Manual Electronically Controlled Transmission Caterpillar h Series Motor Graders

7/25/2019 Manual Electronically Controlled Transmission Caterpillar h Series Motor Graders

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Service TrainingInstructor Module SEGV2613

July 1995

TECHNICAL INSTRUCTION MODULE

H-SERIES MOTOR GRADERS

ELECTRONICALLY CONTROLLED TRANSMISSION
http://www.heavyequipments.org/


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SEGV2613 Table of Contents

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TABLE OF CONTENTS

MODULE DESCRIPTION

PREPARATION CHECKLIST

MODULE PREREQUISITES

MODULE LESSON PLAN

MODULE OBJECTIVES

SLIDE/TEXT REFERENCE

Introduction

Power Flow

Power Train Hydraulic System

Transmission Electrical System

Slide List

LABORATORY EXERCISES

CASE STUDIES

POSTTEST

STUDENT MATERIALS


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SEGV2613 Module Description

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MODULE DESCRIPTION

This module is designed to introduce the student to the H-Series Motor

Grader Electronically Controlled Transmission. Emphasis is placed on

component location, function and diagnostics.

Level II--Field service personnel, resident mechanics, technical

communicators and shop technicians. All students should have some

overall experience with Caterpillar equipment and have a basic working

knowledge of hydraulics.

Service Manual Modules Form No.

12H, 120H, 135H, 140H, 143H, 160H and 163H NA

Versions Motor Grader Power Train--System Operation,

Testing and Adjusting SENR8503

12H, 120H, 135H, 140H, 160H, 143H, and 163H NAVersions Motor Graders Transmission Electronic Control

For Countershaft Transmissions--System Operation,

Testing and Adjusting SENR6982

12H, 140H, and 160H NA Versions Motor Grader--

Electrical Schematic SENR6931

120H and 135H NA Versions Motor Grader--Electrical

Schematic SENR6930

143H and 163H NA Versions Motor Grader--Electrical

Schematic SENR6932

Video Tapes

"H-Series Motor Graders--Introduction" SEVN3022

"H-Series Motor Graders--Hydraulic and Transmission

Systems" SEVN3023

Specification Sheets

120H NA Version Motor Grader AEHQ5020






CONTENT

REFERENCES

AUDIENCE


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SEGV2613 - 1 - Preparation Checklist

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MODULE

PREPARATION

PREPARATION CHECKLIST

Prior to conducting the training session, perform the following steps:

_____ Student Materials (theirs to keep)

H-Series Motor Graders--Electronically Controlled

Transmission Student Materials SEEV2613

_____ Student Reference Materials--Determine which machines will be

covered. Provide each student with a set of the appropriate

Service Manual Modules and Supplemental Materials to cover the

machine selected. Refer to "References" under "Module

Description" for the correct form numbers.

Prior to delivering the classroom training session, perform the followingsteps:

_____ Review the two video tapes.

_____ Review the Lesson Plan to become familiar with the flow of the

training session.

_____ Review the Objectives to become familiar with the topic.

_____ Review the Slide/Text Reference to become familiar with the

topic.

_____ Duplicate enough Student Materials (Form SEEV2613) at the end

of this module for each participant in the training session.

_____ Review the Case Study and the solution.

_____ Review the questions and answers in the Posttest.

_____ Check all Service Magazine articles, Service Letters, and

Technical Information Bulletins related to the topic.

_____ Gather colored pencils for the classroom lab exercises.

_____ Make copies of Lab B Worksheets to be handed out after viewing

the transmission section of the "H-Series Motor Graders--

Hydraulic and Transmission Systems" video tape.

CLASSROOMPREPARATION


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SEGV2613 - 2 - Preparation Checklist

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Prior to conducting lab exercises, perform the following steps:

_____ Review the Laboratory Exercises.

_____ Reserve a Motor Grader.

_____ Reserve two mechanics tool boxes with hand tools (include

metric).

_____ Gather the following test equipment required for the lab exercises:

1 - 1U9366 Tape Measure

1 - 1U5796 Pressure Differential Gauge Group

1 - 1U5481 Pressure Gauge Group

1 - 1U5482 Pressure Adapter Group

1 - 9U7330 Multimeter

1 - 8T8697A Electronic Control Analyzer Programmer (ECAP)

1 - 7X1700 Communication Adapter Group

1 - 7X1851 Cable

1 - 7X1570 Cable

1 - 7X1703 Plate Group

1 - Piece of insulated 16 gauge wire approximately 150 mm (6 in.)

long

1 - Set of colored pencils per student

LABORATORY

PREPARATION


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SEGV2613 Module Prerequisites

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PREREQUISITE TESTS

MODULE PREREQUISITES

All students should have some overall experience with Caterpillar

equipment and have a basic working knowledge of servicing hydraulic

and electrical systems.

The prerequisite tests should be administered at least a few weeks before

the participant takes the course.

Participants should pass the following pretests with a score of 90% or

better:

Basic Hydraulics Pretest SEBV0557

Machine Electrical Pretest SEBV0558

If a participant does not accomplish 90% or better, identify the area of

deficiency, and then refer to the pretest for the recommended course or

courses for the student to review. After ample review time, the student

should retake the test.

The prerequisite courses should be completed prior to participating in this

course.

Interactive Video Course "Fundamentals

of Mobile Hydraulics" TEVR9001

Interactive Video Course "Fundamentals

of Electrical Systems" TEVR9002

PREREQUISITES

PREREQUISITECOURSES


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SEGV2613 - 1 - Lesson Plan

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MODULE LESSON PLAN

Time Estimates

Introduction

Welcome and Course Description 10 min.

