Service Training

SEEV2613
July 1995

STUDENT MATERIALS

PART OF TECHNICAL INSTRUCTION MODULE SEGV2613

H-SERIES MOTOR GRADERS

ELECTRONICALLY CONTROLLED TRANSMISSION

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Student Materials

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 able
to:
Lab A

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.

Lab B

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.

Lab C
Slides 2 -14

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.

Lab D
Slides 7 - 14

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.

Lab E
Slide 15

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.

Lab F

6. Given a motor grader, the appropriate service module and tooling, test
and record the following pressures on a lab worksheet: supply
pressure, lubrication pressure, pilot pressure, eight clutch pressures,
and differential lock pressure.

Posttest

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.

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Student Materials

Lab A: Major Component Location Identification

BACKGROUND
INFORMATION

Shop Lab Exercise

Procedure:

INDIVIDUAL EXERCISE

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

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.

MATERIALS NEEDED

Lab A Worksheets I and II

Motor Grader

Drive Shaft
Differential
Right Final Drive
Left Tandem

C
D
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Parking Brake
Transmission
Left Final Drive
Right Tandem

Directions: Write the letter of the component

in the correct blank.

Lab A: Major Power Train

Component Location
Identification Worksheet I

FRONT
OF MACHINE

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Student Materials

Scavenge Section
Filter
Power Train Oil Cooler

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Control Valve
Differential Housing Sump
Charging Section
Transmission Case

Directions: Write the letter of the component

in the correct blank.

Lab A: Major Power Train

Component Location
Identification Worksheet II

FRONT
OF MACHINE

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Student Materials

Lab B: Component Location and Function

BACKGROUND
INFORMATION

Classroom Exercise
Procedure:

INDIVIDUAL EXERCISE

View the Transmission Section of the video tape "H-Series Motor Graders
--Hydraulic and Transmission Systems." Fill out the worksheets as you
watch the tape.

MATERIALS NEEDED

Class Notes
Power Train Service Manual Module
Lab B Worksheets

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Student Materials

Lab B: Component Location and Function Worksheet

Directions: During the video presentation, use this sheet to take notes on the function of each
component.
PUMP SYSTEM COMPONENTS:
Transmission Pump -

Scavenge Screen and Magnetic Filter -

Charging Screen and Magnetic Filter -

Filter -

Differential Lock Group -

Centershift Lock Group -

CONTROL VALVE COMPONENTS:

Control Valve -

Main Relief Valve -

Priority Reducing Valve -

Manual Modulation Valve (Inching Valve) -

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Student Materials

Lab B: Component Location and Function Worksheet (continued)

Solenoid -

Elevated Drain Valve -

Modulating Reducing Valve -

- Selector Spool -

- Modulation Orifice -

- Load Piston -

- Decay Orifice -

Initial Pressure -

Clutch Stations -

Speed Range Selector Spools -

Speed Selector Spools -

Directional Selector Spools -

Transmission -

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Student Materials

Lab B: Component Location and Function Worksheet (continued)

Cooler Relief Valve -

Lube Relief Valve -

Parking Brake -

Manual Modulation Pressure Switch -

Transmission Shift Lever -

Transmission ECM -

Diagnostic Connector -

Transmission Indicator Lamp -

Transmission Output Speed (TOS) Sensor -

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Student Materials

Lab C: Transmission Hydraulic System Component

Identification using the Hydraulic Schematic
BACKGROUND
INFORMATION

Classroom Exercise
Procedure:

INDIVIDUAL EXERCISE

Fill out the worksheets using the transmission hydraulic schematic.

MATERIALS NEEDED

Transmission hydraulic schematic for the motor grader used in class.

Lab E Worksheets I to III

F
L

2R
3R
4R
5R
6R

3F
4F
5F
6F

8F

7F

1R

2F

1F

PARK

FIRST SPEED FORWARD

TYPICAL H-SERIES MOTOR GRADER TRANSMISSION HYDRAULIC SYSTEM

Directions: Write the name of the component in the blank next to the name of the component on Worksheet II using the schematic on
Worksheet I.

Lab C: Transmission Hydraulic System Component Identification using the Hydraulic Schematic Worksheet I

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Student Materials

Lab C: Transmission Hydraulic System Component Identification using the

Hydraulic 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.

1.

Charging Section

2.

Differential Lock Valve

3.

Centershift Lock Group

4.

Elevated Drain Relief Valve

5.

Filter

6.

Scavenge Section

7.

Transmission Lube Relief Valve

8.

Priority Reducing Valve

9.

Cooler

10.

Manual Modulation Clutch Pressure Switch

11.

Transmission Pump

12.

Transmission Sump

13.

Transmission Lube

14.

Main Relief Valve

15.

Cooler Bypass

16.

Manual Modulation Valve

17.

Differential Sump

18.

Centershift Lock Solenoid

19.

