Service Training

Instructor Module SEGV2613

July 1995

TECHNICAL INSTRUCTION MODULE

H-SERIES MOTOR GRADERS

ELECTRONICALLY CONTROLLED TRANSMISSION
SEGV2613 Table of Contents
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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
SEGV2613 Module Description
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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

SEGV2613 -1- Preparation Checklist
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PREPARATION CHECKLIST

MODULE Prior to conducting the training session, perform the following steps:
PREPARATION
_____ 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 Prior to delivering the classroom training session, perform the following
PREPARATION 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.
SEGV2613 -2- Preparation Checklist
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LABORATORY Prior to conducting lab exercises, perform the following steps:

PREPARATION
_____ 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
SEGV2613 Module Prerequisites
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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 The prerequisite courses should be completed prior to participating in this

COURSES course.

Interactive Video Course "Fundamentals

of Mobile Hydraulics" TEVR9001

Interactive Video Course "Fundamentals

of Electrical Systems" TEVR9002
SEGV2613 -1- Lesson Plan
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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.

• Conduct Lab B Lab B: Component Location and Function 20 min.

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 Lab C: Transmission Hydraulic System Component

Identification using the Hydraulic Schematic 15 min.

• Conduct Lab D Lab D: Trace Oil Flow through the Transmission

Hydraulic System 10 min.

Slide Presentation

• Slide 15 Transmission Electrical System 10 min.

• Conduct Lab E Lab E: Transmission Electrical System 60 min.

SEGV2613 -2- Lesson Plan
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• Conduct Lab F Lab F: Transmission Pressure Tests 60 min.

Supply Pressure

Lubrication Pressure

Pilot Pressure

Clutch Pressures

Differential Lock Pressure

• Hand out Case Study Case Study 20 min.

• Hand out Posttest Posttest

Administer Posttest 15 min.

Review and Discuss Posttest Results 15 min.

Total Estimated Time: 6 hrs.

SEGV2613 Module Objectives
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MODULE OBJECTIVES

Students must view the H-Series Motor Grader Introduction and

Hydraulic and Transmission Systems video tapes before completing the
module objectives. After completing this module, the student will be able
to:
• Lab A 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 3. Given class notes, a hydraulic schematic, and a selector and pressure
• Slides 2 -14 control valve sectional view, identify the transmission hydraulic
system components during a classroom lab exercise.
• Lab D 4. Given a transmission hydraulic system schematic, trace the flow of oil
• Slides 7 - 14 through the system during operation in FIRST FORWARD during a
classroom lab exercise.
• Lab E 5. Given a motor grader, the appropriate service module and tooling, list
• Slide 15 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.
SEGV2613 Slide/Text
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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.
SEGV2613 Laboratory Exercises
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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.).
SEGV2613 -1- Laboratory Exercises
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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
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A
SEGV2613

FRONT
OF MACHINE C

E D

H
-2-

F
Lab A: Major Power Train
Component Location
Identification Worksheet I
G
B
Directions: Write the letter of the component
in the correct blank.
F Parking Brake G Drive Shaft
D Transmission C Differential
H Left Final Drive E Right Final Drive
A Right Tandem B Left Tandem
Laboratory Exercises
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A
SEGV2613

C E

D G
FRONT
OF MACHINE
-3-

B
Lab A: Major Power Train
Component Location
Identification Worksheet II

F
Directions: Write the letter of the component
in the correct blank.
F Control Valve C Scavenge Section
D Differential Housing Sump E Filter
A Charging Section B Power Train Oil Cooler
G Transmission Case
Laboratory Exercises
SEGV2613 -4- Laboratory Exercises
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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
SEGV2613 -5- Laboratory Exercises
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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.
SEGV2613 -6- Laboratory Exercises
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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.
SEGV2613 -7- Laboratory Exercises
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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.
SEGV2613 -8- Laboratory Exercises
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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

Lab C: Transmission Hydraulic System Component Identification using the Hydraulic Schematic Worksheet I
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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.
SEGV2613

TYPICAL H-SERIES MOTOR GRADER TRANSMISSION HYDRAULIC SYSTEM

FIRST SPEED FORWARD
R S F J
G H I

L M
E .

A E
PARK
A 3 E 4
-9-

N N

1F 1R
B F
2F 2R B 1 F 6
3F 3R

4F 4R C G
5F 5R

6F 6R
C 2 G 5
7F

8F
D H
D 8 H 7
P O N

K
Q

D C A B
Laboratory Exercises
SEGV2613 - 10 - Laboratory Exercises
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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
Lab C: Transmission Hydraulic System Component Identification using the Hydraulic Schematic - Common
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Selector and Pressure Control Valve Components Worksheet III

SEGV2613

Directions: Write the letter of the component in the blank next to the name of the component.

