

F. Converts hydraulic energy into mechanical

motion.

Intake manifold temperature sensor

G. Electronic Control Module, governor,

electronic fuel system control.

Engine coolant temperature sensor

H. Stores the oil for the hydraulic systems on

the machine.

SERV1844
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Instructor Handout No. 31

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)

Identification of Components
within a Moving Group

Orange / White Stripes - Reduced Pilot, Charge, or

TC Oil Pressure

Brown - Lubricating Oil

Orange / Crosshatch - 2nd Reduction in Pilot,

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.

SERV1844
November 2007

GLOBAL SERVICE LEARNING

STUDENT MATERIALS

PART OF GLOBAL SERVICE LEARNING MODULE SERV1844

24M MOTOR GRADER

INTRODUCTION

LAB EXERCISES AND POSTTEST

SERV1844
11/07

-2-

Laboratory Exercises
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
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-3-

Laboratory Exercises
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
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Laboratory Exercises
Instructor Handout No. 3

Lab B: Messenger System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component

Function Definition

Service; Tattletale; Tattletale

Active Mode

A. Menu that contains information on

alternator status.

Settings; Transmission

B. Menu that contains information on

maximum recorded coolant temperature.

Service; System Parameters;

Engine

C. Menu that contains total fuel usage.

Service; System Parameters;

Transmission

D. Menu that contains information on

transmission output speed.

Service; System Parameters;

Monitoring System

E. Menu that contains maximum fwd

autoshift gear.

Totals; Lifetime Totals

F. Menu that contains information on inlet

air temperature.

SERV1844
11/07

-5-

Laboratory Exercises
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:
Location:
_____ Primary Fuel Filter
Function:
Location:
_____ Fuel Transfer Pump
Function:
Location:
_____ Electronic Priming Pump
Function:
Location:
_____ Secondary Fuel Filter
Function:
Location:
_____ Electronic Unit Injectors
Function:
Location:
_____ Primary Speed Sensor
Function:
Location:
_____ Secondary Speed Sensor
Function:
Location:

SERV1844
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-6-

Laboratory Exercises
Instructor Handout No. 5

Lab C Worksheet
C18 ACERT Engine Component Identification Worksheet (continued)
_____ Engine Coolant Temperature Sensor
Function:
Location:
_____ Engine Oil Pressure Sensor
Function:
Location:
_____ Intake Manifold Air Pressure Sensor
Function:
Location:
_____ Intake Manifold Air Temperature Sensor
Function:
Location:
_____ Turbo Inlet Pressure Sensor
Function:
Location:
_____ Throttle Control Mode Switch
Function:
Location:
_____ Throttle Resume/Decelerate Switch
Function:
Location:
_____ Throttle Set/Accelerate Switch
Function:
Location:
_____ Throttle Position Sensor
Function:
Location:

SERV1844
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Laboratory Exercises
Instructor Handout No. 6

Lab D: Engine System Components and Functions Posttest

Directions: Match each component to the correct function.
Function Component

Function Definition

Turbo inlet pressure sensor

A. Receives sensor and switch inputs and

controls fan speed and engine rpm

Engine derate

Engine ECM

B. A horsepower limiting event that limits

horsepower and continues to limit the
horsepower once the condition no longer
exists

Fuel transfer pump

C. Final preparation of the fuel before the

fuel enters the fuel gallery
D. Supplies flow to the engine fuel system

Atmospheric pressure sensor

Differential fuel pressure switch

Secondary fuel filter

E. An event that is based on atmospheric

pressure, intake manifold temperature,
and engine rpm
F. A horsepower limiting event that no
longer limits horsepower when the
condition no longer exists

Timing calibration connector

G. An event that limits the engine

horsepower

Non-latching derate

H. Engine ECM uses this sensor to calculate

all other pressure sensors on the engine

Latching derate

I. Used for timing the engine if the Engine

ECM or timing sensor is replaced

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
11/07

-8-

Laboratory Exercises
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:
Location:
_____ Transmission
Function:
Location:
_____ Transmission Pump
Function:
Location:
_____ Transmission Relief Valve
Function:
Location:
_____ Transmission Filter
Function:
Location:
_____ Transmission Modulating Valves
Function:
Location:
_____ Transmission Input Speed Sensor
Function:
Location:
_____ Transmission Output Speed Sensors
Function:
Location:

