Serv2726 Material Del Estudiante Hidraulico y Direccion

SERV2726
ITIM FOR RENR4113

October 2002
Integrated Technical
Instruction Module
H-Series Motor Graders

Implement Hydraulics and
Steering System
SERV2726 2 H-Series Motor Graders ITIM
10/02 ITIM for RENR4113
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Objectives/Student Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Lesson Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Preparation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Visual/Text Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Case Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Posttest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Instructor Answer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Introduction
This Integrated Technical Instruction Module is designed to introduce service technicians to the H-Series
Motor Grader Implement Hydraulics and Steering System. Emphasis is placed on component location,
function and oil flow through the system. This Integrated Technical Instruction Module is designed for
Level II field service personnel, resident mechanics, technical communicators and shop technicians.
Prerequisites
All students should have some overall experience with Caterpillar equipment and have a basic working
knowledge of servicing electrical and electronic systems. Basic computer skills are also required.
Prerequisite tests should be administered at least a few weeks before the participant takes the course.
Participants should pass the following pretests with a score of 90% or better:
Machine Electrical Pretest SEBV0558
Basic Hydraulic Pretest SEBV0557
Graphic Fluid Power Symbols (Pretest) SEBV0556
If a participant does not accomplish 90% or better, identify the area of deficiency and then refer to the
pretest for the recommended course or courses for the student to review. After ample review time, the
student should retake the test.
NOTE:
Understanding the operation and function of the systems on the H-Series Motor Graders is
critical for troubleshooting. It is also important to be able properly test and adjust the systems.
Objectives/Student Evaluation
Student Name: ________________________ Instructor(s):_______________________
Course Name: _________________________ Course Number: ___________________
Pretest Score: ________ Posttest Score: ____________
Instructor
Did student accomplish the following objectives? Additional remarks
Yes No
1. Given an operation and maintenance guide or a service manual
module and a machine, locate and identify the major components
on a worksheet during a lab exercise.
2. Write the function and location of the components on a classroom

worksheet.
3. Given a motor grader and a stop watch, perform a steering cycle

test and all implement system functions cycle tests and record the
times on a lab worksheet.
4. Given a motor grader and the appropriate service module and

tooling, test the following pressures and record the pressures on
the lab worksheet:
low pressure standby
margin
hydraulic system maximum
signal
steering maximum relief
steering accumulator pressures.
5. Given a steering hydraulic system schematic, trace the flow of oil

through the steering system during a class lab activity on the lab
worksheet provided.
6. Given an implement hydraulic system schematic, trace the flow of

oil through the hydraulic system during a class lab activity on the
lab worksheet provided.
7. Given a machine, reference materials and/or tooling, identify

potential system problems caused by malfunctioning components
during a lab exercise.
8. Without using any notes or references, identify the system

components and identify from a list the cause and/or effect of a
component or system malfunction on a posttest.
Instructor(s):
________________________ Student Average Good Excellent
________________________ Student met prerequisites
Training Manager: Class Participation
________________________ Desire to Learn

Lesson Plan
Introduction 15 min.
Discuss objectives and class schedule
Hand out and discuss student material
Visual Presentation: Implement Hydraulics and Steering System Overview 15 min.

H-Series Motor Graders Implement Hydraulics and Transmission video
Introduction (Introduction through Hydraulic Tank and Filter)
Lab A: Locate And Identify Major System Components 15 min.
Lab B: Identify System Components using the Schematic 15 min.
Visual Presentation: Implement Hydraulics and Steering System Operation 1hr. 15 min.
Piston Pump (Hydraulic and Steering)
Combination Valve
Implement System
Control Valve (Implement)
Control Valve (Blade Lift)
Steering System
Metering Pump (Steering)
Lab C: Test Cycle Times 45 min.

Implements
Steering
Lab D: Pressure Tests 60 min.

