You are on page 1of 37

SERV1839

July 2007

GLOBAL SERVICE LEARNING

STUDENT MATERIALS

PART OF GLOBAL SERVICE LEARNING MODULE SERV1839

140M AND 160M MOTORGRADERS

LAB EXERCISES AND POSTTEST ANSWERS


SERV1839 -2- Laboratory Exercises
07/07 Student Handout No. 1

Component Identification
Description
Identify the components of the 140M and 160M Motor Graders. Use the worksheets to take
notes on the types of input components. After locating the components on the schematic, locate
the components on the engine or machine.
Materials Needed
__ Electrical Schematic (for the machine being used)
__ Machine or engine with an electronic control system
SERV1839 -3- Laboratory Exercises
07/07 Student 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_________rpm
2. Engine coolant temperature__________
3. Fuel level__________
4. Lifetime total reverse distance traveled?__________
5. How many languages are available?__________
6. What is the maximum autoshift gear limit (forward and reverse)?_________
7. Equipment identification number?__________
8. Transmission serial number?__________
9. Machine service hours?__________
10. With the engine running at low idle, what is the boost pressure?__________
11. With the engine running at low idle, what is the transmission output speed?________
12. With the engine running at low idle, what is the parking brake switch status?_______
13. With the engine running at low idle, what is the fuel filter status?___________
14. With the engine running at low idle, what is the transmission filter status?_________
15. With the engine running at low idle, what is the hydraulic oil temperature (shown in the
AWD section of Messenger)?_____________
16. What mode is the AWD system in?_____________
SERV1839 -4- Laboratory Exercises
07/07 Student Handout No. 3

Lab B: Messenger System Components and Functions Posttest

Directions: Match each component to the correct function.


Function Component Function Definition

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


Mode Active alternator status.

Settings; Transmission B. Menu that contains information on


maximum recorded coolant temperature.

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


Engine

Service; System Parameters; D. Menu that contains right and left motor
Transmission speed.

Service; System Parameters; E. Menu that contains maximum forward


Monitoring System autoshift gear.

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


air temperature.

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


AWD transmission output speed.
SERV1839 -5- Laboratory Exercises
07/07 Student Handout No. 4

Lab C: Worksheet Answers


C7/C9 ACERT™ Engine Component Identification Worksheet

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

_____ Engine ECM


Function:
Location:

_____ Primary Fuel Filter and Water Separator


Function:
Location:

_____ Electric Fuel Pump


Function:
Location:

_____ Secondary Fuel Filter


Function:
Location:

_____ Hydraulic Electronic Unit Injector (HEUI)


Function:
Location:

_____ Fuel Pressure Regulator


Function:
Location:

_____ Fuel Pressure Sensor


Function: .
Location:

_____ Fuel Differential Pressure Switch


Function:
Location:
SERV1839 -6- Laboratory Exercises
07/07 Student Handout No. 5

Lab C: Worksheet
C7/C9 ACERT™ Engine Component Identification Worksheet (continued)

_____ Injection Actuation Pressure (IAP) Sensor


Function:
Location:

_____ Primary Speed/Timing Sensor


Function:
Location:

_____ Secondary Speed/Timing Sensor


Function:
Location:

_____ Timing Calibration Connector


Function:
Location:

_____ 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:

_____ Atmospheric Pressure Sensor


Function:
Location:

_____ Turbocharger Inlet Pressure Sensor


Function:
Location:
SERV1839 -7- Laboratory Exercises
07/07 Student Handout No. 6

Lab C: Worksheet
C7/C9 ACERT™ Engine Component Identification Worksheet (continued)

_____ Inlet Air Heater


Function:
Location:

_____ Ether Starting Aid


Function:
Location:

_____ Throttle Control Mode Switch


Function:
Location:

_____ Throttle Resume/Decelerate Switch


Function:
Location:

_____ Throttle Set/Accelerate Switch


Function:
Location:

_____ Throttle Position Sensor


Function:
Location:
SERV1839 -8- Laboratory Exercises
07/07 Student Handout No. 7

Lab D: Engine System Components and Functions Posttest

Directions: Match each component to the correct function.


Function Component Function Definition

Differential fuel pressure switch A. Final filtering of the fuel before the fuel
enters the fuel gallery.

Engine ECM B. An event that limits the engine


horsepower.

