RENR8A82-07 Visual Inspection ‘SMCS Code: 3020-095 ‘The ft stop inthe giagnoss of the power tain the performance ofa visual Inpecion. A vital Inspection must be performed pret esi, Before You bogin the checks, refer to Systems Operaten, {esting and Acusting, Machine Preparaion fr Troublesbactng Perfor the fofowing visual checks 1. Check ne tvel of the fornia urn, Check thet fora ar or water Ir nmcasanry, ned 010 the serena. Forte recommended ol grade and visecaty, fer tothe appropeate Operation {nd Maintenance Manta for your mechine 2 Inspect the transmission of for estan on machines tht use engine coclant to cool he Uansrssion of 3. Inspect oltines, hoses, ane connections for damage or eaks. Cook ar ol onthe ground Under the mecane material Remove the tansmssion ol ie 2° inspect the wanerision cl filer for freon ‘teil. Use e magnet in oder to distinguish Detween any orous partes and ony nonerous partes {, The ceive shats and universal jits must be tee {orate excopt when cod ollcadtes a essence Hote: Maka sure tht th folowing codons exist before you perform this fest + The Wonsmision must be i neu + The witels must be of he ground +The parking brake must be disengaged Operational Checks Siics Code: 3020-005 “The operational checks can help kagnose poor perlermance ia the power tain system, 4. Stat the engine. Run the machine nal FORWARD gears and in al REVERSE gears ar Troubleshooting Section 2, Engage the sterent ock whe you are cvieg stealgh. Tu the machine sight, ad watch the ‘ear wheels, The wheels sheus relate atthe sama pood Ifthe diferersl lock Is working comecty Disengape the diferent! tok, 3, Depress the cluch pedal whe you operate the ‘machine, The machine wl slow dawn when the ecole depreseed further. 4, Stop the machine. Engago the parking brake,be RENR482.07 Troubleshooting Secon Symptom Procedures Power Train SMCs Code: 3020-035, Troubleshooting the Power Train Problem: The transmission will not shift into any gear from the Neutral position Probable Causes + Low Ob Level + Low bateryvotage + Wiring harness comecions + Tranemision cont siter er orvard, noir, reverse toggle swith) + Electieal problem with the cuch pedal + Main rit vale + Transmission 08 pump + Rotating ea! leakage inthe transmission + Watple ECPC valves are matnctonng. + The pain brake sytem is malunctining. Problem: The transmission has lost a ‘single gear Probable Causes «+ The iting hamess forthe transmission contot + Tensrission conkal (shifter or orward, peu, reverse teqgle swe) «+ Eletonc contrl module Problem: The motor grader has iost ‘multiple forwardiroverse goar selections. Probable Causes + Wing hammess + The ECPC valve fe malfunctioning + Transmission contol shite or forward, neu, severe togale swith) + actone conto mil + ltertransmision problem Nota: tho vans wl nit ino Fstspeee {ornrd, ith sped foward, or Fist sped verse, ‘eli unt png Boke eter. Problem: The transmission slips Probable Causes + Low sytem presi + erent! ck vate +The ECP vave requtes carat. + Tne ECPC vanes makincionn + Daven lectone cnt moctie + comaminaton + oat shot st «Rotating shat tra + Wen ee + Heche! ete «Te carton ote ech oda + teh lt ea «Te sung has ew aleve + The pumps cauing aration Problem: The motor gradar creeps when the clutch pedal is fully depressed Probable Causes + Catoraton forthe etch pedal + The EOPC valve reaitescaltrtion «The ECPC valve matnconing + Virng hamess forthe EOP vale + Wing harness forthe transmission + Contarinaton «Diver in he elatrone conto! mochie + ntemal een dragReENRas82.07 Problem: When the transmission shifts a hesitation occurs. Probable Causes + The EOPC valve resus calraton + The ECPC vale fs mathnatoning + Contamination in the transmission cont! vale + Of temperature sensor + Drivers in the electron ental madite + Sneed sensors + tremal sea eakage onthe vensrission + Interal pump leakage + Maio eit vale + Different lock valve + Communication nk betwesn engine and transmission +The pump is causing aoraton Problem: The transmission shifts are harsh Probable Causes + Transmission speed sent + Wing harness forthe wansmission speed sensor + Communication Ink between engine ang vensmeson + Ol iemperatire sensor + The ECPC valve requires calvation, +The EGPC valve ie malfunctioning. + Broken spring in the mala reletvave + A spoon the main rit valve ats, + The piston ona catch sks Problem: The transmission shifts are sluggish Probable Causes + Worn cutones + Tha ECPC valve rquies caibaton, 29 “Troubleshooting Section + The EOPG valve is maliurctionin, + Slow cc disengagement + The calaton ofthe proportional sclnoid vale + The parking broke system is mitctonng Problem: The transmission shifts at the wrong point when the