SERV1844

November 2007

GLOBAL SERVICE LEARNING

STUDENT MATERIALS

PART OF GLOBAL SERVICE LEARNING MODULE SERV1844

24M MOTOR GRADER

INTRODUCTION

LAB EXERCISES AND POSTTEST

SERV1844 -2- Laboratory Exercises
11/07 Instructor Handout No. 1

Component Identification
Description
Identify the components of the 24M Motor Grader. 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
SERV1844 -3- Laboratory Exercises
11/07 Instructor Handout No. 2

Lab A: Messenger Monitoring System

Machine Model_____________________________ Date___________________________

Serial Number______________________________ S.M.H.________________________
Directions: List the 4 Main Menu options in Messenger.

__________
Main Menu __________
__________
__________

Directions: Use messenger to find the following parameters.

1. Engine speed __________rpms

2. Engine coolant temperature __________

3. Fuel level__________

4. Lifetime total reverse distance traveled__________

5. Lifetime maximum fuel used__________

6. How many languages are offered__________

7. What is the top gear limit_________

8. Equipment number __________

9. Trans/Chassis ECM software part number__________

10. Machine hours__________

11. With the engine running at low idle, what is the boost pressure__________

12. With the engine running at low idle, what is the transmission output speed__________

13. With the engine running at low idle, what is the parking brake switch
status__________

14. With the engine running at low idle, what is the fuel temperature___________

15. With the engine running at low idle, what is the Power Train filter status__________
SERV1844 -4- Laboratory Exercises
11/07 Instructor Handout No. 3

Lab B: Messenger System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

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

Active Mode 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 information on

Transmission transmission output speed.

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

Monitoring System autoshift gear.

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

air temperature.
SERV1844 -5- Laboratory Exercises
11/07 Instructor Handout No. 4

Lab C Worksheet
C18 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

Function:
Location:

_____ Fuel Transfer Pump

Function:
Location:

_____ Electronic Priming Pump

Function:
Location:

_____ Secondary Fuel Filter

Function:
Location:

_____ Electronic Unit Injectors

Function:
Location:

_____ Primary Speed Sensor

Function:
Location:

_____ Secondary Speed Sensor

Function:
Location:
SERV1844 -6- Laboratory Exercises
11/07 Instructor Handout No. 5

Lab C Worksheet
C18 ACERT™ Engine Component Identification Worksheet (continued)

_____ Engine Coolant Temperature Sensor

Function:
Location:

_____ Engine Oil Pressure Sensor

Function:
Location:

_____ Intake Manifold Air Pressure Sensor

Function:
Location:

_____ Intake Manifold Air Temperature Sensor

Function:
Location:

_____ Turbo Inlet Pressure Sensor

Function:
Location:

_____ Throttle Control Mode Switch

Function:
Location:

_____ Throttle Resume/Decelerate Switch

Function:
Location:

_____ Throttle Set/Accelerate Switch

Function:
Location:

_____ Throttle Position Sensor

Function:
Location:
SERV1844 -7- Laboratory Exercises
11/07 Instructor Handout No. 6

Lab D: Engine System Components and Functions Posttest

Directions: Match each component to the correct function.

Function Component Function Definition

Turbo inlet pressure sensor A. Receives sensor and switch inputs and
controls fan speed and engine rpm

Engine derate B. A horsepower limiting event that limits

horsepower and continues to limit the
horsepower once the condition no longer
Engine ECM exists

C. Final preparation of the fuel before the

Fuel transfer pump fuel enters the fuel gallery

D. Supplies flow to the engine fuel system

Atmospheric pressure sensor
E. An event that is based on atmospheric
pressure, intake manifold temperature,
Differential fuel pressure switch and engine rpm

F. A horsepower limiting event that no

Secondary fuel filter longer limits horsepower when the
condition no longer exists

Timing calibration connector G. An event that limits the engine

horsepower

Non-latching derate H. Engine ECM uses this sensor to calculate

all other pressure sensors on the engine

Latching derate I. Used for timing the engine if the Engine

ECM or timing sensor is replaced

Virtual exhaust derate J. Engine ECM uses this sensor to calculate

air filter restriction

K. Compares the difference between

incoming and outgoing fuel pressure
SERV1844 -8- Laboratory Exercises
11/07 Instructor Handout No. 7

