Service Training Instructor Module
SEGV2613 July 1995
TECHNICAL INSTRUCTION MODULE
H-SERIES MOTOR GRADERS ELECTRONICALLY CONTROLLED TRANSMISSION
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Table of Contents
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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Module Description
MODULE DESCRIPTION CONTENT
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.
AUDIENCE
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.
REFERENCES
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 NA Versions 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
12H NA Version Motor Grader
AEHQ5022
135H NA Version Motor Grader
AEHQ5021
140H NA Version Motor Grader
AEHQ5023
143H NA Version Motor Grader
AEHQ5024
160H NA Version Motor Grader
AEHQ5025
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Preparation Checklist
PREPARATION CHECKLIST MODULE PREPARATION
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.
CLASSROOM PREPARATION
Prior to delivering the classroom training session, perform the following steps: _____ 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.
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Preparation Checklist
Prior to conducting lab exercises, perform the following steps: _____ Review the Laboratory Exercises. _____ Reserve a Motor Grader. _____ Reserve two mechanic’s 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
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Module Prerequisites
MODULE PREREQUISITES PREREQUISITES
All students should have some overall experience with Caterpillar equipment and have a basic working knowledge of servicing hydraulic and electrical systems.
PREREQUISITE TESTS
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. PREREQUISITE COURSES
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
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Lesson Plan
MODULE LESSON PLAN Time Estimates Introduction Welcome and Course Description
10 min.
Discuss Objectives and Class Schedule
10 min.
• Show Video
Show Video "H-Series Motor Graders--Introduction"
30 min.
• Conduct Lab A
Lab A: Major Component Location Identification
15 min.
• Show Video
Show Transmission Section of Video "H-Series Motor Graders--Hydraulics and Transmission"
30 min.
Lab B: Component Location and Function
20 min.
• Conduct Lab B
Slide Presentation • Slides 1 - 2
Introduction
5 min.
• Slides 3 - 4
Power Train Oil Flow
5 min.
• Slides 5 - 14
Power Train Hydraulic System
30 min.
• Conduct Lab C
• Conduct Lab D
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 • Slide 15
• Conduct Lab E
Transmission Electrical System Lab E: Transmission Electrical System
10 min. 60 min.
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• Conduct Lab F
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Lab F: Transmission Pressure Tests
Lesson Plan
60 min.
Supply Pressure Lubrication Pressure Pilot Pressure Clutch Pressures Differential Lock Pressure • Hand out Case Study
Case Study
• Hand out Posttest
Posttest
20 min.
Administer Posttest
15 min.
Review and Discuss Posttest Results
15 min.
Total Estimated Time:
6 hrs.
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Module Objectives
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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Slide/Text
SLIDE/TEXT REFERENCE INSTRUCTOR NOTE
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.
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Laboratory Exercises
LABORATORY EXERCISES INSTRUCTOR NOTE
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 labs are 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.).
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Laboratory Exercises
Lab A: Major Component Location Identification INSTRUCTOR NOTE
Shop Lab Exercise Procedure:
EXERCISE
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.
MATERIALS NEEDED
Lab A Worksheets I and II Motor Grader
F D H A
Parking Brake Transmission Left Final Drive Right Tandem
G C E B
H
E
Drive Shaft Differential Right Final Drive Left Tandem
B
G
F
C D -2-
Directions: Write the letter of the component in the correct blank.
Lab A: Major Power Train Component Location Identification Worksheet I
FRONT OF MACHINE
A
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F D A G
Control Valve Differential Housing Sump Charging Section Transmission Case
C E B
Scavenge Section Filter Power Train Oil Cooler
C
E
F
G
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Directions: Write the letter of the component in the correct blank.
Lab A: Major Power Train Component Location Identification Worksheet II
B
FRONT OF MACHINE
D
A
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Laboratory Exercises
Lab B: Component Location and Function INSTRUCTOR NOTE
Classroom Exercise Procedure:
EXERCISE
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.