autoshift control is in the ON position Probable Causes + Transmission intermediate speed sensor + Transmission input speed sencor + Transmission output speed sersoe + The olctroniccontal mosle has the wrong sransmission contiguaon code Problom: The transmission does not shift into all the gears when the autost in the ON position Probable Caus + Transmission intermeetat speed sansor + Tresmission input speed eensor + Transmission oulpt speed sensor + The op gear tnt sat + The operar verde selected. Problem: The transmission shifis into the wrong gear when the autoshiftis in ‘tho ON position Probable Causes + Transmission intermediate speed sensor + Transision input speed sensor + Transmission out steed sensor + The wing hamees forthe ECPC valve shad +The wing harness forthe iransmision ECM is badey RENR8482.07 Troubleshooting. Section ‘Troubleshooting the Parking Brake System Problem: The parking brake does not hold the machine stationary. Prosable Causes + Tho brake rings fot Ba paring brake are wom, «Tere is gfease raion the brake fg + The poking broke must bo aut. Problem: The parking brake does not ‘engage when the parking brake switch is actuated. Probebie Causes +The parking brake site ful. +The parking brake sclenot is not operating propery. +The main colle valve seitng forthe transmission ‘Sncorec, + The piston seals ae damaged or brokenTesting and Adjusting Section Testing and Adjusting Power Train Charge System Pressure - Test and Adjust sce Code: 57 c25.M St17081-EWr Introduction PR) ‘When teting and adjusting the tranamissfon and in, move the machina to an area clear of Ns, with Safe exhaust vetiation forthe fexhauets. Sudden movernent ofthe machine ore lease of lunder pressure cen cause injury to per the machine, To prevent possible PR) Personal inury ean resut from spring force re- leased when removing eap screws. Intomnal spring force will be released whon eyfin dor assembly cap serows are removed causing i= iy. ‘Always restrain coveras cap screws areloosened, Folfow the estabished procedure in the Service Manual to service these pars NOTICE ‘Care mustbe taken to ensure hat his are contained during performance of nspecton, mainienance, st in, susting, aed repaof the machine. Be prepared to cole the fuld wi suable containers before ‘pening any compartment or csaesemng any cor ponent cantaring Tugs Dispose of ids according to ocal raguetions and mandates “The following procedure is used in oder to test the charge system fr the power van. 1 ssaaiiiae ‘Testing end Adjusting Section Required Tools Procexe Gauge sr.cess | (0% 4000 Hea $o| _eomiom __ 0 Die Presa lest 2 |rse-aao = (gies iat a Pressure Senser Gp 2 |roo-a2s7| @to aes ies Ole ‘20 os) Machine Preparation Reference: Before you perform ts adjustment, refer "esi and Adjusting "Machine Properavon fr Trousiesrentng2 ‘eating and Adjusting Section 4, Operate te machine unt he wanstrission ols atopettingtermporature range of 75°C to 20°C (ier to 194"Fh 2. Stop the machine on a hat level sutaoe. Move the ranemisson cone lever tothe NEUTRAL poaifon. Shutof he engine. Place blecke In ont Stthewheels and place block Behind tre whoa 3, Engage the paring brake (Stas tae Daten Bat woe RENRe482.07 inaroond ‘4, Remave dust cap (2), Attach Toning (A othe fing. Test Procedure 4. ste that he transmission contol vere in the NEUTRAL poston. Stat the engine and run ‘he engine a high ide. 2. Athigh ila, the prassue shoe be 2480 = 35 KPa (602 5 pi. Adjustment Procedure 4. tf the pressure i mre than 2480 #35 KPa (80 £5 ps, remove cover (4) and tum SSdustment screw (3) countrlecice unl preseizereocnos 2480 + 35 kPa (280 25 ps 2. If pressure Is less than 2480 + 35 KPa (G60 £8 psi. remove cover (4) and tun ‘austen sere (3) clecawise etl pressure Feachea 2480 £39 KPa (50 4 5 5). 5. Once the insisted pressure nas been reach, ‘eloase and engage bie parking brake agen {ihe pressure roading hse chenged, repeat ‘Step 1 or Siep 2 unl prossice reading reaches 2480 + 38 Wa (360 +5 pe. 4, Replace the adjustment screw cover ‘5 Turmofftne angina andromove the ost equipment. Insta dust ap (2). CRENAGAI-07 Parking Brake - Test (Use This Test for the 352-5716 Power Train Software Gp and All Newer Software) stics code: 4267-081 Note: Be sure thatthe machine has the 962-5716 Power Train Software Gp or newer before performing thi test. introduction PR) Personal inury can result tthe machine moves ‘while fasting the parking brake, {ithe machine begins to move during th test, re: duce th angin speed immecatly and app) the Service brakes, ‘Th fol test suse! a tern the parking brake is functional This tests intended 9 measure the maximum brake folding effort The brake bong cffort ats ected to pravents