SERV1844
11/07

-9-

Laboratory Exercises
Instructor Handout No. 8

Lab E Worksheet
Power Train Component Identification Worksheet (continued)
_____ Transmission Oil Temperature Sensor
Function:
Location:
_____ Magnetic Screen
Function:
Location:
_____ Power Train Oil Cooler
Function:
Location:
_____ Engine Key Start Switch
Function:
Location:
_____ Engine Start Relay
Function:
Location:
_____ Autoshift Switch (if equipped)
Function:
Location:
_____ Directional Switch
Function:
Location:
_____ Upshift switch
Function:
Location:
_____ Downshift switch
Function:
Location:
_____ Differential Lock Switch
Function:
Location:

SERV1844
11/07

- 10 -

Laboratory Exercises
Instructor Handout No. 9

Lab E Worksheet
Power Train Component Identification Worksheet (continued)
_____ Differential Lock Solenoid
Function:
Location:
_____ Differential
Function:
Location:
_____ Final Drives
Function:
Location:
_____ Back-up Alarm
Function:
Location:

SERV1844
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- 11 -

Laboratory Exercises
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

DIRECTION
Engine at LOW IDLE

WHICH
SOLENOIDS
ARE
ON?

If E.T. is available, record

WHICH
CLUTCHES the following information:
ARE
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
CALIBRATION
COMPLETED

NO

FAULTS PRESENT

SERV1844
11/07

- 12 -

Laboratory Exercises
Instructor Handout No. 11

Lab G: Transmission Hydraulic System Components

and Functions Posttest
Directions: Match each component to the correct function.
Function Component
Differential lock solenoid

Transmission oil cooler

Function Definition
A. Provides speed and directional conversion
of the available engine power.
B. Transmission oil supply stored in the
bottom of the differential case.

Transmission relief valve

C. Removes metal particles from the supply
oil.
Transmission pump

Transmission filter

Transmission modulating valves

Transmission oil reservoir

Magnetic screen

Transmission

D. Filters the oil from the transmission pump

to the transmission hydraulic system.
E. Supplies oil flow to the transmission
hydraulic system.
F. Limits the oil pressure to the proportional
solenoid valves.
G. Controls oil flow and pressure to the
clutches.
H. Cools the transmission hydraulic oil.
I. Controls oil flow to the differential lock.

SERV1844
11/07

- 13 -

Laboratory Exercises
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

Transmission/Chassis ECM

A. Signals the ECM when to energize the

engine start relay.

Autoshift switch

B. Allows the operator to manually

downshift the transmission.

Downshift switch

C. Measures input speed to the

transmission.

Upshift switch

D. Receives sensor and switch inputs and

controls transmission shifting and
engine starting.

Transmission input speed sensor

E. Signals the ECM the shift mode in
which the operator wants to operate.
Transmission modulating valves
F. Measures transmission output speed.
Transmission output speed sensors

G. Measures transmission oil temperature.

Directional switch

H. Allows the operator to manually

upshift the transmission.

Transmission oil temperature sensor

I. Signals the ECM the direction the

operator wants the machine to move.

Engine key start switch

J. Controls oil flow and pressure to the

clutches.

SERV1844
11/07

- 14 -

Laboratory Exercises
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:
Location:
_____ Implement Control Valves
Function:
Location:
_____ Implement and Steering Control Manifold
Function:
Location:
_____ Pilot Pressure Reducing Valve
Function:
Location:
_____ Main Relief Valve
Function:
Location:
_____ Implement and Steering Pressure Sensor
Function:
Location:
_____ Implement and Steering Pump
Function:
Location:
_____ Implement Pump
Function:
Location:
_____ Blade Lift Cylinders
Function:
Location:

SERV1844
11/07

- 15 -

Laboratory Exercises
Instructor Handout No. 14

Lab I Worksheet
Implement Component Identification Worksheet (continued)
_____ Blade Tip Cylinder
Function:
Location:
_____ Sideshift Cylinder
Function:
Location:
_____ Centershift Cylinder
Function:
Location:
_____ Pilot Oil Filter
Function:
Location:
_____ Hydraulic Oil Filters
Function:
Location:
_____ Case drain filter
Function:
Location:
_____ Implement and Steering Joysticks
Function:
Location:
_____ Implement ECM
Function:
Location:
_____ Implement ECM (2)
Function:
Location:
_____ Hydraulic Lockout Switch
Function:
Location:
_____ Hydraulic Lockout Solenoid Valve
Function:
Location:

