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SERV1844 November 2007
INSTRUCTOR MATERIALS
PART OF GLOBAL SERVICE LEARNING MODULE SERV1844
24M MOTOR GRADER
INTRODUCTION
LAB EXERCISES AND POSTTEST ANSWERS
GLOBAL SERVICE LEARNING
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Component Identification
Description
Identify the components of the 24M Motor Grader. Use the worksheets to take notes on thetypes of input components. After locating the components on the schematic, locate thecomponents on the engine or machine.
Materials Needed
__ Electrical Schematic (for the machine being used)
__ Machine or engine with an electronic control system
SERV1844 - 2 - Laboratory Exercises11/07 Instructor Handout No. 1
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SERV1844 - 3 - Laboratory Exercises11/07 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 switchstatus__________
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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SERV1844 - 4 - Laboratory Exercises11/07 Instructor Handout No. 3
Lab B: Messenger System Components and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Service; Tattletale; TattletaleActive Mode
Settings; Transmission
Service; System Parameters;Engine
Service; System Parameters;Transmission
Service; System Parameters;Monitoring System
Totals; Lifetime Totals
A. Menu that contains information onalternator status.
B. Menu that contains information onmaximum recorded coolant temperature.
C. Menu that contains total fuel usage.
D. Menu that contains information ontransmission output speed.
E. Menu that contains maximum fwd autoshift gear.
F. Menu that contains information on inletair temperature.
B
E
F
D
A
C
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Lab C WorksheetC18 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 SwitchFunction: Allows the operator to select the throttle control mode.Location: On the panel to the right of the operator's seat.
_____ Throttle Resume/Decelerate SwitchFunction: 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 SwitchFunction: 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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SERV1844 - 7 - Laboratory Exercises11/07 Instructor Handout No. 6
Lab D: Engine System Components and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Turbo inlet pressure sensor
Engine derate
Engine ECM
Fuel transfer pump
Atmospheric pressure sensor
Differential fuel pressure switch
Secondary fuel filter
Timing calibration connector
Non-latching derate
Latching derate
Virtual exhaust derate
A. Receives sensor and switch inputs and controls fan speed and engine rpm
B. A horsepower limiting event that limitshorsepower and continues to limit thehorsepower once the condition no longer exists
C. Final preparation of the fuel before thefuel enters the fuel gallery
D. Supplies flow to the engine fuel system
E. An event that is based on atmospheric pressure, intake manifold temperature,and engine rpm
F. A horsepower limiting event that nolonger limits horsepower when thecondition no longer exists
G. An event that limits the enginehorsepower
H. Engine ECM uses this sensor to calculateall other pressure sensors on the engine
I. Used for timing the engine if the EngineECM or timing sensor is replaced
J. Engine ECM uses this sensor to calculateair filter restriction
K. Compares the difference betweenincoming and outgoing fuel pressure
J
G
A
D
H
K
C
I
F
B
H
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Lab E WorksheetPower 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 ScreenFunction: 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 SwitchFunction: 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 RelayFunction: 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 SwitchFunction: Allows operator to select desired direction and speed.Location: Mounted in the left steering/implement joystick.
_____ Upshift switchFunction: Allows the operator to manually upshift the transmission.Location: Mounted in the left steering/implement joystick.
_____ Downshift switchFunction: Allows the operator to manually downshift the transmission.Location: Mounted in the left steering/implement joystick.
_____ Differential Lock SwitchFunction: 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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Lab E WorksheetPower Train Component Identification Worksheet (continued)
_____ Differential Lock Solenoid Function: Controls oil flow to the differential lock.Location: Mounted on the differential case.
_____ DifferentialFunction: To send power from the transmission out to the wheels.Location: Mounted in the rear frame near the rear of the machine.
_____ Final DrivesFunction: Provides a final gear reduction to provide the most torque during machine
operation.Location: Mounted on the side of the differential case.
_____ Back-up AlarmFunction: Alerts surrounding area that the machine has been put into reverse.Location: Mounted at the rear of the machine.
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SERV1844 - 11 - Laboratory Exercises11/07 Instructor Handout No. 10
Lab F: Power Train Hydraulic System Tests Worksheet
ACTUALSPECIFICATION
Differential Lock Pressure (kPa/psi)
Lubrication Pressure (kPa/psi)
Transmission Pump Pressure (kPa/psi)
POWER TRAIN HYDRAULIC SYSTEM
WHICHSOLENOIDS
AREON?
