FAULT CODE 4204 - System detects different gear than commanded

FAULT CODE 4204 - System detects different gear than commanded

Repair

4204 - System detects different gear than commanded

Context: : Trax Control detects a different gear than commanded.

Cause:

The gear indicated by the shift rail position sensors is not consistent with the gear the Trax control is commanding.

Possible failure modes:

1. Faulty wiring or connectors

2. Faulty gear switch

3. Faulty Trax control

4. Mechanical problem inside transmission

Solution: :

1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes. Prior to clearing fault codes, record all fault codes, number of occurrences, and engine
hours at last occurrence.

(1) Use the Electronic Service Tool to clear all fault codes.

(2) To check for fault code: Start and operate machine.

A. OK – Fault is not recorded again. Return the machine to service.

B. NOT OK – Fault code is recorded again. Go to Step 2.
2. Verify that the wiring and connectors are free of damage.

TRAX Controller X-300 connector Description Wire ID

6 S2 Solenoid 3043 WH 20GA
7 S3 Solenoid 3593 WH 20GA
9 S1 Solenoid 3013 WH 20GA
15 5 Volt Supply 3151 PK 20GA
17 Signal Ground 0401 BL 20GA
38 S4 Solenoid 3023 WH 20GA
45 Gear Switch 3/4 signal 3451 YE 20GA
54 Gear Switch 1/2 signal 3541 YE 20GA

Schematic legend
 (1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 Solenoid
(5) 27k ohm resistor (12) S4 Solenoid
(6) 62k ohm resistor (13) SP-G11, Cab Ground Side Console on Loader Control
(7) 12k ohm resistor

(1) Inspect Trax connector X-300 and the Gear switch connections. All connections should be secure, tight, free of corrosion, abrasion and/or damage.

(2) Inspect the harness from the Trax Control to the Gear switches. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment.

A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return to Step 1 to confirm elimination of fault.
3. Monitor EST

(1) Connect EST.

(2) Turn the key switch ON, engine OFF. place the transmission into neutral.

(3) Monitor the S-type parameters related to the gear position switches and controls.

A. OK – All parameters are displayed correctly on the EST. Go to Step 4.

B. NOT OK – A fault code is generated, go to the proper troubleshooting procedure. Go to step 1 or the corresponding troubleshooting procedure.

4. (1) Turn the engine on while monitoring the EST. Place the transmission in 1st gear. Monitor the EST screen and diagnostic codes.
 (2) Place the transmission in 2nd gear. Monitor the EST screen and diagnostic codes.

(3) Place the transmission in 3rd gear. Monitor the EST screen and diagnostic codes.

(4) Place the transmission in 4th gear. Monitor the EST screen and diagnostic codes.

A. OK – All parameters are within specs. There is a mechanical problem in the transmission. Go to Step 8.
B. NOT OK – There is a problem in the gear switch circuit. Replace the faulty gear switch. Go to Step 5.
5. Measure the resistance through the gear switch.

(1) Turn the key switch OFF.

(2) Disconnect S1 solenoid connector 361. Measure the resistance through the switch. The resistance should be less than 10 ohms.

(3) Disconnect S2 solenoid connector 360. Measure the resistance through the switch. The resistance should be less than 10 ohms.

(4) Disconnect S3 solenoid connector 362. Measure the resistance through the switch. The resistance should be less than 10 ohms.

(5) Disconnect S4 solenoid connector 363. Measure the resistance through the switch. The resistance should be less than 10 ohms.

A. OK – All resistance measurements were greater than 20,000 ohms. Go to Step 6.

B. NOT OK – One or more resistance measurements are less than 10 ohms. Replace the faulty gear switch. Return to Step 1 to confirm elimination of fault.
6. Measure the resistance through the harness and resistor network

(1) Turn the key switch OFF.

(2) Disconnect X-344/345.

(3) Disconnect Gear Switch connector 361.

(4) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 34.9k Ω ± 10%.

(5) Reconnect connector 361 and disconnect Gear Switch connector 360.

(6) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 12.0k Ω ± 10%.

(7) Reconnect connector 360 and disconnect Gear Switch connector 362.

(8) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k Ω ± 10%.

(9) Reconnect connector 362 and disconnect Gear Switch connector 363.

(10) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k Ω ± 10%.
Resistance measured with the sub harness disconnected from the vehicle harness
Gear Sw 1 Gear Sw 2 Gear Sw 3 Gear Sw 4 Pins B8/A8 Pins B1/A8 Pins B8/C8
Neutral Closed Closed Closed Closed 10.1k Ω 10.1k Ω 17.7k Ω
1ST Gear Open Closed Closed Closed 34.9k Ω 11.0k Ω 21.9k Ω
2ND Gear Closed Open Closed Closed 12.0k Ω 12.0k Ω 51.0k Ω
3RD Gear Closed Closed Open Closed 11.0k Ω 34.9k Ω 21.9k Ω
4TH Gear Closed Closed Closed Open 12.0k Ω 12.0k Ω 27.1k Ω

A. OK – The resistance values were within the limits defined in the table. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm elimination of the
fault.
B. NOT OK – The resistance values were not limits defined in the table. Temporarily replace the harness and retest. Go to Step 1 to confirm elimination of fault.
7. Verify harness after repairs.
 (1) Reconnect all loose connectors.

(2) Turn the key switch ON

(3) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 54 to chassis ground. Refer to the table below for the prober gear switch positions and
voltage measurements.

(4) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 45 to chassis ground. Refer to the table below for the prober gear switch positions and
voltage measurements.
Voltage measured at Trax Control connector X-300
Gear Sw 1 Gear Sw 2 Gear Sw 3 Gear Sw 4 Voltage measured on pin 54 Voltage measured on pin 45
Neutral Closed Closed Closed Closed 3V 3V
1ST Gear Open Closed Closed Closed 1V 3V
2ND Gear Closed Open Closed Closed 4V 3V
3RD Gear Closed Closed Open Closed 3V 1V
4TH Gear Closed Closed Closed Open 3V 4V

8. Measure shift rail position

(1) Turn the key switch OFF.

(2) Remove the first and second shift rail plug (2) and the third and fourth shift rail plug (1) from the rear of the transmission.

(3) Measure the depth of the end of the rail (1) in relation to the edge of the transmission housing.
 Measurement Diagnosis
18 mm (0.709 in) Rail is in 1st or 3rd gear position.
29 mm (1.142 in) Neutral rail position
40 mm (1.575 in) Rail is in 2nd or 3rd gear position.

A. OK – The measurements are correct and all resistance values are correct. Temporarily Replace the Trax Control and retest. Go to Step 1 to confirm elimination of
fault.
B. NOT OK – The rail is out of position. Perform a pressure test to determine which rail is out of position.