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TOOL OPERATING MANUAL 9U-7500 Transmission Analyzer II
SMCS Code 0783
NEHS0644-07 August 2003
The 9U-7500 Transmission Analyzer II shifts electronically-controlled Caterpillar transmissions. These include the Powershift planetary, the Powershift countershaft, the ICM (Individual Clutch Modulation), the Challenger Tractor, the H-Series Motor Grader, and the ECPC (Electronic Clutch Pressure Control) transmissions. The analyzer controls these transmissions by replacing the vehicle harness and the electronic transmission controls that are on board the vehicle. This allows the technician to check Caterpillar transmissions on the hydraulic test bench, independent of the vehicle.
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 2 Machine Model List . . . . . . . . . . . . . . . . . . 3 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9U-7500 Transmission Analyzer Group. . . . 3 Optional Parts . . . . . . . . . . . . . . . . . . . . . . 4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 4 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . 5 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Adjust Screen Contrast . . . . . . . . . . . . . . . 6 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operating on 240 Volts AC. . . . . . . . . . . . 6 Power Requirements for Challenger Transmissions . . . . . . . . . . . . . . . . . . . . . 6 Operating Instructions . . . . . . . . . . . . . . . . 6 Checking Analyzer for Proper Operation . . 7 Updating the Program . . . . . . . . . . . . . . . . . 9 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electronically Actuated Pumps. . . . . . . . . . . 9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Connecting Analyzer Test Cables to Transmission Solenoids . . . . . . . . . . . . . . 10 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . 10 Shift Lever Test . . . . . . . . . . . . . . . . . . . . 12 Transmission Shift Test . . . . . . . . . . . . . . . 13 Using Transmission Analyzer with ICM Transmissions . . . . . . . . . . . . . . . . . . . . . . 14 Setup Instructions . . . . . . . . . . . . . . . . . . 14
The following features are contained in the Transmission Analyzer II: • Easy to read menus, on a lighted LCD display, step the operator through the sequence of operating the Transmission Analyzer II. It performs three different transmission system functions; checks solenoid condition, shifts the transmission, and checks shift lever operation. • Analyzer is controlled by an Intel microprocessor with Flash memory, so the analyzer can be easily updated to new types of transmissions. • Connects directly to the solenoids of an electronically shifted Caterpillar transmission. • Outputs PWM (Pulse Width Modulated) current to the initialized solenoids, as required by Challenger and Electronic Clutch Pressure Control transmissions.
Introduction
• Capable of turning on solenoids in a timeline sequence, as required for the H-Series Motor Grader. It is also capable of modulating current to one, or all, of the initialized solenoids at any point in time. • Performs automatic or manual testing for shorted, and open solenoid coils, on all or any one of the transmission solenoids. The analyzer will also alert you to an intermittent problem with the solenoid coil. • Checks the shift lever to make sure it is functioning properly, on a transmission that is not controlled by the Autoshift electronic transmission control feature.
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Machine Model List
Parts
List of current machines that the 9U-7500 Transmission Analyzer II will support. Future machines will be added through the NETG5021, Annual Subscription, as they become available.
9U-7500 Transmission Analyzer Group
Chart A. Applicable Models Machine Families Articulated Trucks
Model Numbers Version 2003A D250E, D250E II, D300E, D300E II, D350E, D350E II, D400E, D400E II, 725, 730, 735, 740
Backhoe Loaders
416, 426, 428, 436, 438, 446, 446B-001, 446B-2500
Challenger Tractors
35, 45, 55
Compactors
815F, 816F, 825G, 826G, 836G
Dozers
D5M, D6M, D6R, D7R, D8R, D10R, D11N, D11R
H - Series Motor Graders and Reduced Emmisions Motor Graders
12H, 14H, 24H, 120H, 135H, 140H, 143H, 160H, 163H
Integrated Tool Carriers
IT12, IT12B, IT12F, IT14, IT14B, IT14F, IT18F, IT24F, IT24G, IT28F, IT28G, IT38F, IT38G, IT62G
9U-7500 Transmission Analyzer Group. Refer to Chart B for item identifications and description.