B C F
D
G
- 11 -

A
E H
G Initial Pressure Adjustment Screw D Modulation Reducing Valve
C Decay Orifice A Solenoid
E Modulation Orifice F Load Piston
B Selector Spool H Clutch
Laboratory Exercises
SEGV2613 - 12 - Laboratory Exercises
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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
Lab D: Tracing Oil Flow through the Transmission Selector and Pressure Control Valve Hydraulic System
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(Outer Deck) Worksheet I

SEGV2613

Directions: Trace the flow of oil during First Speed Forward using different colored pencils to show the paths.
- 13 -
Laboratory Exercises
Lab D: Tracing Oil Flow through the Transmission Selector and Pressure Control Valve Hydraulic System
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(Inner Deck) Worksheet II

SEGV2613

Directions: Trace the flow of oil during First Speed Forward using different colored pencils to show the paths.
- 14 -
Laboratory Exercises
SEGV2613 - 15 - Laboratory Exercises
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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
SEGV2613 - 16 - Laboratory Exercises
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LAB E: ELECTRICAL FAULTS USING THE ECAP

WORKSHEET I
__________MACHINE MODEL DATE_________________

__________VEHICLE HOURMETER ____________________ SERIAL NUMBER

__________TRANSMISSION ECM HOURMETER

__________TRANSMISSION IDENTIFICATION CODE

DIAGNOSTIC CODES
CODES
NUMBER OF LOGGED AT CURRENT
CID/FMI DESCRIPTION OCCURRENCES FIRST LAST STATUS

1. ______________________________________________________________________

2. ______________________________________________________________________

3. ______________________________________________________________________

4. ______________________________________________________________________

5. ______________________________________________________________________

6. ______________________________________________________________________

7. ______________________________________________________________________

8. ______________________________________________________________________

9. ______________________________________________________________________

10. ____________________________________________________________________

11. ____________________________________________________________________

12. ____________________________________________________________________

13. ____________________________________________________________________

14. ____________________________________________________________________

15. ____________________________________________________________________
SEGV2613 - 17 - Laboratory Exercises
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LAB E: ELECTRICAL FAULTS USING THE

TRANSMISSION INDICATOR LAMP
WORKSHEET II
__________MACHINE MODEL DATE_________________

__________VEHICLE HOURMETER ____________________ SERIAL NUMBER

__________TRANSMISSION IDENTIFICATION CODE

DIAGNOSTIC CODES
FLASH CURRENT
CID/FMI DESCRIPTION CODE STATUS

1. ______________________________________________________________________

2. ______________________________________________________________________

3. ______________________________________________________________________

4. ______________________________________________________________________

5. ______________________________________________________________________

6. ______________________________________________________________________

7. ______________________________________________________________________

8. ______________________________________________________________________

9. ______________________________________________________________________

10. ____________________________________________________________________

11. ____________________________________________________________________

12. ____________________________________________________________________

13. ____________________________________________________________________

14. ____________________________________________________________________

15. ____________________________________________________________________
SEGV2613 - 18 - Laboratory Exercises
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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? 111-7088

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

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
number. B-7 Grid location and 9W1951 Part Number

10. Locate the Transmission Speed Sender on the schematic. List the schematic grid location.
D-15 Grid location
SEGV2613 - 19 - Laboratory Exercises
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11. 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

12. 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? 710 - GN

14. What size fuse is used to protect the Transmission ECM, 10A and what is the grid
location of the fuse? D-9

15. Which Transmission Solenoids are energized in First Speed Reverse? 1, 6, and 8

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 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? Wires that have battery voltage when the
key switch is off.

21. Locate the Transmission Indicator Lamp on the schematic. List the schematic grid location.
E-5 Grid location

22. 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? Engine Speed Sensor

25. What is unique about wires 710-GN and 202-BK? They are a twisted pair of wires.
Lab E: Identifying Transmission ECM Inputs and Outputs Worksheet IV
7/95

Directions: Identify each of the inputs and outputs of the Transmission ECM and write the name in the blank. Use the
SEGV2613

electrical schematic and Student Handout for reference.