machine fom ‘roving at spite engine rm varies dopensing on {he machine, The varatons ae the aterencesn th engine seltng, in tha rower ln eficieney, and in tha brake hong abity Machine Preparation Note: Be sure thatthe machine has the correct ‘Software for the transmission or this tos ‘Check he ate around the machine. Make sure ‘hat te machin is clear Of personnel ard ear of cbetacls, “est te parking bake ona dy lvalsurfecs Fasten the seet belt blore testing the parking brake, Test Procedure 1, Slot the engine ard set he that tothe HIGH IDLE Faice the implements shy 2, Ensure thatthe parking bree is engaged, 3. Depress the trnsmision meutalor contol {inching peda). Note: Do not anny the service brakes, 02 ‘Testing and Adjusting Section ‘4. Depress he up shit canto four tins in erder io suiet5F" The cspay sou ea Note: Tis stop must be completed win 2 seconds. ‘5. Shite transmission tothe FORWARD dieation. ‘Note: When the larsmission is shied ito °F" and th gry baa eraeped # Waring Category ‘6. Win the engine at high i, slowly release the pedal unti the ransmnssin automaticaly shits fo neutral. The engine speed wil recover t he Ina setpoint 7. Shifthe transmission tothe NEUTRAL postion, Run the engine at 100 rpm Tor at east wo ‘minutes in over fo cool be Vansnission ol Note: Do rot shut down the engine unt te i is cooled propery Do not repeat he test praceure unite os cooled caw prop. 8. Lower the implements tothe ground 8, Stop the engine nomics lithe machine moved whe fosting the parking brake, Inspect the parking brake componente for wear OF ‘demege, Repa or replace the wom or damages park ingbrake cmponersas required etre retuning he ‘machine t Parking Brake - Test (Use This Test for All Older Versions of Transmission Control Software) ‘SMCS Code: 4267-051 A Wwarnine Personal injury ean resut ifthe machine moves ‘while testing the parking brake. ‘tthe machine bogins to move during the test, re- duce the engine speed immediatly snd apply the ‘service brakes,94 Testing and Adusting Section 2 Introduction “The folowing tests used te determine ifthe parking brake fe Uneional This ost londed to measure {he maximum Brake Nokng elt. The braka boing ‘fort hats rogues o prevent a macnine fram ‘moving ats specie engin rpm varies depending on ‘hemachine. The vatatone aa the ferences nthe fgine seling, in he power Wain efcleney, and in the brake halaing abi. Machine Preparation Note: Be suo thatthe machine has the correct software forthe transmission For this test. Cece the tea acund the machine. Make sure fiat the machine ls clear of parson od dear of obetaces “Tost tn parking brake ony evel sutace. Fasten the sat bol bor testing the paring broke Test Procedure 4, Star the engine snd set the that tothe LOW IDLE Rais the implements sught 2, Ensure hat the parking rake Is engaged 3. Depressi ‘oda. transmission modster contro "Note: Do not apiy the service brakes. 4, Depress the up sit cone four mes in order to Select 'SP" The dlploy stud read "SF Nota: This step must be completed win 2 seconds 6, Shithe transmission to the FORWARD crecton. ‘Note: When the transmission fs shite nt "SE" and the parking brake fs engages, a Warring Caleyory ‘Sw occur, 6, With the engine ot high il, slowly release the pedal unl the machine sas 7. Shitthe transmission tthe NEUTRAL poston Run te engine at 1800 rp for atleast two frites in oreo ool fe ransmissin of Note: Do not shut down tne engine unit the ols ‘coated propery, Do not repeat Ie est procecixe Untl he fs cooled down propery. 8. Lower the imptemont othe ground. 9. Stop the engine RENR6¢82.07 NOTICE Ifthe machine moved whe testing the parking brake, Inspeet tho parking brake componens for Wear oF damage. Repal or replace the wern or damaged pak ng brace components as equred before reurning tie machine to sence Transmission Lubrication Oil Pressure - Test ‘SMS Code: 3080-082-PX Introduction PR) ‘When testing and adjusting the tranerission and powertrain, move the machine to an area clear of bhstructions, with ate exhaust ventilation forthe exhausts, Sudden movomentofthe machine or re Injury. do the procedure thatfollows before testing and Rajveting the wansmission and power trai. NoTIce Cave must bs taken to ener that ude ara contained furng peformence of inspection, maintenance, test- ing. aejestng, andrepalrof oe mecine. Be prepared tpcosect the ud wth sutsble containers before ‘pening any compatinent ox dsassemtng any com ‘poner containing thes. Dispose ofa ids accoring to local reguatons and mandates ‘The folowing procedure ie used to test he pressure ofthe ranomasion breton ol Required Tools el ine | PORN” Brerin etan oon as | arome| @oitsomee | 1 | Ove (eames [rag 8 M Li | |_ 0s Bia [2 Fe