Global Service Learning: 14M/16M Motor Grader

SERV1832
May 2007
GLOBAL SERVICE LEARNING
INSTRUCTOR MATERIALS
PART OF GLOBAL SERVICE LEARNING MODULE SERV1832
14M/16M MOTOR GRADER
LAB EXERCISES AND POSTTEST ANSWERS

SERV1832 -2- Laboratory Exercises
05/07 Instructor Handout No. 1
Component Identification
Description
Identify the components of the 14M and 16M 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
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__________
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

Active Mode 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
D Service; System Parameters; D. Menu that contains information on

Transmission transmission output speed.
A Service; System Parameters; E. Menu that contains maximum fwd

Monitoring System autoshift gear.
C Totals; Lifetime Totals F. Menu that contains information on inlet

air temperature.
Lab C Worksheet
C11/C13 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, electronic fuel system control.
Location: Mounted on the engine, left side of engine compartment.
_____ Primary Fuel Filter

Function: 10 micron filter, removes large debris which could damage the injectors.
Location: Between the tank and the transfer pump, left side of engine compartment.
_____ Fuel Transfer Pump

Function: Low pressure fuel pump.
Location: On the front of the engine, left rear side of the engine compartment.
_____ Electronic Priming Pump

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

Function: Two micron filter, removes small debris which could damage the injectors.
Location: Downstream of the transfer pump, left side of the engine compartment.
_____ Electronic Unit Injectors

Function: Controlled by the Engine ECM, delivers fuel to the cylinder.
Location: In the cylinder head below valve cover.
_____ Fuel Pressure Regulating Valve

Function: Maintains fuel system pressure.
Location: Mounted in the secondary fuel filter base, left side of engine compartment.
_____ Fuel Temperature Sensor

Function: Fuel temperature measurement for the Engine ECM and high temperature warnings.
Location: Mounted in the secondary fuel filter base.
Lab C Worksheet
C11/C13 ACERT™ Engine Component Identification Worksheet (continued)
_____ 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.
_____ Differential Fuel 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.
_____ Crankshaft Speed Sensor

Function: Engine speed/timing measurement, TDC, and cylinder identification.
Location: Timing gear housing, bottom of engine.
_____ Camshaft Speed Sensor

Function: Engine speed/timing measurement, TDC, and cylinder identification.
Location: 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, temperature
warning.
Location: Below thermostat housing, at the right front of the 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.
Lab C Worksheet
C11/C13 ACERT™ Engine Component Identification Worksheet (continued)
_____ Atmospheric Pressure Sensor

Function: Ambient pressure for gauge pressure measurements, altitude compensation.
Location: In the timing gear housing, next to the camshaft speed timing sensor.
_____ Turbo Inlet Pressure Sensor

Function: Measure air flow restriction from the air filter to the turbocharger.
Location: In the intake air tubing between the air filter housing and the turbocharger.
_____ Throttle Control Mode 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.
_____ Throttle Set/Accelerate Switch

Function: Allows the operator the set the desired engine rpm or increase engine rpm while the
throttle lock is active.
_____ Throttle Position Sensor

Function: Engine speed control.
Location: In the cab, on the throttle pedal assembly.
Lab D: Engine System Components and Functions Posttest

D Differential fuel pressure switch A. Final preparation 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 Turbo inlet pressure sensor D. Compares the difference between
incoming and outgoing fuel pressure
E Fuel transfer pump E. Supplies flow to the engine fuel system
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
K Latching derate J. Engine ECM uses this sensor to calculate
all other pressure sensors on the engine
J Atmospheric pressure sensor K. A horsepower limiting event that limits

horsepower and continues to limit the
horsepower once the condition no longer
exists
Lab E Worksheet
Power Train Component Identification Worksheet
_____ 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: Control 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 speed.
Location: Mounted in the top of the transmission case.
SERV1832 - 10 - Laboratory Exercises
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.
_____ Magnetic Screens