Chart B. Contents of 9U-7500 Transmission Analyzer Group
8 SPD, 7 SPD with Lockup, 4/8 SPD with Sync, 6/7 SPD Scrapers
(621E), (621F), (623E), (623F), (627B), (627E), (627F), (631E), (631F), (633E), (633F), (637D), (637E), (637F), (639D), (639F), (651E), (657B), (657E)
Off-Highway Trucks
(768C), (769C), (776), (776B), (777), (777B), (777D), (785), (789), (793), (772B), (773B), 725, 730
Wheel Loaders
910, 910E, 910F, 918F, 924F, 924G, 928F, 928G, 936, 936F, 938F, 938G, 950F, 950F2, 950G, 960F, 962G, 966F, 966G, 970F, 972G, 980F, 980G, 988F, 988G, 990, 992D, 992G, 994D, 994G
Wheel Skidders
515, 520D, 522D, 525, 525B, 545
Wheel Tractors
814F, 824G, 834G, 836G, 844, 854
Items in ( ) are not called out specifically in software, but are covered by higher level categories.
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Item
Part No
1
1U-7499
Transmission Analyzer II
Description
2
9U-7496
Test Cable Two-pin Deutsch connectors connect directly to solenoids of Caterpillar transmissions with Deutsch connectors. Cable is 152 cm (60 in) long.
3
1U-9486
DC Power Cable Used to connect Transmission Analyzer II to an external DC power supply or battery. DC power must be used when testing Challenger 35, 45, and 55 transmissions. It can also be used when AC power is not available. Refer to "Powering Transmission Analyzer II", for more information.
4
9U-7497
Test Cable Two-pin Sureseal connectors connect directly to solenoids of Caterpillar transmissions with Sureseal connectors. This cable is 152 cm (60 in) long.
5
1U-9485
AC Power Cable Connects conventional utility power to the Transmission Analyzer II. The unit automatically operates on both 120 or 240 Volt 50/60 Hz systems. The 1U-9485 AC Power Cable is configured for 120 Volt AC at 50/60 Hz. Refer to "Powering Transmission Analyzer II", for 240 VAC operation.
Optional Parts
Chart C. Optional Items for 9U-7500 Transmission Analyzer Group (cont.)
1
Item
Part No
7
9U-7495
Test Cable [152 cm (60.0 in) long] Connects standard bulkhead connector on most Wheel Loader Transmissions to the Transmission Analyzer II.
Description
—
9U-74981
Extension Cable [6 m (20 ft) long] Used between Transmission Analyzer II and appropriate test cable.
—
4C-59741
Adapter may be needed for some transmissions.
—
232-10651
Sureseal to Deutsch Adapter for some newer ICM Transmissions.
—
241-48791
3-pin Deutsch to 2-pin Deutsch Adapter needed for some transmissions.
N/S = Not Shown.
Specifications Optional parts used with the 9U-7500 Transmission Analyzer Group.
Chart D. Specifications Description
Chart C. Optional Items for 9U-7500 Transmission Analyzer Group Item
Part No
1 4
1U-9479 1U-9480
2
3
1U-9484
6V-9412
Size Group
Description Tester
Adapter Cables [155 mm (6.0 in) long] Used to change the connectors of 9U-7496 and 9U-7497 Test Cables from pins to sockets. Cables are used mainly when testing the shift lever from the transmission solenoid connections. These cables may also be required when 9U-7496 and the 9U-7497 Test Cables are connected to certain transmissions.
Weight Group Tester DC Power
AC Power
Programming Cable Standard 9 pin serial communications cable, connects the Transmission Analyzer II and a computer. It is also required for upgrading the program in the Transmission Analyzer II.
Memory
Switch Test Adapter Cable Used for connecting the Transmission Analyzer II to the connector on the shift console of machines with ICM (Individual Clutch Modulation) transmissions. Used with the 120-9288 for transmissions with Hall Effect transmission switches.
5
1U-9483
Test Cable [152 cm (60.0 in) long] Used for testing the Challenger 35, 45, and 55 transmissions.
6
1U-9482
Test Cable Used for testing the ICM (Individual Clutch Modulation) transmissions. Connects the Transmission Analyzer II to the gear position switch, Upshift, Downshift, and Lockup solenoids of the ICM transmission.