Screens and Magnetic Filters

Initial Pressure Adjustment Screw

Decay Orifice
Modulation Orifice
Selector Spool

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Modulation Reducing Valve

Solenoid
Load Piston
Clutch

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

Lab C: Transmission Hydraulic System Component Identification using the Hydraulic Schematic - Common
Selector and Pressure Control Valve Components Worksheet III

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Student Materials

Lab D: Tracing Oil Flow through the Transmission

Hydraulic System
BACKGROUND
INFORMATION

Classroom Exercise
Procedure:

INDIVIDUAL EXERCISE

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
Trace the flow of oil during the condition listed above on the
corresponding lab worksheet.
MATERIALS NEEDED

Lab D Worksheets I and II

Colored Pencils

Directions: Trace the flow of oil during First Speed Forward using different colored pencils to show the paths.

Lab D: Tracing Oil Flow through the Transmission Selector and Pressure Control Valve Hydraulic System
(Outer Deck) Worksheet I

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Directions: Trace the flow of oil during First Speed Forward using different colored pencils to show the paths.

Lab D: Tracing Oil Flow through the Transmission Selector and Pressure Control Valve Hydraulic System
(Inner Deck) Worksheet II

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Student Materials

Lab E: Transmission Electrical System

BACKGROUND
INFORMATION

Shop Lab Exercise

Procedure:

INDIVIDUAL EXERCISE

Fill out the worksheets.

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
MATERIALS NEEDED

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 student
1 - Electrical Schematic for the machine used in class

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Student Materials

LAB E: ELECTRICAL FAULTS USING THE ECAP

WORKSHEET I
__________MACHINE MODEL

DATE_________________

__________VEHICLE HOURMETER ____________________ SERIAL NUMBER

__________TRANSMISSION ECM HOURMETER
__________TRANSMISSION IDENTIFICATION CODE

DIAGNOSTIC CODES
CID/FMI

DESCRIPTION

CODES
NUMBER OF
LOGGED AT CURRENT
OCCURRENCES FIRST LAST STATUS

1. ______________________________________________________________________
2. ______________________________________________________________________
3. ______________________________________________________________________
4. ______________________________________________________________________
5. ______________________________________________________________________
6. ______________________________________________________________________
7. ______________________________________________________________________
8. ______________________________________________________________________
9. ______________________________________________________________________
10. ____________________________________________________________________
11. ____________________________________________________________________
12. ____________________________________________________________________
13. ____________________________________________________________________
14. ____________________________________________________________________
15. ____________________________________________________________________

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Student Materials

LAB E: ELECTRICAL FAULTS USING THE

TRANSMISSION INDICATOR LAMP
WORKSHEET II
__________MACHINE MODEL

DATE_________________

__________VEHICLE HOURMETER ____________________ SERIAL NUMBER

__________TRANSMISSION IDENTIFICATION CODE

DIAGNOSTIC CODES
CID/FMI

DESCRIPTION

FLASH
CODE

CURRENT
STATUS

1. ______________________________________________________________________
2. ______________________________________________________________________
3. ______________________________________________________________________
4. ______________________________________________________________________
5. ______________________________________________________________________
6. ______________________________________________________________________
7. ______________________________________________________________________
8. ______________________________________________________________________
9. ______________________________________________________________________
10. ____________________________________________________________________
11. ____________________________________________________________________
12. ____________________________________________________________________
13. ____________________________________________________________________
14. ____________________________________________________________________
15. ____________________________________________________________________

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Student Materials

Lab E: Electrical Quiz Worksheet III

DIRECTIONS: Using an electrical schematic for a 140H Motor grader, complete the following
individual exercises:
1.

Locate the Inching Pedal Pressure Switch on the schematic.

Grid location

2.

What is the part number of the Inching Pedal Pressure Switch?

3.

The actuate pressure is

, the deactuate pressure is
normal condition for the inching pedal pressure switch is

4.

, and the
.

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?

6.

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

7.

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

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.
Grid location and
Part Number

10.

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

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12.

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Student Materials

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

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?

14.

What size fuse is used to protect the Transmission ECM,

location of the fuse?

15.

Which Transmission Solenoids are energized in First Speed Reverse?

16.

Locate the Coolant Temperature Sender on the schematic. What does the dashed ground symbol
represent (explain)?

17.

On the Coolant Temperature Sender, what is the color of the wire that connects to the Coolant
Temperature Gauge?

18.

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

and what is the grid

Grid location
19.

The right side of the schematic represents what part of the machine?

20.

On the schematic, what does the color RED represent?

21.

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

22.

What is the name of the "N" harness?

23.

What is the part number of a 10 amp fuse?

24.

What component sends its signal to the tachometer?

25.

What is unique about wires 710-GN and 202-BK?

