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Systems Operation

TRANSMISSION ELECTRONIC CONTROL FOR COUNTERSHAFT TRANSMISSIO FOR MOTOR


GRADERS
Systems Operation
Introduction


Transmission Electronic Control System
(1) ECM. (2) Start switch. (3) Start relay. (4) Transmission control lever. (5) Transmission indicator lamp. (6) Manual modulation
clutch switch. (7) Buffered transmission output speed. (8) Transmission speed sender. (9) Diagnostic connector. (10) Service tool.
(11) Service tool connector. (12) Control valve. (13) Solenoid A. (14) Solenoid B. (15) Solenoid C. (16) Solenoid D. (17) Solenoid
E. (18) Solenoid F. (19) Solenoid G. (20) Solenoid H. (21) Solenoid return. (22) Dual Horsepower Solenoid (VHP) solenoid. (23)
Backup alarm. (24) Neutral output. (25) EMS output. (26) Action alarm. (27) EMS. (28) Action lamp.
Shutdown SIS

Previous Screen
Product: NO EQUIPMENT SELECTED
Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED
Media Number -SENR6982-02 Publication Date -24/01/1997 Date Updated -09/09/2002
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The transmission Electronic Control Module (ECM) shifts the machine transmission based on transmission
output speed (TOS), Transmission control lever position and transmission modulation (inching pedal)
pressure switch position.
The transmission ECM processes information from the input components. Depending on the speed and
direction requested, the ECM then directs the signal to the specific combination of solenoids for that speed
and direction.
If a fault occurs, the ECM directs a signal to the Electronic Monitoring System (EMS) group to alert the
operator of a problem. The technician has two methods of diagnosing problems with the transmission
electrical system: the Electronic Control Analyzer Programmer (ECAP) via the service tool connector or the
diagnostic connector and flash codes.
There is a unique transmission configuration code that must be programmed into the ECM with an ECAP,
Electronic Technician (ET) or the transmission control lever. If a replacement is made to the ECM, the new
ECM must be programmed with this code. Without this code the machine will not operate. See "Using the
8T-8697 Electronic Control Analyzer Programmer" section in the "Testing And Adjusting" portion of this
module.
NOTE: The transmission solenoids are identified with letters (A through H) in this publication. The
solenoids may also be identified with numbers (1 through 8). Solenoid 1 is Solenoid A, Solenoid 2 is
Solenoid B, etc.
Definitions And Acronyms
CAT Data Link
A digital data communication link which is used to provide sharing of information between electronic
controls and service tools on Caterpillar machines.
CID - Component Identifier
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.
Countershaft Transmission
The transmission used on most "H" series motor graders and is shifted by means of electrohydraulic
valves which provide clutch control oil.
ECAP - Electronic Control Analyzer Programmer
The service tool used by the technician to gain access to the system status and diagnostic information
stored in the transmission ECM.
ECM - Electronic Control Module
The control is located under the operator's seat. It processes the input information which then directs
the proper electrical signals to the appropriate output devices for speeds, directions, and diagnostics.
EMS - Electronic Monitoring System
This is a dash-mounted device which alerts the operator to various machine status conditions.
ET - Electronic Technician
This is a personal computer version of the diagnostic software that is used in ECAP.
FMI - Failure Mode Identifier
A two-digit "F" code that is displayed on the ECAP service tool diagnostic display during servicing.
The number indicates the failure mode of the related component.
J umper
A jumper is a piece of wire used to make an electrical connection during troubleshooting.
Scroll
Scrolling is the process of showing all available sets of diagnostic information, one set at a time. A set
of diagnostic information is shown briefly and then the display automatically advances to the next set.
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TOS - Transmission Output Speed
A transmission signal generated by a magnetic pickup on the transmission output shaft.
VHP - Dual Horsepower Solenoid
Transmission Solenoid Locations


Solenoid Locations (Viewed From The Front Of The Machine)
(1) Solenoid A. (2) Solenoid B. (3) Solenoid C. (4) Solenoid D. (5) Solenoid E. (6) Solenoid F. (7) Solenoid G. (8) Solenoid H.
NOTE: The transmission solenoids are identified with letters (A through H) in this publication. The
solenoids may also be identified with numbers (1 through 8). Solenoid 1 is Solenoid A, Solenoid 2 is
Solenoid B, etc.