Discuss Objectives and Class Schedule 10 min.

Show Video "H-Series Motor Graders--Introduction" 30 min.

Lab A: Major Component Location Identification 15 min.

Show Transmission Section of Video "H-Series Motor

Graders--Hydraulics and Transmission" 30 min.

Lab B: Component Location and Function 20 min.

Slide Presentation

Introduction 5 min.

Power Train Oil Flow 5 min.

Power Train Hydraulic System 30 min.

Lab C: Transmission Hydraulic System Component

Identification using the Hydraulic Schematic 15 min.

Lab D: Trace Oil Flow through the Transmission

Hydraulic System 10 min.

Slide Presentation

Transmission Electrical System 10 min.

Lab E: Transmission Electrical System 60 min.

Conduct Lab C

Conduct Lab D

Conduct Lab A

Conduct Lab B

Slides 3 - 4

Slides 1 - 2

Slides 5 - 14

Slide 15

Show Video

Show Video

Conduct Lab E


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SEGV2613 - 2 - Lesson Plan

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Lab F: Transmission Pressure Tests 60 min.

Supply Pressure

Lubrication Pressure

Pilot Pressure

Clutch Pressures

Differential Lock Pressure

Case Study 20 min.

Posttest

Administer Posttest 15 min.

Review and Discuss Posttest Results 15 min.

Total Estimated Time: 6 hrs.

Hand out Posttest

Hand out Case Study

Conduct Lab F


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Lab A

Lab B

Lab C

Slides 2 -14

Lab D Slides 7 - 14

Lab F

Lab E

Slide 15

Posttest

MODULE OBJECTIVES

Students must view the H-Series Motor Grader Introduction and

Hydraulic and Transmission Systems video tapes before completing the

module objectives. After completing this module, the student will be ableto:

1. Given an operation and maintenance guide or a service manual

module and motor grader, locate and identify the major power train

components during a lab exercise.

2. Given the video tape "H-Series Motor Graders--Hydraulic and

Transmission Systems" and the Lab B Worksheets, list the location

and function of the transmission system components during a

classroom lab exercise.

3. Given class notes, a hydraulic schematic, and a selector and pressure

control valve sectional view, identify the transmission hydraulic

system components during a classroom lab exercise.

4. Given a transmission hydraulic system schematic, trace the flow of oil

through the system during operation in FIRST FORWARD during a

classroom lab exercise.

5. Given a motor grader, the appropriate service module and tooling, list

the logged and active electrical faults in the Transmission ECM

during a lab exercise.

6. Given a motor grader, the appropriate service module and tooling, test

and record the following pressures on a lab worksheet: supplypressure, lubrication pressure, pilot pressure, eight clutch pressures,

and differential lock pressure.

7. Without using any notes, identify the system components and, from a

list, identify the cause and/or effect of a component or system

malfunction during a posttest.

SEGV2613 Module Objectives

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INSTRUCTOR NOTE

SLIDE/TEXT REFERENCE

The following text for this module uses schematics to provide a general

overview of the transmission hydraulic system operation.

The Slide/Text information assumes the user of this material understands

basic hydraulic principles and has a fundamental knowledge of the

machines and their components.

For your convenience, additional copies of the Slide/Text Reference (text

only, slides not included) may be ordered separately as:

H-Series Motor Graders--Electronically

Controlled Transmission

Slide/Text Reference SEBV2613

NOTE: Insert "H-Series Motor Grader--Electronically Controlled

Transmission" Slide/Text Reference (Form SEBV2613) behind this page.

SEGV2613 Slide/Text

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LABORATORY EXERCISES

The following section provides directions to set up, facilitate and assist

during the student lab exercises.

Some lab exercises are the written type with worksheets, while other labsare the traditional "on the iron" labs. Answers are provided for the

worksheet exercises.

The actual student lab sheets along with accompanying materials are

located in the Student Materials section (Form SEEV2613).

At the beginning of each lab, have each student review the lab description

to be sure the student understands what to do.

NOTE: Discuss safety procedures with the students for each shop lab

exercise (i.e. safety glasses, clothing, blocking procedures, etc.).

SEGV2613 Laboratory Exercises

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INSTRUCTOR NOTE


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INSTRUCTOR NOTE

Lab A: Major Component Location Identification

Shop Lab Exercise

Procedure:

After viewing the video tape "H-Series Motor Graders--Introduction,"

have the class walk around the machine and identify the components

listed on the lab worksheets and write the component letter in the blank

next to the corresponding component listed.

Lab A Worksheets I and II

Motor Grader

SEGV2613 - 1 - Laboratory Exercises

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EXERCISE

MATERIALS NEEDED


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Directions:Writetheletterofthecomponent

inthecorrectblank.

ParkingBrake

Transmission

LeftFinalDrive

RightTandem

F D H A

DriveShaft

Differential

RightFinalDrive

LeftTandem


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G C E B

FRONT

OF

MACHINE

A

C

B

D

E

F

G

H

LabA:MajorPowerTrain

ComponentLocation

IdentificationWorksheet

I


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Directions:Writetheletterofthecomponent

inthecorrectblank.

ControlValve

DifferentialHousingSump

ChargingSection

TransmissionCase

F D A G

ScavengeSection

Filter

PowerTrainOilCooler


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C E B

A

FRONT

O

FMACHINE B

D

C

E F

G

LabA:MajorPowerTrain

ComponentLocation

IdentificationWorksheet

II


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Lab B: Component Location and Function

Classroom Exercise

Procedure:

Show the Transmission Section of the video tape "H-Series Motor

Graders--Hydraulic and Transmission Systems." Explain to the class

how to fill out the worksheets as they watch the tape.