394 x 311.2 x 171.5 mm (15.5 x 12.25 x 6.75 in) 394 x 311.2 x 171.5 mm (15.5 x 12.25 x 6.75 in) 6 kg (13.8 lbs) 4 kg (8.9 lbs) 11 - 40 VDC (minimum of 20 Amps for Challenger 35, 45, and 55; minimum of 10 Amps for all other units 110 - 240 VAC 128 Kilobyte CMOS Flash Memory
Microprocessor
Intel 80C51FA
LCD Display Size
43 x 124 mm (1.7 x 4.9 in) four line x 20 character display
Temperature range of ambient air during analyzer operation
-18 to 60°C (0 to 140°F)
Temperature range of ambient air during analyzer storage
-40 to 60°C (-40 to 140° F)
Overcurrent Protection
Protected with a current limiting electronic circuit and is protected against a short circuit fault by a 30 amp quick trip circuit breaker.
Flash Program Requirements Software Computer Operating System Cable Required RAM Required Computer Interface Baud Rate
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Specification
Literature No. NETG5021 DOS 5.0 or higher 9-pin to 9-pin serial cable or 9-pin to 25-pin serial cable 1Meg Serial RS-232C 1200 or 9600
Nomenclature
REV—Selects reverse direction after gear number is selected.
Front Panel
ENTER—Enters the selected command. CLEAR—Erases a selected command or clears a fault that occurs during solenoid testing. Cursor—These arrow keys move the cursor on the LCD screen to select the preferred menu object. MAIN MENU—Selects a list of machine families to choose from. MACH INFO—Selects the last machine worked on and lists descriptive data for that transmission. SHIFT LEVER TEST—Tests shift levers on non-Autoshift transmissions. XMSN TEST—In Transmission Test mode, shifts the transmission to any gear. SOL TEST—In Solenoid Test mode, checks the condition of the solenoids or turns individual solenoids on one at a time.
9U-7500 Transmission Analyzer. (1) Keypad. (2) PROG PORT. (3) TEST CABLE port. (4) DC power connection. (5) DC power switch. (6) AC power connection. (7) AC power switch. (8) Display.
NUMERIC KEYS—Enter the numbers asked for by the Transmission Analyzer II program, and enter the gear numbers when shifting. 2. PROG PORT Plug serial communication cable into connector to program Flash memory. 3. TEST CABLE Transmission test cable is plugged into this connector. 4. DC POWER External DC power cable installs in this connector when using battery power or some other external DC power source. 5. DC Power Switch Turns DC power ON and OFF and protects against DC power overloads. 6. AC POWER External AC power cable is to be plugged into this connector when using utility power to power analyzer.
Enlarged view of keypad (1).
7. AC POWER SWITCH Turns AC power ON and OFF and protects against AC power overloads.
1. Keypad FWD—Selects forward direction after gear number is selected.
8. DISPLAY Four line / 20 Character LCD display.
N—Press this key to go to Neutral from any gear. 5
Operation
Operating Instructions
Adjusting Screen Contrast
With the engine turned OFF, the Transmission Analyzer II can be used in the Solenoid Test or Shift Lever Test modes with the transmission mounted on or off the machine.
To adjust the contrast of the LCD display: 1. Press the up and down arrow keys at the same time. 2. This screen will appear:
To use the Transmission Analyzer II in the Transmission Test mode, which shifts the transmission, the transmission must be mounted on a Hydraulic Test Stand. DO NOT SHIFT THE TRANSMISSION WHILE THE TRANSMISSION IS STILL IN THE MACHINE.
!!CONTRAST ADJUST!! USE "UP" OR "DOWN" ARROW KEY TO ADJUST "ENTER" TO CONTINUE 3. Adjust the contrast to the desired level. 4. Press the "ENTER" key, to return to normal operation.
To test ICM (Individual Clutch Modulation) style transmissions, refer to "Using the Analyzer with ICM Transmissions" section.
Power
1. Turn Transmission Analyzer II ON using the AC Power switch on the front panel. If using external DC power, turn the analyzer ON by turning ON the DC Power switch on the front panel.
Operating on 240 Volts AC The 9U-7500 Transmission Analyzer II can be powered from either 110 or 240 VAC 50/60 Hz. It comes from the factory with a line cord which has a U.S. 120 VAC, 60 Hz plug. To power it with 240 Volt AC, remove (cut-off) the 120 Volt AC plug and install a new 240 Volt AC plug.
a. This first screen appears momentarily. CATERPILLAR SERVICE TECHNOLOGY TRANSMISSION ANALYZER
Power Requirements for Challenger Transmissions The Challenger 35, 45, and 55 Tractors need more power to operate their solenoids than other Caterpillar transmissions. To use the 9U-7500 Transmission Analyzer II on these transmissions, a larger power source must be supplied to the Analyzer.
b. This second screen then appears momentarily. It shows the Serial Number, Version Number, and Version Date.