WHICHCLUTCHES
AREENGAGED? 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
SPEED RANGE ANDDIRECTION
If E.T. is available, recordthe following information:
Engine at LOW IDLE
TRANSMISSION CLUTCH FILL CALIBRATION
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
Third Speed Reverse
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SERV1844 - 12 - Laboratory Exercises11/07 Instructor Handout No. 11
Lab G: Transmission Hydraulic System Componentsand Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Differential lock solenoid
Transmission oil cooler
Transmission relief valve
Transmission pump
Transmission filter
Transmission modulating valves
Transmission oil reservoir
Magnetic screen
Transmission
A. Provides speed and directional conversionof the available engine power.
B. Transmission oil supply stored in the bottom of the differential case.
C. Removes metal particles from the supply
oil.
D. Filters the oil from the transmission pumpto the transmission hydraulic system.
E. Supplies oil flow to the transmissionhydraulic system.
F. Limits the oil pressure to the proportional
solenoid valves.
G. Controls oil flow and pressure to theclutches.
H. Cools the transmission hydraulic oil.
I. Controls oil flow to the differential lock.
I
H
F
E
D
G
B
C
A
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SERV1844 - 13 - Laboratory Exercises11/07 Instructor Handout No. 12
Lab H: Transmission Electronic Control System Componentsand Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Transmission/Chassis ECM
Autoshift switch
Downshift switch
Upshift switch
Transmission input speed sensor
Transmission modulating valves
Transmission output speed sensors
Directional switch
Transmission oil temperature sensor
Engine key start switch
A. Signals the ECM when to energize theengine start relay.
B. Allows the operator to manuallydownshift the transmission.
C. Measures input speed to thetransmission.
D. Receives sensor and switch inputs and controls transmission shifting and engine starting.
E. Signals the ECM the shift mode inwhich the operator wants to operate.
F. Measures transmission output speed.
G. Measures transmission oil temperature.
H. Allows the operator to manuallyupshift the transmission.
I. Signals the ECM the direction theoperator wants the machine to move.
J. Controls oil flow and pressure to theclutches.
D
E
B
H
C
J
F
I
G
A
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Lab I WorksheetImplement Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 ValvesFunction: 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 ValveFunction: 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 ValveFunction: 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 PumpFunction: Supplies oil flow to the implement and steering hydraulic systems.Location: Mounted to the pump drive on the right side of the machine.
_____ Implement PumpFunction: Supplies oil to the implement system.Location: Mounted to the implement/steering pump.
_____ Blade Lift CylindersFunction: To raise and lower the blade.Location: Mounted to the front frame and to the drawbar.
SERV1844 - 14 - Laboratory Exercises11/07 Instructor Handout No. 13
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Lab I WorksheetImplement 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 FiltersFunction: 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 JoysticksFunction: Sends signals to the Implement ECMs based on operator input.Location: On the left side and right side of the seat.
_____ Implement ECMFunction: 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 SwitchFunction: 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 ValveFunction: Controls pilot oil flow to the electrohydraulic pilot control valves.Location: On the steering and implement manifold.
SERV1844 - 15 - Laboratory Exercises11/07 Instructor Handout No. 14
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Lab I WorksheetImplement 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 ControlFunction: Sends a signal to the Implement ECM to raise/lower the ripper.Location: To the right of the operator's seat.
_____ Ripper CylindersFunction: To raise and lower the ripper.Location: Mounted to the rear of the machine.
SERV1844 - 16 - Laboratory Exercises11/07 Instructor Handout No. 15
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Lab J: Implement Hydraulic System Tests Worksheet
SERV1844 - 17 - Laboratory Exercises11/07 Instructor Handout No. 16
Specification Actual Within Specification?
Pilot Pressure
Margin Pressure
Pump Cutoff Pressure
Signal Relief Valve
Main Relief Valve
PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS
IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
COMPENSATOR VALVE PRESSURE AND FLOW ADJUSTMENT
Does the flow compensation valve need adjustment? YES / NODoes the pressure compensator valve need adjustment? YES / NO
Which tests indicate if the flow compensator or the pressure compensator needs adjustment?
_____________________________________________________________________________
Oil Temp ____°F
Cycle times within specifications? Yes No
2nd Test
Blade Circle
CYCLE TIMECHECK
1st Test 3rd Test Average
Sideshift
Centershift
Blade Tip
Blade Lift
Ripper
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SERV1844 - 18 - Laboratory Exercises11/07 Instructor Handout No. 17
L a b
K : I m p l e m e n
t H y d r a u
l i c S y s t e m
I d e n
t i f i c a t i o n
D i r e c
t i o n s :
F i l l i n t h e
b l a n
k s n e x
t t o t h e
l e t t e r s w
i t h t h e c o r r e c
t t e r m .