At the completion of this lab exercise, hand out copies of the Lab B

Worksheets from the Instructor Module for the students to use and keep as

a reference.

Class Notes

Power Train Service Manual Module

Lab B Worksheets


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INSTRUCTOR NOTE

EXERCISE

MATERIALS NEEDED


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Lab B: Component Location and Function Worksheet (continued)

Solenoid - is an on-off poppet-type valve that uses a 24 VDC signal from the transmission ECM to

activate the specific modulating reducing valve. Supply or pilot oil is directed to the selector spool

which then closes a drain and causes the modulating reducing valve to begin clutch modulation.

When the solenoid is deactivated, a drain passage is opened and the selector spool moves, which

causes the modulating reducing valve to begin to reduce the clutch pressure.

Elevated Drain Valve - is located in the bottom manifold and creates a restriction to the flow of

leakage or excess oil from components within the valve body. The valve opens at 14 kPa (2 psi).

Modulating Reducing Valve - provides the proper engagement time and pressure to the

corresponding clutch. Each valve consists of the following components:

- Selector Spool - is moved by the energized solenoid which then starts the modulation of the

modulating reducing valve. Once engaged, adjacent selector spools cannot be engaged which

would cause additional clutches to be engaged.- Modulation Orifice - is contained within the modulating reducing valve and creates a flow

restriction and a time delay so the clutch pressure will increase at a specific rate.

- Load Piston - works in conjunction with the modulating reducing valve to increase the clutch

pressure at a specific rate.

- Decay Orifice - is utilized when the solenoid is de-energized so the clutch pressure will

decrease at a specific rate. This rate of decrease helps prevent power train "unwinding" during

shifts.

Initial Pressure - is the beginning of modulation just before the load piston starts moving, which

causes the clutch pressure to increase at a specific rate. Each modulating reducing valve must be

checked. The outer adjustment screw changes the initial pressure. A special test plate is used on

the control valve to cause each modulating reducing valve to be at initial pressure.

Clutch Stations - refer to this group of components: solenoid, selector spool, load piston, and

modulating reducing valve.

Speed Range Selector Spools - are clutch stations D and H.

Speed Selector Spools - are clutch stations E, F and G.

Directional Selector Spools - are clutch stations A, B and C.

Transmission - is a countershaft design with eight forward speeds and six reverse speeds using eight

clutches on four shafts. The fifth shaft is called an INPUT shaft. The transmission has electrically

actuated hydraulic controls, electronic overspeed protection, a transmission pump, and an oil-cooled

multi-disc parking brake. Most of the components in the transmission arrangements of the 120H

through 163H are common to each transmission. The primary differences between the arrangements are

the gear ratios that drive the HIGH and LOW clutch groups.


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Lab B: Component Location and Function Worksheet (continued)

Cooler Relief Valve - is located in the transmission case just below the control valve and relieves

the excess oil flow from the main relief valve when the pressure increases above 520 kPa (75 psi).

The excess oil is then directed to transmission lube circuit.

Lube Relief Valve - is located in the transmission case just below the control valve and relieves

the excess oil flow from the cooler relief valve when the pressure increases above 520 kPa

(75 psi). The excess oil is then directed to transmission sump.

Parking Brake - is located on the front of the transmission and is an oil-cooled multi-disc type.

Air pressure from the parking brake valve that is actuated by the shift control lever engages and

disengages the parking brake. The parking brake can be removed separately if servicing is

required. Since air pressure is used to release the brake, the group includes a plug to drain

moisture that may accumulate from the machine air system.

Manual Modulation Pressure Switch - is mounted on the outermost valve body and senses the supply

pressure to the directional clutch stations A, B and C. When the manual modulation pedal is depressed,the directional clutch supply pressure is reduced and, at approximately 69 kPa (10 psi), the switch opens

and informs the transmission ECM the position of the pedal.

Transmission Shift Lever - mechanically moved lever which selects PARK, NEUTRAL, one to eight

FORWARD and one to six REVERSE speeds and then directs an electrical signal to the transmission

ECM. The unit is sealed and has no serviceable components. The unit also engages the parking brake.

Transmission ECM - is located below the operators seat and processes the input information which

then directs the proper electrical signals to the appropriate output devices for speeds, directions, and

diagnostics.

Diagnostic Connector - is a Sure-Seal connector that is located to the right of the transmission ECMand is used to diagnose faults in the transmission electrical system without an ECAP or laptop

computer.

Transmission Indicator Lamp - is used in conjunction with the diagnostic connector to visually flash

light code sequences. The lamp is located in the center of the indicator panel in the dash.

Transmission Output Speed (TOS) Sensor - is located on the bottom right of the transmission and

provides an electrical signal to the transmission ECM for engine overspeed information and then to the

speedometer for ground speed.


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Lab C: Transmission Hydraulic System ComponentIdentification using the Hydraulic Schematic

Classroom Exercise

Procedure:

Explain to the class how to fill out the worksheets using the transmission

hydraulic schematic.

Transmission hydraulic schematic for the motor grader used in class.

Lab E Worksheets I to III


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INSTRUCTOR NOTE

INDIVIDUAL EXERCISE

MATERIALS NEEDED


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H7

E4F6G5

N 1R

2R

3R

4R

5R

6R

N1F

2F

3F

4F

5F

6F

7F

8F

PARK

A B C D

E F G H

A B C D3 1 2 8

.