C. An event that is based on atmospheric


Non-latching derate
pressure, intake manifold temperature,
and engine rpm.
Turbocharger inlet pressure sensor D. Compares the difference between inlet
and outlet fuel pressure.

Electric fuel pump E. Supplies fuel.

F. Used for timing the engine if the Engine


Secondary fuel filter
ECM or timing sensor is replaced.

Engine derate G. Receives sensor and switch inputs and


controls fan speed and engine rpm.

Virtual exhaust derate H. A horsepower limiting event that no


longer limits horsepower when the
condition no longer exists.

Timing calibration connector I. Engine ECM uses this sensor to calculate


air filter restriction.

J. Engine ECM uses this sensor to calculate


Latching derate
all other pressure sensors on the engine.

K. A horsepower limiting event that limits


Atmospheric pressure sensor
horsepower when the condition no longer
exists.
SERV1839 -9- Laboratory Exercises
07/07 Student Handout No. 8

Lab E: Worksheet
Power Train Component Identification Worksheet

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

_____ Transmission/Chassis ECM


Function:
Location:

_____ Transmission
Function:
Location:

_____ Transmission Pump


Function:
Location:

_____ Scavenge Pump


Function:
Location:

_____ Transmission Relief Valve


Function:
Location:

_____ Transmission Filter


Function:
Location:

_____ Transmission Modulating Valves


Function:
Location:

_____ Transmission Input Speed Sensor


Function:
Location:
SERV1839 - 10 - Laboratory Exercises
07/07 Student Handout No. 9

Lab E: Worksheet
Power Train Component Identification Worksheet (continued)

_____ Transmission Intermediate Speed Sensors


Function:
Location:

_____ Transmission Output Speed Sensors


Function:
Location:

_____ Transmission Oil Temperature Sensor


Function:
Location:

_____ Transmission Oil Cooler


Function:
Location:

_____ Transmission Lubrication Relief Valve


Function:
Location:

_____ Key Start Switch


Function:
Location:

_____ Engine Start Relay


Function:
Location:

_____ Autoshift Switch (if equipped)


Function:
Location:

_____ Directional Switch


Function:
Location:

_____ Upshift Switch


Function:
Location:
SERV1839 - 11 - Laboratory Exercises
07/07 Student Handout No. 10

Lab E: Worksheet
Power Train Component Identification Worksheet (continued)

_____ Downshift Switch


Function:
Location:

_____ Inching Pedal


Function:
Location:

_____ Inching Pedal Sensor


Function:
Location:

_____ Inching Pedal Switch


Function:
Location:

_____ Differential Lock Switch


Function:
Location:

_____ Differential Lock Solenoid


Function:
Location:

_____ Differential
Function:
Location:

_____ Final Drives


Function:
Location:

_____ Back-up Alarm


Function:
Location:
SERV1839 - 12 - Laboratory Exercises
07/07 Student Handout No. 11

Lab F: Power Train Hydraulic System Tests Worksheet

POWER TRAIN HYDRAULIC SYSTEM SPECIFICATION ACTUAL


Transmission Pump Pressure

Lubrication Pressure

Differential Lock Pressure

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


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

Eighth Speed Forward

Seventh Speed Forward


Sixth Speed Forward

Fifth Speed Forward

Fourth Speed Forward

Third Speed Forward

Second Speed Forward

First Speed Forward

Neutral
First Speed Reverse

Second Speed Reverse

Third Speed Reverse

Fourth Speed Reverse

Fifth Speed Reverse

Sixth Speed Reverse

TRANSMISSION CLUTCH FILL CALIBRATION


YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
SERV1839 - 13 - Laboratory Exercises
07/07 Student Handout No. 12

Lab G: Transmission Hydraulic System Components


and Functions Posttest

Directions: Match each component to the correct function.


Function Component Function Definition

Differential lock solenoid A. Provides speed and directional conversion


of the available engine power.

Transmission oil cooler B. Transmission oil supply stored in the


bottom of the differential case.

Transmission lubrication relief C. Controls oil flow to the differential lock.


valve

Transmission relief valve D. Filters the oil from the transmission pump
to the transmission hydraulic system.

Transmission pump
E. Supplies oil flow to the transmission
hydraulic system.
Transmission filter F. Limits the oil pressure to the proportional
solenoid valves.

Transmission modulating valves G. Transfers oil from the transmission sump


to the differential sump.

Transmission oil reservoir H. Controls oil flow and pressure to the


clutches.