(1) Transmission ECM. (Cover has been removed).
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CAT Data Link Operation
The CAT Data Link provides status information to other machine systems including All Wheel Drive
Control and the ECAP service tool. The following parameters are available:
* Transmission Gear
* Shift Lever Position
* Transmission RPM (TOS)
* Battery Voltage
* Backup Alarm Status
* Start Relay Status
* Transmission Modulator Supply Pressure Status
* Dual Horsepower Status
* System Diagnostic Codes
* Abusive Conditions
* Coasting In Neutral
* In Park With Machine Moving
Transmission ECM Connector Pin Assignments
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Transmission Gear Solenoids
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Transmission Diagnostic Code Conversion
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Electrical Inputs
Battery Voltage
This is a two wire input which provides 24 DCV nominal to drive the electronic circuits within the ECM and
all of the external solenoids.
Start Switch Input
This is a single wire input that provides a battery voltage signal when the key start switch is in the Start
position.
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Transmission Shift Lever
This is a 13 wire input which provides the shift lever position to the ECM. Combinations of the 13 inputs
being grounded correspond to the different shift lever positions.
Manual Modulation Supply Pressure Clutch Switch
This is a normally open switch and is located on the outermost valve body and monitors the supply pressure
to the directional clutches and solenoids (Clutch 3 is Solenoid A, Clutch 1 is Solenoid B and Clutch 2 is
Solenoid C). When the manual modulation 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 or pilot pressure to the three directional modulating reducing valves. The pressure switch will close at
75 kPa (11 psi) and open at 50 kPa (7 psi). It provides the ECM with the status of the manual modulation
pressure.
Transmission Output Speed (TOS) Sensor Input
This is a single wire frequency input which receives a signal from a magnetic pickup speed sensor on the
transmission output.
Diagnostic Connector
This is a 3 wire input which provides a 3 bit code the ECM uses to determine which diagnostic mode to be
in.
Electrical Outputs
Transmission Solenoids
These solenoids are powered by 24 DCV from the ECM and are engaged when the ECM determines the
correct time to be ON.
Start Relay
When the key start switch is turned to the Start position, 24 DCV is directed to the starter relay to engage the
starter motor if the transmission shift lever is not in a speed or direction.
Backup Alarm
When the transmission shift lever is moved to a Reverse speed, the ECM provides power for the backup
alarm.
Dual Horsepower Solenoid (VHP)
When the transmission shift lever is moved to Fourth through Eighth Forward or Third though Sixth
Reverse, the ECM provides power for the dual horsepower solenoid.
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NOTE: If the machine is a 143H or 163H All Wheel Drive, the ECM will provide power to the dual
horsepower solenoid any time the all wheel drive switch is moved to the Manual or Automatic position.
Diagnostic Output To EMS (Pin 8 On ECM)
The transmission ECM is connected to the EMS Panel Lamp Position 5 which is called the EMS Action
Light. If there is a problem in the transmission ECM system, the ECM disconnects the ground and the lamp
illuminates.
Neutral Output To 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 I or a Category III.
Service Tool Connector
This is a 2 wire digital data communication link that allows two way communication of the ECAP, ET or
service tool with the transmission ECM.
Transmission Indicator Lamp
This is used in conjunction with the diagnostic connector to visually flash light code sequences when
diagnosing transmission electrical system faults.
Buffered Transmission Output Speed (TOS)
This is the output from the transmission output speed sender after it goes through the ECM to the
speedometer.
Modes Of Operation
Power-up
Upon power-up, Solenoids D and G are energized and all other solenoids are de-energized. Normal operation
is established once the shift lever has been moved to the Neutral or Park position.
Start
The transmission ECM has a neutral start feature. The operator controlled key switch is an input to the ECM
with the start relay being powered by an output from the ECM. This 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 start relay to be energized.
Upshift
When the shift handle is moved from the current gear position to a higher gear position, the ECM will shift
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the transmission immediately. If an upshift is attempted with the transmission modulator pedal depressed, no
action by the ECM is taken until the transmission modulator pedal is released.
Downshift
When the shift handle is moved from the current gear position to a lower gear position, the ECM will shift
the transmission immediately. If a downshift is attempted with the transmission modulator pedal depressed,
no action is taken until the transmission modulator pedal is released. After it is released, the ECM will
determine the proper gear.
