09/04/2021 TRANSMISSION ELECTRONIC CONTROL FOR COUNTERSHAFT TRANSMISSIO FOR MOTOR GRADERS Caterpillar

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TRANSMISSION ELECTRONIC CONTROL SIS Information

FOR COUNTERSHAFT TRANSMISSIO FOR
General Service Information
MOTOR GRADERS Caterpillar Schematic
Specifications
Systems Operation
Testing and Adjusting
Troubleshooting

479 Dhs 784 Dhs 571 Dhs 288 Dhs 420 Dhs Disassembly and Assembly
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Manual

Systems Operation

Usage:

Introduction

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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.

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.

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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.

Jumper
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.

TOS - Transmission Output Speed

A transmission signal generated by a magnetic pickup on the transmission output shaft.

VHP - Dual Horsepower Solenoid

Transmission Solenoid Locations

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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).

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
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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.

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.

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.

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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 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.

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
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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 0°C
(32.0°F) and a warning light in the center gage cluster alerts the operator to this condition.

The warning light is on if the oil is 0°C (32.0°F) 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
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).

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Keys For Charts 1 And 2

Chart 1

Open - Solenoid either Open or Shorted to Ground (solenoid OFF)

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.

Design, Manufactur Troubleshooting Transmission Parts 2005/11/28 Caterpillar

and Supply - DC motor Telehandler Available - Contact Us
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My AVS trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used
for reference purposes only.
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descriptions are for reference only.

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