Pesan [OHRENR482.07 Machine Preparation Before you being th test, refer to the Power Train Sysiame Operation Testing ans Ad\sting, Mache Preperation for Troubleshooting 4. Operate fe machin uni he wansnecion ois at operating temperate of 51°C (124 F 2 Stop the machine ona haré level surface. Engage the barking brake. Tum off he engin, (00m 3, Remove plug (1) rom the ransrsion ease Insti Tooting (Oj nto he pot Ane Tong (A) nla Testes (0), 4, Pic the machine on lands so that he rer ‘wheel 20 of the grouna Note: Make sure tnt the All Whos! Dive system is ‘wined of Note: Suppor the tandem inorder to prevent the tandem tam trang when te teria Brake fs, eoplied Test Procedure 41 Stat the engine 2 lr the parking beske, Tum the erent lok {othe ON" poston. Cperate the machine In NEUTRAL alow il, The pressure onthe gauge shoul be a mininum of 14 «Pa (2 ps). Record the gouge reading in Table S 98 “Testing and Adjusting Section 3, Operate the machine in NEUTRAL at high ile The pressure onthe gauge shoud be a minimum ‘of 276 ¥Pa (40 pal, Record re gauge reed in Tab 6 4. Disengage tne parking brake: Operate the snactune it FIRST GEAR FORWARD at lw ile “The gauge prossure enouls be @ mraenum KPa (tps), Roca the gauge reading in Table 5. ', Operate ha machine n FIRST GEAR EORWARD thigh ble. The gauge presse shod be a rinimusn £35 KPa (20 pal. Reco the gauge reaing in Table 6 6, Repeat Step 2 through Stop 5 wih the diferent lock n the OFF positon. Tansmissionlibreaion ‘reseures that vary wth tbe eiferental ook Oe ‘GW poston Inccate leakage inthe diferentat lock system 7. Slop the machine 8, Tum of he engine 8. Remove te stands that were lnslalld under the machine 10, Remove he test eauipment 11tntal the plug that was removed in Stop 3. Worksheet Trrsin inva Pana nun “aramiesion Labricatin Presto Diferentat tock he “OFF” Poston Neutral] First Gear | [fener6 RENR@482-07 “Testing and Adjusting Section a Transmission Pressures - Test and Adjust ‘SMCS Code: 3030-925-PX; 2030.06. "9073:025-2X: 3073-081-8%; 3074-025 PX; 3074-081-PX Introduction A warnins ‘When testing and adjusting the transmission and power tra, move the machine to an area clear of ‘Sbstmuctions, with safe exhaust ventilation Tor ie ‘hauls Sudden movement of the machine or re- tease of oi under pressure can cause injury to per- ‘sons on or near the machine. To provent possible injury, do the procedure that fellows before testing and adjusting the wansmigsion and power ta PN Personal injury ean tosult from spring force re- leased when removing cap screws, Infernal spring force wil be released when cylin ‘dor assembly eap sorewe are removed causing I~ uy. ‘Always restrain coveras cap screwsareloosenei, Follow tho established procedure in the Service ‘Manual to service these pat NOTICE ‘Care must he taken io ence at Mids are contained uring performance of Inspection, meinienance, est. tng, sjusting, ane repaof the machine, Be prepared {2 coloot the fd wih sutable containers before ‘pening any omparimen or dsassemélng any com> ‘ponent contig Mics, Dispose ofa fide according loca reguatoné and mandate “The faowing le used to test the ransmision prosares Required Tools Sa a | ot-osss | teams oto | + Ce ep rel (a [ersiee | re ce ma [irr-7ico] SSA, [ie e|OPer n faa-2284) Da nestor | 4 Pressra Sensor Gp ea |roa-aaer) @toausiPa ole | 1 500 ps) al ‘Mester cabins | 1 a | 100-4206 10 | ot [308-0026] tranemisin Tesi Cover| 1 Machine Preparation Reterence: Before you begin the test, refer Eyators Operation Tooting and Ajusig, Machine Preparation for Troubleshooting. 4. Opetate the machine ntl the ransrission ol ‘Sat operating terperature of 75 © 10 90°C (167 "Fic 194 7) 2, Stop tho machine on a hats joel surace, Pisce the transmission th NEUTRAL. Tu of the tenane, Place Blocks i fant of the wheels and pce blocks bering the weesRENR#82-07 ea “Teting and Adjusting Secon ares ase eran sata mas auezae ioe samccsemse RERESE iam, 3. Remove cover (8 ro the ansmissio, “4, Romove the drive haf quad, 8, Remove the diferent dive aha. 6 Assemble Toolng (0) withthe 26¢ mm (7.00 inch) fumper 7. Use the bolt oles for he arive shat quae in xcar to.atiachTooing (0) otha paring brake housing, Test Procedure 4 Alach Tooting (A) oF Tocing (8) to test ports (8) ‘2nd (6) Operate the engine ah dl wih the {ensmieson in NEUTRAL. Tootng (A) o Toaing (8) should rand 2480 + 76 kPa (360 £0 po Record the pressure reatings in Table 7. Remove ‘oaing (A) 6 Teog (8), 2. Attach Tsing (A) Tooting (8) to eat por (1,16. ‘and (7). Opeata the engine at high ala wth fe tersinisson in RST GEAR FORWARD. Tooling (Aor Toolng (2) should read 2400 > 70 KPa (860 10 ps. Record the pressure readings in “ae 7. Remove Tootng (A) er Tong (0 3. Altach Tolng (A) oF Tong (6) to test pete (@)- (2), and (7). Operate the engine at high 'ale wih the Lensnission in SECOND GEAR FORWARD. Tooling (A) or Tealng (2) should read 2480 +70 kPa (360: 10 ps). Recerd the pcossure readings Table 7. Toetng (8) oF Tooing (6). 