Transmission Synchronizer Event Codes
E1289 Transmission Synchronizer #1 Not Responding to Command
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| Illustration 1 | g03695823 |
Machine Response:
The XMSN is unable to engage in FORWARD from NEUTRAL, but may engage to REVERSE from NEUTRAL. XMSN will not shift into HIGH REVERSE range.
Note: XMSN Synchronizer #1 is associated with XMSN ranges LOW FORWARD and HIGH REVERSE
Note: Troubleshoot all related electrical diagnostics prior to starting this troubleshooting procedure. Related diagnostics include: (CID 2832) XMSN Synchronizer #1 Solenoid #1. (CID 2833) XMSN Synchronizer #1 Solenoid #2. (CID 2816) XMSN Synchronizer Modulation Solenoid. (CID 2817) XMSN Synchronizer #1 Position Sensor.
- Confirm the XMSN Synchronizer #1 Position Sensor is properly seated in the XMSN case and the bolts are torqued to specification. Check the synchronizer modulation ON/OFF valves (XMSN Synchronizer #1 Valve #1 and XMSN Synchronizer #1 Valve #2 ) for any visible leaks.
- Check the coil resistance for XMSN Synchronizer #1 Solenoid #1 and XMSN Synchronizer #1 Solenoid #2. Resistance will vary with coil temperature. If the coil resistance is out of specification, replace the coil. Otherwise, continue to the next step.
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Table 1 461-6614 Coil (1) Temperature Resistance (Ohms) 20°C (68 °F) 21.0 ± 2.0 -40.0 °C (-40 °F) 10.7 ± 2.0 120 °C (248 °F) 46.5 ± 2.0 Show/hide table(1) If available, use the 462-9804 Coil replacement. - Check the coil resistance for XMSN Synchronizer Modulation Solenoid. Resistance will vary with coil temperature. If the coil resistance is out of specification, replace the coil. Otherwise, continue to the next step.
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Table 2 312-8629 Coil Temperature Resistance (Ohms) 25 °C (77 °F) 5.0 ± 1.0 -40.0 °C (-40 °F) 3.7 ± 1.0 100 °C (212 °F) 6.5 ± 1.0 - Prepare to run the ET Synchronizer Pressure service test procedure. Add current measurement for XMSN Synchronizer Modulation Solenoid. Add
3500 kPa (508 psi) gauges for charge pressure XMSN Synchronizer #1 Valve #1, and XMSN Synchronizer #1 Valve #2. Warm up the XMSN to 40 °C (104 °F) XMSN inlet oil temperature. Reference the XMSN control valve service literature for valve and pressure port locations. - Run the ET Synchronizer Pressure service test procedure. Record the measurements noted in the previous step along with information provided on the ET service test screen. Fill out the following table during the noted conditions (expected results are shown in the table).
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Table 3 XMSN Synchronizer Modulation Solenoid Current (A) XMSN Modulation Valve Pressure (kPa) XMSN Charge Pressure XMSN Synchronizer #1 Valve #1 Pressure (kPa) XMSN Synchronizer #1 Valve #2 Pressure (kPa) XMSN Synchronizer #1 Position (% Duty Cycle) Maximum pressure modulation valve.
ON/OFF valves OFF~ 1.9 A 2500 ± 200 kPa (363 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 0 kPa (~ 0 psi) ~ 0 kPa (~ 0 psi) 50 ± 5 Modulation pressure OFF.
ON/OFF valves ON~ 0.0 A ~ 0 kPa (~ 0 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 0 kPa (~ 0 psi) ~ 0 kPa (~ 0 psi) 50 ± 5 Modulation pressure 690 kPa (100) .
ON/OFF valves ON~ 0.7 A ~ 690 ± 200 kPa (100 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 690 ± 200 kPa (100 ± 29 psi) ~ 690 ± 200 kPa (100 ± 29 psi) 50 ± 5 Modulation pressure 1380 kPa (200) .
ON/OFF valves ON~ 1.1 A ~ 1380 ± 200 kPa (200 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 1380 ± 200 kPa (200 ± 29 psi) ~ 1380 ± 200 kPa (200 ± 29 psi) 50 ± 5 Modulation pressure 2070 kPa (300) .
