You are on page 1of 37

SERV1839

July 2007

GLOBAL SERVICE LEARNING

INSTRUCTOR 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

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


Mode Active alternator status.

E Settings; Transmission B. Menu that contains information on


maximum recorded coolant temperature.

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


Engine

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

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


Monitoring System autoshift gear.

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


air temperature.

D 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: Electronic Control Module governor, and electronic fuel system control.
Location: Mounted on the engine, left side of engine compartment.

_____ Primary Fuel Filter and Water Separator


Function: Ten micron filter, removes large debris which could damage the injectors and removes
water from fuel. Drain water daily.
Location: Left side of engine compartment.

_____ Electric Fuel Pump


Function: Primes fuel system from the tank through the filters to the injectors.
Location: Mounted on the primary fuel filter housing.

_____ Secondary Fuel Filter


Function: Two micron filter, removes small debris which could damage the injectors.
Location: Next to primary fuel filter, left-side of the engine compartment.

_____ Hydraulic Electronic Unit Injector (HEUI)


Function: Controlled by the Engine ECM, delivers fuel to the injectors.
Location: In the cylinder head below valve cover.

_____ Fuel Pressure Regulator


Function: Maintains fuel system pressure.
Location: Mounted in the fuel gallery.

_____ Fuel Pressure Sensor


Function: Fuel pressure measurement for the Engine ECM, and high and low pressure
warnings.
Location: Mounted on the secondary fuel filter base.

_____ Fuel Differential Pressure Switch


Function: Compares the filter inlet pressure to the filter outlet pressure for the Engine ECM and
filter bypass warning.
Location: Mounted on the secondary fuel filter base.
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: Measures hydraulic actuation pressure and sends pressure reading to engine ECM.
Location: Top of the engine block, left side engine compartment.

_____ Primary Speed/Timing Sensor


Function: Engine speed/timing measurement, TDC, and cylinder identification and compression
timing.
Location: Rear of timing gear housing, left side engine compartment.

_____ Secondary Speed/Timing Sensor


Function: Times the engine if the primary sensor malfunctions.
Location: Rear of timing gear housing, left side of engine compartment.

_____ Timing Calibration Connector


Function: Connects the timing probe when installed in the rear housing, to the Engine ECM.
Location: In the engine wiring harness, above the Engine ECM.

_____ Engine Coolant Temperature Sensor


Function: Coolant temperature measurement for Engine ECM, instrument panel, and
temperature warning.
Location: Left side engine compartment.

_____ 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.

_____ Atmospheric Pressure Sensor


Function: Ambient pressure for gauge pressure measurements, engine derate altitude
compensation, calculating boost, and air filter restriction.
Location: In the valve cover, next to the intake manifold air pressure sensor and intake manifold
air temperature sensor.
SERV1839 -7- Laboratory Exercises
07/07 Student Handout No. 6

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

_____ Turbocharger 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 in the
right-side engine compartment.

_____ Inlet Air Heater Relay


Function: Activated by the Engine ECM to energize the intake air heater
Location: On the left side of the engine compartment by the intake air heater.

_____ Ether Starting Aid


Function: Controlled by the Engine ECM. Helps to start the machine in cold weather
conditions. Works with the intake manifold air heater.
Location: Left side engine compartment.

_____ Throttle Control Mode Switch


Function: Allows the operator to select the throttle control mode.
Location: On the panel to the right of the operator's seat.

_____ Throttle Resume/Decelerate Switch


Function: Allows the operator to resume the previous set engine rpm or decrease engine rpm
while the throttle lock is active.
Location: On the panel to the right of the operator's seat.

_____ Throttle Set/Accelerate Switch


Function: Allows the operator the set the desired engine rpm or increases 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.
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

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

G Engine ECM B. An event that limits the engine


horsepower.

C. An event that is based on atmospheric


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

E Electric fuel pump E. Supplies fuel.

F. Used for timing the engine if the Engine


A Secondary fuel filter
ECM or timing sensor is replaced.

B Engine derate G. Receives sensor and switch inputs and


controls fan speed and engine rpm.

C Virtual exhaust derate H. A horsepower limiting event that no


longer limits horsepower when the
condition no longer exists.

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


air filter restriction.

J. Engine ECM uses this sensor to calculate


K Latching derate
all other pressure sensors on the engine.

K. A horsepower limiting event that limits


J 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: Electronic Control Module, transmission shifting, engine starting, and secondary
steering.
Location: Rear of the transmission.