4. Atach Tooting (A) or Teling (8) fo test ports {3} (8), sod (7) Operate he engine at high ick wih the tansmisson FIRST GEAR REVERSE. Toolng (A) or Tooting (B) should ead 2480 = 70 4 (360 #10 pa). Record the pressure readings n Table 7. Remove Tookng (A) or Toatng 2) 5. Tum of he engin, 3. Remove Toorg (6). 7. Insal the cover (8) andthe ferent ive shat Note: If everyone ofthe pressure resins ave nct hin te speciiog pressure range tat sisted In Table 8 the main et valve may need to be atusted, Roler to Tesing and Adjusting, “Power ‘ain Charge System Presse Tet snd Adjust for ‘oration aout asin te mat eet vate To ‘Testing snd Adusteg, FA Tepe forte Transmssion ‘Cutch-Caltrate" procedure wil ot afect he lop pressure of te cue Note: If some of he pressure readings are not within the spectied pressure range ha ated in Tae 8, ‘hose meculating valves may nead tobe replacedRENRE482.07 ‘Testing snd Aajusting Secon Worksheet inst GEAR |_REVERSE. 8.047 (000 pat ‘2900 2 70 KPa (2004 {0-pah (9%2(0.00 pe) 20478 @00ps 00}. ep corn ea0mm) | 00% 09050 aah 210s cowsceop | eovPasconee pete 000 pa 1904 (200 pa) 36603 70 ws (0340 ph y | 90%ee 000 a aoWea 000 pan ceoure ooops | 702 (oN 00 We 00a) Bi 2 70a | 2A8ds TO MPs io Sector G60 + 10 pi (602 10 pail wap e7ow= | goirecmmee) | o0rre esp) | cOWA oor Fill Time for the Transmission Clutch - Calibrate SMCS Code: 3155-524-FW Introduction ‘The folowing procedute is used to caltate the fl ‘ine fr tho taramssion cuthes Improper catration of te transmission csc wi ‘sause vanerssion sing problems. The automat: {alten procedure for seting the tsnarision ‘Stich fe wil achive greater constency. The main rol vale must be calrated Referonce: Refer to Testing and Adjusting, Power ‘Train Charge Systor Presavte Tost ard Adjust for information spout sting te rele vave. ‘Note: Do not perform this procedure If software nas [st been Uploaded into the Tensmssion’Ghaseis, Slecronic contol reedule. Cys the power forthe lronsmissinchaccisolacronic contrat module prior to perorming the procedure.RENREA82-07 scone Baer nean moat Sacra tan ora ieeesac gaa iy (Gi Meatotng wove orci 6 gyre) Prasat ono oes nnd on Te ee Oe ae rooghe ego nektin sr Resi comnnte Saber han, eticaealsee seas ‘eltotelncpegl ong Sse + Mean ve fr it (1) ware igh + Modan ave for teh 2} owed ow) + Moaudetng va for cute 2) ove) + Motdatng seve for uh (4 cond speed) + Meta vate ott 5 (6) he pane) + Media vv or cht (6) st spect) + Wehr ve och 7(7) flow range) ‘+ Modulating valve for clutch 8 (8) {high cango) Required Tools | Required Toe | “Tost ‘essen Oy > | Siar taaneecn | 0 Testing ana Adjusting Section Machine Preparation sonal injury oF death can result rom sudden ‘machine movement. ‘Sudden movement of the machine can cause in- {ty to persons on or near the machine. ravent possible injury by performing the proce- sure that follows before working an the machine. RoTice Do not connector alsconnect hose iting to o rom the quick lsconnect apples when thee fs presse In the system. Ths wil provent damage to the teats that cei he tng. Notice Core must be akon to ansura thal id ae contained Sting prformance af nspecion, maintenance, Wst- ing. adjusting, anc rerar of he produc. Be prepares to collect the uid with suilaie: contaners betxre ‘opaning any compartment rdiaeserbing any Cort Donent containing tds. Refer to Specs Pubueaion, NENG2500, “Dealer Sar. Vee Tool Caaloa for loos ard supoiss sulable Cotect and conan Mid on Cat products Dispose of al als according to local reguations and mandates The folowing conditions must be mat before calbraton: + The main rel valve must be catbrated +The machine speed must be ze, +The engine must be runing + The pking brake must be set +The implement lockout swich must be in ha locked positon + The transmission fier bypass must not be bypassing. “+ The tansmission ol tomparature must be at an ‘operating temperature of 0" 2 10°C (178° # 18°F) +The inching pedal mst be fy reoaged in rd {o'alow ihe aulomate casbrston tunevon to eat +The service brake pedal must be fly lead in ‘rer to afew tne automate caltraon funn toate100 RENRO462.07 ‘Tettng ond Adjusting Section Reference: Rafer to Testing and Adjusting, “Power {Tran Charge System Pressure Test and Adust for ‘ormetion bout song the rele valve, Note: Bumping of he or burprg ofthe NGS BME Bote ding te slonatraten {Snoton wi cauve te calraton pres o be moved Nota: fnew modulating vaive was Inetalod sort