H-SERIES MOTOR GRADER

TRANSMISSION ELECTRONIC CONTROL MODULE
3
START SWITCH CONTROL VALVE
10
4
START RELAY ECM SOLENOID #1
11
SOLENOID #2

28-40 12
TRANSMISSION SOLENOID #3
SHIFT LEVER
13
SOLENOID #4

19 14
TRANSMISSION SOLENOID #5
INDICATOR LAMP
- 20 -

15
SOLENOID #6
20
MANUAL MODULATION
CLUTCH SWITCH 17
SOLENOID #7

BUFFERED TRANSMISSION 25 16
SOLENOID #8
OUTPUT SPEED MPH
6
TRANSMISSION SPEED 18 SOLENOID RETURN
SENDER
21-23 6
DIAGNOSTIC CONNECTOR VHP SOLENOID

5
BACKUP ALARM
26-27
SERVICE TOOL 7 P

8 EMS

SERVICE TOOL CONNECTOR

ACTION ACTION
ALARM LAMP
Laboratory Exercises
SEGV2613 - 21 - Laboratory Exercises
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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.
SEGV2613 - 22 - Laboratory Exercises
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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.
SEGV2613 - 23 - Laboratory Exercises
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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.
SEGV2613 - 24 - Laboratory Exercises
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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."
SEGV2613 - 25 - Laboratory Exercises
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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.
SEGV2613 - 26 - Laboratory Exercises
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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
SEGV2613 - 27 - Laboratory Exercises
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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 H-7

PARK • •

NEUTRAL • •

1-F • • •

2-F • • •

3-F • • •

4-F • • •

5-F • • •

6-F • • •

7-F • • •

8-F • • •

1-R • • •

2-R • • •

3-R • • •

4-R • • •

5-R • • •

6-R • • •

CLUTCH
PSI ± ± ± ± ± ± ± ±
LUBE IN NEUTRAL
LOW IDLE ( ± PSI) AT HIGH IDLE ( ± PSI)
LUBE IN FIRST FORWARD
LOW IDLE ( ± PSI) AT HIGH IDLE ( ± PSI)
PUMP IN NEUTRAL
LOW IDLE ( ± PSI) AT HIGH IDLE ( ± PSI)
PILOT PRESSURE
LOW IDLE ( ± PSI) AT HIGH IDLE ( ± PSI)

DIFFERENTIAL LOCK PRESSURE

SEGV2613 Case Study
7/95

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.

SEGV2613 -1- Case Study
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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?

SEGV2613 -2- Case Study
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DIAGNOSTIC CHECKS • 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 Posttest
7/95

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.
SEGV2613 -1- Posttest
7/95

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.

transmission
Example: F 1. This is a hydraulic systems class.

three
F 1. The motor grader engages two clutches for each speed.

T 2. The differential housing is used as the main oil sump.

main relief
F 3. 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.

air pressure.
F 6. The parking brake is released by hydraulic oil from the transmission pump.

shims are
F 7. 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.

transmission
F 9. 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.
SEGV2613 -2- Posttest
7/95

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, 6. service tool connector

the ECM goes into the diagnostics mode.
7. configuration
7 The ______________ code is unique to each model
of motor grader. 8. open

5 Each clutch solenoid is connected to the harness by 9. ECM

a ______________ connector.
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
SEGV2613 -3- Posttest
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TRANSMISSION HYDRAULIC
SYSTEM POSTTEST
ANSWERS
Directions: Write the name of the component in the blank under each photo.

2 4
3

1. Parking Brake
4. Oil Cooler
2. Pump

3. Control Valve

6
8
7

9
5

5. Pilot Pressure Tap

8. Transmission Indicator Lamp
6. 8 Clutch Pressure Taps
9. EMS Transmission Alert Indicator
7. 8 Solenoids
SEGV2613 -4- Posttest
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TRANSMISSION HYDRAULIC
SYSTEM POSTTEST
ANSWERS
Directions: Write the name of the component in the blank under each photo.

10 13
11
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

SEGV2613 -5- Posttest
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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. A. diagnostic connector must be
uncoupled
B Transmission speed signal is incorrect.
B. transmission speed sender
I Motor grader "creeps" with the inching pedal fully output low
depressed.
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, F. drive shaft

the __________ must be removed.
G. cooler bypass open
E Preferred method of diagnosing a problem with the
transmission system. H. transmission configuration
code
H If a transmission ECM is replaced, the ______________
must be entered. I. inching pedal is out of
adjustment
C This group can be removed without removing the
transmission. J. solenoid A is defective

A To activate the diagnostic program within the ECM, the

______________ .
SEGV2613 Student Materials
7/95

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.