140H 2ZK DAWI Trans. Troubleshooting

140H NA Motor Grader 2ZK00001-UP (MACHINE) POWERED BY 330...
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Product: MOTOR GRADER

Model: 140H NA MOTOR GRADER 2ZK
Configuration: 140H NA Motor Grader 2ZK00001-UP (MACHINE) POWERED BY 3306 Engine
Troubleshooting
120H, 12H, 135H, 140H, 143H, 160H and 163H Motor Graders Power Train
Media Number -SENR8503-03 Publication Date -01/12/2005 Date Updated -15/12/2005
i02643819
Power Train
SMCS - 3030-035
Troubleshooting
Performance Check
Problem
The motor grader will not start or stop, and the transmission will not shift into any gear
from the NEUTRAL position.
Note: When you troubleshoot electrical problems or electronic problems, use the most
recent electrical schematic for your machine.
Note: Shift quickly from the NEUTRAL position to the desired gear. Always return the
transmission to the NEUTRAL position between gear selections.
1. Attempt to operate the machine in all gears forward and reverse. Shift the machine
from the NEUTRAL position to the FIRST GEAR FORWARD position. Note the
response of the machine and shift the machine back to the NEUTRAL position.
2. Shift the transmission from the NEUTRAL position to the SECOND GEAR
FORWARD position. Note the response of the machine. Shift the machine back to the
NEUTRAL position. Proceed in the same manner until all gears have been checked.
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140H NA Motor Grader 2ZK00001-UP (MACHINE) POWERED BY 330... Page 2 of 10
3. Check the 10 amp transmission control fuse that is located in the fuse panel at the base
of the steering console. If necessary, replace the fuse. Otherwise, proceed to Step 4.
Illustration 1 g00279578
Transmission Electronic Control Module (ECM)
(1) Connector "J1"
(2) Connector "J2"
4. The Electronic Control Module (ECM) is located under the operator seat. While the
engine is running disconnect connector "J1" (1) . Contacts 1, 6 and 40 are common to
each other and the contacts are used to provide system voltage to the ECM. Contacts 2
and 5 are common to each other and the contacts are used for machine ground.
Measure the voltage between the power contacts 1, 6 and 40 to ground in order to
check for power to the ECM.
5. If the voltage that is measured in Step 4 is 18 Volts DC to 32 Volts DC, the ECM
voltage is acceptable for proper operation of the ECM. If the voltage that is measured
is less than 18 Volts DC, there is a problem with the charging system. Refer to Special
Instruction, "Charging System Troubleshooting" for information on troubleshooting
the charging system. If no voltage was measured in Step 4, proceed to Step 6.
6. Check the fuse for the Transmission ECM. If the fuse is good, check the 126-PK wires
in the machine harness for an open circuit, or for a poor connection. If a problem is
found, repair the harness or replace the harness.
Problem
The motor grader has lost a single gear.
1. Start the engine. Operate the machine in order to determine the inoperable gear.
2. Stop the machine. Engage the parking brake and turn the key start switch to the OFF
position.
3. Check the pressure of the suspect clutch. Refer to Testing and Adjusting,
"Transmission Pressures" for the correct pressure and for the testing procedure. If the
clutch pressure is equal to or greater than the minimum clutch pressure that is given,
inspect the suspect clutch. If the clutch pressure is less than the minimum pressure,
proceed to Step 4.
4. Disconnect connectors"J1" (1) and connector"J2" (2) from the Electronic Control
Module (ECM). Measure the resistance between the contact that is associated with the
clutch solenoid of the suspect gear and one of the following contacts:contact 7 of "J1"
and contact 3 of "J2"
Note: Refer to the following example. The clutch for the FIRST GEAR FORWARD
position does not engage. The clutch for the FIRST GEAR REVERSE position
engages. Measure the resistance from contact 10 of "J1" (1) to either of the following
contacts:contact 7 of "J1" and contact 3 of "J2"
5. If the resistance that is measured in Step 4 was in the range of 20 to 50 ohms, the
solenoid valve is functioning properly. This solenoid valve is controlling the pressure
to the suspect clutch. Proceed to Step 6.
6. If the resistance that is measured in Step 4 is less than 20 ohms, the wiring harness that
connects to the solenoid has a short circuit or the solenoid has a short circuit. If the
resistance that is measured in Step 4 is greater than 50 ohms, the wiring harness has an
open circuit or the solenoid has an open circuit.
7. If the solenoid valve that controls the suspect clutch appears to function but the clutch
pressure is below the minimum pressure, check the supply pressure at high idle with
the transmission in the inoperable gear. Refer to Testing and Adjusting, "Transmission
Pressures".
8. If the supply pressure is 3240 kPa (470 psi), inspect the solenoid valve. If the supply
pressure is below 3240 kPa (470 psi), inspect the rotating shaft seals and the piston