theengine and anf tha Vansmission for at least 12 limes into speed ora drecton hat uses the new ‘teh Solenedt modulating valve. Refer to Table 10 ‘rorcer to ently tbe duthes Mat are ongaged for cach deecton an osch goat ‘we 10 “G2 |] caus | Game | Sam | gam | ou | cus] (oraz (eons | 5 ‘ie | bor 7 Mom | weve) | Spoac) | pect) | sosed) | ronae) | reno) x x x x x x x x x x x x x x x x x | Eup speed [ X 7] Fora a a 7 x [x x x x x x x x x x xRENRGA.O7 Calibration Procedure ‘The Calerplir Eloctonic Technician (ET) is wed to access he calalion procedures. A message on Cat EY screen nl gveinctustons tat guide the user trough the callrtion procedure Retr to ‘he Merual thal is provided with Cat ET for more Information about Cot ET (8) Sere concn 4, Connect Cat ET to sevice connector (9) 2. Opan Cat ET Select he ransmssion Electronic Control Module (ECM) fer the mani tats being calvated, 23. Ifthe conditions thet ro lites above in earaton fr Callcation Procedure ae me, the «splay wit norte tecnica fo press NEXT ‘rer to advance i the neat sing Note: During th calibration ofthe transmission ‘cto fi, many transmission euth l are occuring Remain seated. Thera wil be seme vbraton and noise as te chtches aro being carbeted any che conditions for eabraton are vided during th caltxation the calibaion wl be stopped. Bo ‘not operate the airconditioning or hydraulics ‘uring ine eafbeaton of tho solenoida. During the Automat calibration function, aveld performing, ‘Steering movements Note: At any tine during the ealbraion, the user ‘an ater he calloration by pressing the CANCEL Button Depressing the cutch pedal or depressing the serve brake pedal wil lso abort the cation 44 The EOM wi command the enginato run at 1700 rom 1 Testing and Acusting Section Note:The engine must achieve te oquested speed Ina raximur of fve seconds. Ifthe engine doesnot {each the requestod am te qivenarpaunt of tie, ‘ha ECM wil abor the ealbrasan due to an nearest engine speed 5. The display wil conlouousy aepty “Calibrating ‘Chteh #9" The ECA wit fi ctch @ and the ECM ‘Wi erin clutch elght several ines. The ECM ‘wl formulate the eptins! Rat cunt and the ‘ptt ramp levels for Ine sora hat operates the modulating valve tr cuten 8 When the EC has conpleted caibratng his cicn, Gat ET sufomatcaly moves to Un rent ston 6. Te depay wil conicuslyeepay *Cabrating Cuch #7" The ECM wit chen ane the EM 192 drain cltch soven several times. The ECM ‘wa formate the opinal Pot current and the ‘pleral amp fevela far the solonld tat operates ‘he modulating valve fer cach 7. When Be ECM has completed ealratng tis ton, Cat EF ‘xiomaically moves ta Ute ned sto 7. The doptay wit continuously cepa "Catbrating ‘ten #6", The ECM wi lt ten 8 and the ECM wil crain dutch sic several times. The ECM wit Foca te optimal hold caren an the opti ‘amp levels for to slerold thet operates he ‘eduatng valve for etch & Wiben the ECM tras cometeted calling this cute, Gel ET ‘ulomatcaly maves to ihe nod ste, 8. The dapay wit continuous deplay “Calratng Cutan #5" The ECM wil uton§ and he BOM ‘el ran th five several ime. Tae ECM wi Formlate te optial old cuenta the optimal ram levels for re sosenc thet operates the modulating vale fr auten 5 en the ECM has competed caitratig tis cute, Cat ET aulomatealy movos to the next te, 9. The apa nl comncusy deploy “Caleratin hich Ee te CoM fc dade ew ‘le chou saver tes The ECM wih. itr be otal fol eonet aa the ral ‘am lev forthe sled far opatee ‘radsing va for teh Viner fe Et as competes sarang his teh, Cat EF Sutrtealy moves toe et lop 10.qhe clslay wil contrucusiycepay "Cabbrating ‘Gteh 83" The EeM wi filcleteh 9 and the ECM ‘nikdrain oh tivee several times The ECM ‘i Formulate tre opera hoe crrent an the ‘optimal ramp loves fr the scereid rat operates the modulating vale for sluts 2. When the ECHA has completed carbrating tus cten, Cat ET automate moves to he het stp.402 fing ana Acustng Section ‘4. The iepay sl cortinuouely splay "Calibrating ‘Guten 42. The ECA wil cuz 2 andthe ECM ‘il ran cites to Several mes. The ECIM vail formulate the opine old curent and the optimal ramp levele forthe solenoid that operates the tmoditatng va fo euach 2 ven the ECM has competed cattrating this itch, Cat ET fviomatcaly moves tothe nen step. 42. The cep il continous cpl “Calbrating ‘Guten #1" The ECM wif cuten 7 and he ECM ‘st eran ich one several times, The ECM wit forouiste the aptinal hold current andthe optnal ‘amp levels for he solenoid fat operas the Trodustng vaWe fr cut 1. When the ECM Fas completed catbratng this cteh, Cat ET Ausomateaty owes othe net step. 13-The ECM wil command the engin to resuma ioral operations. 