A .
M a i n
R e l
i e f V a l v e
B .
P i l o t P r e s s u r e
R e d u c
i n g
V a l v e
C .
P i l o t S h u t o f f V a l v e
D .
P i l o t O i l F i l t e r
E .
R e s o l v e r
F . A r t
i c u l a t
i o n
C y l
i n d e r s
G .
L i n e
R e l
i e f V a l v e
H .
B l a d e A c c u m u l a t o r
I . B l a d e L i f t C y l
i n d e r
J . E l e c t r o
h y d r a u
l i c S o l e n o
i d V a l v e
K .
S i g n a l
R e l
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L .
W h e e l
L e a n
C y l
i n d e r
M .
C i r c l e
D r i v e
M o t o r
N .
C e n
t e r
S h i f t C y l
i n d e r
O .
S i d e S h i f t C y l
i n d e r
P . S w i v e l
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SERV1844 - 19 - Laboratory Exercises11/07 Instructor Handout No. 18
A. Controls pilot oil to the implement controlspools.
B. Controls the electrohydraulic pilot controlvalve.
C. Reduces the pressure of the Implement and
Steering System to the pressure setting for the pilot system.
D. Signals the ECM that the operator wantsthe implement hydraulics disabled.
E. An input to the Implement ECMcontrolling implement functions.
F. Controls oil flow to the implementcylinders.
G. Used to connect the blade accumulators tothe blade cylinders.
H. Limits the maximum load signal that is sentto the Implement and Steering Pump.
I. Supplies oil for the implement and steeringsystems.
Implement and steering joysticks
Implement ECM
Electrohydraulic pilot controlvalves
Implement control valves
Signal relief valve
Pilot pressure reducing valve
Implement and steering pump
Hydraulic lockout switch
Blade cushion solenoid valve
E
B
A
F
H
C
I
D
G
Lab L: Implement System Components and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
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Lab M WorksheetSteering Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 PumpFunction: 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 ValveFunction: 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 ValveFunction: 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 JoysticksFunction: Sends signals to the Implement ECMs based on operator input.Location: On the left side and right side of the seat.
_____ Steering CylindersFunction: To turn the front wheels to the left or to the right.Location: Front of the machine.
_____ Steering Cylinder Position SensorsFunction: To send a signal to the Implement ECM indicating steering cylinder position.Location: Inside of the steering cylinders.
SERV1844 - 20 - Laboratory Exercises11/07 Instructor Handout No. 19
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Lab M WorksheetSteering Component Identification Worksheet (continued)
_____ Secondary Steering PumpFunction: 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 ValvesFunction: 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: A lerts the operator of a failure of the primary steering system.
Location:On the right side of the dash.
_____ Secondary Steering Indicator Function: A lerts the operator that the secondary steering system is activated.Location: On the right side of the dash.
_____ Secondary Steering System Test SwitchFunction: 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 SensorsFunction: 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 SwitchFunction: 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 SwitchesFunction: 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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SERV1844 - 22 - Laboratory Exercises11/07 Instructor Handout No. 21
Lab N: Steering System Tests
Margin Pressure
Pump Cutoff Pressure
Signal Relief Valve
Main Relief Valve
STEERING SYSTEM PRESSURE TESTS
Specification Actual Within Specification?
ARTICULATION SOLENOIDS CALIBRATION
YES NOCALIBRATIONCOMPLETED
FAULTS PRESENT
STEERING CYLINDER POSITION SENSOR CALIBRATION
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
ARTICULATION POSITION SENSORS CALIBRATION
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
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SERV1844 - 23 - Laboratory Exercises11/07 Instructor Handout No. 22
Lab O: Steering System Components andFunctions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Hydraulic tank
Implement and steering pump
Secondary steering solenoid valves
Implement and steering pumpcontrol valve
Articulation position sensors
Steering control valve
Primary steering indicator
Secondary steering motor and pump
Implement and steering joystick
Secondary steering indicator
A. Supplies steering system flow if the primary steering system or engine failureoccurs.
B. Directs oil to the spools in the steeringcontrol valve for secondary steeringoperation.
C. An input to the Implement ECMcommunicating the articulation angle of themachine.
D. An input to the Implement ECM to controlsteering functions.
E. Alerts the operator of a failure of the primary steering system.
F. Controls pump flow and pressure.
G. Alerts operator that the secondary steeringsystem is activated.
H. Supplies oil to the steering system whenthe engine is running.
I. Stores the oil for the hydraulic systems onthe machine.
J. Directs oil to the steering cylinders to turnthe machine.
I
H
B
F
C
J
E
A
D
G
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Lab P WorksheetBrake Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 PumpFunction: 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 ValveFunction: Gives the brake system priority over the fan system and maintains accumulator
pressure.Location: Left side of the machine near the articulation hitch.