Low Pressure Standby
Margin Pressure
Hydraulic System Maximum Pressure
Signal Network Pressure
Steering System Maximum Pressure
Steering Accumulator Precharge Pressure
Lab E: Trace Oil Flow through the Steering Hydraulic System 30 min.
Lab F: Trace Oil Flow through the Implement Hydraulic System 30 min.
Lab G: Diagnostics 60 min.
Case Study 30 min.
Posttest 30 min.
Administer Posttest
Review and Discuss Posttest Results
Total Estimated Time 7 hours

Preparation Checklist
Prior to conducting the training session, gather and review the following H-Series Motor Grader Materials:
__ Implement Hydraulics and Steering Systems Operation - (e.g., RENR4113 for 143H/163H)
__ Visual / Text Reference Materials
Have at least one copy of the following materials available for student and instructor reference during
classroom presentations and laboratory use, for the specific motor grader model to be used in laboratory
exercises. (The materials listed below in parentheses, for example, cover the 143H and 163H Motor
Graders.)
__ Service Manual (complete) - (RENR4135)
__ Hydraulic System Schematic - (RENR4148)
__ Electrical System Schematic - (RENR4149)
__ Operation and Maintenance Manual - (SEBU7473)
__ Parts Manual - (SEBP3297 for 143H or SEBP3298 for 163H)
__ H-Series Motor Graders -- Hydraulics and Transmission Systems Video SEVN3023
Gather the following special tools and materials:
__ Mechanics Tool Box with hand tools
__ Pressure Gauge Group
__ Multimeter
__ Lettered or numbered tags for component identification
__ PC Laptop Computer (See NOTE)
__ "ET Service Tool Software/Getting Started"
__ "ET Service Tool Software/Users Manual"
__ Universal Data Link Cable
__ Communication Adapter II
__ SPM for Communication Adapter, Version 1.2 or later
__ Serial Cable
NOTE:
Refer to the recommendations in the Booklet "ET Service Tool Software/Getting Started" for a PC
Laptop selection suitable for ET software.
Visual/Text Reference
This training package does not contain the traditional Slide Text Reference included in Technical
Instruction Modules. Instead, the Service Manual systems operations module "Implement Hydraulics and
Steering System" (for the motor grader model to be used in class laboratory exercises) must be used for
preparation and self study. The Lesson Plan serves as a guide through the Service Manual module.
The visual presentation is separated into sections covering the implement hydraulics and steering
system. Lab exercises provide the student with an opportunity to locate and identify the system
components and perform testing and adjusting procedures on selected components and systems.
The visual .pdf presentation file labeled "All_Visuals" contains every visual represented in the Service
Manual module. The visual presentation labeled "Instructor_Visuals" contains the visuals needed for
classroom instruction and eliminates duplicate visuals that are shown in Service Manual module.
Laboratory Exercises
The pages that follow provide lab exercises to reinforce the visual presentation.
Some lab exercises are the written type with worksheets, while other labs are the traditional "on the iron"
labs. Some answers are provided for the worksheet exercise, while other labs reference the Testing and
Adjusting procedures of the System Operation/ Testing and Adjusting Manual. Answers, when
applicable, are provided in the Instructor Answer Key.
Review and perform the labs before delivering this module.
At the beginning of each lab, have all students review the lab description to be sure the students
understand what to do during the lab.
The labs are:
Lab A: Locate and Identify Major System Components
Lab B: Identify System Components using the Schematic
Lab C: Cycle Time Tests
Lab D: Pressure Tests
Lab E: Trace Oil Flow through the Steering Hydraulic System
Lab F: Trace Oil Flow through the Implement Hydraulic System
Lab G: Diagnostics
NOTE:
Discuss safety procedures with the students for each shop lab. (i.e. safety glasses, clothing).

Lab A Worksheet 1
Directions: Place the correct letter next to the component name. During the visual presentation, use
this worksheet to take notes as the location and function of each component is explained.
___ RIGHT VALVE BANK
___ ACCUMULATOR
___ HAND METERING UNIT
___ HYDRAULIC TANK
___ LEFT VALVE BANK
___ FLOW COMPENSATOR AND PRESSURE CONTROL VALVE
___ COMBINATION VALVE
___ IMPLEMENT AND STEERING PUMP
NOTE:
Tags with letters A through H should be placed on machine components, per the location map
on Worksheet 2, and students should conduct this lab on the machine. Alternately, when a
machine is not available Worksheet 2 may be used as a classroom lab exercise.
10/02