Scavenge pump I. Cools the transmission hydraulic oil.

Transmission J. Limits the pressure in the lubrication


passages of the transmission.
SERV1839 - 14 - Laboratory Exercises
07/07 Student Handout No. 13

Lab H: Transmission Electronic Control System Components


and Functions Posttest

Directions: Match each component to the correct function.


Function Component Function Definition

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


engine start relay.

Inching pedal position sensor B. Senses pedal position so current can


be varied to the directional solenoids
during machine operation.

Autoshift switch C. Allows the operator to manually


downshift the transmission.

Downshift switch D. Measures input speed to the


transmission.

Upshift switch E. Receives sensor and switch inputs


and controls transmission shifting and
engine starting.

Transmission input speed sensor F. Signals the Transmission/Chassis ECM


the shift mode (automatic or manual)
in which the operator wants to operate.

Transmission modulating valves G. Measures transmission output speed.

Transmission output speed sensors H. Measures transmission oil temperature.

Directional switch I. Allows the operator to manually


upshift the transmission.

Transmission oil temperature sensor J. Signals the Transmission/Chassis ECM


the direction (forward or reverse) the
operator wants the machine to move.

Engine key start switch K. Controls oil flow and pressure to the
clutches.
SERV1839 - 15 - Laboratory Exercises
07/07 Student Handout No. 14

Lab I: Worksheet
AWD Component Identification Worksheet

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

____ AWD Control Switch


Function:
Location:

____ AWD Aggression Dial


Function:
Location:

____ AWD Engaged Indicator


Function:
Location:

____ AWD Warning Indicator


Function:
Location:

____ Charge Pumps


Function:
Location:

____ Charge Oil Filters


Function:
Location:

____ Piston Pumps


Function:
Location:

____ Pump Displacement Solenoids


Function:
Location:
SERV1839 - 16 - Laboratory Exercises
07/07 Student Handout No. 15

Lab I: Worksheet
AWD Component Identification Worksheet (continued)

____ AWD Control Valve


Function:
Location:

____ Clutch Solenoids


Function:
Location:

____ Motor Displacement Solenoids


Function:
Location:

____ AWD Pressure Sensors


Function:
Location:

____ AWD Wheel Motors


Function:
Location:

____ Wheel Motor Speed Sensor


Function:
Location:

____ AWD Wheel Stations


Function:
Location:

____ Wheel Station Clutch


Function:
Location:

____ Hydraulic Cooler Bypass Valve


Function:
Location:

____ AWD Temperature Sensor


Function:
Location:

____ Hydraulic Oil Cooler


Function:
Location:
SERV1839 - 17 - Laboratory Exercises
07/07 Student Handout No. 17

Lab J: AWD Hydraulic System Tests Worksheet


AWD SYSTEM PRESSURE TESTS
Specification Actual Within Specification?
Charge Pressure (Right Pump)

Charge Pressure (Left Pump)

POR Pressure

FWD/REV Clutch Pressures

AWD AGRESSION CONTROL DIAL CALIBRATION


YES NO FAULTS PRESENT
CALIBRATION
COMPLETED

AWD PUMP AND MOTOR CALIBRATION


YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
SERV1839 - 18 - Text Reference
07/07

Lab K: AWD System Components and Functions Posttest

Directions: Match each component to the correct function.


Function Component Function Definition

Aggression control dial A. Selects mode of operation.

AWD control valve B. Controls the amount of aggression


provided by front wheels.

AWD warning indicator C. Indicates AWD system is turned ON.

AWD control switch D. Indicates a problem with the AWD


system.

Charge pumps E. Provides continuous pressure to the


piston pumps.

AWD engaged indicator F. Provides oil flow to the piston motors.

Hydraulic oil cooler G. Routes oil flow between the piston


pump and wheel motors.

Wheel motor speed sensor H. Converts fluid power into mechanical


power.

AWD piston pumps I. Provides the AWD ECM with the


actual wheel.

Charge pump oil filters J. Cleans the oil before sending it to the
control valve and wheel motors.

Wheel motors K. Maintains normal hydraulic oil


operating temperatures.
SERV1839 - 19 - Laboratory Exercises
07/07 Student Handout No. 16

Lab L: Worksheet
Implement Component Identification Worksheet

Directions: During the visual presentation, use these worksheets to take notes as the function of
each component is explained.