SERV1844
11/07

- 16 -

Laboratory Exercises
Instructor Handout No. 15

Lab I Worksheet
Implement Component Identification Worksheet (continued)
_____ Blade Cushion Switch (if equipped)
Function:
Location:
_____ Blade Cushion Accumulators (if equipped)
Function:
Location:
_____ Ripper Control
Function:
Location:
_____ Ripper Cylinders
Function:
Location:

SERV1844
11/07

- 17 -

Laboratory Exercises
Instructor Handout No. 16

Lab J: Implement Hydraulic System Tests Worksheet

PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS
Actual
Within Specification?
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?
Does the pressure compensator valve need adjustment?

YES
YES

NO
/

NO

Which tests indicate if the flow compensator or the pressure compensator needs adjustment?
_____________________________________________________________________________

CYCLE TIME
CHECK

1st Test

2nd Test

3rd Test

Average

Blade Lift
Blade Tip
Centershift
Sideshift
Blade Circle
Ripper
Oil Temp ____F
Cycle times within specifications?

Yes

No

IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS

YES
CALIBRATION
COMPLETED

NO

FAULTS PRESENT

P.

O.

N.

Return
Filter

Return
Filter
Case
Drain
Filter

Hydraulic Tank

N
F

Steering
Control
Valve

- 18 -

M.

L.

K.

J.

I.

H.

G.

F.

E.

D.

C.

B.

A.

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

Lab K: Implement Hydraulic System Identification

SERV1844
11/07
Laboratory Exercises
Instructor Handout No. 17

SERV1844
11/07

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Laboratory Exercises
Instructor Handout No. 18

Lab L: Implement System Components and Functions Posttest

Directions: Match each component to the correct function.
Function Component

Function Definition

Implement and steering joysticks

A. Controls pilot oil to the implement control

spools.

Implement ECM

B. Controls the electrohydraulic pilot control

valve.

Electrohydraulic pilot control

valves

C. Reduces the pressure of the Implement and

Steering System to the pressure setting for
the pilot system.

Implement control valves

D. Signals the ECM that the operator wants

the implement hydraulics disabled.

Signal relief valve

E. An input to the Implement ECM

controlling implement functions.

Pilot pressure reducing valve

F. Controls oil flow to the implement

cylinders.

Implement and steering pump

G. Used to connect the blade accumulators to

the blade cylinders.

Hydraulic lockout switch

H. Limits the maximum load signal that is sent

to the Implement and Steering Pump.

Blade cushion solenoid valve

I. Supplies oil for the implement and steering

systems.

SERV1844
11/07

- 20 -

Laboratory Exercises
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:
Location:
_____ Implement and Steering Pump
Function:
Location:
_____ Implement and Steering Control Manifold
Function:
Location:
_____ Main Relief Valve
Function:
Location:
_____ Implement and Steering Pump Pressure Sensor
Function:
Location:
_____ Steering Control Valve
Function:
Location:
_____ Implement and Steering Joysticks
Function:
Location:
_____ Steering Cylinders
Function:
Location:
_____ Steering Cylinder Position Sensors
Function:
Location:

SERV1844
11/07

- 21 -

Laboratory Exercises
Instructor Handout No. 20

Lab M Worksheet
Steering Component Identification Worksheet (continued)
_____ Secondary Steering Pump
Function:
Location:
_____ Secondary Steering Solenoid Valves
Function:
Location:
_____ Primary Steering Indicator
Function:
Location:
_____ Secondary Steering Indicator
Function:
Location:
_____ Secondary Steering System Test Switch
Function:
Location:
_____ Articulation Cylinders
Function:
Location:
_____ Articulation Position Sensors
Function:
Location:
_____ Articulation Auto Recenter Switch
Function:
Location:
_____ Wheel Lean Cylinder
Function:
Location:
_____ Wheel Lean Switches
Function:
Location:

SERV1844
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- 22 -

Laboratory Exercises
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
CALIBRATION
COMPLETED

NO

FAULTS PRESENT

SERV1844
11/07

- 23 -

Laboratory Exercises
Instructor Handout No. 22

Lab O: Steering System Components and

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

Function Definition

Hydraulic tank

A. Supplies steering system flow if the

primary steering system or engine failure
occurs.

Implement and steering pump

B. Directs oil to the spools in the steering

control valve for secondary steering
operation.