Lab A Worksheet 2
Directions: Place the correct letter next to the component name.
STEERING AND IMPLEMENT HYDRAULIC SYSTEM
C D
A B
E
G H
F
___ RIGHT VALVE BANK
___ ACCUMULATOR
___ HAND METERING UNIT
___ HYDRAULIC TANK
___ LEFT VALVE BANK
___ FLOW COMPENSATOR AND PRESSURE CONTROL VALVE
___ COMBINATION VALVE
___ IMPLEMENT AND STEERING PUMP


Lab B Worksheet 1
PRESSURE AND FLOW

COMPENSATOR VALVE
FLOW COMPENSATOR
COMPENSATOR BLEED SCREW
PRESSURE COMPENSATOR

Lab B Worksheet 2
A B COMBINATION
VALVE
HOLD
C
D
E
F
G H
SIGNAL RESOLVER VALVE
LOAD CHECK VALVE
STEERING PRIORITY VALVE
STEERING ACCUMULATOR
SIGNAL PURGE VALVE
SIGNAL RELIEF VALVE
MAIN RELIEF VALVE
STEERING RELIEF VALVE


Lab B Worksheet 3
TYPICAL
A
B IMPLEMENT VALVE
C
HOLD
E F G H
LOCK VALVE PISTON
ROTARY ACTUATOR
CONTROL VALVE STEM
LOCK VALVE POPPET
COUNTERBALANCE SPRING
CENTERING SPRING
SIGNAL CHECK VALVE
COMPENSATOR VALVE

Lab B Worksheet 4
BLADE LIFT VALVE

A B C D HOLD
E
F
G H I
J K
MANIFOLD
LOCK VALVE PISTON DETENT SPRING
ROTARY ACTUATOR LINE RELIEF VALVE
CONTROL VALVE STEM LOCK VALVE POPPET
COUNTERBALANCE SPRING CENTERING SPRING
SIGNAL CHECK VALVE COMPENSATOR VALVE

Lab C: Cycle Time Tests

Lab C Worksheet
Directions: Following procedures in the Systems Operation, Testing and Adjusting Service Manual
Module for the machine used, note the service manual cycle times and record actual cycle times:
IMPLEMENT CYLINDER MANUAL CYCLE TIME ACTUAL CYCLE TIME
BLADE LIFT ROD IN
ROD OUT
BLADE TIP ROD IN
ROD OUT
WHEEL LEAN ROD IN
ROD OUT
CENTERSHIFT ROD IN
ROD OUT
SIDESHIFT ROD IN
ROD OUT
SCARIFIER ROD IN
ROD OUT
RIPPER TO GROUND ROD IN
ROD OUT
ARTICULATION ROD IN
ROD OUT
CIRCLE ROTATION ROD IN
ROD OUT
STEERING ROD IN
ROD OUT
Lab D: Pressure Tests

Lab D Worksheet
Directions: Following procedures in the Systems Operation, Testing and Adjusting Service Manual
Module for the machine used, note the service manual pressures specified, then obtain and record actual
pressures:
PRESSURE TEST MANUAL PRESSURE ACTUAL PRESSURE
LOW PRESSURE STANDBY
Bleed valve on pump compensator CLOSED
Bleed valve on pump compensator OPEN
MARGIN PRESSURE
MAXIMUM SYSTEM PRESSURE
Taken at the pump pressure test port
STEERING SYSTEM MAXIMUM PRESSURE
Taken at the pump pressure test port
STEERING ACCUMULATOR
Accumulator pressure
Accumulator precharge pressure
SIGNAL NETWORK (Signal relief valve)

Lab E: Trace Oil Flow through the Steering Hydraulic System

Lab E Worksheet 1
Directions: Trace the flow of oil through the system using colored pencils to show:
Pump supply pressure oil Red
First supply pressure reduction Red / white stripes
Second supply pressure reduction Red / white hatched
Signal pressure oil Orange
First signal pressure reduction Orange / white stripes
Second signal pressure reduction Orange / white hatched
Tank or case drain oil Green
Moving component or activated valve envelope Yellow
STEERING
CYLINDERS STEERING HAND GEROTOR
METERING UNIT
ROTARY
SLEEVE
STEERING HYDRAULIC SYSTEM
RIGHT TURN SUPPLY
CHECK VALVE
ANTI-CAVITATION
LINE RELIEFS WITH CHECK VALVE
ANTI-CAVITATION VALVES
PRESSURE
COMPENSATOR
SIGNAL
RESOLVER
SIGNAL PRIORITY
BLEED VALVE
SIGNAL
RELIEF
TANK MAIN
RELIEF ACCUMULATOR
IMPLEMENT PUMP STEERING