Example: _____Pilot Pump


Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold, and pilot systems.

_____ Hydraulic Tank


Function:
Location:

_____ Implement Control Valves


Function:
Location:

_____ Implement and Steering Control Manifold


Function:
Location:

_____ Pilot Pressure Reducing Valve


Function:
Location:

_____ Main Relief Valve


Function:
Location:

_____ Implement and Steering Pump Pressure Sensor


Function:
Location:

_____ Implement and Steering Pump


Function:
Location:

_____ Blade Lift Cylinders


Function:
Location:
SERV1839 - 20 - Text Reference
07/07

Lab L: Worksheet
Implement Component Identification Worksheet (continued)

_____ Blade Tip Cylinder


Function:
Location:

_____ Sideshift Cylinder


Function:
Location:

_____ Centershift Cylinder


Function:
Location:

_____ Pilot Oil Filter


Function:
Location:

_____ Hydraulic Oil Filter


Function:
Location:

_____ Implement and Steering Joysticks


Function:
Location:

_____ Implement ECM


Function:
Location:

_____ Implement ECM 1


Function:
Location:

_____ Implement ECM 2 (if equipped)


Function:
Location:

_____ Hydraulic Lockout Switch


Function:
Location:
SERV1839 - 21 - Text Reference
07/07

Lab L: Worksheet
Implement Component Identification Worksheet (continued)

_____ Implement Lockout Solenoid Valve


Function:
Location:

_____ Centershift Lock Switch


Function:
Location:

_____ Centershift Lock


Function:
Location:

_____ Blade Cushion Switch (if equipped)


Function:
Location:

_____ Blade Cushion Accumulator (if equipped)


Function:
Location:

_____ Ripper Control (if equipped)


Function:
Location:

_____ Ripper Cylinders (if equipped)


Function:
Location:

_____ Scarifier Control (if equipped)


Function:
Location:

_____ Scarifier Cylinders (if equipped)


Function:
Location:

_____ Auxiliary Hydraulic Controls (if equipped)


Function:
Location:
SERV1839
SERV1807 - 22 - Laboratory
LaboratoryExercises
Exercise
02/06
07/07 Instructor Handout
HandoutNo.
No.173

Lab M: Implement Hydraulic


Lab KSystem TestsAnswers
Worksheet Worksheet
Locate
PILOTand Identify
AND Cooling and
IMPLEMENT Return PRESSURE
SYSTEM Systems Components
TESTS
appropriate lettersActual
Specification
INSTRUCTOR NOTE: Fill in the or numbersWithin Specification?
as you attach tags to
the components.
Pilot Pressure
Directions: Place the correct letter or number next to the component. During the visual
Margin Pressure
presentation, use these worksheets to take notes as the function of each component is explained.
Pump Cutoff Pressure
Example: _____ Pilot Pump
Signal Relief Valve
Location: The single section gear pump mounted on left main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold and pilot systems.
Main Relief Valve
COMPENSATOR
_____ VALVE PRESSURE AND FLOW ADJUSTMENT
Hydraulic Oil Cooler
Does the flow compensation valve need adjustment? YES / NO
Location: At the left rear corner of the machine in front of the engine.
Does the pressure
Function: Providescompensator
cooling for valve need adjustment?
the hydraulic oil. YES / NO
Which testsRadiator
_____ indicate if the flow compensator or the pressure compensator needs adjustment?
_____________________________________________________________________________
Location: At the left rear corner of the machine in front of the engine.
CYCLE
Function: TIME
Provides Test coolant.2nd Test
1stengine
cooling for the 3rd Test Average
CHECK
_____ Fuel Cooler
Blade Lift
Location: At the left rear corner of the machine in front of the engine.
Function:
Blade TipProvides cooling for the engine diesel fuel.
_____ Air to Air After-cooler
Centershift
Location:
SideshiftAt the left rear corner of the machine in front of the engine.
Function: Provides cooling for the air going into the intake manifold
Blade Circle
_____ Case Drain Filter
Scarifier (if equipped)
Location: Inside the pump compartment, behind the pilot filter.
Function:
Ripper (ifFilters the case drain oil from the pumps and motors.
equipped)
Oil_____
TempReturn
____°FOil Filter

Cycle times
Location: within
Inside specifications?
the hydraulic tank. Yes No
Function: Filter all the return oil from the implements, swing and travel circuits.
me Part No.
IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS
YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
Lab N: Implement Hydraulic System Identification
07/07