Secondary steering solenoid valves

C. An input to the Implement ECM

communicating the articulation angle of the
machine.

Implement and steering pump

control valve

D. An input to the Implement ECM to control

steering functions.

Articulation position sensors

E. Alerts the operator of a failure of the

primary steering system.

Steering control valve

F. Controls pump flow and pressure.

Primary steering indicator

G. Alerts operator that the secondary steering

system is activated.

Secondary steering motor and pump

H. Supplies oil to the steering system when

the engine is running.

Implement and steering joystick

I. Stores the oil for the hydraulic systems on

the machine.

Secondary steering indicator

J. Directs oil to the steering cylinders to turn

the machine.

SERV1844
11/07

- 24 -

Laboratory Exercises
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:
Location:
_____ Brake and Fan Pump
Function:
Location:
_____ Accumulator Charging Valve
Function:
Location:
_____ Brake Accumulators
Function:
Location:
_____ Service Brake Valve
Function:
Location:
_____ Service Brake Pressure Sensor
Function:
Location:
_____ Service Brakes
Function:
Location:
_____ Parking Brake Solenoid
Function:
Location:

SERV1844
11/07

- 25 -

Laboratory Exercises
Instructor Handout No. 24

Lab P Worksheet
Brake Component Identification Worksheet (continued)
_____ Parking Brake Pressure Switch
Function:
Location:
_____ Parking Brake
Function:
Location:

SERV1844
11/07

- 26 -

Laboratory Exercises
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
11/07

- 27 -

Laboratory Exercises
Instructor Handout No. 26

Lab R: Brake System Components and

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

Component

Function Definition

Hydraulic tank

A. Primary brakes for stopping the machine.

Parking brake

B. Supplies oil to the brake and fan systems.

Brake and fan pump

C. Stores the oil for the hydraulic systems on

the machine.

Service brakes

D. Supply oil to the brake system when the

engine is OFF.

Service brake pressure sensor

E. Controls oil flow and pressure to the service

brakes.

Parking brake valve

F. Prevents movement of the machine when

engaged.

Service brake valve

G. Maintains accumulator pressure between

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

Parking brake pressure switch

H. Sends parking brake oil pressure signal to

the Power Train ECM.

Brake accumulators

I. An input to the Trans/Chassis ECM

communicating the pressure in the brake
system.

Accumulator charging valve

J. Controls oil flow to release parking brake.

SERV1844
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- 28 -

Laboratory Exercises
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:
Location:
_____ Brake and Fan Pump
Function:
Location:
_____ Fan Solenoid Valve
Function:
Location:
_____ Fan Motor
Function:
Location:
_____ Oil Cooler
Function:
Location:
_____ Engine ECM
Function:
Location:
_____ Engine Coolant Temperature Sensor
Function:
Location:
_____ Intake Manifold Temperature Sensor
Function:
Location:

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Laboratory Exercise
Instructor Handout No. 28

Lab S Worksheet
Fan Component Identification Worksheet (continued)
_____ Hydraulic Oil Temperature Sensor
Function:
Location:

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Laboratory Exercises
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?
Does the pressure compensator valve need adjustment?

YES
YES

NO
/

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:

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Laboratory Exercises
Instructor Handout No. 30

Lab U: Fan System Components and

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

Component

Function Definition

Hydraulic tank

A. Coolant temperature measurement for

Engine ECM, instrument panel, temperature
warning.

Fan solenoid valve

B. Sends a load signal to the brake and fan

pump to upstroke or destroke the brake and
fan pump.

Brake and fan pump

C. Hydraulic oil temperature measurement for

the Implement ECM and temperature
warning.

Fan motor

D. Supplies oil to the brake and fan systems.

Hydraulic oil temperature sensor

E. Intake air temperature measurement for

Engine ECM and temperature warning.

Engine ECM

F. Converts hydraulic energy into mechanical

motion.

Intake manifold temperature sensor

G. Electronic Control Module, governor,

electronic fuel system control.

Engine coolant temperature sensor

H. Stores the oil for the hydraulic systems on

the machine.

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Instructor Handout No. 31

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)

Identification of Components
within a Moving Group

Orange / White Stripes - Reduced Pilot, Charge, or

TC Oil Pressure

Brown - Lubricating Oil

Orange / Crosshatch - 2nd Reduction in Pilot,

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.