_____ Brake AccumulatorsFunction: Supplies oil to the brake system.Location: Mounted on the rear of the operator's station.
_____ Service Brake ValveFunction: 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 BrakesFunction: 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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Lab P WorksheetBrake Component Identification Worksheet (continued)
_____ Parking Brake Pressure SwitchFunction: Send the Trans/Chassis ECM a signal when the parking brake is released.Location: On the parking brake valve.
_____ Parking BrakeFunction: Prevents movement of the machine when engaged.Location: In the wheel stations of the tandem housing.
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SERV1844 - 26 - Laboratory Exercises11/07 Instructor Handout No. 25
BRAKE SYSTEM PRESSURE TEST
SPECIFICATION ACTUAL
Right Service Brake Control Valve Pressure
Left Service Brake Control Valve Pressure
Lab Q: Brake System Tests Worksheet
ACCUMULATOR PRESSURE TEST
SPECIFICATION ACTUAL
Charging Valve Cut-in Pressure
Charging Valve Cut-out 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?
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SERV1844 - 27 - Laboratory Exercises11/07 Instructor Handout No. 26
Lab R: Brake System Components andFunctions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Hydraulic tank
Parking brake
Brake and fan pump
Service brakes
Service brake pressure sensor
Parking brake valve
Service brake valve
Parking brake pressure switch
Brake accumulators
Accumulator charging valve
A. Primary brakes for stopping the machine.
B. Supplies oil to the brake and fan systems.
C. Stores the oil for the hydraulic systems onthe machine.
D. Supply oil to the brake system when theengine is OFF.
E. Controls oil flow and pressure to the service brakes.
F. Prevents movement of the machine whenengaged.
G. Maintains accumulator pressure between4485 kPa (2100 psi) CUT-OUT and11725 kPa (1700 psi) CUT-IN.
H. Sends parking brake oil pressure signal tothe Power Train ECM.
I. An input to the Trans/Chassis ECMcommunicating the pressure in the brakesystem.
J. Controls oil flow to release parking brake.
C
F
B
A
I
J
E
H
D
G
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Lab S WorksheetFan Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 PumpFunction: 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 ValveFunction: 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 ECMFunction: 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.
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Lab S WorksheetFan 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.
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SERV1844 - 30 - Laboratory Exercises11/07 Instructor Handout No. 29
Lab T: Fan System Tests Worksheet
FAN SYSTEM TEST
Where any faults present during the calibration (Yes or No)?
If faults were present, list the faults:
Specification Actual Within Specification?
Margin Pressure
High Pressure Cutoff
Minimum Fan Speed
Maximum Fan Speed
FAN SYSTEM TEST
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?
_____________________________________________________________________________
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SERV1844 - 31 - Laboratory Exercises11/07 Instructor Handout No. 30
Lab U: Fan System Components andFunctions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Hydraulic tank
Fan solenoid valve
Brake and fan pump
Fan motor
Hydraulic oil temperature sensor
Engine ECM
Intake manifold temperature sensor
Engine coolant temperature sensor
A. Coolant temperature measurement for Engine ECM, instrument panel, temperaturewarning.
B. Sends a load signal to the brake and fan pump to upstroke or destroke the brake and fan pump.
C. Hydraulic oil temperature measurement for the Implement ECM and temperaturewarning.
D. Supplies oil to the brake and fan systems.
E. Intake air temperature measurement for Engine ECM and temperature warning.
F. Converts hydraulic energy into mechanicalmotion.
G. Electronic Control Module, governor,electronic fuel system control.
H. Stores the oil for the hydraulic systems onthe machine.
H
B
D
F
C
G
E
A
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HYDRAULIC SCHEMATIC COLOR CODE
This illustration identifies the meanings of the colors used in the hydraulic schematics andcross-sectional views shown throughout this presentation.
