Pgina 140H NA Motor Grader 2ZK00001-UP (MACHINE) POWERED BY 3306 Engine...

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produtos: MOTOR GRADER
Modelo: 140H NA MOTOR GRADER 2ZK
Configurao: 140H NA Motor Grader 2ZK00001-UP (MACHINE) POWERED
BY 3306 Engine

Localizao e Soluo de Problemas

120H, 12H, 135H, 140H, 143H, 160H and 163H Motor Graders Power Train
Nmero de Mdia -SENR8503-03

Data de Publicao -01/12/2005

Data de Atualizao -15/12/2005

i02643819

Power Train
SMCS - 3030-035

Troubleshooting
Performance Check
Problem
The motor grader will not start or stop, and the transmission will not shift into any gear from the
NEUTRAL position.
Note: When you troubleshoot electrical problems or electronic problems, use the most recent electrical
schematic for your machine.
Note: Shift quickly from the NEUTRAL position to the desired gear. Always return the transmission to the
NEUTRAL position between gear selections.
1. Attempt to operate the machine in all gears forward and reverse. Shift the machine from the
NEUTRAL position to the FIRST GEAR FORWARD position. Note the response of the machine
and shift the machine back to the NEUTRAL position.
2. Shift the transmission from the NEUTRAL position to the SECOND GEAR FORWARD position.
Note the response of the machine. Shift the machine back to the NEUTRAL position. Proceed in the
same manner until all gears have been checked.
3. Check the 10 amp transmission control fuse that is located in the fuse panel at the base of the
steering console. If necessary, replace the fuse. Otherwise, proceed to Step 4.

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Illustration 1
Transmission Electronic Control Module (ECM)

g00279578

(1) Connector "J1"

(2) Connector "J2"

4. The Electronic Control Module (ECM) is located under the operator seat. While the engine is
running disconnect connector "J1" (1) . Contacts 1, 6 and 40 are common to each other and the
contacts are used to provide system voltage to the ECM. Contacts 2 and 5 are common to each other
and the contacts are used for machine ground. Measure the voltage between the power contacts 1, 6
and 40 to ground in order to check for power to the ECM.
5. If the voltage that is measured in Step 4 is 18 Volts DC to 32 Volts DC, the ECM voltage is
acceptable for proper operation of the ECM. If the voltage that is measured is less than 18 Volts DC,
there is a problem with the charging system. Refer to Special Instruction, "Charging System
Troubleshooting" for information on troubleshooting the charging system. If no voltage was
measured in Step 4, proceed to Step 6.
6. Check the fuse for the Transmission ECM. If the fuse is good, check the 126-PK wires in the
machine harness for an open circuit, or for a poor connection. If a problem is found, repair the
harness or replace the harness.
Problem
The motor grader has lost a single gear.
1. Start the engine. Operate the machine in order to determine the inoperable gear.
2. Stop the machine. Engage the parking brake and turn the key start switch to the OFF position.
3. Check the pressure of the suspect clutch. Refer to Testing and Adjusting, "Transmission Pressures"
for the correct pressure and for the testing procedure. If the clutch pressure is equal to or greater than
the minimum clutch pressure that is given, inspect the suspect clutch. If the clutch pressure is less
than the minimum pressure, proceed to Step 4.
4. Disconnect connectors"J1" (1) and connector"J2" (2) from the Electronic Control Module (ECM).
Measure the resistance between the contact that is associated with the clutch solenoid of the suspect
gear and one of the following contacts:contact 7 of "J1" and contact 3 of "J2"