Two different DC power sources are available for the transmission analyzer. First, a 12 Volt battery and the DC power connection with the DC power cable supplied with the unit can be used. Second, a DC power supply with filtered output that is capable of supplying 12 VDC at 20 Amps, can be used. This is a large power supply and can be quite expensive to purchase. Do not use a battery charger of any type to power the transmission analyzer.
COPYRIGHT 1994, 1995 VERSION 2.08-04-95 SERIAL# TA2-00000000
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b. From this screen any of the following tests can be selected.
c. The third screen to appear is the "Main Menu" screen.
SOLENOID TEST AUTOMATIC MANUAL etc.
♦ ARTICULATED TRUCKS
BACKHOE LOADERS CHALLENGER TRACTOR ↓ COMPACTORS
GEAR SELECTOR TEST TRANSMISSION SHIFT TEST
2. Move cursor, using arrow keys on keyboard, to select machine family, and press "ENTER".
Checking Analyzer for Proper Operation
a. The up and down arrows on the screen, show that there are more machines available by pressing the up and down arrow keys.
The Transmission Shift Analyzer II has the capability of testing its own operation. This can be done by entering the unit's self-diagnostic test mode. To enter the self-diagnostic mode, use the following procedure.
b. TOOL CARRIERS have been selected in this example. ↑ DOZERS
1. Make sure the "MACH INFO" screen is active.
MOTOR GRADERS ♦ TOOL CARRIERS ↓ SCRAPERS/TRUCKS
2. Press and hold down the "REV" and "FWD" keys at the same time. 3. This diagnostics menu will appear:
3. Move cursor, using arrow keys on keyboard, to select machine number, and press "ENTER". The IT12 INTEGRATED TOOL CARRIER was selected in this example. ♦ IT12--24V
IT12F-24V IT14F-24V IT24B-24V
1. 2. 3. 4.
IT12B-24V IT14B-24V IT18F-24V IT28F-24V
4. Press a number key to select the appropriate test. 5. If the "LOGIC TEST" is selected, the analyzer will perform a diagnostic test to check the RAM, EEPROM, Analog - Digital Converter, and Flash Memory.
4. This screen should now appear. It is called the "Machine Information" screen. IT12TOOL CARRIER 3F - 3R
LOGIC TEST DISPLAY TEST TEST 24V SUPPLY INPUT/OUTPUT TEST
6. If an error occurs during this test, one of the following error messages will be displayed. RAM Fault EEPROM Fault ADC Fault Flash Mem Fault
24-VOLT
(SELECT A TEST KEY)
7. If one of the errors is displayed, the unit should be returned to Caterpillar Service Technology for repair.
a. Verify that the information on this screen is for the transmission selected for the test.
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10. If the "INPUT/OUTPUT TEST" is selected this screen will appear
8. If the "DISPLAY TEST" is selected, these choices will appear on the display. 1. 2. 3. 4.
SCROLL SCREEN TEST CONTRAST TEST BACKLIGHT EXIT DISPLAY TEST
1. TEST CURRENTS 2. TEST I/O 3. EXIT TEST
a. The "TEST CURRENTS" selection performs a test on the input pins of the "TEST CABLE" connector, testing a current level that is produced by the analyzer.
a. The "SCROLL SCREEN" moves characters across the screen for a few seconds. If the characters do not appear correctly, return analyzer to Caterpillar Service Technology for repair.
To perform this test, all test cables must be removed. If there is no error, the analyzer will return to the test screen when the test is complete. If the current is outside the specified limits, the test will stop and an error will be displayed on the screen.
b. The "TEST CONTRAST" will adjust the contrast of the display up and down six times. If the contrast does not appear to be functional, return analyzer to Caterpillar Service Technology for repair. c. The "TEST BACKLIGHT" will blink the backlight ON and OFF to check the backlight operation. If the backlight does not appear to be functioning, return analyzer to Caterpillar Service Technology for repair.
To continue the test, press the "CLEAR" key. If an error occurs, return transmission analyzer to Caterpillar Service Technology for repair. b. The "TEST I/O" selection will test the voltage levels of each pin of the "TEST CABLE" connector.
d. The "EXIT DISPLAY TEST" will exit the"DISPLAY TEST" mode. 9. If the "TEST 24V SUPPLY" is selected, the analyzer will check the supply voltage to make sure the 24 Volt internal power supply is operating correctly. The display will show the voltage reading. If the reading is too high or too low, an error message will appear. If an error occurs, return the analyzer to Caterpillar Service Technology for repair.