TYPICALH-SERIESMOTORGRAD

ERTRANSMISSIO

NHYDRAULICSY

STEM

FIRSTSPEEDFORWARD

S

F

RE P

Q

D

C

ANM

L

O

G

H K

J

I

B

LabC:TransmissionHy

draulicSystemComponentIdentificationusingthe

HydraulicSchematicWo

rksheetI

Directions:Writethenameofthecomponentintheblanknexttothenameofthecomponent

onWorksheetIIusingtheschematicon

WorksheetI.


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Charging Section

Differential Lock Valve

Centershift Lock Group

Elevated Drain Relief Valve

Filter

Scavenge Section

Transmission Lube Relief ValvePriority Reducing Valve

Cooler

Manual Modulation Clutch Pressure Switch

Transmission Pump

Transmission Sump

Transmission Lube

Main Relief ValveCooler Bypass

Manual Modulation Valve

Differential Sump

Centershift Lock Solenoid

Screens and Magnetic Filters

1. L

2. E

3. D

4. K

5. O

6. M

7. P8. I

9. S

10. H

11. N

12. B

13. R

14. J15. F

16. G

17. C

18. Q

19. A

Lab C: Transmission Hydraulic System Component Identification using theHydraulic Schematic Worksheet II

Directions: Write the letter of the component in the blank next to the name of the component on

Worksheet II using the schematic on Worksheet I.


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LabC:TransmissionHy

draulicSystemComponentIdentificationusingthe

HydraulicSchematic-Common

SelectorandPressureCo

ntrolValveComponentsWorksheetIII

Directions:Writetheletterof

thecomponentintheblanknex

ttothenameofthecomponent.

A

B

C

D

E

F

G

H

InitialPressureAdjustm

entScrew

DecayOrifice

ModulationOrifice

SelectorSpool

G C E B

M

odulationReducingValve

S

olenoid

L

oadPiston

C

lutch

D A F H


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Lab D: Tracing Oil Flow through the TransmissionHydraulic System

Classroom Exercise

Procedure:

Explain to the class how to fill out the worksheets. The following colors

should be used to trace the different paths the oil takes through the

system:

Red - Pump supply pressure

Red and White Stripes - Clutch pressure

Red Dots - Pilot pressure

Blue - Blocked oil

Green - Tank or case drain

TRANSMISSION HYDRAULIC SYSTEM CONDITION

First Speed Forward

Have each student trace the flow of oil during the condition listed above

on the corresponding lab worksheet. See slides No. 9 and 10 to check the

results.

Lab D Worksheets I and II

Colored Pencils


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INSTRUCTOR NOTE

INDIVIDUAL EXERCISE

MATERIALS NEEDED


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LabD:TracingOilFlow

throughtheTransmissionSelectorandPressureC

ontrolValveHydraulicSy

stem

(OuterDeck)Worksheet

I

Directions:Tracetheflowof

oilduringFirstSpeedForwardusingdifferentcoloredpencilstoshowthepaths.


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LabD:TracingOilFlow

throughtheTransmissionSelectorandPressureC

ontrolValveHydraulicSy

stem

(InnerDeck)WorksheetII

Directions:Tracetheflowof

oilduringFirstSpeedForwardusingdifferentcoloredpencilstoshowthepaths.


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Lab E: Transmission Electrical System

Shop Lab Exercise

Procedure:

Explain to the class how to complete the lab exercise and how to fill out

the worksheets.

Monitor the exercise and assist if necessary.

Have the students perform the following tests listed in the Power Train

Systems Operation, Testing and Adjusting Service Manual Module for the

lab machine used:

Worksheet I Electrical Faults using the ECAP

Worksheet II Electrical Faults using the Transmission Indicator Lamp

Worksheet III Electrical Component Quiz

Worksheet IV Transmission ECM Inputs and Outputs Quiz

Class Notes

Lab C Worksheets I to IV

Lab C Student Handout

1 - 9U7330 Multimeter

1 - 8T8697A Electronic Control Analyzer Programmer (ECAP)

1 - 7X1700 Communication Adapter Group

1 - 7X1851 Cable

1 - 7X1570 Cable

1 - 7X1703 Plate Group

1 - Piece of insulated 16 gauge wire approximately 150 mm (6 in.)

long

1 - Set of colored pencils per student1 - Electrical Schematic for the machine used in class


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INSTRUCTOR NOTE

EXERCISE

MATERIALS NEEDED


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LAB E: ELECTRICAL FAULTS USING THE ECAP

WORKSHEET I

__________MACHINE MODEL DATE_________________

__________VEHICLE HOURMETER ____________________ SERIAL NUMBER

__________TRANSMISSION ECM HOURMETER

__________TRANSMISSION IDENTIFICATION CODE

DIAGNOSTIC CODES

CODES

NUMBER OF LOGGED AT CURRENTCID/FMI DESCRIPTION OCCURRENCES FIRST LAST STATUS

1.______________________________________________________________________

2.______________________________________________________________________

3.______________________________________________________________________

4.______________________________________________________________________

5.______________________________________________________________________

6.______________________________________________________________________

7.______________________________________________________________________

8.______________________________________________________________________

9.______________________________________________________________________

10. ____________________________________________________________________

11. ____________________________________________________________________

12. ____________________________________________________________________

13. ____________________________________________________________________

14. ____________________________________________________________________

15. ____________________________________________________________________


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LAB E: ELECTRICAL FAULTS USING THE