seals. The rotating seals can be checked without removing the transmission. Checking
the piston seals will require removing the transmission.
Problem
Loss of a single gear selection in both the forward gear and the reverse gear
1. Start the engine. Operate the machine in order to locate the inoperative gear.
2. Stop the machine. Engage the parking brake and turn the engine start switch to the
OFF position.
3. Disconnect connector"J1" (1) . Check the wiring harness that is located between the
ECM and the transmission direction and speed control. The transmission direction and
speed control should be in the position of the lost gear. Use contact 2 or contact 5 of
connector "J1" (1) to check the continuity. Measure the continuity between contact 2
and the contact for the gear that is not working.
4. Check the continuity between contact 29 of connector "J1" (1) and contact 2 of
connector "J1" (1) if FIRST GEAR FORWARD and REVERSE are inoperative. If the
continuity exists, proceed to Step 5.
5. Step 4 tested a portion of the machine harness and a portion of the transmission
direction and speed control. The test determined that the transmission direction and
speed control is inoperable. Shift the transmission direction and speed control into a
forward gear. Check the continuity between contact 37 and 2 of connector "J1" (1) . If
continuity exists, the ECM is not functioning. If continuity does not exist, the
transmission direction and speed control is not functioning.
6. Either the machine harness has failed or the transmission direction and speed control
has failed in Step 4. Remove the 24 contact connector from the transmission direction
and speed control. Measure the continuity at the contact point on the transmission
direction and speed control between using contact 2 of connector "J1" (1) and the
contact that is associated with the inoperative gear.
7. Check the continuity between contact 3 of the 24 contact connector and contact 2 of
connector "J1" (1) if FIRST GEAR FORWARD is not operable. If continuity exists,
the transmission direction and speed control is functioning and the machine harness
has failed. If continuity does not exist, the transmission direction and speed control has
failed and the machine harness is functioning.
Problem
Slippage of the transmission under load
1. Start the engine. Operate the machine in order to determine the gear that is slipping.
2. Stop the machine and engage the parking brake. Turn the engine start switch to the
OFF position.
3. Check the transmission oil level. If the oil level is too high or too low, adjust the oil to
the proper level.
4. If the transmission continues to slip, check the transmission supply pressure. Refer to
Testing and Adjusting, "Transmission Pressures". If the supply pressure is at least
3240 kPa (470 psi) in the PARK position and at high idle, proceed to Step 5. If the
supply pressure is low, proceed to Step 8.
5. The direction clutches are clutch 1, clutch 2 and clutch 3. Direction clutch 1 is
controlled by solenoid (B) . Direction clutch 2 is controlled by solenoid (C) . Direction
clutch 3 is controlled by solenoid (A) . Measure the directional clutch pressure that is
associated with the slipping gear. Refer to the Testing and Adjusting, "Transmission
Pressures".
6. For example, if the first gear forward is slipping, clutch 1 (solenoid (B) ) is the
associated direction clutch. Install the pressure port. Start the engine and operate the
engine at high idle. Operate the machine in the slipping gear.
7. Depress the transmission modulator pedal and stop the machine. Slowly release the
transmission modulator pedal. If the direction clutch pressure reaches a minimum
pressure of 2080 kPa (302 psi), inspect the direction clutch. If the directional clutch
pressure does not reach a minimum of 2085 kPa (302 psi), adjust the linkage for the
clutch pedal.
8. From Step 4, the transmission control valve is suspect. Inspect the main relief valve for
damage. If necessary, repair the main relief valve. If the main relief valve is
functioning correctly, proceed to Step 9.
9. From Step 6, excessive slippage indicates leakage from the rotating seals or the clutch
pistons. If necessary, inspect or repair these items.
Problem
The Motor grader creeps when the transmission modulator pedal is fully depressed.
1. Start the engine. Operate the engine in order to determine the gears that allow the
machine to inch when the transmission modulator pedal is fully depressed.
2. Stop the machine and engage the parking brake. Turn the engine start switch to the
OFF position.
3. Check the adjustment of inching pedal linkage. Refer toTesting and Adjusting, "Clutch
Pedal - Adjusting" for the correct adjustment procedure.
4. While the transmission modulator pedal is depressed, measure the direction clutch that
is associated with the gear that causes the problem. Refer to Testing and Adjusting,
"Transmission Pressures".
Illustration 2 g00925967
5. The direction clutches are clutch 1, clutch 2 and clutch 3. Direction clutch 1 is