To perform this test, all test cables must be removed. The test will verify that the outputs to the pins are going high and low when they are commanded to do so. It will also check that no outputs are shorted together or to ground. c. The "EXIT TEST" will exit the "INPUT/OUTPUT TEST" mode. 11. If all the tests are acceptable (no errors) return to the DIAGNOSTICS MENU and press CLEAR to return to normal operation.
8
Updating the Program
Service
1. To keep the Transmission Analyzer II up-todate with the latest transmissions, there is a NETG5021 Software Subscription available from Caterpillar.
If the 9U-7500 Transmission Analyzer II does not operate properly, perform the "Checking Analyzer for Proper Operation" test in this manual. If the analyzer is faulty, it can be sent to Caterpillar Service Technology Group’s Tool Repair. Tools that are less than one year old will be repaired under warranty (except for abuse). The cost of out-of-warranty repair will be charged to the owner.
2. After receiving the NETG5021 Software from Caterpillar (3 1/2 inch floppy disk), initialize your computer. Put the floppy disk in your computer’s disk drive. 3. Connect a 1U-9484 Serial Communications Cable between the computer’s RS-232C serial port and the PROG PORT on the unit. 4. Operate your computer in DOS Mode, or open a command prompt window.
When returning units to Caterpillar’s Tool Repair Service, be sure to enclose a letter that describes the problem and give the date of purchase. If the tool is out of warranty, include a Purchase Order Number with the shipment.
5. To run the Flash program, type: "flash.bat" at the DOS A:\ prompt.
Send the tool to one of the CSTG addresses and mark it, "Attn: Tool Repair".
6. Follow the step-by-step instructions in the Flash program.
Electronically Actuated Pumps
7. After completing the Flash program instructions, turn the Transmission Analyzer II OFF.
The 9U-7500 Transmission Analyzer II now has the capability to test electronically actuated pumps installed on the hydraulic test bench. The analyzer controls these pumps by energizing the actuating solenoids inside the pump. CSTG has developed test procedures for these pumps using the Transmission Analyzer II. These test procedures have been added to NEHT5000 Bench Testing Hydraulic Components. Caterpillar Service Authoring is continuing to develop new test procedures and is releasing them on Cat Service Information System (SIS). If you have already obtained a copy of Bench Testing Hydraulic Components that does not have the test procedure for electronically actuated pumps; check SIS for special instructions on the pump.
8. Disconnect the programming cable. 9. Turn the Transmission Analyzer II ON. 10. Check the program version listed on the startup screen. If the new version number appears on the startup screen, the unit is ready to use the updated program.
9
Testing
Solenoid Test
Connecting Analyzer Test Cables to Transmission Solenoids
1. From the selected machine information screen, select "SOLENOID TEST", by pressing the "SOL TEST" key. This screen will appear. CONNECT SOLENOID TEST CABLE “ENTER” TO CONTINUE “CLEAR” TO EXIT
2. Connect the cable called for on the transmission analyzer display (refer to previous section). Push "ENTER".
1. AUTOMATIC TEST 2. MANUAL TEST 3. TURN ON ONE SOL. Connecting an analyzer test cable.
NOTE: When testing Challenger Tractors, there are more than three choices available on this screen. These choices allow you to perform certain functions, such as initializing two solenoids at the same time. They are on the Challenger menu to allow the necessary adjustments to be made to the transmission.
To connect an analyzer test cable to the transmission solenoids, use the following steps. 1. Disconnect the vehicle harness connectors from the solenoids of the transmission. 2. Select the test cable which has the same connector type as the vehicle harness connectors that have been disconnected.
3. Press the number "2" key. This screen will appear.
NOTE: Match the letter and/or number of the test cable to the letter/number of the solenoid that is being tested. This letter/number is molded into the solenoid valve body.
MANUAL SOLENOID TEST ENTER SOLENOID NUMBER TO TEST
3. Insert the 2-pin test cable connector into the solenoid connector. 4. Connect the 31-pin connector of the test cable into the analyzer or the 9U-7498 Extension Cable.
4. Select solenoid number "1" by pressing the number "1" key. This screen will appear. MANUAL SOLENOID TEST SOLENOID # 1 “ENTER” TO CONTINUE
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8. When finished with the "AUTO SOLENOID TEST", return to the "SOLENOID TEST MENU" screen by pressing the "SOL TEST" key. This screen will appear.