26-27

21-23

25

ECM

18

16

17

15

14

13

12

11

10

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SERVICE TOOL

MPH

20

19

28-40

H-SERIES MOTOR GRADER

TRANSMISSION ELECTRONIC CONTROL MODULE

Directions: Identify each of the inputs and outputs of the Transmission ECM and write the name in the blank. Use the
electrical schematic and Student Handout for reference.

Lab E: Identifying Transmission ECM Inputs and Outputs Worksheet IV

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Student Materials

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 provide
sharing 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 to
gain 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 the
ECAP 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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Student Materials

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 valve inside
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 the
transmission 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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Student Materials

Lab E: Transmission Electrical System Student Handout (continued)

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 not met. 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 appropriate speed. 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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Student Materials

Lab E: Transmission Electrical System Student Handout (continued)

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 Fault indicator 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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Student Materials

Lab E: Transmission Electrical System Student Handout (continued)

V. SPECIFIC FAILURE MODES
1.

Solenoid Faults - The detection of a system fault which prevents energizing a solenoid for the
selected 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 is
requested. 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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Student Materials

Lab F: Transmission Pressure Tests

BACKGROUND
INFORMATION

Shop Lab Exercise

Procedure:

INDIVIDUAL EXERCISE

Fill out the worksheet.

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

MATERIALS NEEDED

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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Student Materials

Lab F: Transmission Pressure Tests Worksheet

SOLENOIDS ENERGIZED / CLUTCHES ENGAGED
SPEED

A-3

B-1

C-2

D-8

E-4

F-6

G-5

PARK

NEUTRAL

1-F

2-F

3-F

4-F

5-F

6-F

8-F

1-R

2-R

3-R

4-R

5-R

6-R

CLUTCH
PSI

7-F

LUBE IN NEUTRAL
LOW IDLE (

PSI)

AT HIGH IDLE (

PSI)

LUBE IN FIRST FORWARD

LOW IDLE (

PSI)

AT HIGH IDLE (

PSI)

PUMP IN NEUTRAL
LOW IDLE (

PSI)

AT HIGH IDLE (

PSI)

PILOT PRESSURE
LOW IDLE (

PSI)

AT HIGH IDLE (

PSI)

DIFFERENTIAL LOCK PRESSURE

H-7

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Student Materials

Transmission Case Study

DIRECTIONS

Students may use service manual modules and their class notes to
complete the case study.

SITUATION

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 of
suggestions.

QUESTIONS

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?

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Student Materials

TRANSMISSION HYDRAULIC
SYSTEM POSTTEST
Directions: 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.

Example:

transmission
1. This is a hydraulic systems class.

1.

The motor grader engages two clutches for each speed.

2.

The differential housing is used as the main oil sump.

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.

6.

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

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.

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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Student Materials

TRANSMISSION ELECTRICAL
SYSTEM POSTTEST
Directions: Complete the statement on the left with the word(s) on the right. Write the correct number
in the blank.
Selects the speeds and directions

1. manual modulation valve

Controls each shift

2. transmission indicator lamp

Disengages the transmission

3. transmission speed sender

Is used to display the ECM flash codes

4. diagnostic

Provides the ECM with ground speed

5. Sure-Seal

When the ______________ connector is uncoupled,

the ECM goes into the diagnostics mode.

6. service tool connector

7. configuration

The ______________ code is unique to each model

of motor grader.
Each clutch solenoid is connected to the harness by
a ______________ connector.

8. open
9. ECM
10. return

The ______________ is located on the shift console.

11. transmission shift lever
The clutch pressure switch is normally____________.
12. compensator valve
The ______________ wires of all the solenoids are
connected.

13. Deutsch
14. closed

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Student Materials

TRANSMISSION HYDRAULIC
SYSTEM POSTTEST
Directions: Write the name of the component in the blank under each photo.

1.
4.
2.
3.
6
8
7

5.
6.
7.

8.
9.

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Student Materials

TRANSMISSION HYDRAULIC
SYSTEM POSTTEST
Directions: Write the name of the component in the blank under each photo.

10

13

11

12

10.

12.

11.

13.

15
16

14

14. \

15. \
16. \

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Student Materials

TRANSMISSION HYDRAULIC
SYSTEM POSTTEST
Directions: Read the statement on the left and select the correct answer from the right and place the
letter in the blank.
DIAGNOSTICS:
The temperature of the system oil is too hot.

A. diagnostic connector must be

uncoupled

Transmission speed signal is incorrect.

Motor grader "creeps" with the inching pedal fully
depressed.

B. transmission speed sender

output low
C. parking brake

Transmission does not shift into any gears forward or

reverse.

D. loss of pilot pressure

Transmission will not shift into reverse.

E. ECAP

When testing the transmission pressures on the machine,

the __________ must be removed.

F. drive shaft
G. cooler bypass open

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
______________.

H. transmission configuration
code
I. inching pedal is out of
adjustment
J. solenoid A is defective