_____ Transmission
Function: Provides speed and directional conversion of the available engine power.
Location: Mounted to the rear of the engine.

_____ Transmission Pump


Function: Supplies oil flow to the torque converter and transmission hydraulic system.
Location: Mounted to the right-side of the transmission housing.

_____ Scavenge Pump


Function: Transfers oil from the transmission sump to the differential sump.
Location: Mounted to the right-side of the transmission housing.

_____ Transmission Relief Valve


Function: Limits oil pressure to the transmission proportional solenoid valves.
Location: Mounted to the left-side of the transmission housing.

_____ Transmission Filter


Function: Filters the oil from the transmission pump to the transmission hydraulic system.
Location: Mounted at the right rear of the transmission.

_____ Transmission Modulating Valves


Function: Controls oil flow and pressure to the speed and directional clutches.
Location: Mounted to the left-side of the transmission case.

_____ Transmission Input Speed Sensor


Function: Measures transmission input shaft speed.
Location: Mounted in the top of the transmission case.
SERV1839 - 10 - Laboratory Exercises
07/07 Student Handout No. 9

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

_____ Transmission Intermediate Speed Sensors


Function: Measures transmission intermediate gear speed.
Location: Mounted in the upper right-side of the transmission case.

_____ Transmission Output Speed Sensors


Function: Measures transmission output speed.
Location: Mounted in the lower right-side of the transmission case.

_____ Transmission Oil Temperature Sensor


Function: Measures transmission oil temperature.
Location: Mounted on the left-side of the transmission case.

_____ Transmission Oil Cooler


Function: Cools the transmission hydraulic oil.
Location: Mounted on the right-side of the engine compartment.

_____ Transmission Lubrication Relief Valve


Function: Limits the maximum lubrication pressure in the transmission.
Location: Mounted on the left-side of the transmission case by the transmission temperature
sensor.

_____ Key Start Switch


Function: Signals the Transmission/Chassis ECM when to energize the engine starter relay.
Location: Mounted in the front console of the operators station.

_____ Engine Start Relay


Function: Activated by the Transmission/Chassis ECM to energize the starter motor.
Location: Mounted inside of the left-side engine compartment.

_____ 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 operators seat.

_____ Directional Switch


Function: Allows operator to select desired direction (forward or reverse).
Location: Mounted in the left steering/implement joystick.

_____ Upshift Switch


Function: Allows the operator to manually upshift the transmission.
Location: Mounted in the left steering/implement joystick.
SERV1839 - 11 - Laboratory Exercises
07/07 Student Handout No. 10

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

_____ Downshift Switch


Function: Allows the operator to manually downshift the transmission.
Location: Mounted in the left steering/implement joystick.

_____ Inching Pedal


Function: Allows the operator to control the maximum speed in a desired gear.
Location: Left pedal in the operators station in front of the seat.

_____ Inching Pedal Sensor


Function: Sends a signal to the Implement ECM indicating if the inching pedal is being used.
Location: Above the inching pedal inside the front console.

_____ Inching Pedal Switch


Function: Is a backup to the inching pedal sensor to determine if the inching pedal is being
used.
Location: Above the inching pedal inside the front console.

_____ Differential Lock Switch


Function: Sends a signal to the Transmission/Chassis ECM to energize or de-energize the
differential lock solenoid.
Location: In the right operator joystick.

_____ Differential Lock Solenoid


Function: Controls oil flow to the differential lock.
Location: Mounted on the differential case, on the left-side rear of the machine.

_____ Differential
Function: Sends power from the transmission to the wheels.
Location: Mounted in the rear frame near the rear of the machine.

_____ Final Drives


Function: Provides a final gear reduction to provide the most torque during machine operation.
Location: Mounted on the side of the differential case.

_____ Back-up Alarm


Function: Alerts surrounding area that the machine has been put into reverse.
Location: Mounted at the rear of the machine.
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 (kPa/psi)

Lubrication Pressure (kPa/psi)

Differential Lock Pressure (kPa/psi)

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

C Differential lock solenoid A. Provides speed and directional conversion


of the available engine power.

I Transmission oil cooler B. Transmission oil supply stored in the


bottom of the differential case.

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


valve

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

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

H Transmission modulating valves G. Transfers oil from the transmission sump


to the differential sump.

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


clutches.

G Scavenge pump I. Cools the transmission hydraulic oil.

A 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

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


engine start relay.

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


be varied to the directional solenoids
during machine operation.