controlled by solenoid (B) . Direction clutch 2 is controlled by solenoid (C) . Direction
clutch 3 is controlled by solenoid (A) .
6. For example, if first speed forward is inching, clutch 1 (solenoid (B) ) is the associated
direction clutch. Install the pressure gauge in the associated pressure port. Start the
engine. Operate the engine at high idle and in the suspect gear.
7. Depress the transmission modulator pedal and stop the machine. If the directional
clutch pressure exceeds 30 kPa (4 psi), repeat Step 3. If the directional clutch pressure
is less than 30 kPa (4 psi), inspect the transmission for warped clutch plates.
Problem
First gear out of neutral is the only working gear.
1. Start the engine. Determine the gears that are working.
2. Stop the machine. Engage the parking brake. Turn the engine start switch to the OFF
position.
3. Use a jumper wire in order to bypass the pressure switch for manual modulation. The
pressure switch for manual modulation is the same switch as the pressure switch for
the inching pedal. This will determine if the pressure switch is working. The pressure
switch for manual modulation is located on the transmission control valve.
4. Disconnect the 2 contact connector at the pressure switch. This connector will be
located close to the pressure switch. Place a jumper wire between contact 1 and
contact 2 of the receptacle on the machine wiring harness. Proceed to Step 5.
5. Start the machine and attempt to operate the machine in all gears. If the machine has
more than one gear out of neutral then the pressure switch has failed. If first gear out
of neutral is the only available gear , proceed to Step 6.
6. The wiring harness between the manual modulation pressure switch (inching pressure
switch) and the transmission Electronic Control Module (ECM) is suspect. Disconnect
connector "J1" (1) and connector "J2" (2) at the ECM. Check the continuity between
contact 11 of "J2" connector (2) and contact 2 of connector "J1" (1) .
7. The Electronic Control Module has failed if continuity is obtained with the jumper
wire in place. The wiring harness between the Electronic Control Module and the
pressure switch has failed if continuity is not obtained.
Problem
The Transmission Output Speed TOS signal is incorrect.
position.
2. The transmission output speed sensor (TOS) is located at the rear of the transmission.
Locate the 2 contact connector at the sensor. Disconnect the TOS sensor from the
machine wiring harness. Use a voltmeter in order to measure the voltage between
contacts. Connect the voltmeter to contact 4 (202-BK) and connect the voltmeter to
contact 1 (710-GN) of the machine wiring harness.
3. Operate the machine in FIRST gear at HIGH idle. If the measured voltage at high idle
is less than 10 volts AC, replace the TOS sensor. If the measured voltage is greater
than 10 volts AC, the TOS sensor is functioning.
4. Remove the Electronic Control Module that is located under the operator seat. Then,
disconnect connector "J1" (1) . Replace the TOS sensor with a jumper wire. Measure
continuity between contacts 2 and 9 at connector "J1" (1) . If continuity is obtained the
transmission is not functioning. If continuity is not obtained, proceed to step 5.
5. The wiring harness between the ECM and the TOS sensor is suspect. Connect
connector "J1" (1) at the ECM and move back the TOS sensor. Remove the jumper
wire from the receptacle and measure the voltage between contact 2 710-GN and the
frame. If any voltage (AC) exists, then repair wire 202-BK in the wiring harness. If
voltage does not exist, repair wire 710-GN on the wiring harness.
Problem
The parking brake does not function properly.
1. Start the engine. Operate the machine in order to determine if the parking brake is
functioning.
position.
3. The parking brake solenoid valve is located under the right side of the cab.
4. Start the engine. Use a screwdriver and lightly touch the end of the parking brake
solenoid valve in order to determine the presence of a electromagnetic force. If the
screwdriver is drawn to the solenoid, the solenoid is functioning.
5. To further test the solenoid, turn the engine key start switch from STOP to RUN and
back to STOP. The parking brake solenoid valve will click when the position of the
key has changed. If the solenoid is functioning proceed to Step 6. If the solenoid is not
functioning, proceed to Step 10.
6. Check the mechanical parking brake valve in the transmission direction and speed
control for proper adjustment. Start the engine. Allow the brake pressure to increase to
the normal operating pressure of at least 800 kPa (115 psi). Depress the service brake.
Shift the transmission direction and the speed lever to the NEUTRAL position. Engage
the parking brake. When the parking brake is engaged, the operator should briefly hear
air that is venting.
7. When the transmission direction and speed control is placed in the PARKING BRAKE
position and the parking brake vents, the mechanical parking brake valve is properly