ON/OFF valves ON~ 1.5 A ~ 2070 ± 200 kPa (300 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 2070 ± 200 kPa (300 ± 29 psi) ~ 2070 ± 200 kPa (300 ± 29 psi) 50 ± 5 Modulation pressure 2500 kPa (363) .
ON/OFF valves ON~ 1.9 A ~ 2500 ± 200 kPa (362 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 2500 ± 200 kPa (362 ± 29 psi) ~ 2500 ± 200 kPa (362 ± 29 psi) 50 ± 5 Result 1: The XMSN Synchronizer Modulation Solenoid current is incorrect. Troubleshoot the XMSN harness and ECM.
Result 2: The XMSN charge pressure is low during the test procedure. Troubleshoot the XMSN charge pump and hydraulic circuit.
Result 3: The XMSN Synchronizer Modulation valve pressure is incorrect. Replace the synchronizer modulation valve.
Result 4: The XMSN Synchronizer Modulation Valve pressure is correct, but the XMSN Synchronizer #1 Valve #1 pressure OR XMSN Synchronizer #1 Valve #2 pressure is incorrect. The pressure differential between the two ON/OFF solenoids will cause the XMSN Synchronizer #1 Position Sensor to deviate from the desired position.
Result 5: The XMSN charge pressure is low during the test procedure. Troubleshoot the XMSN charge pump and hydraulic circuit.
Result 6: Test completed successfully, continue to next step.
- Check the synchronizer #1 position sensor PWM duty cycle. Ensure that the duty cycle reading is 50% ± 40%. If outside this range, replace the synchronizer #1 position sensor.
- Check the synchronizer #1 position sensor frequency. Ensure that the frequency reading is 250 Hz ± 50 Hz. If outside this range, replace the synchronizer #1 position sensor.
- Check accumulator precharge pressure.
- Inspect the synchro actuation hardware (pistons & seals). Refer to D&A for procedure.
- Check transmission suction screen for debris.
Note: If not able to resolve, contact CAT product support and provide EDT and PSRT file from CatET.
E1290 Transmission Synchronizer #2 Not Responding to Command
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| Illustration 2 | g03695905 |
Machine Response:
The XMSN is unable to engage in REVERSE from NEUTRAL, but may engage to FOWARD from NEUTRAL. The XMSN will not shift into HIGH FORWARD
Note: The XMSN Synchronizer #2 is associated with XMSN ranges LOW REVERSE and HIGH FORWARD
Note: Troubleshoot all related electrical diagnostics prior to starting this troubleshooting procedure. Related diagnostics include: (CID 2834) XMSN Synchronizer #2 Solenoid #1. (CID 2835) XMSN Synchronizer #2 Solenoid #2. (CID 2816) XMSN Synchronizer Modulation Solenoid. (CID 2818) XMSN Synchronizer #2 Position Sensor.
- Confirm the XMSN Synchronizer #2 Position Sensor is properly seated in the XMSN case and the bolts are torqued to specification. Check the synchronizer modulation ON/OFF valves (XMSN Synchronizer #2 Valve #1 and XMSN Synchronizer #2 Valve #2) for any visible leaks.
- Check the coil resistance for the XMSN Synchronizer #2 Solenoid #1 and XMSN Synchronizer #2 Solenoid #2. Resistance will vary with coil temperature. If the coil resistance is out of specification, replace the coil. Otherwise, continue to the next step.
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Table 4 461-6614 Coil (1) Temperature Resistance (Ohms) 20°C (68 °F) 21.0 ± 2.0 -40.0 °C (-40 °F) 10.7 ± 2.0 120 °C (248 °F) 46.5 ± 2.0 Show/hide table(1) If available, use the 462-9804 Coil replacement. - Check the coil resistance for the XMSN Synchronizer Modulation Solenoid. Resistance will vary with coil temperature. If the coil resistance is out of specification, replace the coil. Otherwise, continue to the next step.