SERV1844 - 32 - Instructor Handout No. 3111/07
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SERV1844 November 2007
STUDENT MATERIALS
PART OF GLOBAL SERVICE LEARNING MODULE SERV1844
24M MOTOR GRADER
INTRODUCTION
LAB EXERCISES AND POSTTEST
GLOBAL SERVICE LEARNING
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Component Identification
Description
Identify the components of the 24M Motor Grader. Use the worksheets to take notes on thetypes of input components. After locating the components on the schematic, locate thecomponents 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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SERV1844 - 3 - Laboratory Exercises11/07 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 switchstatus__________
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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SERV1844 - 4 - Laboratory Exercises11/07 Instructor Handout No. 3
Lab B: Messenger System Components and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Service; Tattletale; TattletaleActive Mode
Settings; Transmission
Service; System Parameters;Engine
Service; System Parameters;Transmission
Service; System Parameters;Monitoring System
Totals; Lifetime Totals
A. Menu that contains information onalternator status.
B. Menu that contains information onmaximum recorded coolant temperature.
C. Menu that contains total fuel usage.
D. Menu that contains information ontransmission output speed.
E. Menu that contains maximum fwd autoshift gear.
F. Menu that contains information on inletair temperature.
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Lab C WorksheetC18 ACERT ™ Engine Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 ECMFunction:Location:
_____ Primary Fuel Filter
Function:Location:
_____ Fuel Transfer PumpFunction:Location:
_____ Electronic Priming PumpFunction:Location:
_____ Secondary Fuel Filter Function:Location:
_____ Electronic Unit InjectorsFunction:Location:
_____ Primary Speed SensorFunction:
Location:
_____ Secondary Speed Sensor Function:Location:
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Lab C WorksheetC18 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 SwitchFunction:Location:
_____ Throttle Resume/Decelerate SwitchFunction:Location:
_____ Throttle Set/Accelerate SwitchFunction:Location:
_____ Throttle Position Sensor Function:Location:
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SERV1844 - 7 - Laboratory Exercises11/07 Instructor Handout No. 6
Lab D: Engine System Components and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Turbo inlet pressure sensor
Engine derate
Engine ECM
Fuel transfer pump
Atmospheric pressure sensor
Differential fuel pressure switch
Secondary fuel filter
Timing calibration connector
Non-latching derate
Latching derate
Virtual exhaust derate
A. Receives sensor and switch inputs and controls fan speed and engine rpm
B. A horsepower limiting event that limitshorsepower and continues to limit thehorsepower once the condition no longer exists
C. Final preparation of the fuel before thefuel enters the fuel gallery
D. Supplies flow to the engine fuel system
E. An event that is based on atmospheric pressure, intake manifold temperature,and engine rpm
F. A horsepower limiting event that nolonger limits horsepower when thecondition no longer exists
G. An event that limits the enginehorsepower
H. Engine ECM uses this sensor to calculateall other pressure sensors on the engine
I. Used for timing the engine if the EngineECM or timing sensor is replaced
J. Engine ECM uses this sensor to calculateair filter restriction
K. Compares the difference betweenincoming and outgoing fuel pressure
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Lab E WorksheetPower Train Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 ECMFunction:Location:
_____ TransmissionFunction:Location:
_____ Transmission PumpFunction:Location:
_____ Transmission Relief ValveFunction:Location:
_____ Transmission Filter Function:Location:
_____ Transmission Modulating ValvesFunction:Location:
_____ Transmission Input Speed Sensor Function:Location:
_____ Transmission Output Speed SensorsFunction:Location:
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Lab E WorksheetPower Train Component Identification Worksheet (continued)
_____ Transmission Oil Temperature Sensor Function:Location:
_____ Magnetic ScreenFunction:Location:
_____ Power Train Oil Cooler Function:Location:
_____ Engine Key Start SwitchFunction:Location:
_____ Engine Start RelayFunction:Location:
_____ Autoshift Switch (if equipped)Function:Location:
_____ Directional SwitchFunction:Location:
_____ Upshift switchFunction:Location:
_____ Downshift switchFunction:Location:
_____ Differential Lock SwitchFunction:Location:
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Lab E WorksheetPower Train Component Identification Worksheet (continued)
_____ Differential Lock Solenoid Function:Location:
_____ DifferentialFunction:Location:
_____ Final DrivesFunction:Location:
_____ Back-up AlarmFunction:Location:
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SERV1844 - 11 - Laboratory Exercises11/07 Instructor Handout No. 10
Lab F: Power Train Hydraulic System Tests Worksheet
ACTUALSPECIFICATION
Differential Lock Pressure (kPa/psi)
Lubrication Pressure (kPa/psi)
Transmission Pump Pressure (kPa/psi)
POWER TRAIN HYDRAULIC SYSTEM
WHICHSOLENOIDS
AREON?