Directions: Fill in the blanks next to the letters with the correct term.
SERV1839

A _____________________________
P
B _____________________________
M N O Q
C _____________________________

D _____________________________

E _____________________________

F _____________________________

G _____________________________
H I L
F
H _____________________________
- 23 -

K
I _____________________________ G

J _____________________________

K _____________________________
J
Steering
L _____________________________ Control
E Valve

M _____________________________
Hydraulic
B
N _____________________________ Tank

Implement / Steering A
Pump
C
O _____________________________ D

P _____________________________ Return Filter

Q _____________________________
Student Handout No. 18
Laboratory Exercises
SERV1839 - 24 - Laboratory Exercises
07/07 Student Handout No. 19

Lab O: Implement System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

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

Implement ECM (Master) B. Controls the outputs to the electrohydraulic


pilot control valve.

Electrohydraulic pilot control C. Reduces the pressure of the implement and


valves steering system to the pressure setting for
the pilot system.

Implement control valves D. Signals the Implement ECM that the


operator wants the implement hydraulics
disabled.

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


implement functions.

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


cylinders.

Implement and steering pump G. Routes oil from the blade accumulators to
the blade cylinders.

Hydraulic lockout switch H. Limits the maximum load signal that is sent
to the implement and steering pump.

Blade cushion solenoid valve I. Supplies oil for the implement and steering
systems.
SERV1839 - 25 - Laboratory Exercises
07/07 Student Handout No. 20

Lab P: Worksheet
Steering Component Identification Worksheet

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

_____ Hydraulic Tank


Function:
Location:

_____ Implement and Steering Pump


Function:
Location:

_____ Implement and Steering Control Manifold


Function:
Location:

_____ Main Relief Valve


Function:
Location:

_____ Implement and Steering Pump Pressure Sensor


Function:
Location:

_____ Steering Control Valve


Function:
Location:

_____ Implement and Steering Joysticks


Function:
Location:

_____ Steering Cylinders


Function:
Location:

_____ Steering Cylinder Position Sensors


Function:
Location:
SERV1839 - 26 - Laboratory Exercises
07/07 Student Handout No. 21

Lab P: Worksheet
Steering Component Identification Worksheet (continued)

_____ Secondary Steering Motor and Pump


Function:
Location:

_____ Secondary Steering Solenoid Valves


Function:
Location:

_____ Primary Steering Indicator


Function:
Location:

_____ Secondary Steering Indicator


Function:
Location:

_____ Secondary Steering System Test Switch


Function:
Location:

_____ Articulation Cylinders


Function:
Location:

_____ Articulation Position Sensors


Function:
Location:

_____ Articulation Auto Recenter Switch


Function:
Location:

_____ Wheel Lean Cylinder


Function:
Location:

_____ Wheel Lean Switches


Function:
Location:
SERV1839
SERV1839 -- 27
27 -- Laboratory Exercises
Text Reference
07/07
07/07 Instructor Handout No. 22

Lab Q: Steering System Tests

STEERING SYSTEM PRESSURE TESTS


Specification Actual Within Specification?
Margin Pressure

Pump Cutoff Pressure

Signal Relief Valve

Main Relief Valve

ARTICULATION SOLENOIDS CALIBRATION


YES NO FAULTS PRESENT
CALIBRATION
COMPLETED

ARTICULATION POSITION SENSORS CALIBRATION


YES NO FAULTS PRESENT
CALIBRATION
COMPLETED

STEERING CYLINDER POSITION SENSOR CALIBRATION


YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
SERV1839 - 28 - Laboratory Exercises
07/07 Student Handout No. 23

Lab R: Steering System Components and


Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

Hydraulic tank A. Supplies steering system flow if the


primary steering system or engine failure
occurs.

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

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


communicating the articulation angle of the
machine.

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


control valve steering functions.

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


primary steering system.

Steering control valve F. Controls pump flow and pressure.

Primary steering indicator light G. Alerts operator that the secondary steering
system is activated.