AND CONTROLS RELIEF
COMBINATION VALVE

Lab F Worksheet 1
PORT A PORT B
BLADE LIFT VALVE
COMPENSATOR FULLY SHIFTED TO THE RIGHT
VALVE
SIGNAL
CONTROL FROM CHECK BALL
STEM PUMP
TO COMBINATION
VALVE
MANIFOLD

Lab F Worksheet 2
TYPICAL IMPLEMENT VALVES

IMPLEMENT VALVE WITH
LOWEST LOAD
HIGHEST LOAD
PORT A PORT B PORT A PORT B
COMPENSATOR
COMPENSATOR
VALVE
VALVE
TO TANK
CONTROL
STEM
SIGNAL SIGNAL
CHECK BALL CHECK BALL
FROM PUMP FROM PUMP
(OPEN) (SEATED)
TO
COMBINATION
VALVE
MANIFOLD
Lab G: Diagnostics
Lab G Worksheet
Directions: The laboratory exercise machine has a bug installed by the instructor. As a result, the
machines performance is such that the operator has complained the machine works slow or even quits
working.
1. Create a list of potential problems which could account for the symptoms reported:
2. Create a list of tests to perform to diagnose the potential problems above.
3. Troubleshoot the machine by performing the tests above.
4. List symptoms identified/confirmed through testing.
5. List the test results.
6. State what the problem was.

Case Study
Directions: Students may use appropriate service literature and class notes to complete this case study.
Situation: The operator of a motor grader complained that, even though all the implements were
working, all implements were slow except for the Wheel Lean. The dealer service technician confirmed
that Wheel Lean cycle time was within service manual specifications, but that other implement operations
were slow.
Gather Information: List at least three questions you would ask the operator.
1.
2.
3.
Verify: Verify the problem exists. Operate the motor grader, if possible, to verify the problem exists.
Perform sensory checks such as looking, listening, touching, and smelling.
Perform Visual Inspection: When troubleshooting always perform a visual inspection first. Look for the
obvious. List at least three items that should be inspected during a visual inspection.
4.
5.
6.
State Problem: After verifying a problem exists, state in your own words what the problem is (not
solution).
7.
List Possible Faults: List possible causes of the problem. Identify systems and components that could
be causing the problem, including the obvious.
8.
9.
10.
Test to Determine Root Cause: List the tests that could be performed to find the root cause of the
problem.
11.
12.
Fix Machine: Perform tests if necessary and fix the motor grader.
13.
Verify Repair: After completing the repair, always verify the machine is operating correctly.
14.
Implement Hydraulics and Steering System Posttest

Directions: Circle the correct letter indicating the best answer for each question.
1. Each implement control valve contains one ..
A. line relief valve

B. signal check valve
C. spring
D. pressure setting
2. The H-Series motor graders use a hydraulic system.
A. proportional priority pressure compensated

B. load sensing and pressure compensated
C. proportional pilot pressure compensated
D. pilot priority pressure compensated
3. The most likely reason that the temperature of the system oil is too hot is ..
A. the signal relief pressure is set too high

B. the steering accumulator has lost precharge
C. the oil is contaminated
D. the main relief valve is set too low
4. The controls the precise flow to the cylinders.
A. the counterbalance spring

B. the position of the implement control valve stem
C. the line relief valve
D. the signal relief valve
5. The priority valve gives the steering system priority of pump supply oil flow over the implements.
A. TRUE
B. FALSE
6. The steering accumulator helps prevent erratic operation (jerkiness) in the steering operation:
A. TRUE
B. FALSE
7. The priority valve is contained within .
A. each line relief valve