TRANSMISSION INDICATOR LAMP

WORKSHEET II

__________MACHINE MODEL DATE_________________

__________VEHICLE HOURMETER ____________________ SERIAL NUMBER

__________TRANSMISSION IDENTIFICATION CODE

DIAGNOSTIC CODES

FLASH CURRENTCID/FMI DESCRIPTION CODE STATUS

1.______________________________________________________________________

2.______________________________________________________________________

3.______________________________________________________________________

4.______________________________________________________________________

5.______________________________________________________________________

6.______________________________________________________________________

7.______________________________________________________________________

8.______________________________________________________________________

9.______________________________________________________________________

10. ____________________________________________________________________

11. ____________________________________________________________________

12. ____________________________________________________________________

13. ____________________________________________________________________

14. ____________________________________________________________________

15. ____________________________________________________________________


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Lab E: Electrical Quiz Worksheet III

DIRECTIONS: Using an electrical schematic for a 140H Motor grader, complete the following

exercises:

1. Locate the Inching Pedal Pressure Switch on the schematic.

D-15 Grid location

2. What is the part number of the Inching Pedal Pressure Switch? 111-7088

3. The actuate pressure is 10.9 psi max , the deactuate pressure is 7.3 psi min , and the normal

condition for the inching pedal pressure switch is Normally Open .

4. What gauge wires are attached to the switch in question 3?

a. 14 gauge c. 18 gauge

b. 16 gauge d. 20 gauge

5. What is the letter and part number of the Machine Harness Assembly for the switch in question 3?

F - 101-8168

6. What is the Electronic Transmission Shift Control Service Manual module literature number?

SENR6982

7. Locate the Transmission Diagnostic Connector on the schematic. List the schematic grid location.

A-7

8. What type of connector is used for the Transmission Diagnostic Connector?

a. Sure-Seal connector

b. Deutsch connector

c. Hard wire connections

9. Locate the Service Tool Connector on the schematic. List the schematic grid location and the part

number. B-7 Grid location and 9W1951 Part Number

10. Locate the Transmission Speed Sender on the schematic. List the schematic grid location.

D-15 Grid location


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11. What is the part number of the Transmission Speed Sender Harness?

a. 104-7842 b. 104-8588

c. 115-3600 d. none of the above

12. What type of connector is used to connect the Transmission Speed Sender to the machine harness?

a. Sure-Seal connector

b. Deutsch connector

c. Hard wire connections

13. What is the wire number and color of the Transmission Speed Sender signal wire? 710 - GN

14. What size fuse is used to protect the Transmission ECM, 10A and what is the grid

location of the fuse? D-9

15. Which Transmission Solenoids are energized in First Speed Reverse? 1, 6, and 8

16. Locate the Coolant Temperature Sender on the schematic. What does the dashed ground symbol

represent (explain)? The component is threaded into the engine block and is internally

grounded.

17. On the Coolant Temperature Sender, what is the color of the wire that connects to the Coolant

Temperature Gauge? orange

18. Locate the Articulation Sender on the schematic. List the schematic grid location.

D-12 Grid location

19. The right side of the schematic represents what part of the machine? The front

20. On the schematic, what does the color RED represent? Wires that have battery voltage when the

key switch is off.

21. Locate the Transmission Indicator Lamp on the schematic. List the schematic grid location.

E-5 Grid location

22. What is the name of the "N" harness?

Transmission

23. What is the part number of a 10 amp fuse? 3K8782

24. What component sends its signal to the tachometer? Engine Speed Sensor

25. What is unique about wires 710-GN and 202-BK? They are a twisted pair of wires.


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LabE:IdentifyingTransmissionECMInputsand

OutputsWorksheetIV

Directions:Identifyeach

oftheinputsandoutputsoftheTransmissionECMandwritethenameintheblan

k.Usethe

electricalschematicandStudentHandoutforreferenc

e.


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SERVICETOOL

SOLENOID#1

SOLENOID#2

SOLENOID#3

SOLENOID#4

SOLENOID#5

SOLENOID#6

SOLENOID#7

SOLENOID#8

7 8

EMS

ACT

ION

ALA

RM

ACTION

LAMP

P

10

11

12

13

14

15

16

17

20

26-27

SERVICETOOLCONNECTOR

MANUALMODULATION

CLUTCHSWITCH

TRANSMISSIONSPEED

SENDER

ECM

H-SERIES

MOTORGRADER

TR

ANSMISSIONELEC

TRONICCONTROL

MODULE

3

28-40

STARTSWITCH

TRANSMISSION

INDICATORLAMP

4 6

SOLE

NOIDRETURN

18

BUFFEREDTRANSMISSION

OUTPUTSPEED

19

DIAGNOSTICCONNECTOR

21-23

6

CONTROLVALVE

VHPSOLENOID

5

BACKUPALARM

25

MPH

STARTRELAY

TRANSMISSION

SHIFTLEVER


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Lab E: Transmission Electrical System Student Handout

I. DEFINITIONS, ACRONYMS, AND ABBREVIATIONS

1. CAT Data Link - A medium speed digital data communication link which is used to providesharing of sensor information between electronic controls and service tools on Caterpillar

Machines.

2. Component Identifier (CID) - A three-digit number that is displayed to the technician on the

ECAP Service Tool diagnostic display during servicing. The number indicates the system

component in question.

3. Countershaft Transmission - The transmission used on the H-Series Motor Graders and is shifted

by means of electro-hydraulic valves which provide clutch control oil.

4. Electronic Control Analyzer Programmer (ECAP) - The Service Tool used by the technician togain access to the system status and diagnostic information stored in the Transmission ECM.

5. Transmission Electronic Control Module (ECM) - The control is located below the operators

seat and processes the input information which then directs the proper electrical signals to the

appropriate output devices for speeds, directions, and diagnostics.