14.0nce the catirallon tas been completed ‘sccessuly, ee EOM wil wie the catbration data io meron, 415. Operate the machinay i err to chack the ‘unity of wenssion sit Drive Chain - Check SNCS Code! 226%; 4068 Introduction “The folowing procedure is used inorder io check the ‘lorgaton ofa ave chains, 114s important to check the chains inside the tandem ‘ives for wear Norma eperaton wil cause te pins, Tinks, and alr in the chains to wear The chart sl the menu ines of chain wear fora gven nner ‘fchan links. Ekngalon of Ie chain due to wear is ‘considered normal, Eongaton of 388 normal or alt mol grees. The chain enould be replaced whan the chain roaches the maximum allowable wear. This Seton wl prevent possibe mage that coud be used by a broken chain. ‘Note: A broken chain can wedge Inthe tandem housing, A medged cham ean camage the ftewing tems: sprockes, spines, and Rousing. Machine Preparation RRoferonce: Refer tothe Power Tain Disassery ‘and Assembly, “Dive Chain Remove" 4. Remove the Orve Chain kom the motor grader. RENRG462.07 Test Procedure 4, Inspect the chains. Replace the cbans forthe falpwing canaaions: + Cracks + Broken components + Deformation ‘Note If the cheln doesnot pase the inspection the ‘te chan must bp repaced. Aways oplave both haine ina tandem peueing a he same time. Do. ‘ot splice a naw section of cham on a worn section Sf chaln, Norn chaine wl rat engage re sprockets propery and inereased damage lo the sprocket my AWARNING PPereonal injury or death can result from improper Iiking or blocking. \wmen a hoistor jackie used to it any part or com- ponent, stond elear ofthe area, Be eure the hoist ‘Gr jack hae the correct capacty to Mt 2 compo ‘et. Intal locks or stands before performance ff any work under a heavy component. Approximate weights of the components: are ‘Shown: Clean all surfaces where parts are to bo {stalled 2, Suspend te ebsin rom th hoist 4, Hang a sulabe scale fom the chan. The scale ‘rust be able t measure the chain tension thats Fete in Table. 4. Facto fae ond ofthe scala tothe motor grader. Reterance: Refer tothe Oneralion and Maintenance Manual, "Uflng ad Tying Down the Machine” forthe proper tng locations fr 8 motor grader. ‘5. Aoply the proper amount of chan tension. Refer fo Table 11, Enoute hat a of the slack out oF the chain before a meszuromerts akon, 6, Measure the number ofchaln inks that ae Etod te Tabi, 7. The elongation ofthe cain must be less than he ‘poeabon in Table 1.RENR«82.07 109 “Testing snd Adjusting Section Note: the elongation of the chain Is not wtiy speofcalions, the chain must Be resioced. Replace the entre chai. Always replace both chelns i 9 tandem housing atime same ume. Do cot ace ‘ew secton of chain on worn tecten of chan. ‘Worm chains wil ot engage te sprockets propery ‘and increased teamage tthe sprockel may occir 8. You may ruse the old chan the chain passed the checks for chan wear Otherwise instal a cew chan. Reforence: Refs tothe Power Tran Disassembly ‘and Assembly, “Drive Chain “Ina Refer tote folowing table forte is fr han ‘Weasureent of conan Pech | Hate cL | new Mossorement | MeMumEnt OF |” Csi Tension v 73 om i 287 wm 477 men einen, | _Gs%5he) | Goeonet, Sa 10 | sxsmm@asnen 384g 700%) ‘9 Tie gigs leroy er ts olbsene he sngeraw fie dn Tl Differential Lock Pressure - Check SMCS Code: 3272:595-°x Introduction ‘When testing and adjusting the transmission and powertrain, move the machine to an area clear of ‘obstructions, with safe exhaust veniaion forthe ‘exhausts, Sudden movementof the machine or te= lease ofoitundor preseure can cause injury fo er ‘Sons on or near the machine, To prevert posed ‘injury, dothe procedure that follows before testing and adjusting the ansmission and powertrain, nomice Care must be akon to ensure a fis ae contained during pexormanee ofinepecon, memtenance, test ing. adusing, and ropa of a machine. Ge prepared focotect the flid wah sistabie containers belore ‘pening any compartment or aisassemsing any com nent canting eds Dispose of aids according to local egulatons ond mrangates “The following procadwe ie used inorder to test the ‘operation ore aiferental os,304 ‘esting and Adjusting Section RENREAED.07 Required Tools Machine Preparation Reference: Before you perform this adjusiment fer {o Tesing ana Adjusing, “Mactine Preparation for Traublesnootng” 1. Operate the mectine until the namission of islt operaing temperature of 75 -C 10 90°C (67 Pio 194") 2, Stop the machine ena hard level surece, Engage the paring brake, Ghat of he engine YY ps, A & ee : So ination 30 Bea 3. Remove the dust cap. Atach Tooling (A) or Tooling (8) to test por (1. Test Procedure 4 Star the engine and run the engine at high id 2, Move te diferent lock switch othe ON poston 3. The gouge should reed 2480 £ 70 kPa (260° 10 pa) I tha proseure reading is too hgh or # he pressure raacng 1s too fo. the tvansmssion rte valve may need t be aust, Reference: Refer to Testing and Adjusting "Power Tain Charge Syston Prescur - Tect and ‘Agel for mare ifernation about seting the tronsrssion rele valve. 