B. the flow compensator and pressure control valve
C. the hydraulic filter base
D. the combination valve
8. The signal bleed valve prevents a trapped signal pressure condition by continuously leaking a small
flow of oil out of the circuit.
A. implement signal
B. steering signal
C. main implement
D. main steering
9. If additional implement valves need to be added to a machine, the existing valve bank .
A. must be removed
B. does not need to be removed
10. Lock check valves have been incorporated into each implement control valve:
A. TRUE
B. FALSE
11. The most likely reason that the steering system would have hard, or jerky, spots when an implement
is used is that .
A. the steering relief valve is set too high

C. the blade lift line relief valve is set too high
D. the main relief valve is set too high
12. The limits the implement signal pressure.
A. flow compensator valve

B. signal resolver valve
C. signal check valve
D. signal relief valve
13. The most likely reason that blade float will not function in one valve is that .
A. the steering line relief in the HMU is set too low

B. there is contamination within the stem
C. the HMU is leaking internally
14. The steering line relief valves are located in the combination valve:
A. TRUE
B. FALSE
15. To balance the lever force in both directions of implement lever travel, a spring
is added at one end of the stem.
A. detent
B. centering
C. counterbalance
D. torsional
16. The most likely reason that the pump does not return to low pressure standby after an implement
pump is used is .
A. the HMU is leaking internally

B. the control lever does not return to HOLD position
C. the main relief valve is set too high
D. the steering relief valve is set too high
17. The most likely reason that the steering wheel does not stop when the operator steers against the
stop is .

D. the steering line relief valve in the HMU is set too low
18. The most likely reason for no pump pressure is .
A. the steering accumulator has lost precharge

B. the main relief valve is set too high
C. the hydraulic system is low on oil
D. none of the above would result in loss of pump pressure
19. The blade tip valve contains the float function:
A. TRUE
B. FALSE
20. Hydraulic oil filtration is accomplished by a reverse flow filter:
A. TRUE
B. FALSE
21. The pump signal resolver selects the higher of the pressures that enter the combination valve from
the implement circuit and the circuit.
A. steering
B. all wheel drive
C. transmission charge
D. none of the above
22. If the operator requests more oil flow from the pump than the pump is capable of producing, oil will
stop flowing to one or more implements, based on the priority of the implement circuits.
A. TRUE
B. FALSE
23. The signal pressure relief valve limits the pressure to the implement pump.
A. cutoff
B. charge
C. purge
D. signal
24. The steering accumulator helps maintain consistent pressure to the hand metering unit (HMU):
A. TRUE
B. FALSE
25. The most likely reason the operator would complain that steering wheel does not turn the correct
number of turns is .
A. the main relief valve is set too high

B. the HMU is leaking internally
C. the signal relief pressure is set too high
D. a signal ball check valve in an implement control valve is stuck open
26. The most likely reason that the implements do not work but the steering does is .

D. the signal resolver valve is malfunctioning
27. Margin pressure affects the speed of the implement:
A. TRUE
B. FALSE
28. The main relief valve protects the system if the compensator fails to destroke the pump at .
A. margin pressure
B. signal relief pressure
C. high pressure cutoff pressure
D. lift circuit line relief pressure
29. The most likely reason the operator would complain that only one implement circuit is functioning
properly is .

30. The most likely reason the operator would complain that the implements will not function properly
when one circuit is stalled is .

Instructor Answer Key

The following section contains answers to the lab exercises, case study, and posttest. Some lab
exercises, may not have a specific answer and are represented by NA (not applicable).
Lab A
STEERING AND IMPLEMENT HYDRAULIC SYSTEM
C D
A B
E
G H
F
B RIGHT VALVE BANK
F ACCUMULATOR
A HAND METERING UNIT
D HYDRAULIC TANK
E LEFT VALVE BANK
H FLOW COMPENSATOR AND PRESSURE CONTROL VALVE
G COMBINATION VALVE
C IMPLEMENT AND STEERING PUMP