F Autoshift switch C. Allows the operator to manually


downshift the transmission.

C Downshift switch D. Measures input speed to the


transmission.

I Upshift switch E. Receives sensor and switch inputs


and controls transmission shifting and
engine starting.

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


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

K Transmission modulating valves G. Measures transmission output speed.

G Transmission output speed sensors H. Measures transmission oil temperature.

J Directional switch I. Allows the operator to manually


upshift the transmission.

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


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

A 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: Controls the pumps, solenoids, and switches for the front wheel motors.
Location: Behind the operators seat.

____ AWD Control Switch


Function: Used to select modes of operation which are CREEP, OFF, or ON.
Location: In the operators compartment to the right of the operator seat.

____ AWD Aggression Dial


Function: Used to turn OFF, to decrease, or to increase the AWD system aggression.
Location: In the operators compartment to the right of the operator seat.

____ AWD Engaged Indicator


Function: When AWD system is in use, the light will be turned on (green).
Location: In the operators compartment to the right of the operator seat.

____ AWD Warning Indicator


Function: Any warning event or diagnostic from the AWD ECM will illuminate the light.
Location: In the operators compartment to the right of the operator seat.

____ Charge Pumps


Function: Provides continuous pressure in the closed-loop charge circuit of the AWD system.
Location: On the right-side of the motor grader in the engine compartment, mounted to the
piston pumps.

____ Charge Pump Oil Filters


Function: Cleans the oil from each of the two charge pumps before sending it to the control
valve and wheel motors.
Location: Below the radiator at the rear of the machine.

____ Piston Pumps


Function: Provide oil flow in both the forward and reverse direction to the piston motors.
Location: On the right-side of the motor grader in the engine compartment.

____ Pump Displacement Solenoids


Function: An output of the AWD ECM that controls the oil flow from the AWD pumps.
Location: Mounted on the AWD pumps.
SERV1839 - 16 - Laboratory Exercises
07/07 Student Handout No. 15

Lab I: Worksheet
AWD Component Identification Worksheet (continued)

____ AWD Control Valve


Function: Controls both the engagement and the disengagement of the clutches for the wheel
motors; controls the oil flow to the motors.
Location: At the front of the machine, mounted to the top of the front frame.

____ Clutch Solenoids


Function: An ouput of the AWD ECM that engages/disengages the clutch in the wheel station.
Location: Mounted in the AWD control valve.

____ Motor Displacement Solenoids


Function: An output of the AWD ECM that controls the displacement of the wheel motors.
Location: Mounted in the AWD control valve.

____ AWD Clutch Pressure Sensors


Function: Sends a signal to the AWD ECM indicating clutch pressure in the wheel stations.
Location: Mounted in the AWD control valve.

____ AWD Wheel Motors


Function: Variable-displacement piston motors convert fluid power into mechanical power.
Location: Mounted to the front wheel stations.

____ Wheel Motor Speed Sensor


Function: Sends a signal to the AWD ECM indicating the front wheel speed.
Location: On the front side of the wheel motor.

____ AWD Wheel Stations


Function: Attaches the wheel motor to the wheel.
Location: Mounted to the front axle.

____ Wheel Station Clutch


Function: Connects the wheel motor to the planetary set inside the wheel station.
Location: Inside the wheel station.

____ Hydraulic Cooler Bypass Valve


Function: Controls the oil flow returning from the AWD motors based on the oil temperature.
Location: At the right rear of the machine below the radiator.

____ AWD Temperature Sensor


Function: An input to the AWD ECM for derates of the AWD system.
Location: Located at the right rear of the machine next to the hydraulic cooler bypass valve.

____ Hydraulic Oil Cooler


Function: Cools the oil in the hydraulic system to normal operating temperatures.
Location: In front of the radiator (closest to the engine) at the rear of the machine.
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

B Aggression control dial A. Selects mode of operation.

G AWD control valve B. Controls the amount of aggression


provided by front wheels.

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

A AWD control switch D. Indicates a problem with the AWD


system.

E Charge pumps E. Provides continuous pressure to the


piston pumps.

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

K Hydraulic oil cooler G. Routes oil flow between the piston


pump and wheel motors.

I Wheel motor speed sensor H. Converts fluid power into mechanical


power.

F AWD piston pumps I. Provides the AWD ECM with the


actual wheel.

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

H 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: Stores the oil for the hydraulic systems on the machine.
Location: Behind the engine near the left-side rear of the machine.