4. tf tne geting for the ransmission refit valve is ‘otrct and he presour reading is sl co rect ‘nepec he diferent nck va. ithe deren look vale appears toe worina propery the ‘Sterol tock cc ay need to be sence. ‘5, Shutoffhe engine. Remove ho teet equipment,RENRE482.07 Final Drive Bearing End Play - Check ‘SMCS Code: 4050.535.80 BIN Bett -p SN: B91-Up Introduction ‘The folowing procedure used in order to check the end play ofthe ta des, Required Tools Note: The threaded rods 58-18. The Wweaded rod 8266.7 mm (105 nes) ong Machine Preparation 4. Remove the tndems fom the machine Reference: Retort the Power Tein Disassembly ang Assembly, Housing (Tandem) -Remave and Insta forte proper procedure, 108 “esting and Adjusting Section (1 aoe (2 Teco ta (8 tos 2. Install the folowing took st Location (A) end ocaton (8) azcorang tition 85 + One adaptor (2) + One theeaded ro (2) + Two nts (3) + Two wathors (4)198 ‘Tesing and Adsing Section Test Procedure iis of he atin sow 4 Insta ial nist (6) according to istration 97 Zero ti da incest ite fhe mans sour, ities ne hey 2, Loosen both of tho lnige nuts sway from the Fausig, Tighten beth of tha outside nuts event ‘Tas aetien wil push the housing toward the ‘mci, Loasen bath of be nuts on the ouside (fhe pate evenly. Move the ouside nuts away from the outing. RENR54S2.07 atone woes hth etn shown (yadaper {2 tvcaes rs ru Bates ‘3, Tighton both of the insite rats evenly. This action {a oan ye Rousing sway rome re ia aceon both ofthe sion tuts evenly 4. The diandeater (6) should read 0.00 0.051 mm (01000 6 0.002 inch Reference: Reletto the Power Train Disassembiy land Assembiy, "Final Dives’ ithe reading n Step ‘isnot correct 65, Fhe reesing In Step 4s corect, cemnove all, tealng 6, Insal the tandems onthe machine. Reference: Refer to he Power Tisn Disassembly ‘ang Assembly, Housing (Tandem) - Remove and Insta for the proper preceduRENRE82.07 Index . Diferenal ans Borel ear. 1e Diferentl Lock Pressure Chk as reason 8 Actin Preparin, tou Renored Yo, {ot Test Proce, {ot Dive Chain- Check joa Insesucion ina Macros Prearsion ia Tet Process ia F Fl Tne rine Tansmssen Ch - Carat. £8 ‘Calaton Pcedre ‘at Inrodvten sens 2 acne Prato s Require Too, = fl Deve and Toa eve Ca Fal Dre Baatng ene Ply “Chaco Isvodvcten 168 Hosting Friis ios equ Teal. Jed Pees 6 ° Gear Purp (Trananision Chasing ond Scnvone| u Generalitati, a ‘Septic CoorCoses e 1 Important Sate nternaton rr Intoducten “aes ‘Diferanol snd evel Saar a Final Deve end Tondo Drv a ‘anemasion ‘ TTaramsson Cont Vive ‘ L L2eain of Components 5 Eeatal Gonpenents 3 Fyre Conger: 5 Ls Power Tran Componsnie t ™ MactioeProparaton or Trobe ass 8 107 : : Inder Section Moguting vv (rarsnsion Cs). 2 ‘General afermaton 2 ess Than Masimum Signal % Maximus Signa Fa ho Signa 2 ° OWE (Power Tan) i n Operational Checes " e Pasting Brake we 19 ‘Location of Components ard Furie 13 Parking Brako Operation, 6 Parking rake » Tou (Uso This Tot ioe Ail Gust ‘Versions of Transmission Cantol Sotwere) 89 Inteichon. on Maciine Preparation % Tost Procedure, 96 Parking Brake ~ Tesi (Use Tis Tel fo the S718 ower Tan Stirs Op and A Never Scnvar % Truce s oct Presi = Teabroctre & Powe i a Teno ts Pai ake jk Traubesootng te Powe tran % Deron che Stn resi lad Sat n ‘ajo Pred @ tntaceten con Maciel, a Rewured Toe an Tea oonare @ ows: Ts yas yas 6 “Tonemaeoh Ctch Enso x ‘rantmasen Libicaiet io R Rear he ogo 8 Rete! Valve (ransinissionlierale Contr. 28 s Symptom Procedures, 8 ‘Systems Operation Sesion eae 1 “Table of Contes - 2 Testing ond Agus oat“eating and Adjusting St ‘Transmenen (ubreaion ection ot 7 Olt Pressure —TeSk ns 94 f ‘nvoouston oe feed Tb Sree ool ‘eal Procadue 88 Wonehest a rwanamesin Bor Fi 2 Tih Speed Forward cn ee Fh Speed Ferwars a Eth Speed Reverse on Fst Speed Ferra 3 Fist Speed Reverse conn mns nsw 88 Fur Speed Formac cou Faurh Speed Revco. s enerl oration os Neat gets a Second Speed Fone : % Second Speed Revers 2 ‘Seven Spoed Foard Sah Specs Forward 2 Shin Speed Revotse o-oo ra “Tc Speed Fowrerd £0 “Thre Speee Reverea m8 ‘tonareton Pressure “Test ad Adj, 8 ‘rosicton % titoine Prepaain a8 Reqare Tos oe oe wel Process " C Ware! Ss ‘rvbleshotng Sion cas v Visval nspeton sete OF w ‘wheel Group a4 eaniocateaar Gat, Cate, crepe nos, “Calpr Velo” athe Panes ge PhiedInUS.A Siripisrcwes Watacieen. sel usr a rosie! ety tod ar, oe Weems ‘ot Carpio and my ot be used wins persion