If an overspeed condition occurs, the transmission is shifted to the lowest gear possible using special shift
points. Unit sequential downshifts result in the desired gear. If the TOS has not lowered below an overspeed
condition, the ECM will upshift to the appropriate gear.
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 gear 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 gear will cause an overspeed condition, the ECM will shift to the
lowest gear possible.
When a shift out of Neutral is attempted with the transmission modulator pedal depressed, one of two things
will happen:
* If the TOS is below First gear high idle, the shift is made immediately.
* If the TOS is above First gear high idle, No Shift will be made until the TOS drops below First gear
high idle or the transmission modulator pedal is released.
Shift Into Neutral
When the shift handle is moved from a gear position to Neutral, the ECM will shift the transmission to
Neutral immediately. The status of the transmission modulator pedal or the TOS value does not matter.
Directional Shift
A directional shift is when the shift handle is moved from one gear position to another gear position of the
opposite direction or where a shift out of Neutral is requested with the machine moving in the opposite
direction requested.
If the shift is requested with the TOS lower than Third gear high idle, the shift will be made immediately. If
the shift is requested with the TOS higher than Third gear high idle, the following steps will be taken:
1. The ECM will attempt to downshift the transmission to the lowest gear possible gear. If the TOS is
lowered below the Third gear high idle, the directional shift is made.
2. If the machine has not slowed to Third gear high idle, special shift points are used to downshift the
transmission until the TOS is below Third gear high idle.
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When a directional shift is requested with the transmission modulator pedal depressed, the following occurs:
1. If the TOS is at First gear low idle, the shift is made immediately.
2. If the transmission modulator pedal is released when TOS is below Third gear high idle, the shift
will be made immediately.
Overspeed
The ECM will automatically upshift above the shift lever position whenever the transmission reaches the
preset overspeed upshift 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 rpms are lowered and then match the shift lever position.
Diagnostic/Protection Mode
The transmission ECM will take special actions based on the present gear 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.
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 using flash codes. This can be used when an
ECAP is not available.
Clutch Phasing
The transmission solenoids are disengaged and engaged with special timing to control the transmission
clutch pressures during shifts. Clutch phasing extends the life of the transmission clutches and makes for
smoother shifts.
Low Battery Voltage
When battery voltage drops below a certain level, the ECM will turn OFF all transmission solenoids except
Solenoids D and G. If Solenoids D or G are already ON, they will be held on.
C Warning And Control Action Light
This warning system alerts the operator about operating the machine prior to the transmission oil being
warmed up. After machine startup, a temperature switch located at the transmission control valve determines
that the oil is below 0C (32.0F) and a warning light in the center gage cluster alerts the operator to this
condition.
The warning light is on if the oil is 0C (32.0F) or below, the light will also come on if there is an open
circuit. If the lamp in the gage panel is burned out, a level two alarm will come on.
Failure Modes
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Solenoid Faults
The detection of a system fault which prevents proper solenoid engagement for the selected gear 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).


Keys For Charts 1 And 2
Chart 1
Open - Solenoid either Open or Shorted to Ground (solenoid OFF)
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NEU - Solenoid D & G Neutral
GNE - Solenoid G Neutral
DNE - Solenoid D Neutral
Chart 2
Sht+B - Solenoid Short to +Battery (solenoid ON)
NEU - Solenoid D & G Neutral
NCN - No Clutch Neutral
Shift Lever Switch Open Faults
The loss of a shift lever switch contact when leaving Neutral, First Forward, First Reverse, Second Forward,
or Second Reverse will result in the machine remaining in Neutral. Loss of a shift lever switch contact when
in Third Forward or higher or Third Reverse or higher will result in remaining in the present gear. Whenever
a shift lever switch contact is lost and either the Redundant Neutral or Neutral switches is lost, the
transmission will be neutralized.
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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 direction signal is determined.
Loss Of Or Erratic Transmission Output Speed (TOS) Signal
Loss of or erratic TOS will only result in the EMS Action Lamp and Action Alarm being turned ON to alert
the operator that further operation of the machine could cause damage. The overspeed feature will NOT
function.
Copyright 1993 - 2011 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
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