Function: Removes metal particles from the supply oil.
Location: Mounted at the rear of the transmission case near the transmission and scavenge
pumps.
_____ Power Train 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.
_____ Engine Key Start Switch

Function: Signals the Trans/Chassis ECM when to energize the engine starter relay.
Location: Mounted in the front console of the operator's station.
_____ Engine Start Relay

Function: Activated by the Power Train ECM to energize the starter motor.
Location: Mounted inside of the left service center.
_____ Autoshift Switch (if equipped)

Function: Allows operator to select the desired shift mode; automatic or manual.
Location: In the service panel to the right of the operator’s seat.
_____ Directional Switch

Function: Allows operator to select desired direction and speed.
Location: Mounted in the left steering/implement joystick.
Lab E Worksheet
Power Train Component Identification Worksheet (continued)
_____ Upshift switch

Function: Allows the operator to manually upshift the transmission.
_____ Downshift switch

Function: Allows the operator to manually downshift the transmission.
_____ Inching Pedal

Function: Allows the operator to control the maximum speed in a desired gear.
Location: On the left side of the operator’s station in front of the seat.
_____ Inching Pedal Sensor

Function: Sends a signal to the Implement ECM indicating the if the inching pedal is being
used.
Location: Above the inching pedal in 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 in the front console.
_____ Differential Lock Switch

Location: Sends a signal to the Trans/Chassis ECM to energize or de-energize the differential
lock solenoid.
_____ Differential Lock Solenoid

Function: Controls oil flow to the differential lock.
Location: Mounted on the differential case.
_____ Differential
Function: To send power from the transmission out 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.
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
Lab G: Transmission Hydraulic System Components

and Functions Posttest

K 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. Removes metal particles from the supply

valve oil
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
I. Cools the transmission hydraulic oil

C Magnetic screens
J. Limits the pressure in the lubrication

G Scavenge pump passages of the transmission
A Transmission K. Controls oil flow to the differential lock

Lab H: Transmission Electronic Control System Components

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

engine start relay
B Inching pedal position sensor B. Varies the current 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 ECM the shift mode 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
I. Allows the operator to manually

J Directional switch upshift the transmission
J. Signals the ECM the direction the

H Transmission oil temperature sensor operator wants the machine to move
A Engine key start switch K. Controls oil flow and pressure to the
clutches
Lab I Worksheet
Implement Component Identification Worksheet
_____ Hydraulic Tank
Function: Stores the oil for the hydraulic systems on the machine.
Location: Behind the engine near the rear of the machine.
_____ Implement Control Valves

Function: To direct supply oil out to the machine’s cylinders.
Location: In front of the operator’s stations and at the front of the front frame.
_____ 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.
_____ Implement and Steering Pressure Sensor

Function: Sends the Implement ECM indicating the pressure in the implement and steering
systems..
_____ 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.
_____ Blade Tip Cylinder

Function: Allows the operator to tilt the blade.
Location: Mounted to the blade and to the drawbar.
Lab I Worksheet
Implement Component Identification Worksheet (continued)
_____ 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 side and right side of the seat.
_____ Implement ECM

Function: Receives inputs and controls outputs of the implement hydraulic system.
Location: Rear of the operator's station behind the seat..
_____ Implement ECM (1)

Location: Rear of the operator's station behind the seat.
_____ Implement ECM (2) (if equipped)

Location: Rear of the operator's station behind the seat.
_____ Hydraulic Lockout Switch

Function: Energizes or de-energizes the hydraulic lockout solenoid valve.
_____ Hydraulic 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.
Lab I Worksheet
Implement Component Identification Worksheet (continued)
_____ Centershift Lock

Function: Allows the operator to move the drawbar to the desired position.
Location: Mounted on the front frame.
_____ Blade Cushion Switch (if equipped)

Function: To activate or deactivate the blade cushion.
_____ Blade Cushion Accumulators (if equipped)