_____ Implement Control Valves


Function: To direct supply oil out to the machines implement cylinders.
Location: In front of the operators stations and at the front of the machine.

_____ Implement and Steering Control Manifold


Function: Directs supply oil to the implement, steering, and pilot hydraulic systems.
Location: Behind the engine on the left-side of the machine.

_____ Pilot Pressure Reducing Valve


Function: Reduces the pressure of the implement and steering supply oil to be used in the
implement control valves.
Location: Mounted in the implement and steering manifold.

_____ Main Relief Valve


Function: Protects the implement and steering systems from high pressure.
Location: Mounted in the implement and steering manifold.

_____ Implement and Steering Pump Pressure Sensor


Function: Sends the Implement ECM a signal indicating the pressure in the implement and
steering systems.
Location: Mounted in the implement and steering manifold.

_____ Implement and Steering Pump


Function: Supplies oil flow to the implement and steering hydraulic systems.
Location: Mounted in the pump stack behind the engine on the left-side of the machine.

_____ Blade Lift Cylinders


Function: To raise and lower the blade.
Location: Mounted to the front frame and to the drawbar.
SERV1839 - 20 - Text Reference
07/07

Lab L: Worksheet
Implement Component Identification Worksheet (continued)

_____ Blade Tip Cylinder


Function: Allows the operator to tilt the blade.
Location: Mounted to the blade and to the drawbar.

_____ Sideshift Cylinder


Function: Allows the operator to shift the blade from side-to-side.
Location: Mounted to the blade and to the drawbar.

_____ Centershift Cylinder


Function: Allows the operator to move the drawbar to the left or to the right.
Location: Mounted to the front frame and to the drawbar.

_____ Pilot Oil Filter


Function: Filters the pilot oil before the oil enters the implement control valves.
Location: Mounted at the rear of the transmission on the left-side of the machine.

_____ Hydraulic Oil Filter


Function: Filters oil returning to the hydraulic tank.
Location: By the hydraulic tank on the left-side of the machine.

_____ Implement and Steering Joysticks


Function: Sends signals to the Implement ECMs based on operator input.
Location: On the left and right of the seat.

_____ Implement ECM


Function: Receives inputs from the operator joystick and controls outputs of the implement
hydraulic system.
Location: Behind the operators seat.

_____ Implement ECM 1


Function: Receives inputs from the primary Implement ECM and controls outputs of the
implement hydraulic system.
Location: Behind the operators seat.

_____ Implement ECM 2 (if equipped)


Function: Receives inputs from the primary Implement ECM and controls outputs of the
implement attachments hydraulic system.
Location: Behind the operators seat.

_____ Hydraulic Lockout Switch


Function: Energizes or de-energizes the hydraulic lockout solenoid valve.
Location: In the service panel to the right of the operators seat.
SERV1839 - 21 - Text Reference
07/07

Lab L: Worksheet
Implement Component Identification Worksheet (continued)

_____ Implement Lockout Solenoid Valve


Function: Controls pilot oil flow to the electrohydraulic pilot control valves.
Location: On the steering and implement manifold.

_____ Centershift Lock Switch


Function: Sends a signal to the Implement ECM to energize or de-energize the centershift
solenoid valve.
Location: In the service panel to the right of the operators seat.

_____ Centershift Lock


Function: Allows the operator to lock the drawbar in the desired position.
Location: Mounted on the front frame above the blade.

_____ Blade Cushion Switch (if equipped)


Function: To activate or deactivate the blade cushion.
Location: In the service panel to the right of the operators seat.

_____ Blade Cushion Accumulator (if equipped)


Function: Provides a cushion for the blade lift cylinders in case the blade contacts an
immoveable object.
Location: Mounted on the front frame by the blade lift cylinders.

_____ Ripper Control (if equipped)


Function: Sends a signal to the Implement ECM to raise or lower the ripper.
Location: To the right of the operators seat next to the joystick.

_____ Ripper Cylinders (if equipped)


Function: To raise and lower the ripper.
Location: Mounted to the rear of the machine.

_____ Scarifier Control (if equipped)


Function: Sends a signal to the Implement ECM to raise or lower the scarifier.
Location: To the right of the operators seat next to the joystick.

_____ Scarifier Cylinders (if equipped)


Function: To raise and lower the scarifier.
Location: Mounted to the front frame.