6. Electronic Monitoring System (EMS) - A dash-mounted panel which alerts the operator to

various vehicle status conditions.

7. Failure Mode Identifier (FMI) - A two-digit "F" code that is displayed to the technician on theECAP Service Tool diagnostic display during servicing. The number indicates the failure mode of

the related component.

8. Transmission Output Speed (TOS) - A transmission signal generated by a magnetic pickup on

the transmission output shaft.

II. ELECTRICAL INPUTS

1. Battery Voltage - A two wire input which provides 24 VDC nominal to drive the electronic

circuits within the ECM and all the external solenoids.

2. Start Switch Input - A single wire input that provides a battery voltage signal when the key start

switch is in the START position.

3. Transmission Shift Lever - Mechanical lever which selects PARK, NEUTRAL, one to eight

FORWARD and one to six REVERSE speeds and then directs the electrical signal to the

transmission ECM. The unit is sealed and has no serviceable components. The unit also actuates

the parking brake.


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Lab E: Transmission Electrical System Student Handout (continued)

4. Manual Modulation Clutch Pressure Switch - A normally open switch which is located on the

outermost valve body and monitors the supply pressure to the directional clutch stations A, B and

C. When the manual modulation (or inching) pedal is depressed, the manual modulation valveinside the transmission control valve disengages or reduces the power transmitted to the drive

wheels by reducing the supply pressure to the three directional modulating reducing valves. The

pressure switch will open and/or close at approximately 70 kPa (10 psi) and provides the ECM

with the status of the manual modulation pedal.

5. Transmission Output Speed (TOS) Sender - Located on the bottom right of the transmission and

provides an electrical signal to the transmission ECM for engine overspeed information and then

to the speedometer for ground speed.

6. Diagnostic Connector - A Sure-Seal connector which is located to the right of the transmission

ECM and is used to diagnose faults in the transmission electrical system.

III. ELECTRICAL OUTPUTS

1. Transmission Solenoids - These solenoids are powered by 24 VDC from the ECM and are

engaged when the ECM determines the correct time to be ON.

2. Starter Relay - When the key start switch is turned to the START position, 24 VDC is directed to

the starter relay to engage the starter motor if the transmission shift lever is not in a speed or

direction.

3. Back-up Alarm - When the transmission shift lever is moved to a REVERSE speed, the ECM

provides power for the back-up alarm.

4. Dual Horsepower Solenoid (VHP) - When the transmission shift lever is moved to four to eight

FORWARD or three to six REVERSE speeds, the ECM provides power for the dual horsepower

solenoid. If the model is a 143H or 163H All Wheel Drive machine, the ECM will provide power

to the dual horsepower solenoid any time the AWD mode switch is moved to MANUAL or

AUTOMATIC.

5. Output to EMS (pin 8 on ECM) - The transmission ECM is connected to the EMS panel lamp

position 5 which is called the "Transmission Electrical Fault lamp." If a problem is detected in thetransmission ECM system, the ECM disconnects the ground and the lamp illuminates.

6. Output to the EMS (pin 7 on ECM) - The transmission ECM is connected to pin 9 (Neutral) at

the EMS control. Pin 9 has a function called "Program Code 1" and is used to control the category

of Alert Indicator 7 which is the Parking Brake indicator. Depending on the condition, the Parking

Brake can be either a Category 1 or 3 indication.

7. Service Tool Connector - A two wire digital data communication link that allows two way

communication of the ECAP or service tool with the transmission ECM.


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8. Transmission Indicator Lamp - Used in conjunction with the diagnostic connector to visually

flash light code sequences when diagnosing transmission electrical system faults.

9. Buffered Transmission Output Speed (TOS) - The output from the transmission speed sender

after it goes through the ECM and then to the speedometer.

IV. MODES OF OPERATION

1. Power-up Operation - Upon power-up, solenoids D and G are energized and all other solenoids

are de-energized.

2. Start Operation - The Transmission ECM has a neutral-start feature. The operator controlled key

start switch is an input to the ECM with the starter relay being powered by an output from the

ECM. This feature allows the ECM to inhibit starting the machine if certain conditions are notmet. The shift lever must be in NEUTRAL or PARK before the ECM will allow the starter relay

to be energized.

3. Upshift Operation - When the shift handle is moved from the current speed position to a higher

speed position, the ECM will shift the transmission immediately. If an upshift is attempted with

the inching pedal depressed, no action by the ECM is taken until the inching pedal is released.

4. Downshift Operation - When the shift handle is moved from the current speed position to a lower

speed position, the ECM will shift the transmission immediately. If an overspeed condition

occurs, the transmission is shifted to the lowest speed possible using special shift points. If the

TOS has not lowered below an overspeed condition, the ECM will upshift to the appropriatespeed. If a downshift is attempted with the inching pedal depressed, no action is taken until the

inching pedal is released. After the pedal is released, the ECM will determine the proper speed.

5. Shift Out of Neutral - When the shift handle is moved from NEUTRAL into a position which

matches the direction the machine is moving, the ECM will first check the TOS and determine if

the requested speed can be obtained without overspeeding the transmission. If no overspeed

condition will occur, then the shift is made.

If a shift out of NEUTRAL to the requested speed will cause an overspeed condition, the ECM

will shift to the lowest speed possible.

When a shift out of NEUTRAL is attempted with the inching pedal depressed, one of two things

will happen: 1. If the TOS is below the FIRST speed shift point, the shift is made immediately.

2. If the TOS is above the FIRST speed shift point, NO SHIFT will be made until the TOS drops

below the FIRST speed shift point or the inching pedal is released.