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:

_____ Transmission Relief Valve

Function:
Location:

_____ Transmission Filter

Function:
Location:

_____ Transmission Modulating Valves

Function:
Location:

_____ Transmission Input Speed Sensor

Function:
Location:

_____ Transmission Output Speed Sensors

Function:
Location:
SERV1844 -9- Laboratory Exercises
11/07 Instructor Handout No. 8

Lab E Worksheet
Power Train Component Identification Worksheet (continued)

_____ Transmission Oil Temperature Sensor

Function:
Location:

_____ Magnetic Screen

Function:
Location:

_____ Power Train Oil Cooler

Function:
Location:

_____ Engine Key Start Switch

Function:
Location:

_____ Engine Start Relay

Function:
Location:

_____ Autoshift Switch (if equipped)

Function:
Location:

_____ Directional Switch

Function:
Location:

_____ Upshift switch

Function:
Location:

_____ Downshift switch

Function:
Location:

_____ Differential Lock Switch

Function:
Location:
SERV1844 - 10 - Laboratory Exercises
11/07 Instructor Handout No. 9

Lab E Worksheet
Power Train Component Identification Worksheet (continued)

_____ Differential Lock Solenoid

Function:
Location:

_____ Differential
Function:
Location:

_____ Final Drives

Function:
Location:

_____ Back-up Alarm

Function:
Location:
SERV1844 - 11 - Laboratory Exercises
11/07 Instructor Handout No. 10

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 %

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

TRANSMISSION CLUTCH FILL CALIBRATION

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
SERV1844 - 12 - Laboratory Exercises
11/07 Instructor Handout No. 11

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 relief valve
C. Removes metal particles from the supply
oil.
Transmission pump
D. Filters the oil from the transmission pump
to the transmission hydraulic system.
Transmission filter

E. Supplies oil flow to the transmission

Transmission modulating valves hydraulic system.

F. Limits the oil pressure to the proportional

Transmission oil reservoir
solenoid valves.

Magnetic screen G. Controls oil flow and pressure to the

clutches.

Transmission
H. Cools the transmission hydraulic oil.

I. Controls oil flow to the differential lock.

SERV1844 - 13 - Laboratory Exercises
11/07 Instructor Handout No. 12

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.

Autoshift switch B. Allows the operator to manually

downshift the transmission.

Downshift switch C. Measures input speed to the

transmission.

Upshift switch D. Receives sensor and switch inputs and

controls transmission shifting and
engine starting.
Transmission input speed sensor
E. Signals the ECM the shift mode in
which the operator wants to operate.
Transmission modulating valves
F. Measures transmission output speed.

Transmission output speed sensors G. Measures transmission oil temperature.

H. Allows the operator to manually

Directional switch upshift the transmission.

I. Signals the ECM the direction the

Transmission oil temperature sensor operator wants the machine to move.

J. Controls oil flow and pressure to the

Engine key start switch clutches.
SERV1844 - 14 - Laboratory Exercises
11/07 Instructor Handout No. 13

Lab I 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 Pressure Sensor

Function:
Location:

_____ Implement and Steering Pump

Function:
Location:

_____ Implement Pump

Function:
Location:

_____ Blade Lift Cylinders

Function:
Location:
SERV1844 - 15 - Laboratory Exercises
11/07 Instructor Handout No. 14

Lab I 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 Filters

Function:
Location:

_____ Case drain filter

Function:
Location:

_____ Implement and Steering Joysticks

Function:
Location:

_____ Implement ECM

Function:
Location:

_____ Implement ECM (2)

Function:
Location:

_____ Hydraulic Lockout Switch

Function:
Location:

_____ Hydraulic Lockout Solenoid Valve

Function:
Location:
SERV1844 - 16 - Laboratory Exercises
11/07 Instructor Handout No. 15

Lab I Worksheet
Implement Component Identification Worksheet (continued)

_____ Blade Cushion Switch (if equipped)

Function:
Location:

_____ Blade Cushion Accumulators (if equipped)

Function:
Location:

_____ Ripper Control

Function:
Location:

_____ Ripper Cylinders

Function:
Location:
SERV1844 - 17 - Laboratory Exercises
11/07 Instructor Handout No. 16