WHICHCLUTCHES
AREENGAGED? 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
SPEED RANGE ANDDIRECTION
If E.T. is available, recordthe following information:
Engine at LOW IDLE
TRANSMISSION CLUTCH FILL CALIBRATION
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
Third Speed Reverse
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SERV1844 - 12 - Laboratory Exercises11/07 Instructor Handout No. 11
Lab G: Transmission Hydraulic System Componentsand Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Differential lock solenoid
Transmission oil cooler
Transmission relief valve
Transmission pump
Transmission filter
Transmission modulating valves
Transmission oil reservoir
Magnetic screen
Transmission
A. Provides speed and directional conversionof the available engine power.
B. Transmission oil supply stored in the bottom of the differential case.
C. Removes metal particles from the supply
oil.
D. Filters the oil from the transmission pumpto the transmission hydraulic system.
E. Supplies oil flow to the transmissionhydraulic system.
F. Limits the oil pressure to the proportional
solenoid valves.
G. Controls oil flow and pressure to theclutches.
H. Cools the transmission hydraulic oil.
I. Controls oil flow to the differential lock.
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SERV1844 - 13 - Laboratory Exercises11/07 Instructor Handout No. 12
Lab H: Transmission Electronic Control System Componentsand Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Transmission/Chassis ECM
Autoshift switch
Downshift switch
Upshift switch
Transmission input speed sensor
Transmission modulating valves
Transmission output speed sensors
Directional switch
Transmission oil temperature sensor
Engine key start switch
A. Signals the ECM when to energize theengine start relay.
B. Allows the operator to manuallydownshift the transmission.
C. Measures input speed to thetransmission.
D. Receives sensor and switch inputs and controls transmission shifting and engine starting.
E. Signals the ECM the shift mode inwhich the operator wants to operate.
F. Measures transmission output speed.
G. Measures transmission oil temperature.
H. Allows the operator to manuallyupshift the transmission.
I. Signals the ECM the direction theoperator wants the machine to move.
J. Controls oil flow and pressure to theclutches.
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Lab I WorksheetImplement Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 ValvesFunction:
Location:
_____ Implement and Steering Control Manifold Function:Location:
_____ Pilot Pressure Reducing ValveFunction:Location:
_____ Main Relief Valve
Function:Location:
_____ Implement and Steering Pressure Sensor Function:Location:
_____ Implement and Steering PumpFunction:Location:
_____ Implement PumpFunction:Location:
_____ Blade Lift CylindersFunction:Location:
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Lab I WorksheetImplement Component Identification Worksheet (continued)
_____ Blade Tip Cylinder Function:Location:
_____ Sideshift Cylinder Function:Location:
_____ Centershift Cylinder Function:Location:
_____ Pilot Oil Filter Function:Location:
_____ Hydraulic Oil FiltersFunction:Location:
_____ Case drain filter Function:Location:
_____ Implement and Steering JoysticksFunction:Location:
_____ Implement ECMFunction:Location:
_____ Implement ECM (2)Function:Location:
_____ Hydraulic Lockout SwitchFunction:Location:
_____ Hydraulic Lockout Solenoid ValveFunction:Location:
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Lab I WorksheetImplement Component Identification Worksheet (continued)
_____ Blade Cushion Switch (if equipped)Function:Location:
_____ Blade Cushion Accumulators (if equipped)Function:Location:
_____ Ripper ControlFunction:Location:
_____ Ripper CylindersFunction:Location:
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Lab J: Implement Hydraulic System Tests Worksheet
SERV1844 - 17 - Laboratory Exercises11/07 Instructor Handout No. 16
Specification Actual Within Specification?
Pilot Pressure
Margin Pressure
Pump Cutoff Pressure
Signal Relief Valve
Main Relief Valve
PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS
IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
COMPENSATOR VALVE PRESSURE AND FLOW ADJUSTMENT
Does the flow compensation valve need adjustment? YES / NODoes the pressure compensator valve need adjustment? YES / NO
Which tests indicate if the flow compensator or the pressure compensator needs adjustment?
_____________________________________________________________________________
Oil Temp ____°F
Cycle times within specifications? Yes No
2nd Test
Blade Circle
CYCLE TIMECHECK
1st Test 3rd Test Average
Sideshift
Centershift
Blade Tip
Blade Lift
Ripper
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SERV1844 - 18 - Laboratory Exercises11/07 Instructor Handout No. 17
L a b
K :
I m p l e m e n
t H y d r a u
l i c S y s t e m
I d e n
t i f i c a
t i o n
D i r e c
t i o n s :
F i l l i n t h e
b l a n
k s n e x
t t o t h e
l e t t e r s w
i t h t h e c o r r e c
t t e r m .