Lab B1
PRESSURE AND FLOW

COMPENSATOR VALVE
C FLOW COMPENSATOR
A COMPENSATOR BLEED SCREW
B PRESSURE COMPENSATOR
Lab B2
A B COMBINATION
VALVE
HOLD
C
D
E
F
G H
G SIGNAL RESOLVER VALVE
B LOAD CHECK VALVE
C STEERING PRIORITY VALVE
A STEERING ACCUMULATOR
H SIGNAL PURGE VALVE
F SIGNAL RELIEF VALVE
E MAIN RELIEF VALVE
D STEERING RELIEF VALVE

Lab B3
TYPICAL
A
B IMPLEMENT VALVE
C
HOLD
E F G H
B LOCK VALVE PISTON
H ROTARY ACTUATOR
F CONTROL VALVE STEM
A or C LOCK VALVE POPPET
E COUNTERBALANCE SPRING
G CENTERING SPRING
I SIGNAL CHECK VALVE
D COMPENSATOR VALVE
Lab B4
BLADE LIFT VALVE

A B C D HOLD
E
F
G H I
J K
MANIFOLD
B or C LOCK VALVE PISTON G DETENT SPRING
K ROTARY ACTUATOR F LINE RELIEF VALVE
I CONTROL VALVE STEM A or D LOCK VALVE POPPET
H COUNTERBALANCE SPRING J CENTERING SPRING
L SIGNAL CHECK VALVE E COMPENSATOR VALVE

Lab C
N/A
Lab D
N/A
Lab E
STEERING
CYLINDERS STEERING HAND GEROTOR
METERING UNIT
ROTARY
SLEEVE
STEERING HYDRAULIC SYSTEM
RIGHT TURN SUPPLY
CHECK VALVE
ANTI-CAVITATION
LINE RELIEFS WITH CHECK VALVE
ANTI-CAVITATION VALVES
PRESSURE
COMPENSATOR
SIGNAL
RESOLVER
SIGNAL PRIORITY
BLEED VALVE
SIGNAL
RELIEF
TANK MAIN
RELIEF ACCUMULATOR
IMPLEMENT PUMP STEERING

AND CONTROLS RELIEF
COMBINATION VALVE
Lab F1
PORT A PORT B
BLADE LIFT VALVE
COMPENSATOR FULLY SHIFTED TO THE RIGHT
VALVE
SIGNAL
CONTROL FROM CHECK BALL
STEM PUMP
TO COMBINATION
VALVE
MANIFOLD
Lab F2
TYPICAL IMPLEMENT VALVES

LOWEST LOAD
HIGHEST LOAD
PORT A PORT B PORT A PORT B
COMPENSATOR
COMPENSATOR
VALVE
VALVE
TO TANK
CONTROL
STEM
SIGNAL SIGNAL
CHECK BALL CHECK BALL
FROM PUMP FROM PUMP
(OPEN) (SEATED)
TO
COMBINATION
VALVE
MANIFOLD
Lab G
Directions: The laboratory exercise machine has a bug installed by the instructor. As a result, the
machines performance is such that the operator has complained the machine works slow or even quits
working.
The instructor has bugged the machine by lowering the signal relief valve pressure by turning the
adjustment screw out one (1) turn.
This bug will simulate a broken spring in the signal relief valve.
The bug will cause very slow, or no response from an implement when the implement control lever is
moved, because signal pressure in the flow compensator spring chamber is low and the flow
compensator valve will destroke the pump prematurely.
Students should identify reduced signal pressure as a potential problem, and perform the pressure test to
identify / confirm that the signal relief valve pressure is low.
Case Study
Directions: Students may use appropriate service literature and class notes to complete this case study.
Situation: The operator of a motor grader complained that, even though all the implements were
working, all implements were slow except for wheel lean. The service technician confirmed that Wheel
Lean cycle time was within service manual specifications, but that other implement operations were slow.
Gather Information: List at least three questions you would ask the operator.
1. When did the problem first occur?
2. What were you doing when the problem started?
3. What happens if the wheel lean lever is moved at the same time another implement lever is
moved?
Verify: Verify the problem exists. Operate the motor grader, if possible, to verify the problem exists.
Perform sensory checks such as looking, listening, touching, and smelling.
Perform Visual Inspection: When troubleshooting always perform a visual inspection first. Look for the
obvious. List at least three items that should be inspected during a visual inspection.
4. Signs of damage to implement control valves.
5. Signs of damage or leaks at any hose/connectors.
6. Signs of damage to wiring harnesses.
State Problem: After verifying a problem exists, state in your own words what the problem is (not
solution).
7. All implements are responding slowly except for the Wheel Lean.
List Possible Faults: List possible causes of the problem. Identify systems and components that could
be causing the problem, including the obvious.
8. Implement pump (including flow and pressure control valve) problem.
9. Combination valve problem.
10. Implement control valve problem.
Test to Determine Root Cause: List the tests that could be performed to find the root cause of the
problem.
11. Check low pressure standby and hydraulic system maximum pressure.
12. Check implement signal to compare signal pressure from wheel lean control valve and others.
Fix Machine: Perform tests if necessary and fix tractor.