Function: Provides a cushion for the blade lift cylinders in case the blade contacts an
immovable object.
Location: Mounted on the front frame by the blade lift cylinders.
_____ Ripper Control (if equipped)

Function: Sends a signal to the Implement ECM to raise/lower the ripper.
Location: To the right of the operator’s seat.
_____ 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/lower the scarifier.
_____ 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.
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
Scarifier (if equipped)
Ripper (if equipped)
Oil Temp ____°F
Cycle times within specifications? Yes No
IMPLEMENT CONTROL VALVE SOLENOID CALIBRATIONS

CALIBRATION
COMPLETED
Lab K: Implement Hydraulic System Identification
05/07
Directions: Fill in the blanks next to the letters with the correct term.
SERV1832
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____________
- 19 -
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 Center Shift Cylinder__________ D
P Side Shift Cylinder __________ Return Filter
Q Swivel_______________________
Instructor Handout No. 18
Laboratory Exercises
Lab L: Implement System Components and Functions Posttest
E Implement and steering joysticks A. Controls pilot oil to the implement control
spools
B Implement ECM B. Controls 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 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. Used to connect 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
Lab M Worksheet
Steering Component Identification Worksheet
_____ 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.
_____ Implement and Steering Pump Pressure Sensor

Function: Sends the Implement ECM a signal indicating the pressure in the implement and
steering systems..
_____ Steering Control Valve

Function: Directs oil to the steering cylinders to turn the machine.
Location: In front of the operator’s station mounted on the front frame.
_____ Implement and Steering Joysticks

Function: Sends signals to the Implement ECMs based on operator input.
Location: On the left side and right side 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.
Lab M 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: Right side 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 operator’s station above the steering control valve.
_____ Primary Steering Indicator

Function: Alerts the operator of a failure of the primary steering system.
Location: On the right side of the dash.
_____ Secondary Steering Indicator

Function: Alerts the operator that the secondary steering system is activated.
Location: On the right side of the dash.
_____ Secondary Steering System Test Switch

Function: Manually activates the secondary steering system for test purposes.
Location: Front console in operator's station.
_____ Articulation Cylinders

Function: To articulate the machine to the left or to the right.
Location: Mounted to the front and rear frames.
_____ Articulation Position 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: In the left implement and steering joystick.
_____ Wheel Lean Cylinder

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

Function: Allows the operator to lean the front wheels to the left or right.
Location: In the left implement and steering joystick.
Lab N: Steering System Tests
STEERING SYSTEM PRESSURE TESTS

Margin Pressure
Pump Cutoff Pressure
Signal Relief Valve
Main Relief Valve
ARTICULATION SOLENOIDS CALIBRATION

CALIBRATION
COMPLETED
ARTICULATION POSITION SENSORS CALIBRATION

CALIBRATION
COMPLETED
STEERING CYLINDER POSITION SENSOR CALIBRATION

CALIBRATION
COMPLETED
Lab O: Steering System Components and

Functions Posttest
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 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 J. Directs oil to the steering cylinders to turn

the machine
Lab P Worksheet
Brake Component Identification Worksheet
_____ 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.
_____ Accumulator Charging Valve

Function: Gives the brake system priority over the fan system and maintains accumulator
pressure.
Location: Mounted on the right side of the engine compartment.
_____ Brake Accumulators

Function: Supplies oil to the brake system.
Location: Mounted on the rear of the operator’s station..
_____ 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 operator’s station.
_____ Service Brake Pressure Sensor

Function: Sends the Trans/Chassis ECM a signal indicating the pressure in the brake
accumulators.
Location: Mounted on the accumulator charging valve.
_____ Service Brakes

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

Function: Controls oil flow to the parking brake.
Location: Mounted on the differential housing.
Lab P Worksheet
Brake Component Identification Worksheet (continued)
_____ Parking Brake Pressure Switch

Function: Send the Trans/Chassis ECM a signal when the parking brake is released.
Location: On the parking brake valve.
_____ Parking Brake