adjusted. Proceed to Step 8, if the parking brake does not vent. Adjust the mechanical
parking brake valve.
8. Stop the engine. Place blocks in front of the wheels and behind the wheels. Install a
1000 kPa (145 psi) pressure gauge in the parking brake.
9. Start the engine. Depress the service brake pedal. Move the transmission direction and
speed control from the PARKING BRAKE position to the NEUTRAL position and
back to the PARKING BRAKE position. When the transmission direction and speed
control is not in the PARK position, the brake pressure should be 800 to 930 kPa (115
to 135 psi). If the brake pressure is 0 kPa (0 psi), inspect the brakes. Brake pressure
should be relieved to 0 kPa (0 psi) when the transmission direction and speed control
is in the PARK position. Inspect the air lines if the brake pressure does not go to 0 kPa
(0 psi).
10. From Step 5, the parking brake valve is suspect. When the engine key start switch is in
the RUN position and the engine is OFF, the parking brake solenoid will be energized.
11. Disconnect the 2 contact connector at the parking brake solenoid. Measure the voltage
across contact 1 (126-PK) and contact 2 (200-BK) at the machine harness. If battery
voltage is measured at this point the solenoid has failed. If no voltage or reduced
voltage is measured at this point proceed to Step 12.
12. Measure the voltage at the parking brake solenoid valve between contact 1 (126-PK)
and the frame. If the battery voltage is present, repair wire 200-BK. If the battery
voltage is not present repair wire 126-PK.
Problem
The backup alarm does not sound.
1. Stop the engine. Engage the parking brake. Turn the engine key start switch to the
OFF position. Disconnect connector "J1" (1) and the "J2" connector (2) from the
ECM. On the machine harness, check for continuity between contact 2 of connector
"J1" (1) and contact 37 of the connector "J2" (2) . If continuity exists, the wiring to the
backup alarm and the alarm is operational. Proceed to Step 2.
2. Check the continuity between contact 2 of connector "J1" (1) and contact 31 of
connector "J1" (1) with the transmission in a REVERSE GEAR position. If continuity
exists, the transmission ECM has failed. If continuity does not exist, connect the "J1"
and "J2" connectors to the correct position at the transmission ECM and proceed to
Step 3.
3. Disconnect the 24 contact connector at the transmission direction and speed control.
With the transmission direction and speed control in the REVERSE position, check the
continuity between contact 2 and contact 12 of the 24 contact connector. If continuity
is obtained, repair the wiring harness between the controller and the transmission
direction and speed control. If continuity is not obtained, replace the transmission
direction and speed control.
4. In Step 2, the wiring harness between the transmission ECM and the backup alarm is
suspect. Disconnect the 6 contact connector from the back alarm. This connector will
be located at the left rear of the machine. While the transmission direction and speed
control is in the REVERSE position, measure the voltage between contact 5 (321-BR)
and contact 6 (200-BK) of the machine harness connector. If system voltage is present,
the backup alarm has failed. If voltage is not present, the harness has failed. Proceed to
Step 5.
5. While the transmission direction and speed control is in the REVERSE position,
measure the voltage between contact 5 (321-BR) and the frame. If the 24 VDC exists,
repair the 200-BK. If voltage does not exist, repair wire 321-BR.
Problem
The power train oil filler tube assembly is cracking at the base.
The power train oil filler tube assembly is used as a grab handle. The tube failure is most
common on machines with the snow wing attachment. A bracket can be added in order to
support the tube assembly.
1. Inspect the power train filler tube at the base for cracks or leaks.
2. If there are cracks or leaks, the tube will need to be replaced.
3. The broken tube will need to be removed.
4. The new filler tube will need to be installed.
Refer to Service Magazine19 April 2004, "A New Support Bracket for the Filler Tube
for the Power Train Oil Is Now Available" in order to install the bracket assembly.
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140H NA Motor Grader 2ZK00001-UP (MACHINE) POWERED BY 330...

Product: MOTOR GRADER

Transmission Electronic Control Module (ECM)

(1) Connector "J1"

(2) Connector "J2"

The motor grader has lost a single gear.

Slippage of the transmission under load

First gear out of neutral is the only working gear.

1. Start the engine. Determine the gears that are working.

The Transmission Output Speed TOS signal is incorrect.

The parking brake does not function properly.

The backup alarm does not sound.

2. If there are cracks or leaks, the tube will need to be replaced.

3. The broken tube will need to be removed.

4. The new filler tube will need to be installed.

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