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

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

Secondary steering indicator light J. Directs oil to the steering cylinders to turn
the machine.
SERV1839 - 29 - Laboratory Exercises
07/07 Student Handout No. 24

Lab S: Worksheet
Brake Component Identification Worksheet

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

_____ Brake and Fan Pump


Function:
Location:

_____ Combination Valve


Function:
Location:

_____ Priority Valve


Function:
Location:

_____ Cut-In Valve


Function:
Location:

_____ Cut-Out Valve


Function:
Location:

_____ Brake Accumulators


Function:
Location:

_____ Brake Accumulator Pressure Sensor


Function:
Location:

_____ Service Brake Valve


Function:
Location:
SERV1839 - 30 - Laboratory Exercises
07/07 Student Handout No. 25

Lab S: Worksheet
Brake Component Identification Worksheet (continued)

_____ Service Brakes


Function:
Location:

_____ Parking Brake


Function:
Location:

_____ Parking Brake Solenoid Valve


Function:
Location:

_____ Parking Brake Pressure Switch


Function:
Location:
SERV1839 - 31 - Laboratory Exercises
07/07 Student Handout No. 26

Lab T: Brake System Tests Worksheet

ACCUMULATOR PRESSURE TEST


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

BRAKE SYSTEM PRESSURE TEST

SPECIFICATION ACTUAL
Right Service Brake Control Valve Pressure

Left Service Brake Control Valve Pressure


Parking Brake 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?
SERV1839 - 32 - Laboratory Exercises
07/07 Student Handout No. 27

Lab U: Brake System Components and


Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

Hydraulic tank A. Primary brakes for stopping the machine.

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

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

Service brakes D. Supplies oil to the brake system when the


engine is OFF.

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

Parking brake actuator F. Prevents movement of the machine when


engaged.

Service brake control valve G. Maintains accumulator pressure between


cut-out and cut-in pressures.

Parking brake pressure sensor H. Sends parking brake oil pressure signal to
the Transmission/Chassis ECM.

Service brake accumulators I. Sends Transmission/Chassis ECM a signal


if the brake accumulator charge oil pressure
is low.

Accumulator charging valve and J. Controls oil flow to release the parking
fan manifold brake.
SERV1839 - 33 - Laboratory Exercises
07/07 Student Handout No. 28

Lab V: Worksheet
Fan Component Identification Worksheet

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

_____ Brake and Fan Pump


Function:
Location:

_____ Combination Valve


Function:
Location:

_____ Priority Valve


Function:
Location:

_____ Fan Speed Solenoid Valve


Function:
Location:

_____ Hydraulic Oil Cooler


Function:
Location:

_____ Fan Motor


Function:
Location:

_____ Engine ECM


Function:
Location:
SERV1839 - 34 - Text Reference
07/07

Lab V: Worksheet
Fan Component Identification Worksheet (continued)

_____ Engine Coolant Temperature Sensor


Function:
Location:

_____ Intake Manifold Temperature Sensor


Function:
Location:

_____ Hydraulic Oil Temperature Sensor


Function:
Location:
SERV1839 - 35 - Text Reference
07/07

Lab W: Fan System Tests Worksheet

FAN SYSTEM TEST


Specification Actual Within Specification?
Margin Pressure

High Pressure Cutoff

Minimum Fan Speed

Maximum Fan Speed


COMPENSATOR VALVE PRESSURE AND FLOW ADJUSTMENT
Does the flow compensation valve need adjustment? YES / NO
Does the pressure compensator valve need adjustment? YES / NO
Which tests indicate if the flow compensator or the pressure compensator needs adjustment?
_____________________________________________________________________________

FAN SYSTEM TEST

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


If faults were present, list the faults:
SERV1839 - 36 - Laboratory Exercises
07/07 Instructor Handout No. 30

Lab X: Fan System Components and


Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

Hydraulic tank A. Coolant temperature measurement for


Engine ECM, instrument panel, temperature
warning.

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

Brake and fan pump C. Hydraulic oil temperature measurement


for the Implement ECM and temperature
warning.

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

Hydraulic oil temperature sensor E Intake air temperature measurement for


Engine ECM and temperature warning.

Engine ECM F. Converts hydraulic energy into mechanical


motion.

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


electronic fuel system control.

Engine coolant temperature sensor H. Stores the oil for the hydraulic systems on
the machine.
SERV1839 - 37 - Student Handout No. 31
07/07

HYDRAULIC SCHEMATIC COLOR CODE

Black - Mechanical Connection. Seal Red - High Pressure Oil

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

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

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

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

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

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

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

Green / White Stripes -


Scavenge / Suction Oil or Hydraulic Void

HYDRAULIC SCHEMATIC COLOR CODE

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