Lab J: Implement Hydraulic System Tests Worksheet

PILOT AND IMPLEMENT SYSTEM PRESSURE TESTS
Specification Actual Within Specification?
Pilot Pressure

Margin Pressure

Pump Cutoff Pressure

Signal Relief Valve

Main Relief Valve

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?
_____________________________________________________________________________

CYCLE TIME 1st Test 2nd Test 3rd Test Average

CHECK

Blade Lift
Blade Tip
Centershift
Sideshift
Blade Circle

Ripper
Oil Temp ____°F

Cycle times within specifications? Yes No

IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS

YES NO FAULTS PRESENT
CALIBRATION
COMPLETED
Lab K: Implement Hydraulic System Identification
11/07

Directions: Fill in the blanks next to the letters with the correct term.
SERV1844

A.

B.

C.

D.

E.
P
F. Q
M N
G. H I F
O
H. G
- 18 -

I.

K
J.

K. J
Steering
Control
Valve
L. E

Hydraulic Tank
M. B C

N. A
D
Return
Filter
O.
Case
Return Drain
Filter Filter

P.
Instructor Handout No. 17
Laboratory Exercises
SERV1844 - 19 - Laboratory Exercises
11/07 Instructor Handout No. 18

Lab L: 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 B. Controls 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 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. Used to connect 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.
SERV1844 - 20 - Laboratory Exercises
11/07 Instructor Handout No. 19

Lab M 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:
SERV1844 - 21 - Laboratory Exercises
11/07 Instructor Handout No. 20

Lab M Worksheet
Steering Component Identification Worksheet (continued)

_____ Secondary Steering 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:
SERV1844 - 22 - Laboratory Exercises
11/07 Instructor Handout No. 21

Lab N: 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
SERV1844 - 23 - Laboratory Exercises
11/07 Instructor Handout No. 22

Lab O: 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 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 J. Directs oil to the steering cylinders to turn

the machine.
SERV1844 - 24 - Laboratory Exercises
11/07 Instructor Handout No. 23

Lab P 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:

_____ Accumulator Charging Valve

Function:
Location:

_____ Brake Accumulators

Function:
Location:

_____ Service Brake Valve

Function:
Location:

_____ Service Brake Pressure Sensor

Function:
Location:

_____ Service Brakes

Function:
Location:

_____ Parking Brake Solenoid

Function:
Location:
SERV1844 - 25 - Laboratory Exercises
11/07 Instructor Handout No. 24

Lab P Worksheet
Brake Component Identification Worksheet (continued)

_____ Parking Brake Pressure Switch

Function:
Location:

_____ Parking Brake

Function:
Location:
SERV1844 - 26 - Laboratory Exercises
11/07 Instructor Handout No. 25

Lab Q: 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?
SERV1844 - 27 - Laboratory Exercises
11/07 Instructor Handout No. 26

Lab R: 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. Supply 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 valve F. Prevents movement of the machine when

engaged.

Service brake valve G. Maintains accumulator pressure between

4485 kPa (2100 psi) CUT-OUT and
11725 kPa (1700 psi) CUT-IN.

Parking brake pressure switch H. Sends parking brake oil pressure signal to
the Power Train ECM.

Brake accumulators I. An input to the Trans/Chassis ECM

communicating the pressure in the brake
system.

Accumulator charging valve J. Controls oil flow to release parking brake.

SERV1844 - 28 - Laboratory Exercises
11/07 Instructor Handout No. 27

Lab S 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:

_____ Fan Solenoid Valve

Function:
Location:

_____ Fan Motor

Function:
Location:

_____ Oil Cooler

Function:
Location:

_____ Engine ECM

Function:
Location:

_____ Engine Coolant Temperature Sensor

Function:
Location:

_____ Intake Manifold Temperature Sensor

Function:
Location:
SERV1844 - 29 - Laboratory Exercise
11/07 Instructor Handout No. 28

Lab S Worksheet
Fan Component Identification Worksheet (continued)

_____ Hydraulic Oil Temperature Sensor

Function:
Location:
SERV1844 - 30 - Laboratory Exercises
11/07 Instructor Handout No. 29

Lab T: 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:
SERV1844 - 31 - Laboratory Exercises
11/07 Instructor Handout No. 30

Lab U: 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.
SERV1844 - 32 - Instructor Handout No. 31
11/07

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.