5. Push "ENTER" and this screen will appear. MANUAL SOLNOID TEST TESTING # 1 RESISTANCE **.* OHMS “(COIL CONDITION)”
1. AUTOMATIC TEST 2. MANUAL TEST 3. TURN ON ONE SOL.
These are the possible coil conditions: COIL OPEN COIL SHORTED SOLENOID O.K. RTN SHORTED TO GND COIL SHORTED TO GND INVALID SOLENOID # OHMS OUT OF RANGE
9. If the number "3" key is pressed, this screen will be displayed. The analyzer will prompt the operator to enter a solenoid number. It will then turn ON the selected solenoid. In this mode the analyzer only turns ON the solenoid and does not display a message stating a fault, if one should occur.
6. To test solenoids automatically, press the "SOL TEST" key to return to this screen:
TURN ON ONE SOL.
1. AUTOMATIC TEST 2. MANUAL TEST 3. TURN ON ONE SOL.
ENTER SOLENOID # PRESS “ENTER”
10. When finished with the "SOLENOID TEST SCREEN", return to the machine information screen by pressing the "MACH INFO" key. This screen will appear.
7. If the number "1" key is pressed, this screen will be displayed. The analyzer will cycle through the solenoids and it will continue to cycle until it finds a fault. At that time the analyzer will stop on the solenoid showing the fault and display the problem. This is a good method for finding intermittent faults.
IT12 3F-3R
TOOL CARRIER 24-VOLT
(SELECT A TEST KEY)
AUTO SOLENOID TEST TESTING # 1 RESISTANCE **.* OHMS “(COIL CONDITION)”
11. Stop here by turning OFF the Transmission Analyzer II or go to another test procedure.
Refer to Step 5 for the different coil conditions.
11
4. With no gear shift lever connected to the analyzer, the display will show "GEAR SELECTOR PROBLEM".
Shift Lever Test The transmission analyzer can be used to test switch assemblies and switch harnesses. However, the shift lever for models with the Autoshift Transmission control feature cannot be tested with the Transmission Analyzer II. These models have diagnostic features on the machine which check the shift lever functions.
GEAR SHIFT TEST “GEAR SELECTOR” “PROBLEM”
1. From the selected "MACHINE INFORMATION" screen select "SHIFT LEVER TEST", by pressing the "SHIFT LEVER TEST" key. This screen will appear.
5. When finished with the gear selector test, return to the main information screen by pressing the "MACH INFO" key. This screen will appear.
CONNECT SHIFT LEVER TEST CABLE “ENTER” TO CONTINUE “CLEAR” TO EXIT
IT12 3F-3R
TOOL CARRIER 24-VOLT
(SELECT A TEST KEY) 2. Select the cable adapters that are best suited for the transmission being tested. Connect the test cables to the machine harness connected to the solenoids. Push the "ENTER" key.
6. Stop here by turning OFF the Transmission Analyzer II or go to another test procedure.
GEAR SHIFT TEST “GEAR SELECTOR” “NEUTRAL”
3. Move transmission gear selector lever in machine cab to desired gear (for example, 3F). This screen will appear. GEAR SHIFT TEST “GEAR SELECTOR” “3F”
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When the selected gear is entered, that gear number and direction will appear where the "NEUTRAL" appears in the display above. If a gear that is not valid for the selected machine is entered, a message stating "!!INVALID GEAR!!" will appear on the screen. This message will also be displayed if an "R", "N", or "F" is entered when not needed.
Transmission Shift Test 1. From the selected machine menu, select the "TRANSMISSION TEST SCREEN", by pressing the "TRANS TEST" key. This screen will appear. CONNECT XMSN TEST CABLE “ENTER” TO CONTINUE “CLEAR” TO EXIT
3. Continue to shift between different gears, stop testing, or go to a "Shift Lever Test". a. To stop testing, or to go to a "Shift Lever Test", first leave the "TRANSMISSION TEST" mode by pressing the "MACH INFO" key.
2. Connect the cable called for on the transmission analyzer display (refer to the "Connecting Analyzer Test Cables to Transmission Solenoids" section to connect cables from analyzer to transmission solenoids). Push "ENTER".
b. If the transmission has not been shifted into "NEUTRAL", the analyzer will continue with the screen telling the operator to shift into "NEUTRAL". This screen will appear as follows.