13. The signal check valve in the wheel lean control valve was leaking. When any other control valve is
moved, signal pressure will seat all the other check balls. But because the wheel lean check ball is
leaking, the signal pressure will be directed to the tank and cause the pump not to upstroke. Wheel
lean will be the only implement circuit to have the correct cycle time. The procedure is to move
each control lever. When the implement that moves the fastest is located, this control valve has the
leaking signal check valve.
Verify Repair: After completing the repair, always verify the machine is operating correctly.
14.
Implement Hydraulics and Steering System Posttest

Directions: Circle the correct letter indicating the best answer for each question.
1. Each implement control valve contains one ..
A. line relief valve

B. signal check valve
C. spring
D. pressure setting
2. The H-Series motor graders use a hydraulic system.
A. proportional priority pressure compensated

B. load sensing and pressure compensated
C. proportional pilot pressure compensated
D. pilot priority pressure compensated
3. The most likely reason that the temperature of the system oil is too hot is ..
A. the signal relief pressure is set too high

C. the oil is contaminated
D. the main relief valve is set too low
4. The controls the precise flow to the cylinders.
A. the counterbalance spring

B. the position of the implement control valve stem
C. the line relief valve
D. the signal relief valve
5. The priority valve gives the steering system priority of pump supply oil flow over the implements.
A. TRUE
B. FALSE
6. The steering accumulator helps prevent erratic operation (jerkiness) in the steering operation:
A. TRUE
B. FALSE
7. The priority valve is contained within .
A. each line relief valve

B. the flow compensator and pressure control valve
C. the hydraulic filter base
D. the combination valve
8. The signal bleed valve prevents a trapped signal pressure condition by continuously leaking a small
flow of oil out of the circuit.
A. implement signal
B. steering signal
C. main implement
D. main steering
9. If additional implement valves need to be added to a machine, the existing valve bank .
A. must be removed
B. does not need to be removed
10. Lock check valves have been incorporated into each implement control valve:
A. TRUE
B. FALSE
11. The most likely reason that the steering system would have hard, or jerky, spots when an implement
is used is that .
A. the steering relief valve is set too high

C. the blade lift line relief valve is set too high
12. The limits the implement signal pressure.
A. flow compensator valve

B. signal resolver valve
C. signal check valve
D. signal relief valve
13. The most likely reason that blade float will not function in one valve is that .
A. the steering line relief in the HMU is set too low

B. there is contamination within the stem
C. the HMU is leaking internally
14. The steering line relief valves are located in the combination valve:
A. TRUE
B. FALSE
15. To balance the lever force in both directions of implement lever travel, a spring
is added at one end of the stem.
A. detent
B. centering
C. counterbalance
D. torsional
16. The most likely reason that the pump does not return to low pressure standby after an implement
pump is used is .

D. the steering relief valve is set too high
17. The most likely reason that the steering wheel does not stop when the operator steers against the
stop is .

