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SEEV2613
July 1995
STUDENT MATERIALS
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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
Lab B
Lab C
Slides 2 -14
Lab D
Slides 7 - 14
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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INDIVIDUAL EXERCISE
MATERIALS NEEDED
Drive Shaft
Differential
Right Final Drive
Left Tandem
C
D
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Parking Brake
Transmission
Left Final Drive
Right Tandem
FRONT
OF MACHINE
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Scavenge Section
Filter
Power Train Oil Cooler
-5-
Control Valve
Differential Housing Sump
Charging Section
Transmission Case
FRONT
OF MACHINE
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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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Filter -
Control Valve -
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- Selector Spool -
- Modulation Orifice -
- Load Piston -
- Decay Orifice -
Initial Pressure -
Clutch Stations -
Transmission -
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Parking Brake -
Transmission ECM -
Diagnostic Connector -
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Classroom Exercise
Procedure:
INDIVIDUAL EXERCISE
MATERIALS NEEDED
F
L
2R
3R
4R
5R
6R
3F
4F
5F
6F
8F
7F
1R
2F
1F
PARK
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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1.
Charging Section
2.
3.
4.
5.
Filter
6.
Scavenge Section
7.
8.
9.
Cooler
10.
11.
Transmission Pump
12.
Transmission Sump
13.
Transmission Lube
14.
15.
Cooler Bypass
16.
17.
Differential Sump
18.
19.
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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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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
- Clutch pressure
Red Dots
- Pilot pressure
Blue
- Blocked oil
Green
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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INDIVIDUAL EXERCISE
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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DATE_________________
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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DATE_________________
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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2.
3.
4.
, and the
.
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.
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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11.
12.
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b. 104-8588
c. 115-3600
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.
15.
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.
Grid location
19.
The right side of the schematic represents what part of the machine?
20.
21.
Locate the Transmission Indicator Lamp on the schematic. List the schematic grid location.
Grid location
22.
23.
24.
25.
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
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.
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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.
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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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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INDIVIDUAL EXERCISE
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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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)
PSI)
AT HIGH IDLE (
PSI)
PUMP IN NEUTRAL
LOW IDLE (
PSI)
AT HIGH IDLE (
PSI)
PILOT PRESSURE
LOW IDLE (
PSI)
AT HIGH IDLE (
PSI)
H-7
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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
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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.
2.
3.
The priority reducing valve limits the main system pressure to the clutches.
4.
5.
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.
9.
10. The scavenge section of the pump is used to scavenge oil from the transmission housing.
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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
4. diagnostic
5. Sure-Seal
8. open
9. ECM
10. return
13. Deutsch
14. closed
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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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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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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.
E. ECAP
F. drive shaft
G. cooler bypass open
H. transmission configuration
code
I. inching pedal is out of
adjustment
J. solenoid A is defective