_____ Auxiliary Hydraulic Controls (if equipped)


Function: Sends a signal to the Implement ECM to control the auxiliary hydraulic functions.
Location: To the right of the operators seat next to the joystick.
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 Main Relief Valve_____________


P
B Pilot Pressure Reducing Valve___
M N O Q
C Hydraulic Lockout Solenoid____

D Pilot Oil Filter________________

E Resolver Valve________________

F Articulation Cylinders_________

G Line Relief Valve______________


H I L
F
H Blade Accumulator____________
- 23 -

K
I Blade Lift Cylinder____________ G

J Electrohydraulic Solenoid Valve_

K Signal Relief Valve____________


J
Steering
L Centershift Lock______________ Control
E Valve

M Wheel Lean Cylinder__________


Hydraulic
B
N Circle Drive Motor____________ Tank

Implement / Steering A
Pump
C
O Centershift Cylinder__________ D

P Sideshift Cylinder __________ Return Filter

Q Swivel_______________________
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

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

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


pilot control valve.

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


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

F Implement control valves D. Signals the Implement ECM that the


operator wants the implement hydraulics
disabled.

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


implement functions.

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


cylinders.

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

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

G 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: Stores the oil for the hydraulic systems on the machine.
Location: Behind the engine near the left-side rear of the machine.

_____ Implement and Steering Pump


Function: Supplies oil flow to the implement and steering hydraulic systems.
Location: Mounted in the pump stack behind the engine on the left-side of the machine.

_____ Implement and Steering Control Manifold


Function: Directs supply oil to the implement, steering, and pilot hydraulic systems.
Location: Behind the engine on the left-side of the machine.

_____ Main Relief Valve


Function: Protects the implement and steering systems from high pressure.
Location: Mounted in the implement and steering manifold.

_____ Implement and Steering Pump Pressure Sensor


Function: Sends the Implement ECM a signal indicating the pressure in the implement and
steering systems.
Location: Mounted in the implement and steering manifold.

_____ Steering Control Valve


Function: Directs oil to the steering cylinders to turn the machine.
Location: In front of the operators station mounted on the frame.

_____ Implement and Steering Joysticks


Function: Sends signals to the Implement ECMs based on operator input.
Location: On the left and right of the seat.

_____ Steering Cylinders


Function: To turn the front wheels to the left or to the right.
Location: Front of the machine.

_____ Steering Cylinder Position Sensors


Function: To send a signal to the Implement ECM indicating steering cylinder position.
Location: Inside of the steering cylinders.
SERV1839 - 26 - Laboratory Exercises
07/07 Student Handout No. 21

Lab P: Worksheet
Steering Component Identification Worksheet (continued)

_____ Secondary Steering Motor and Pump


Function: Supplies steering system flow if the primary steering system or engine failure occurs.
Location: Center of rear frame near the articulation hitch.

_____ Secondary Steering Solenoid Valves


Function: Allows the operator to steer the machine when the primary solenoid valves have
failed.
Location: In front of the operators station above the steering control valve.

_____ Primary Steering Indicator


Function: Alerts the operator of a failure of the primary steering system.
Location: On the left-side of the dash display.

_____ Secondary Steering Indicator


Function: Alerts the operator that the secondary steering system is activated.
Location: On the right-side of the dash display.

_____ Secondary Steering System Test Switch


Function: Manually activates the secondary steering system for test purposes.
Location: Front console in operators station.

_____ Articulation Cylinders


Function: To articulate the machine to the left or to the right.
Location: Mounted to the front and rear frames on each side of the machine.

_____ Articulation Position Sensors


Function: Sends a signal to the Implement ECM indicating how far the machine has been
articulated.
Location: On top of the articulation pins in the articulation hitch.

_____ Articulation Auto Recenter Switch


Function: To automatically recenter the front and rear frames.
Location: On the left implement and steering joystick.

_____ Wheel Lean Cylinders


Function: To lean the front wheels to the left or to the right.
Location: On the front of the machine.

_____ Wheel Lean Switches


Function: Allows the operator to lean the front wheels to the left or right.
Location: On the left implement and steering joystick.
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

I Hydraulic tank A. Supplies steering system flow if the


primary steering system or engine failure
occurs.

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

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


communicating the articulation angle of the
machine.

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


control valve steering functions.

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


primary steering system.

J Steering control valve F. Controls pump flow and pressure.

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

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

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

G 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: Stores the oil for the hydraulic systems on the machine.
Location: Behind the engine near the rear of the machine.

_____ Brake and Fan Pump


Function: Supplies oil flow to the brake and fan hydraulic systems.
Location: Mounted on the left side of the engine compartment.