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Note: Refer to the following example. The clutch for the FIRST GEAR FORWARD position does
not engage. The clutch for the FIRST GEAR REVERSE position engages. Measure the resistance
from contact 10 of "J1" (1) to either of the following contacts:contact 7 of "J1" and contact 3 of "J2"
5. If the resistance that is measured in Step 4 was in the range of 20 to 50 ohms, the solenoid valve is
functioning properly. This solenoid valve is controlling the pressure to the suspect clutch. Proceed to
Step 6.
6. If the resistance that is measured in Step 4 is less than 20 ohms, the wiring harness that connects to
the solenoid has a short circuit or the solenoid has a short circuit. If the resistance that is measured in
Step 4 is greater than 50 ohms, the wiring harness has an open circuit or the solenoid has an open
circuit.
7. If the solenoid valve that controls the suspect clutch appears to function but the clutch pressure is
below the minimum pressure, check the supply pressure at high idle with the transmission in the
inoperable gear. Refer to Testing and Adjusting, "Transmission Pressures".
8. If the supply pressure is 3240 kPa (470 psi), inspect the solenoid valve. If the supply pressure is
below 3240 kPa (470 psi), inspect the rotating shaft seals and the piston seals. The rotating seals can
be checked without removing the transmission. Checking the piston seals will require removing the
transmission.
Problem
Loss of a single gear selection in both the forward gear and the reverse gear
1. Start the engine. Operate the machine in order to locate the inoperative gear.
2. Stop the machine. Engage the parking brake and turn the engine start switch to the OFF position.
3. Disconnect connector"J1" (1) . Check the wiring harness that is located between the ECM and the
transmission direction and speed control. The transmission direction and speed control should be in
the position of the lost gear. Use contact 2 or contact 5 of connector "J1" (1) to check the continuity.
Measure the continuity between contact 2 and the contact for the gear that is not working.
4. Check the continuity between contact 29 of connector "J1" (1) and contact 2 of connector "J1" (1) if
FIRST GEAR FORWARD and REVERSE are inoperative. If the continuity exists, proceed to Step
5.
5. Step 4 tested a portion of the machine harness and a portion of the transmission direction and speed
control. The test determined that the transmission direction and speed control is inoperable. Shift the
transmission direction and speed control into a forward gear. Check the continuity between contact
37 and 2 of connector "J1" (1) . If continuity exists, the ECM is not functioning. If continuity does
not exist, the transmission direction and speed control is not functioning.
6. Either the machine harness has failed or the transmission direction and speed control has failed in
Step 4. Remove the 24 contact connector from the transmission direction and speed control. Measure
the continuity at the contact point on the transmission direction and speed control between using
contact 2 of connector "J1" (1) and the contact that is associated with the inoperative gear.
7. Check the continuity between contact 3 of the 24 contact connector and contact 2 of connector
"J1" (1) if FIRST GEAR FORWARD is not operable. If continuity exists, the transmission direction
and speed control is functioning and the machine harness has failed. If continuity does not exist, the
transmission direction and speed control has failed and the machine harness is functioning.
Problem
Slippage of the transmission under load

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1. Start the engine. Operate the machine in order to determine the gear that is slipping.
2. Stop the machine and engage the parking brake. Turn the engine start switch to the OFF position.
3. Check the transmission oil level. If the oil level is too high or too low, adjust the oil to the proper
level.
4. If the transmission continues to slip, check the transmission supply pressure. Refer to Testing and
Adjusting, "Transmission Pressures". If the supply pressure is at least 3240 kPa (470 psi) in the
PARK position and at high idle, proceed to Step 5. If the supply pressure is low, proceed to Step 8.
5. The direction clutches are clutch 1, clutch 2 and clutch 3. Direction clutch 1 is controlled by solenoid
(B) . Direction clutch 2 is controlled by solenoid (C) . Direction clutch 3 is controlled by solenoid
(A) . Measure the directional clutch pressure that is associated with the slipping gear. Refer to the
Testing and Adjusting, "Transmission Pressures".
6. For example, if the first gear forward is slipping, clutch 1 (solenoid (B) ) is the associated direction
clutch. Install the pressure port. Start the engine and operate the engine at high idle. Operate the
machine in the slipping gear.
7. Depress the transmission modulator pedal and stop the machine. Slowly release the transmission
modulator pedal. If the direction clutch pressure reaches a minimum pressure of 2080 kPa (302 psi),
inspect the direction clutch. If the directional clutch pressure does not reach a minimum of 2085 kPa
(302 psi), adjust the linkage for the clutch pedal.
8. From Step 4, the transmission control valve is suspect. Inspect the main relief valve for damage. If
necessary, repair the main relief valve. If the main relief valve is functioning correctly, proceed to
Step 9.
9. From Step 6, excessive slippage indicates leakage from the rotating seals or the clutch pistons. If
necessary, inspect or repair these items.
Problem
The Motor grader creeps when the transmission modulator pedal is fully depressed.
1. Start the engine. Operate the engine in order to determine the gears that allow the machine to inch
when the transmission modulator pedal is fully depressed.
2. Stop the machine and engage the parking brake. Turn the engine start switch to the OFF position.
3. Check the adjustment of inching pedal linkage. Refer toTesting and Adjusting, "Clutch Pedal Adjusting" for the correct adjustment procedure.
4. While the transmission modulator pedal is depressed, measure the direction clutch that is associated
with the gear that causes the problem. Refer to Testing and Adjusting, "Transmission Pressures".