MATERIALS NEEDED
Class Notes Power Train Service Manual Module Lab B Worksheets
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Laboratory Exercises
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 - a two section pump that contains a charging and scavenge section. The scavenge section transfers oil from the transmission sump to the differential housing sump. The charging section transfers oil from the differential housing sump to the transmission filter inlet. Scavenge Screen and Magnetic Filter - located just below the transmission pump; filters the scavenge oil that is transferred to the differential. Charging Screen and Magnetic Filter - contained within the housing bolted to the pump; filters the charging oil from the differential. Filter - located at the right rear of the inside frame; filters the oil from the pump to the control valve. Differential Lock Group - uses transmission pump oil to engage and disengage the electrically controlled differential. Centershift Lock Group - uses transmission pump oil to engage and disengage the electrically controlled centershift lock group. CONTROL VALVE COMPONENTS: Control Valve - this valve provides the proper flows and pressures to engage the desired transmission clutches and contains the following components: • Main Relief Valve - located in the upper top front quadrant of the innermost valve body and provides a restriction in flow that determines the transmission pump outlet pressure at 2700 kPa (392 psi) at 750 rpm. The excess oil that passes through the relief valve flows to the transmission oil cooler. • Priority Reducing Valve - located in the top rear quadrant of the innermost valve body and reduces the supply or pilot pressure to the selector valves and solenoids from 2700 kPa (392 psi) to 1380 kPa (200 psi). The valve also provides priority over transmission clutch fill and modulation to supply the selector valves and solenoids. • Manual Modulation Valve (Inching Valve) - located in the uppermost portion of the outermost valve body and is connected to the modulation pedal with a push/pull cable. The valve disengages or reduces the power transmitted to the drive wheels by reducing the supply or pilot pressure to the directional modulating reducing valves. Fully depressing the pedal reduces the supply or pilot pressure to 0 kPa (0 psi) and, as the pedal is slowly released, supply or pilot pressure gradually increases following pedal movement to approximately 840 kPa (121 psi). Once the pressure reaches 840 kPa (121 psi), the pressure automatically modulates to 2460 kPa (357 psi) minimum after approximately 0.2 seconds. The 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.
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Laboratory Exercises
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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Laboratory Exercises
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 operator’s 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 ECM and 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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Laboratory Exercises
Lab C: Transmission Hydraulic System Component Identification using the Hydraulic Schematic INSTRUCTOR NOTE
Classroom Exercise Procedure:
INDIVIDUAL EXERCISE
Explain to the class how to 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
Q
P
E
R
D
S
.
C
O
F L
A
N
M
1R 2R 3R 4R 5R 6R
1F 2F 3F 4F 5F 6F
8F
7F
N
N
PARK
D
C
B
A
FIRST SPEED FORWARD
G
B
8
2
1
3
K
D
C
B
A
H
H
G
F
E
J
H
G
F
E
I
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
7
5
6
4
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Laboratory Exercises
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.
L
Charging Section
2.
E
Differential Lock Valve
3.
D
Centershift Lock Group
4.
K
Elevated Drain Relief Valve
5.
O
Filter
6.
M
Scavenge Section
7.
P
Transmission Lube Relief Valve
8.
I
Priority Reducing Valve
9.
S
Cooler
10. H
Manual Modulation Clutch Pressure Switch
11. N
Transmission Pump
12. B
Transmission Sump
13. R
Transmission Lube
14. J
Main Relief Valve
15. F
Cooler Bypass
16. G
Manual Modulation Valve
17. C
Differential Sump
18. Q
Centershift Lock Solenoid
19. A
Screens and Magnetic Filters
A
G C E B
B
Initial Pressure Adjustment Screw Decay Orifice Modulation Orifice Selector Spool
C
E D A F H
F
H
D
G
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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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Laboratory Exercises
Lab D: Tracing Oil Flow through the Transmission Hydraulic System INSTRUCTOR NOTE
Classroom Exercise Procedure:
INDIVIDUAL EXERCISE
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. 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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Laboratory Exercises
Lab E: Transmission Electrical System INSTRUCTOR NOTE
Shop Lab Exercise Procedure:
EXERCISE
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 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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Laboratory Exercises
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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Laboratory Exercises
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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Laboratory Exercises
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?
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
111-7088
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 Grid location and 9W1951 Part Number number. B-7
10.
Locate the Transmission Speed Sender on the schematic. List the schematic grid location. D-15
Grid location
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11.
12.
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Laboratory Exercises
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? D-9
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)? 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
10A
710 - GN
and what is the grid
1, 6, and 8
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? key switch is off.
21.
Locate the Transmission Indicator Lamp on the schematic. List the schematic grid location. E-5
22.
Wires that have battery voltage when the
Grid location
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?
25.
What is unique about wires 710-GN and 202-BK? They are a twisted pair of wires.
Engine Speed Sensor
26-27
21-23
6
25
SERVICE TOOL CONNECTOR
MPH
20
19
28-40
4
3
ECM
8
7
5
6
18
16
17
15
14
13
12
11
10
ACTION ALARM
P
BACKUP ALARM
VHP SOLENOID
SOLENOID RETURN
SOLENOID #8
SOLENOID #7
SOLENOID #6
SOLENOID #5
SOLENOID #4
SOLENOID #3
SOLENOID #2
SOLENOID #1
CONTROL VALVE
ACTION LAMP
EMS
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SERVICE TOOL
DIAGNOSTIC CONNECTOR
TRANSMISSION SPEED SENDER
BUFFERED TRANSMISSION OUTPUT SPEED
MANUAL MODULATION CLUTCH SWITCH
TRANSMISSION INDICATOR LAMP
TRANSMISSION SHIFT LEVER
START RELAY
START SWITCH
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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Laboratory Exercises
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 operator’s 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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Laboratory Exercises
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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Laboratory Exercises
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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Laboratory Exercises
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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Laboratory Exercises
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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Laboratory Exercises
Lab F: Transmission Pressure Tests INSTRUCTOR NOTE
Shop Lab Exercise Procedure:
EXERCISE
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
MATERIALS NEEDED
Class Notes Lab F Worksheet Mechanic’s tools The following test equipment: 1 - 1U5481 Pressure Gauge Group 1 - 1U5482 Pressure Adapter Group
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Laboratory Exercises
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
•
•
DIFFERENTIAL LOCK PRESSURE
• •
•
•
•
•
•
7-F
CLUTCH PSI ± ± ± LUBE IN NEUTRAL LOW IDLE ( ± PSI) LUBE IN FIRST FORWARD LOW IDLE ( ± PSI) PUMP IN NEUTRAL LOW IDLE ( ± PSI) PILOT PRESSURE LOW IDLE ( ± PSI)
•
•
•
• •
•
•
• •
±
H-7
•
• • • ±
±
±
±
AT HIGH IDLE (
±
PSI)
AT HIGH IDLE (
±
PSI)
AT HIGH IDLE (
±
PSI)
AT HIGH IDLE (
±
PSI)
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Case Study
CASE STUDY INSTRUCTOR NOTE
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 Materials section (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.
