Students Material

8/18/2019 Students Material

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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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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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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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Lab D: Engine System Components and Functions Posttest



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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_____ 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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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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Lab G: Transmission Hydraulic System Componentsand Functions Posttest



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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Lab H: Transmission Electronic Control System Componentsand Functions Posttest



Transmission/Chassis ECM

Autoshift switch

Downshift switch

Upshift switch

Transmission input speed sensor


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.



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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.



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_____ 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.



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Lab J: Implement Hydraulic System Tests Worksheet


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


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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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




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Lab M WorksheetSteering Component Identification Worksheet




_____ 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.



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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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Lab N: Steering System Tests

Margin Pressure


Signal Relief Valve

Main Relief Valve

STEERING SYSTEM PRESSURE TESTS


ARTICULATION SOLENOIDS CALIBRATION

YES NOCALIBRATIONCOMPLETED

FAULTS PRESENT

STEERING CYLINDER POSITION SENSOR CALIBRATION

YES NO


FAULTS PRESENT

ARTICULATION POSITION SENSORS CALIBRATION

YES NO


FAULTS PRESENT


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Lab O: Steering System Components andFunctions Posttest



Hydraulic tank


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




_____ 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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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


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?



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Lab R: Brake System Components andFunctions Posttest



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




_____ 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.

SERV1844 - 29 - Laboratory Exercise11/07 Instructor Handout No. 28


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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:


Margin Pressure

High Pressure Cutoff

Minimum Fan Speed

Maximum Fan Speed

FAN SYSTEM TEST


Does the flow compensation valve need adjustment? YES / NO

Does the pressure compensator valve need adjustment? YES / NO


_____________________________________________________________________________


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Lab U: Fan System Components andFunctions Posttest



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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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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Lab B: Messenger System Components and Functions Posttest



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


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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Lab D: Engine System Components and Functions Posttest



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



_____ 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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_____ 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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_____ Differential Lock Solenoid Function:Location:

_____ DifferentialFunction:Location:

_____ Final DrivesFunction:Location:

_____ Back-up AlarmFunction:Location:



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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


FAULTS PRESENT

Third Speed Reverse


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Lab G: Transmission Hydraulic System Componentsand Functions Posttest



Differential lock solenoid

Transmission oil cooler

Transmission relief valve

Transmission pump

Transmission filter


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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Lab H: Transmission Electronic Control System Componentsand Functions Posttest



Transmission/Chassis ECM

Autoshift switch

Downshift switch

Upshift switch

Transmission input speed sensor


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



_____ 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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_____ 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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_____ 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



Pilot Pressure

Margin Pressure


Signal Relief Valve

Main Relief Valve

PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS

IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS

YES NO


FAULTS PRESENT


Does the flow compensation valve need adjustment? YES / NODoes the pressure compensator valve need adjustment? YES / NO


_____________________________________________________________________________

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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L a b

K :

I m p l e m e n

t H y d r a u

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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

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A .

B .

C .

D .

E .

F . G .

H . I . J . K

. L

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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


Hydraulic lockout switch

Blade cushion solenoid valve

Lab L: Implement System Components and Functions Posttest




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Lab M WorksheetSteering Component Identification Worksheet




_____ 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:



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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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Lab N: Steering System Tests

Margin Pressure


Signal Relief Valve

Main Relief Valve

STEERING SYSTEM PRESSURE TESTS


ARTICULATION SOLENOIDS CALIBRATION

YES NOCALIBRATIONCOMPLETED

FAULTS PRESENT

STEERING CYLINDER POSITION SENSOR CALIBRATION

YES NO


FAULTS PRESENT

ARTICULATION POSITION SENSORS CALIBRATION

YES NO


FAULTS PRESENT


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Lab O: Steering System Components andFunctions Posttest



Hydraulic tank


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




_____ 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:



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Lab P WorksheetBrake Component Identification Worksheet (continued)

_____ Parking Brake Pressure SwitchFunction:Location:

_____ Parking BrakeFunction:Location:



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BRAKE SYSTEM PRESSURE TEST


Right Service Brake Control Valve Pressure

Left Service Brake Control Valve Pressure

Lab Q: Brake System Tests Worksheet

ACCUMULATOR PRESSURE TEST


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?


PARKING BRAKE TEST

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



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Lab R: Brake System Components andFunctions Posttest



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




_____ 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:



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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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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:


Margin Pressure

High Pressure Cutoff

Minimum Fan Speed

Maximum Fan Speed

FAN SYSTEM TEST


Does the flow compensation valve need adjustment? YES / NO

Does the pressure compensator valve need adjustment? YES / NO


_____________________________________________________________________________


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Lab U: Fan System Components andFunctions Posttest



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

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