6. Shift Into Neutral - When the shift handle is moved from a speed position to NEUTRAL, the

ECM will shift the transmission to NEUTRAL immediately. The status of the inching pedal or the

TOS rpm does not matter.


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7. Directional Shift - A directional shift occurs when the shift handle is moved from one speed

position to another speed position of the opposite direction or when a shift out of NEUTRAL is

requested with the machine moving in the opposite direction.

If the shift is requested with the TOS lower than the THIRD speed shift point, the shift will be

made immediately. If the shift is requested with the TOS higher than the THIRD speed shift point,

the following steps will be taken:

1. The ECM will attempt to downshift the transmission to the lowest speed possible. If the TOS is

lowered below the THIRD speed shift point, the directional shift is made.

2. If the machine has not slowed to the THIRD speed shift point, special shift points are used to

downshift the transmission until the TOS is below the THIRD speed shift point.

When a directional shift is requested with the inching pedal depressed, the following occurs:

3. If the TOS is below the FIRST speed shift point, the shift is made immediately.

4. If the TOS is above the FIRST speed shift point, the shift will only be made if the TOS drops

below the FIRST speed shift point or the inching pedal is released.

5. If the inching pedal is released when TOS is above the FIRST speed shift point but below the

THIRD speed shift point, the shift will be made immediately.

6. If the TOS is above the THIRD speed shift point when the inching pedal is released, the

directional shift will be made, using the logic in statements 1 and 2 of this section.

8. Overspeed - The ECM will automatically upshift above the shift lever position whenever the

transmission reaches the preset overspeed upshift engine rpm. There is NO LIMIT to the number

of upshifts allowed. If the ECM has already automatically upshifted because of an engine

overspeed condition, the ECM will automatically downshift whenever the engine rpm are lowered

and then match the shift lever position.

9. Diagnostic/Protection Mode - The transmission ECM will take special actions based on the

present speed position and the type of fault detected. The EMS Transmission Electrical Faultindicator lamp will turn on and remain on until the fault is removed.

10. Service Mode - The Service Mode is enabled by uncoupling the Diagnostic Connector from the

machine harness. This feature allows the technician to diagnose problems with the system.

11. Clutch Phasing - The transmission solenoids are energized and de-energized with special timing

to control the transmission clutch pressures during shifts. Clutch phasing extends the life of the

transmission clutches and provides smoother shifts because certain clutches are not disengaged

between shifts which keeps the power train from "unwinding."


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V. SPECIFIC FAILURE MODES

1.Solenoid Faults

- The detection of a system fault which prevents energizing a solenoid for theselected speed will result in the ECM causing the transmission to go to NEUTRAL by using

solenoids D and G (preferred), solenoid D, solenoid G, or all solenoids OFF (least preferred).

2. Shift Lever Switch Open Faults - The loss of a shift lever switch contact when leaving

NEUTRAL, 1F, 1R, 2F, or 2R will result in NEUTRAL. Loss of a shift lever switch contact when

in 3F or higher or 3R or higher will result in remaining in the present gear. If either the Redundant

Neutral or Neutral switch is lost, the transmission will be neutralized whenever another switch

contact is lost.

3. Shift Lever Switch Short Active Faults - Two active speed switches will result in the

transmission remaining in the present gear until a valid speed signal is detected or NEUTRAL isrequested. If the forward or reverse switches are active, then the transmission will be neutralized

until a valid directional signal is determined.

4. Loss of or Erratic Transmission Output Speed (TOS) Signal - Loss of or erratic TOS will only

result in the EMS lamp and horn being turned ON to alert the operator that further operation of the

machine could cause damage. The overspeed feature will not function since the TOS will always

be 0 rpm.


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Lab F: Transmission Pressure Tests

Shop Lab Exercise

Procedure:

Explain to the class how to complete the lab exercise and how to fill out

the worksheet.

Monitor the exercise and assist if necessary.

Have the students perform the following tests listed in the Power Train

Systems Operation, Testing and Adjusting Service Manual Module for the

lab machine used:

Supply Pressure

Lubrication Pressure

Pilot Pressure

Clutch Pressures

Differential Lock Pressure

Class Notes

Lab F Worksheet

Mechanics tools

The following test equipment:

1 - 1U5481 Pressure Gauge Group

1 - 1U5482 Pressure Adapter Group


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INSTRUCTOR NOTE

EXERCISE

MATERIALS NEEDED


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CASE STUDY

The following section provides a case study and possible solutions. You

may want to work through the case study and make your own notes. The

actual case study without the solution is located in the Student Materialssection (Form SEEV2613).

The case study is designed to promote logical troubleshooting procedures.

To do this, the students can complete the case study in either of the

following ways:

A. Students may complete the case study on an individual basis

and then discuss the solution as a class.

B. Students may complete the case study in small groups and

discuss the solution as a class.

Students may use their notes and provided reference material.

SEGV2613 Case Study

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INSTRUCTOR NOTE


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Transmission Case Study

Students may use service manual modules and their class notes to

complete the case study.

While grading a county road, the operator noticed that the transmission

would not allow the machine to move in third speed forward. The

operator also tried both first and second forward, but neither would move

the machine. The EMS indicated a Category 2 problem in the

transmission system. The Operation and Maintenance Manual stated that

the machine should be stopped and the cause should be investigated.

The operator called back to the shop to tell his supervisor of the problem

and wanted to know what to do. The supervisor called the Caterpillar

dealer for assistance. The field dispatcher did not have anyone available

immediately, but wanted to talk to the operator and give him a couple ofsuggestions.