A .
B .
C .
D .
E .
F . G .
H . I . J . K
. L
. M
. N
. O
. P .
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SERV1844 - 19 - Laboratory Exercises11/07 Instructor Handout No. 18
A. Controls pilot oil to the implement controlspools.
B. Controls the electrohydraulic pilot controlvalve.
C. Reduces the pressure of the Implement and
Steering System to the pressure setting for the pilot system.
D. Signals the ECM that the operator wantsthe implement hydraulics disabled.
E. An input to the Implement ECMcontrolling implement functions.
F. Controls oil flow to the implementcylinders.
G. Used to connect the blade accumulators tothe blade cylinders.
H. Limits the maximum load signal that is sentto the Implement and Steering Pump.
I. Supplies oil for the implement and steeringsystems.
Implement and steering joysticks
Implement ECM
Electrohydraulic pilot controlvalves
Implement control valves
Signal relief valve
Pilot pressure reducing valve
Implement and steering pump
Hydraulic lockout switch
Blade cushion solenoid valve
Lab L: Implement System Components and Functions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
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Lab M WorksheetSteering Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 PumpFunction:
Location:
_____ Implement and Steering Control Manifold Function:Location:
_____ Main Relief ValveFunction:Location:
_____ Implement and Steering Pump Pressure Sensor
Function:Location:
_____ Steering Control ValveFunction:Location:
_____ Implement and Steering JoysticksFunction:Location:
_____ Steering CylindersFunction:Location:
_____ Steering Cylinder Position SensorsFunction:Location:
SERV1844 - 20 - Laboratory Exercises11/07 Instructor Handout No. 19
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Lab M WorksheetSteering Component Identification Worksheet (continued)
_____ Secondary Steering PumpFunction:Location:
_____ Secondary Steering Solenoid ValvesFunction:Location:
_____ Primary Steering Indicator Function:Location:
_____ Secondary Steering Indicator Function:Location:
_____ Secondary Steering System Test SwitchFunction:Location:
_____ Articulation CylindersFunction:Location:
_____ Articulation Position SensorsFunction:Location:
_____ Articulation Auto Recenter SwitchFunction:Location:
_____ Wheel Lean Cylinder Function:Location:
_____ Wheel Lean SwitchesFunction:Location:
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SERV1844 - 22 - Laboratory Exercises11/07 Instructor Handout No. 21
Lab N: Steering System Tests
Margin Pressure
Pump Cutoff Pressure
Signal Relief Valve
Main Relief Valve
STEERING SYSTEM PRESSURE TESTS
Specification Actual Within Specification?
ARTICULATION SOLENOIDS CALIBRATION
YES NOCALIBRATIONCOMPLETED
FAULTS PRESENT
STEERING CYLINDER POSITION SENSOR CALIBRATION
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
ARTICULATION POSITION SENSORS CALIBRATION
YES NO
CALIBRATIONCOMPLETED
FAULTS PRESENT
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SERV1844 - 23 - Laboratory Exercises11/07 Instructor Handout No. 22
Lab O: Steering System Components andFunctions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Hydraulic tank