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Case Study
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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DIAGNOSTIC CHECKS
-2-
Case Study
• 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.
ACTUAL SOLUTION
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 7/95
Posttest
POSTTEST INSTRUCTOR NOTE
The following posttest is designed to measure a student’s 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 copy in the Student Materials without answers can be duplicated for future use.
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Posttest
TRANSMISSION HYDRAULIC SYSTEM POSTTEST ANSWERS 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:
F
transmission 1. This is a hydraulic systems class.
F
1.
three The motor grader engages two clutches for each speed.
T
2.
The differential housing is used as the main oil sump.
F
3.
main relief The priority reducing valve limits the main system pressure to the clutches.
T
4.
The drive shaft connects the parking brake to the differential.
T
5.
The transmission pump supplies oil to the centershift lock group.
6.
air pressure. The parking brake is released by hydraulic oil from the transmission pump.
F
F
7.
shims are To change a clutch pressure, the modulation reduction valve initial pressure screw is adjusted.
T
8.
The manual modulation valve is also called the inching valve.
F
9.
transmission The pump is mounted directly on the engine.
T
10. The scavenge section of the pump is used to scavenge oil from the transmission housing.
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Posttest
TRANSMISSION ELECTRICAL SYSTEM POSTTEST ANSWERS Directions: Complete the statement on the left with the word(s) on the right. Write the correct number in the blank. 11
Selects the speeds and directions
1. manual modulation valve
9
Controls each shift
2. transmission indicator lamp
1
Disengages the transmission
3. transmission speed sender
2
Is used to display the ECM flash codes
4. diagnostic
3
Provides the ECM with ground speed
5. Sure-Seal
4
When the ______________ connector is uncoupled, the ECM goes into the diagnostics mode.
6. service tool connector
7
The ______________ code is unique to each model of motor grader.
7. configuration
5
Each clutch solenoid is connected to the harness by a ______________ connector.
8. open 9. ECM 10. return
6
The ______________ is located on the shift console. 11. transmission shift lever
8
The clutch pressure switch is normally____________. 12. compensator valve
10
The ______________ wires of all the solenoids are connected.
13. Deutsch 14. closed
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Posttest
TRANSMISSION HYDRAULIC SYSTEM POSTTEST ANSWERS Directions: Write the name of the component in the blank under each photo.
2
4
3
1
1. Parking Brake 4. Oil Cooler 2. Pump 3. Control Valve 6 8 7
9
5
5. Pilot Pressure Tap 6. 8 Clutch Pressure Taps 7. 8 Solenoids
8. Transmission Indicator Lamp 9. EMS Transmission Alert Indicator
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Posttest
TRANSMISSION HYDRAULIC SYSTEM POSTTEST ANSWERS Directions: Write the name of the component in the blank under each photo.
10 11
13 12
10. Manual Modulation Pressure Switch
12. Transmission ECM
11. Transmission Speed Sender
13. Transmission Diagnostic Connector
15 16
14
14. Clutch Housings
15. Service Tool Connector 16. Transmission Shift Lever
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Posttest
TRANSMISSION HYDRAULIC SYSTEM POSTTEST ANSWERS Directions: Read the statement on the left and select the correct answer from the right and place the letter in the blank. DIAGNOSTICS: G
The temperature of the system oil is too hot.
B
Transmission speed signal is incorrect.
I
Motor grader "creeps" with the inching pedal fully depressed.
A. diagnostic connector must be uncoupled B. transmission speed sender output low C. parking brake
D
Transmission does not shift into any gears forward or reverse.
D. loss of pilot pressure
J
Transmission will not shift into reverse.
E. ECAP
F
When testing the transmission pressures on the machine, the __________ must be removed.
F. drive shaft G. cooler bypass open
E
H
C
A
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
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Student Materials
STUDENT MATERIALS INSTRUCTOR NOTE
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. Materials may 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 Controlled Transmission" Student Materials (Form SEEV2613) behind this page.