Function: Prevents movement of the machine when engaged.
Location: In the driveline of the machine.
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?
Lab R: Brake System Components and

Functions Posttest
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. Supply 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 valve F. Prevents movement of the machine when

engaged.
E Service brake valve G. Maintains accumulator pressure between

4485 kPa (2100 psi) CUT-OUT and
11725 kPa (1700 psi) CUT-IN
H Parking brake pressure switch H. Sends parking brake oil pressure signal to
the Power Train ECM
D Brake accumulators I. An input to the Trans/Chassis ECM

communicating the pressure in the brake
system.
G Accumulator charging valve J. Controls oil flow to release parking brake

Lab S Worksheet
Fan Component Identification Worksheet
_____ 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.
_____ Fan 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 on the right side of the engine compartment.
_____ Fan Motor

Function: Converts hydraulic energy into mechanical motion.
Location: At the rear of the engine compartment.
_____ Oil Cooler

Function: To cool oil returning to the hydraulic tank from the fan motor.
Location: At the rear of the engine compartment.
_____ Engine ECM

Function: Electronic Control Module, governor, electronic fuel system control.
Location: Mounted on the engine, left side of engine compartment.
_____ 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.
_____ Hydraulic Oil Temperature Sensor

Function: Hydraulic oil temperature measurement for the Implement ECM and temperature
warning.
Location: At the rear of the engine compartment by the fan oil cooler.
Lab T: Fan System Tests Worksheet
FAN SYSTEM TEST

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:
Lab U: Fan System Components and

Functions Posttest
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.
SERV1832 - 32 - Instructor Handout No. 31
05/07
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.

Global Service Learning: 14M/16M Motor Grader

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SERV1832

GLOBAL SERVICE LEARNING

PART OF GLOBAL SERVICE LEARNING MODULE SERV1832

14M/16M MOTOR GRADER

LAB EXERCISES AND POSTTEST ANSWERS

Lab A: Messenger Monitoring System

Machine Model_____________________________ Date___________________________

Directions: Use messenger to find the following parameters.

1. Engine speed __________rpms

2. Engine coolant temperature __________

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__________

Lab B: Messenger System Components and Functions Posttest

Directions: Match each component to the correct function.

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

E Settings; Transmission B. Menu that contains information on

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

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

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

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

_____ Engine ECM

_____ Primary Fuel Filter

_____ Fuel Transfer Pump

_____ Electronic Priming Pump

_____ Secondary Fuel Filter

_____ Electronic Unit Injectors

_____ Fuel Pressure Regulating Valve

_____ Fuel Temperature Sensor

_____ Fuel Pressure Sensor

_____ Differential Fuel Pressure Switch

_____ Crankshaft Speed Sensor

_____ Camshaft Speed Sensor

_____ Timing Calibration Connector

_____ Engine Coolant Temperature Sensor

_____ Engine Oil Pressure Sensor

_____ Intake Manifold Air Pressure Sensor

_____ Intake Manifold Air Temperature Sensor

_____ Atmospheric Pressure Sensor

_____ Turbo Inlet Pressure Sensor

_____ Throttle Control Mode Switch

_____ Throttle Resume/Decelerate Switch

_____ Throttle Set/Accelerate Switch

_____ Throttle Position Sensor

Lab D: Engine System Components and Functions Posttest

Directions: Match each component to the correct function.

G Engine ECM B. An event that limits the engine

C. An event that is based on atmospheric

E Fuel transfer pump E. Supplies flow to the engine fuel system

F. Used for timing the engine if the Engine

B Engine derate G. Receives sensor and switch inputs and

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

J Atmospheric pressure sensor K. A horsepower limiting event that limits

_____ Transmission Pump

_____ Scavenge Pump

_____ Transmission Relief Valve

_____ Transmission Filter

_____ Transmission Modulating Valves

_____ Transmission Input Speed Sensor

Machine Model___ Date_