D. the steering line relief valve in the HMU is set too low
18. The most likely reason for no pump pressure is .
A. the steering accumulator has lost precharge

B. the main relief valve is set too high
C. the hydraulic system is low on oil
D. none of the above would result in loss of pump pressure
19. The blade tip valve contains the float function:
A. TRUE
B. FALSE
20. Hydraulic oil filtration is accomplished by a reverse flow filter:
A. TRUE
B. FALSE
21. The pump signal resolver selects the higher of the pressures that enter the combination valve from
the implement circuit and the circuit.
A. steering
B. all wheel drive
C. transmission charge
D. none of the above
22. If the operator requests more oil flow from the pump than the pump is capable of producing, oil will
stop flowing to one or more implements, based on the priority of the implement circuits.
A. TRUE
B. FALSE
23. The signal pressure relief valve limits the pressure to the implement pump.
A. cutoff
B. charge
C. purge
D. signal
24. The steering accumulator helps maintain consistent pressure to the hand metering unit (HMU):
A. TRUE
B. FALSE
25. The most likely reason the operator would complain that steering wheel does not turn the correct
number of turns is .

26. The most likely reason that the implements do not work but the steering does is .

D. the signal resolver valve is malfunctioning
27. Margin pressure affects the speed of the implement:
A. TRUE
B. FALSE
28. The main relief valve protects the system if the compensator fails to destroke the pump at .
A. margin pressure
B. signal relief pressure
C. high pressure cutoff pressure
D. lift circuit line relief pressure
29. The most likely reason the operator would complain that only one implement circuit is functioning
properly is .

30. The most likely reason the operator would complain that the implements will not function properly
when one circuit is stalled is .


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SERV2726

ITIM FOR RENR4113

H-Series Motor Graders

Case Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Instructor Answer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Machine Electrical Pretest SEBV0558

Basic Hydraulic Pretest SEBV0557

Graphic Fluid Power Symbols (Pretest) SEBV0556

Course Name: _________________________ Course Number: ___________________

Pretest Score: ________ Posttest Score: ____________

2. Write the function and location of the components on a classroom

3. Given a motor grader and a stop watch, perform a steering cycle

4. Given a motor grader and the appropriate service module and

5. Given a steering hydraulic system schematic, trace the flow of oil

6. Given an implement hydraulic system schematic, trace the flow of

7. Given a machine, reference materials and/or tooling, identify

8. Without using any notes or references, identify the system

________________________ Student Average Good Excellent

________________________ Student met prerequisites

Training Manager: Class Participation

________________________ Desire to Learn

Visual Presentation: Implement Hydraulics and Steering System Overview 15 min.

Lab A: Locate And Identify Major System Components 15 min.

Lab B: Identify System Components using the Schematic 15 min.

Lab C: Test Cycle Times 45 min.

Lab D: Pressure Tests 60 min.

Lab G: Diagnostics 60 min.

Case Study 30 min.

Total Estimated Time 7 hours

__ Visual / Text Reference Materials

__ Service Manual (complete) - (RENR4135)

__ Hydraulic System Schematic - (RENR4148)

__ Electrical System Schematic - (RENR4149)

__ Operation and Maintenance Manual - (SEBU7473)

__ Parts Manual - (SEBP3297 for 143H or SEBP3298 for 163H)

__ H-Series Motor Graders -- Hydraulics and Transmission Systems Video SEVN3023

Gather the following special tools and materials:

__ Mechanics Tool Box with hand tools

__ Pressure Gauge Group

__ Lettered or numbered tags for component identification

__ PC Laptop Computer (See NOTE)

__ "ET Service Tool Software/Getting Started"

__ "ET Service Tool Software/Users Manual"

__ Universal Data Link Cable

__ SPM for Communication Adapter, Version 1.2 or later

Review and perform the labs before delivering this module.

The labs are:

Lab A: Locate and Identify Major System Components

Lab B: Identify System Components using the Schematic

Lab C: Cycle Time Tests

Lab D: Pressure Tests

Lab E: Trace Oil Flow through the Steering Hydraulic System

Lab F: Trace Oil Flow through the Implement Hydraulic System

Lab A: Locate and Identify Major System Components

___ RIGHT VALVE BANK

___ HAND METERING UNIT

___ HYDRAULIC TANK

___ LEFT VALVE BANK

___ FLOW COMPENSATOR AND PRESSURE CONTROL VALVE

___ COMBINATION VALVE

___ IMPLEMENT AND STEERING PUMP

Lab A: Locate and Identify Major System Components

STEERING AND IMPLEMENT HYDRAULIC SYSTEM

___ RIGHT VALVE BANK

Course Name: _______ Course Number: _

Pretest Score: Posttest Score: ____