Implement and steering pump
Secondary steering solenoid valves
Implement and steering pumpcontrol valve
Articulation position sensors
Steering control valve
Primary steering indicator
Secondary steering motor and pump
Implement and steering joystick
Secondary steering indicator
A. Supplies steering system flow if the primary steering system or engine failureoccurs.
B. Directs oil to the spools in the steeringcontrol valve for secondary steeringoperation.
C. An input to the Implement ECMcommunicating the articulation angle of themachine.
D. An input to the Implement ECM to controlsteering functions.
E. Alerts the operator of a failure of the primary steering system.
F. Controls pump flow and pressure.
G. Alerts operator that the secondary steeringsystem is activated.
H. Supplies oil to the steering system whenthe engine is running.
I. Stores the oil for the hydraulic systems onthe machine.
J. Directs oil to the steering cylinders to turnthe machine.
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Lab P WorksheetBrake Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 PumpFunction:
Location:
_____ Accumulator Charging ValveFunction:Location:
_____ Brake AccumulatorsFunction:Location:
_____ Service Brake Valve
Function:Location:
_____ Service Brake Pressure Sensor Function:Location:
_____ Service BrakesFunction:Location:
_____ Parking Brake Solenoid Function:Location:
SERV1844 - 24 - Laboratory Exercises11/07 Instructor Handout No. 23
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Lab P WorksheetBrake Component Identification Worksheet (continued)
_____ Parking Brake Pressure SwitchFunction:Location:
_____ Parking BrakeFunction:Location:
SERV1844 - 25 - Laboratory Exercises11/07 Instructor Handout No. 24
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SERV1844 - 26 - Laboratory Exercises11/07 Instructor Handout No. 25
BRAKE SYSTEM PRESSURE TEST
SPECIFICATION ACTUAL
Right Service Brake Control Valve Pressure
Left Service Brake Control Valve Pressure
Lab Q: Brake System Tests Worksheet
ACCUMULATOR PRESSURE TEST
SPECIFICATION ACTUAL
Charging Valve Cut-in Pressure
Charging Valve Cut-out 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?
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SERV1844 - 27 - Laboratory Exercises11/07 Instructor Handout No. 26
Lab R: Brake System Components andFunctions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Hydraulic tank
Parking brake
Brake and fan pump
Service brakes
Service brake pressure sensor
Parking brake valve
Service brake valve
Parking brake pressure switch
Brake accumulators
Accumulator charging valve
A. Primary brakes for stopping the machine.
B. Supplies oil to the brake and fan systems.
C. Stores the oil for the hydraulic systems onthe machine.
D. Supply oil to the brake system when theengine is OFF.
E. Controls oil flow and pressure to the service brakes.
F. Prevents movement of the machine whenengaged.
G. Maintains accumulator pressure between4485 kPa (2100 psi) CUT-OUT and11725 kPa (1700 psi) CUT-IN.
H. Sends parking brake oil pressure signal tothe Power Train ECM.
I. An input to the Trans/Chassis ECMcommunicating the pressure in the brakesystem.
J. Controls oil flow to release parking brake.
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Lab S WorksheetFan Component Identification Worksheet
Directions: During the visual presentation, use these worksheets to take notes as the functionof each component is explained.
Example: _____ Pilot PumpLocation: 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 PumpFunction:
Location:
_____ Fan Solenoid ValveFunction:Location:
_____ Fan Motor Function:Location:
_____ Oil Cooler
Function:Location:
_____ Engine ECMFunction:Location:
_____ Engine Coolant Temperature Sensor Function:Location:
_____ Intake Manifold Temperature Sensor Function:Location:
SERV1844 - 28 - Laboratory Exercises11/07 Instructor Handout No. 27
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Lab S WorksheetFan Component Identification Worksheet (continued)
_____ Hydraulic Oil Temperature Sensor Function:Location:
SERV1844 - 29 - Laboratory Exercise11/07 Instructor Handout No. 28
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SERV1844 - 30 - Laboratory Exercises11/07 Instructor Handout No. 29
Lab T: Fan System Tests Worksheet
FAN SYSTEM TEST
Where any faults present during the calibration (Yes or No)?
If faults were present, list the faults:
Specification Actual Within Specification?
Margin Pressure
High Pressure Cutoff
Minimum Fan Speed
Maximum Fan Speed
FAN SYSTEM TEST
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?
_____________________________________________________________________________
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SERV1844 - 31 - Laboratory Exercises11/07 Instructor Handout No. 30
Lab U: Fan System Components andFunctions Posttest
Directions: Match each component to the correct function.
Function Component Function Definition
Hydraulic tank
Fan solenoid valve
Brake and fan pump
Fan motor
Hydraulic oil temperature sensor
Engine ECM
Intake manifold temperature sensor
Engine coolant temperature sensor
A. Coolant temperature measurement for Engine ECM, instrument panel, temperaturewarning.
B. Sends a load signal to the brake and fan pump to upstroke or destroke the brake and fan pump.
C. Hydraulic oil temperature measurement for the Implement ECM and temperaturewarning.
D. Supplies oil to the brake and fan systems.
E. Intake air temperature measurement for Engine ECM and temperature warning.
F. Converts hydraulic energy into mechanicalmotion.
G. Electronic Control Module, governor,electronic fuel system control.
H. Stores the oil for the hydraulic systems onthe machine.
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HYDRAULIC SCHEMATIC COLOR CODE
This illustration identifies the meanings of the colors used in the hydraulic schematics andcross-sectional views shown throughout this presentation.
SERV1844 - 32 - Instructor Handout No. 3111/07
Top Related