_____ Combination Valve


Function: Controls the oil flow from the brake and fan pump out to the brake and fan systems.
Location: Mounted on the right side of the engine compartment.

_____ Priority Valve


Function: Gives the brake system priority over the fan system.
Location: Mounted in the accumulator charging valve.

_____ Cut-In Valve


Function: Controls the cut-in and cut-out pressures in the brake system.
Location: Mounted in the accumulator charging valve.

_____ Cut-Out Valve


Function: Opens momentarily to allow the cut-in valve to shift during cut-out.
Location: Mounted in the accumulator charging valve.

_____ Brake Accumulators


Function: Supplies oil to the brake system.
Location: Mounted on the rear of the operators station.

_____ Brake Accumulator Pressure Sensor


Function: Sends the Transmission/Chasis ECM a signal indicating the pressure of the brake
accumulators.
Location: Mounted on the accumulator charging valve.

_____ Service Brake Valve


Function: Controls oil flow and pressure to the service brakes.
Location: Connected to the brake pedal and mounted on the front of the operators station.
SERV1839 - 30 - Laboratory Exercises
07/07 Student Handout No. 25

Lab S: Worksheet
Brake Component Identification Worksheet (continued)

_____ Service Brakes


Function: Primary brakes for stopping the machine.
Location: In the wheel stations of the tandem housing.

_____ Parking Brake


Function: Prevents movement of the machine when engaged.
Location: In the driveline of the machine.

_____ Parking Brake Solenoid Valve


Function: Controls oil flow to the parking brake.
Location: Mounted on the differential housing.

_____ Parking Brake Pressure Switch


Function: Send the Transmission/Chassis ECM a signal when the parking brake is released.
Location: On the parking brake valve.
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

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

C Hydraulic tank A. Primary brakes for stopping the machine.

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

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

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


engine is OFF.

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

J Parking brake actuator F. Prevents movement of the machine when


engaged.

E Service brake control valve G. Maintains accumulator pressure between


cut-out and cut-in pressures.

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

D Service brake accumulators I. Sends Transmission/Chasis ECM a signal if


the brake accumulator charge oil pressure is
low.

G 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: Stores the oil for the hydraulic systems on the machine.
Location: Behind the engine near the rear of the machine on the left-side of the machine.

_____ Brake and Fan Pump


Function: Supplies oil flow to the brake and fan hydraulic systems.
Location: Mounted on the left-side in the engine compartment.

_____ Combination Valve


Function: Controls the oil flow from the brake and fan pump out to the brake and fan systems.
Location: Mounted on the right side of the engine compartment.

_____ Priority Valve


Function: Gives the brake system priority over the fan system.
Location: Mounted in the accumulator charging valve.

_____ Fan Speed Solenoid Valve


Function: Sends a load signal to the brake and fan pump to upstroke or destroke the brake and
fan pump.
Location: In the accumulator charging valve and fan manifold on the right-side engine
compartment.

_____ Hydraulic Oil Cooler


Function: To cool oil returning to the hydraulic tank from the hydraulic system.
Location: At the rear of the engine compartment in front of the radiator.

_____ Fan Motor


Function: Converts hydraulic energy into mechanical motion.
Location: On the outboard side of the radiator.

_____ Engine ECM


Function: Electronic Control Module, governor, electronic fuel system control.
Location: Mounted on the engine, left side of engine compartment.
SERV1839 - 34 - Text Reference
07/07

Lab V: Worksheet
Fan Component Identification Worksheet (continued)

_____ Engine Coolant Temperature Sensor


Function: Coolant temperature measurement for Engine ECM, instrument panel, temperature
warning.
Location: Below thermostat housing, at the right front of the engine compartment.

_____ 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.

_____ Hydraulic Oil Temperature Sensor


Function: Hydraulic oil temperature measurement for the Implement ECM and temperature
warning indicators.
Location: At the rear of the machine on the outboard-side of the radiator on the 140M and by
the transmission filter on the 160M.
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

H Hydraulic tank A. Coolant temperature measurement for


Engine ECM, instrument panel, temperature
warning.

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

D Brake and fan pump C. Hydraulic oil temperature measurement


for the Implement ECM and temperature
warning.

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

C Hydraulic oil temperature sensor E Intake air temperature measurement for


Engine ECM and temperature warning.

G Engine ECM F. Converts hydraulic energy into mechanical


motion.

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


electronic fuel system control.

A 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.