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2006/04/01 Systems Operation (SENR9167-02)

SMCS - SENR91670001

Introduction
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Transmission Electronic Control System

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The transmission Electronic Control Module (ECM) shifts the machine transmission based on transmission output speed (TOS), Transmission
control lever position and transmission modulation (inching pedal) pressure switch position.

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The transmission ECM processes information from the input components. Depending on the speed and direction requested, the ECM then directs

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theignal 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 cab. It processes the input information which then directs the proper electrical signals to the appropriate output
devices for speeds, directions, and diagnostics.

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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

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.

Electronic Control Module (ECM)

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Electronic Control Module (ECM

(1) Connector J1. (2) Connector J2.
The ECM makes decisions based on input and memory information, then the corresponding response is made through the outputs. The inputs and
outputs of the ECM are joined to the machine harness by two 40 contact connectors.

Inputs
Numerous inputs inform the ECM of the status of the machine conditions. Two types of inputs exist; switch type and sensor type. Switches provide
an open, grounded, or +battery signal to the switch inputs of the ECM. Sensors provide a constantly changing signal to the sensor inputs of the
ECM. The inputs are listed on the Contact Description Chart.

Outputs
The ECM responds to decisions by sending electrical signals through the various outputs. The outputs either create an action or provide
information. The outputs are listed on the Contact Description Chart.

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
* Transmission Modulator Supply Pressure Status
* Dual Horsepower Status
* System Diagnostic Codes

* Abusive Conditions
* Coasting In Neutral
* In Park With Machine Moving

Transmission ECM Connector Pin Assignments

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Transmission Gear Solenoids

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Transmission Diagnostic Code Conversion

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Electrical Inputs
Battery Voltage
This is a two wire input which provides 24 DCV nominal to drive the electronic circuits within the ECM and all of the external solenoids.

Start Switch Input

This is a single wire input that provides a battery voltage signal when the key start switch is in the Start position.

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
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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.

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 J2-28 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 J2-40 On ECM)

The transmission ECM is connected to Pin 9 (Neutral) at the EMS control. Pin 9 has a function called Program Code 1 and is used to control the
category of Alert Indicator 7 which is the Parking Brake indicator. Depending on the condition, the Parking Brake can be either a Category I or a
Category III.

Service Tool Connector

This is a 2 wire digital data communication link that allows two way communication of the ECAP, ET or service tool with the transmission ECM.

Transmission Indicator Lamp

This is used in conjunction with the diagnostic connector to visually flash light code sequences when diagnosing transmission electrical system
faults.

Buffered Transmission Output Speed (TOS)

This is the output from the transmission output speed sender after it goes through the ECM to the speedometer.

Modes Of Operation
Power-up
Upon power-up, Solenoids D and G are energized and all other solenoids are de-energized. Normal operation is established once the shift lever
has been moved to the Neutral or Park position.

Start
The transmission Neutral Start Module (NSM) has a neutral start feature. The operator controlled key switch is an input to the NSM with the start
relay being powered by an output from the NSM. This allows the NSM to inhibit starting the machine if certain conditions are not met. The shift
lever must be in Neutral or Park before the NSM 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.

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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
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.

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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).

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

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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.

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.

PIP-10853253
2023/01/28
02:08:50-03:00
SENR91670001
© 2023 Caterpillar Inc.
Caterpillar:
Confidential Green

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