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Illustration 2

g00925967

5. The direction clutches are clutch 1, clutch 2 and clutch 3. Direction clutch 1 is controlled by solenoid
(B) . Direction clutch 2 is controlled by solenoid (C) . Direction clutch 3 is controlled by solenoid
(A) .
6. For example, if first speed forward is inching, clutch 1 (solenoid (B) ) is the associated direction
clutch. Install the pressure gauge in the associated pressure port. Start the engine. Operate the engine
at high idle and in the suspect gear.
7. Depress the transmission modulator pedal and stop the machine. If the directional clutch pressure
exceeds 30 kPa (4 psi), repeat Step 3. If the directional clutch pressure is less than 30 kPa (4 psi),
inspect the transmission for warped clutch plates.
Problem
First gear out of neutral is the only working gear.
1. Start the engine. Determine the gears that are working.
2. Stop the machine. Engage the parking brake. Turn the engine start switch to the OFF position.
3. Use a jumper wire in order to bypass the pressure switch for manual modulation. The pressure switch
for manual modulation is the same switch as the pressure switch for the inching pedal. This will
determine if the pressure switch is working. The pressure switch for manual modulation is located on
the transmission control valve.
4. Disconnect the 2 contact connector at the pressure switch. This connector will be located close to the
pressure switch. Place a jumper wire between contact 1 and contact 2 of the receptacle on the
machine wiring harness. Proceed to Step 5.
5. Start the machine and attempt to operate the machine in all gears. If the machine has more than one
gear out of neutral then the pressure switch has failed. If first gear out of neutral is the only available
gear , proceed to Step 6.
6. The wiring harness between the manual modulation pressure switch (inching pressure switch) and
the transmission Electronic Control Module (ECM) is suspect. Disconnect connector "J1" (1) and

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connector "J2" (2) at the ECM. Check the continuity between contact 11 of "J2" connector (2) and
contact 2 of connector "J1" (1) .
7. The Electronic Control Module has failed if continuity is obtained with the jumper wire in place. The
wiring harness between the Electronic Control Module and the pressure switch has failed if
continuity is not obtained.
Problem
The Transmission Output Speed TOS signal is incorrect.
1. Stop the machine. Engage the parking brake. Turn the engine start switch to the OFF position.
2. The transmission output speed sensor (TOS) is located at the rear of the transmission. Locate the 2
contact connector at the sensor. Disconnect the TOS sensor from the machine wiring harness. Use a
voltmeter in order to measure the voltage between contacts. Connect the voltmeter to contact 4 (202BK) and connect the voltmeter to contact 1 (710-GN) of the machine wiring harness.
3. Operate the machine in FIRST gear at HIGH idle. If the measured voltage at high idle is less than 10
volts AC, replace the TOS sensor. If the measured voltage is greater than 10 volts AC, the TOS
sensor is functioning.
4. Remove the Electronic Control Module that is located under the operator seat. Then, disconnect
connector "J1" (1) . Replace the TOS sensor with a jumper wire. Measure continuity between
contacts 2 and 9 at connector "J1" (1) . If continuity is obtained the transmission is not functioning. If
continuity is not obtained, proceed to step 5.
5. The wiring harness between the ECM and the TOS sensor is suspect. Connect connector "J1" (1) at
the ECM and move back the TOS sensor. Remove the jumper wire from the receptacle and measure
the voltage between contact 2 710-GN and the frame. If any voltage (AC) exists, then repair wire
202-BK in the wiring harness. If voltage does not exist, repair wire 710-GN on the wiring harness.
Problem
The parking brake does not function properly.
1. Start the engine. Operate the machine in order to determine if the parking brake is functioning.
2. Stop the machine. Engage the parking brake. Turn the engine start switch to the OFF position.
3. The parking brake solenoid valve is located under the right side of the cab.
4. Start the engine. Use a screwdriver and lightly touch the end of the parking brake solenoid valve in
order to determine the presence of a electromagnetic force. If the screwdriver is drawn to the
solenoid, the solenoid is functioning.
5. To further test the solenoid, turn the engine key start switch from STOP to RUN and back to STOP.
The parking brake solenoid valve will click when the position of the key has changed. If the solenoid
is functioning proceed to Step 6. If the solenoid is not functioning, proceed to Step 10.
6. Check the mechanical parking brake valve in the transmission direction and speed control for proper
adjustment. Start the engine. Allow the brake pressure to increase to the normal operating pressure of
at least 800 kPa (115 psi). Depress the service brake. Shift the transmission direction and the speed
lever to the NEUTRAL position. Engage the parking brake. When the parking brake is engaged, the
operator should briefly hear air that is venting.