TRANSMISSION TEST “NEUTRAL”
SHIFTING TO NEUTRAL! WAIT FOR OUTPUTS TO STOP BEFORE EXITING. “ENTER” TO EXIT
ENTER GEAR:
This screen shows that the Transmission Analyzer II is outputting a signal placing the transmission in "NEUTRAL". Enter the gear number and direction (for example, 1R, 1F, 2F, etc.) at the "ENTER GEAR" prompt; then press the "ENTER" key.
4. Wait for transmission to stop and hit the "ENTER" key. This screen will appear. IT12 3F-3R
Exceptions: For ICM transmissions, Scrapers/Trucks and Articulated Trucks, there is no need to put in the number for direction unless there is more than one reverse gear or neutral.
TOOL CARRIER 24-VOLT
(SELECT A TEST KEY)
5. Stop here by turning the Transmission Analyzer II OFF, or go to another test procedure.
Example: R, N, 1, 2, 3, etc. for 1 reverse and 1 neutral. Example: 2R, 1R, N, 1, 2, 3, etc. for 2 reverses and 1 neutral. Example: R, 2N, 1N, 1, 2, 3, etc. for 1 reverse and 2 neutrals. NOTE: Always be aware of how many neutrals and reverses are in the transmission being tested. Shifting errors will occur if the wrong transmission is selected. 13
For Off-Highway Trucks Only, Follow Steps 6 through 15.
Using Transmission Analyzer with ICM (Individual Clutch Modulation) Transmissions
6. Move the machine to a smooth, level location away from working machines and personnel. Put the transmission shift lever in the NEUTRAL position. 7. Activate the parking brake. Raise the body (bed) and install the body retaining pins. Stop the engine. DO NOT move the hoist lever to the LOWER, FLOAT, or RAISE position while the engine is in operation.
Use of the Transmission Analyzer II can result in sudden movement of the machine, which can cause injury to persons on or near the machine. To prevent possible injury, use the procedure that follows before installing the Transmission Analyzer II.
8. Remove both drive axles. 9. Permit only one operator on the machine. Keep all other personnel away from the machine and/or in view of the operator.
Setup Instructions
Steps 10 through 15 Are for Wheel Tractor Scrapers and Off-Highway Trucks.
For Wheel Tractor Scrapers Only, Follow Steps 1 through 5 and Then Steps 10 through 15.
10. Install the 9U-7500 Transmission Shift Analyzer II cables between the Analyzer and the transmission.
1. Move the machine to a smooth, level location away from working machines and personnel. Put the transmission shift lever in the Neutral position. Stop the tractor and scraper engine(s).
11. Turn the engine ON and run at low idle speed only. 12. Operate the engine until oil is at normal operating temperature. Cold oil may give incorrect results.
2. Activate the parking brake. Lower the bowl to the ground. Lower the apron to the ground. 3. Move the cushion-hitch (and bail) control lever to LOCK DOWN/BAIL DOWN position. Make sure the bail (if equipped) is down. Make sure that the rear bracket assembly of the hitch is down and against (resting on) the front hitch assembly.
Do not go above 1st speed, as machine damage may result.
4. Remove both axles from the tractor or scraper, whichever one is being tested.
13. Perform a NEUTRAL to 1st shift with the transmission analyzer.
5. Permit only one operator on the machine. Keep all other personnel away from the machine and/or in the view of the operator.
14. Check the rotary switch assembly position by going to the "Shift Lever Test" and verifying that the switch is in 1st gear. For the 4/8 SPD, the LOCKUP solenoid should be turned ON.
NOTICE
15. Go back to the Transmission Test screen and perform a 1st to Reverse shift.
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16. Check the rotary switch assembly position by going to the "Shift Lever Test" and verifying the switch is in Reverse gear. For the 4/8 SPD, the LOCKUP solenoid should be turned ON. NOTE: If the transmission takes too much time making its shifts, the Transmission Shift Analyzer II will display a message saying, it is "SHIFTING SLOW". If it takes too long to shift between gears, return the transmission to NEUTRAL and turn the engine OFF. 17. Use the Transmission Shift Analyzer II to return to NEUTRAL. 18. Failure of the transmission to pass this test sequence indicates mechanical or hydraulic problems within the transmission, or an intermittent electrical problem.
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For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax)
[email protected] (E-mail) or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (79) 217 27 45 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)
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