What is the first step that should be performed in a logical troubleshooting

procedure?

What components or faults in the system could cause this problem?

SEGV2613 - 1 - Case Study

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DIRECTIONS

SITUATION

QUESTIONS


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DIAGNOSTIC CHECKS

ACTUAL SOLUTION

Talk to the operator.

Questions for the operator could be:

-When did the problem occur?

-Does it happen in all speeds or just one?

Visually check the transmission system for damage and oil leaks.

The problem was that the H solenoid, which energizes clutch No. 7, was

open. This clutch is used for speeds 1 - 4 FORWARD and 1 - 3

REVERSE. The field service dispatcher had the operator try moving the

shift lever from NEUTRAL to FIRST, NEUTRAL to SECOND, and

through each speed to determine if the machine would move. When the

operator went from NEUTRAL to FIFTH, the machine moved and he

drove it back to the shop.

SEGV2613 - 2 - Case Study

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INSTRUCTOR NOTE

POSTTEST

The following posttest is designed to measure a students knowledge after

the presentation of the course. Two copies of the posttest are included.

One copy in the Instructor Guide contains the answers and the other copyin the Student Materials without answers can be duplicated for future use.

SEGV2613 Posttest

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TRANSMISSION HYDRAULICSYSTEM POSTTEST

ANSWERSDirections: Modified True/False. If a statement is false, underline the word or words that make the

statement incorrect and replace the word(s) to make the statement correct.

transmission

Example: F 1. This is a hydraulic systems class.

SEGV2613 - 1 - Posttest

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F

T

F

T

T

F

F

T

F

T

three

1. The motor grader engages two clutches for each speed.

2. The differential housing is used as the main oil sump.

main relief

3. The priority reducing valve limits the main system pressure to the clutches.

4. The drive shaft connects the parking brake to the differential.

5. The transmission pump supplies oil to the centershift lock group.

air pressure.

6. The parking brake is released by hydraulic oil from the transmission pump.

shims are

7. To change a clutch pressure, the modulation reduction valve initial pressure screw is

adjusted.

8. The manual modulation valve is also called the inching valve.

transmission

9. The pump is mounted directly on the engine.

10. The scavenge section of the pump is used to scavenge oil from the transmission housing.


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TRANSMISSION ELECTRICALSYSTEM POSTTEST

ANSWERSDirections: Complete the statement on the left with the word(s) on the right. Write the correct number

in the blank.


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Selects the speeds and directions

Controls each shift

Disengages the transmission

Is used to display the ECM flash codes

Provides the ECM with ground speed

When the ______________ connector is uncoupled,

the ECM goes into the diagnostics mode.

The ______________ code is unique to each model

of motor grader.

Each clutch solenoid is connected to the harness by

a ______________ connector.

The ______________ is located on the shift console.

The clutch pressure switch is normally____________.

The ______________ wires of all the solenoids are

connected.

1. manual modulation valve

2. transmission indicator lamp

3. transmission speed sender

4. diagnostic

5. Sure-Seal

6. service tool connector

7. configuration

8. open

9. ECM

10. return

11. transmission shift lever

12. compensator valve

13. Deutsch

14. closed

11

9

1

2

3

4

7

5

6

8

10


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23

1

4

7

5

6

1. Parking Brake

2. Pump

3. Control Valve

4. Oil Cooler

5. Pilot Pressure Tap

6. 8 Clutch Pressure Taps

7. 8 Solenoids


ANSWERSDirections: Write the name of the component in the blank under each photo.


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8

9

8. Transmission Indicator Lamp

9. EMS Transmission Alert Indicator


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1110 13

12

14. Clutch Housings

10. Manual Modulation Pressure Switch

11. Transmission Speed Sender

12. Transmission ECM

13. Transmission Diagnostic Connector

15. Service Tool Connector

16. Transmission Shift Lever

14

1615


ANSWERSDirections: Write the name of the component in the blank under each photo.


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DIAGNOSTICS:

G

B

I

D

J

F

E

H

C

A

The temperature of the system oil is too hot.

Transmission speed signal is incorrect.

Motor grader "creeps" with the inching pedal fully

depressed.

Transmission does not shift into any gears forward or

reverse.

Transmission will not shift into reverse.

When testing the transmission pressures on the machine,

the __________ must be removed.

Preferred method of diagnosing a problem with the

transmission system.

If a transmission ECM is replaced, the ______________

must be entered.

This group can be removed without removing the

transmission.

To activate the diagnostic program within the ECM, the

______________ .


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ANSWERSDirections: Read the statement on the left and select the correct answer from the right and place the

letter in the blank.

A. diagnostic connector must be

uncoupled

B. transmission speed sender

output low

C. parking brake

D. loss of pilot pressure

E. ECAP

F. drive shaft

G. cooler bypass open

H. transmission configurationcode

I. inching pedal is out of

adjustment

J. solenoid A is defective


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INSTRUCTOR NOTE

STUDENT MATERIALS

The following section contains the objectives, lab worksheets used during

the lab exercises, case study, and the posttest for students. You may want

to add additional information to this section before duplicating. Materialsmay be distributed to the students at the beginning of the training session

or at a time when they will need them during the class.

For your convenience, additional copies of the "Student Materials" may

be ordered separately as:

H-Series Motor Graders--Electronically Controlled

Transmission

Student Materials SEEV2613

NOTE: Insert "H-Series Motor Graders--Electronically ControlledTransmission" Student Materials (Form SEEV2613) behind this page.

SEGV2613 Student Materials

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Documents

Manual Electronically Controlled Transmission Caterpillar h Series Motor Graders