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7. When the transmission direction and speed control is placed in the PARKING BRAKE position and
the parking brake vents, the mechanical parking brake valve is properly adjusted. Proceed to Step 8,
if the parking brake does not vent. Adjust the mechanical parking brake valve.
8. Stop the engine. Place blocks in front of the wheels and behind the wheels. Install a 1000 kPa (145
psi) pressure gauge in the parking brake.
9. Start the engine. Depress the service brake pedal. Move the transmission direction and speed control
from the PARKING BRAKE position to the NEUTRAL position and back to the PARKING
BRAKE position. When the transmission direction and speed control is not in the PARK position,
the brake pressure should be 800 to 930 kPa (115 to 135 psi). If the brake pressure is 0 kPa (0 psi),
inspect the brakes. Brake pressure should be relieved to 0 kPa (0 psi) when the transmission direction
and speed control is in the PARK position. Inspect the air lines if the brake pressure does not go to 0
kPa (0 psi).
10. From Step 5, the parking brake valve is suspect. When the engine key start switch is in the RUN
position and the engine is OFF, the parking brake solenoid will be energized.
11. Disconnect the 2 contact connector at the parking brake solenoid. Measure the voltage across contact
1 (126-PK) and contact 2 (200-BK) at the machine harness. If battery voltage is measured at this
point the solenoid has failed. If no voltage or reduced voltage is measured at this point proceed to
Step 12.
12. Measure the voltage at the parking brake solenoid valve between contact 1 (126-PK) and the frame.
If the battery voltage is present, repair wire 200-BK. If the battery voltage is not present repair wire
126-PK.
Problem
The backup alarm does not sound.
1. Stop the engine. Engage the parking brake. Turn the engine key start switch to the OFF position.
Disconnect connector "J1" (1) and the "J2" connector (2) from the ECM. On the machine harness,
check for continuity between contact 2 of connector "J1" (1) and contact 37 of the connector
"J2" (2) . If continuity exists, the wiring to the backup alarm and the alarm is operational. Proceed to
Step 2.
2. Check the continuity between contact 2 of connector "J1" (1) and contact 31 of connector "J1" (1)
with the transmission in a REVERSE GEAR position. If continuity exists, the transmission ECM has
failed. If continuity does not exist, connect the "J1" and "J2" connectors to the correct position at the
transmission ECM and proceed to Step 3.
3. Disconnect the 24 contact connector at the transmission direction and speed control. With the
transmission direction and speed control in the REVERSE position, check the continuity between
contact 2 and contact 12 of the 24 contact connector. If continuity is obtained, repair the wiring
harness between the controller and the transmission direction and speed control. If continuity is not
obtained, replace the transmission direction and speed control.
4. In Step 2, the wiring harness between the transmission ECM and the backup alarm is suspect.
Disconnect the 6 contact connector from the back alarm. This connector will be located at the left
rear of the machine. While the transmission direction and speed control is in the REVERSE position,
measure the voltage between contact 5 (321-BR) and contact 6 (200-BK) of the machine harness
connector. If system voltage is present, the backup alarm has failed. If voltage is not present, the
harness has failed. Proceed to Step 5.
5. While the transmission direction and speed control is in the REVERSE position, measure the voltage
between contact 5 (321-BR) and the frame. If the 24 VDC exists, repair the 200-BK. If voltage does
not exist, repair wire 321-BR.

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Problem
The power train oil filler tube assembly is cracking at the base.
The power train oil filler tube assembly is used as a grab handle. The tube failure is most common on
machines with the snow wing attachment. A bracket can be added in order to support the tube assembly.
1. Inspect the power train filler tube at the base for cracks or leaks.
2. If there are cracks or leaks, the tube will need to be replaced.
3. The broken tube will need to be removed.
4. The new filler tube will need to be installed.
Refer to Service Magazine19 April 2004, "A New Support Bracket for the Filler Tube for the Power
Train Oil Is Now Available" in order to install the bracket assembly.
Direitos Autorais 1993 - 2016 Caterpillar Inc.
Todos os Direitos Reservados.
Rede Particular Para Licenciados SIS.

Thu Oct 27 2016 09:25:36 GMT+0100 (Hora de Vero de GMT)

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