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Table 5 312-8629 Solenoid Temperature Resistance (Ohms) 25 °C (77 °F) 5.0 ± 1.0 -40.0 °C (-40 °F) 3.7 ± 1.0 100 °C (212 °F) 6.5 ± 1.0 - Prepare to run the ET Synchronizer Pressure service test procedure. Add current measurement for XMSN Synchronizer Modulation Solenoid. Add
3500 kPa (508 psi) gauges for charge pressure XMSN Synchronizer #2 Valve #1, and XMSN Synchronizer #2 Valve #2. Warm up the XMSN to 40 °C (104 °F) XMSN inlet oil temperature. Reference the XMSN control valve service literature for valve and pressure port locations. - Run the ET Synchronizer Pressure service test procedure. Record the measurements noted in the previous step along with information provide on the ET service test screen. Fill out the following table during the noted conditions (expected results are shown in the table).
Show/hide table
Table 6 XMSN Synchronizer Modulation Solenoid Current (A) XMSN Modulation Valve Pressure (kPa) XMSN Charge Pressure XMSN Synchronizer #2 Valve #1 Pressure (kPa) XMSN Synchronizer #2 Valve #2 Pressure (kPa) XMSN Synchronizer #2 Position (% Duty Cycle) Maximum pressure modulation valve.
ON/OFF valves OFF~ 1.9 A 2500 ± 200 kPa (363 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 0 kPa (~ 0 psi) ~ 0 kPa (~ 0 psi) 50 ± 5 Modulation pressure OFF.
ON/OFF valves ON~ 0.0 A ~ 0 kPa (~ 0 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 0 kPa (~ 0 psi) ~ 0 kPa (~ 0 psi) 50 ± 5 Modulation pressure 690 kPa (100) .
ON/OFF valves ON~ 0.7 A ~ 690 ± 200 kPa (100 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 690 ± 200 kPa (100 ± 29 psi) ~ 690 ± 200 kPa (100 ± 29 psi) 50 ± 5 Modulation pressure 1380 kPa (200) .
ON/OFF valves ON~ 1.1 A ~ 1380 ± 200 kPa (200 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 1380 ± 200 kPa (200 ± 29 psi) ~ 1380 ± 200 kPa (200 ± 29 psi) 50 ± 5 Modulation pressure 2070 kPa (300) .
ON/OFF valves ON~ 1.5 A ~ 2070 ± 200 kPa (300 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 2070 ± 200 kPa (300 ± 29 psi) ~ 2070 ± 200 kPa (300 ± 29 psi) 50 ± 5 Modulation pressure 2500 kPa (363) .
ON/OFF valves ON~ 1.9 A ~ 2500 ± 200 kPa (362 ± 29 psi) 2500 ± 200 kPa (363 ± 29 psi) ~ 2500 ± 200 kPa (362 ± 29 psi) ~ 2500 ± 200 kPa (362 ± 29 psi) 50 ± 5 Result 1: The XMSN Synchronizer Modulation Solenoid current is incorrect. Troubleshoot the XMSN harness and ECM.
Result 2: The XMSN charge pressure is low during the test procedure. Troubleshoot the XMSN charge pump and hydraulic circuit.
Result 3: The XMSN Synchronizer Modulation valve pressure is incorrect. Replace the synchronizer modulation valve.
Result 4: The XMSN Synchronizer Modulation Valve pressure is correct, but the XMSN Synchronizer #2 Valve #1 pressure OR the XMSN Synchronizer #2 valve #2 pressure is incorrect. The pressure differential between the two ON/OFF solenoids will cause the XMSN synchronizer #2 position sensor to deviate from the desired position.
Result 5: The XMSN charge pressure is low during the test procedure. Troubleshoot the XMSN charge pump and hydraulic circuit.
Result 6: Test completed successfully, continue to next step.
- Check the synchronizer #2 position sensor PWM duty cycle. Ensure that the duty cycle reading is 50% ± 40%. If outside this range, replace the synchronizer #2 position sensor.
- Check the synchronizer #2 position sensor frequency. Ensure that the frequency reading is 250 Hz ± 50 Hz. If outside this range, replace the synchronizer #2 position sensor.
- Check accumulator precharge pressure.
- Inspect the synchro actuation hardware (pistons & seals). Refer to D&A for procedure.
- Check transmission suction screen for debris.
Note: If not able to resolve, contact CAT product support and provide EDT and PSRT file from CatET.
E1291 Transmission Synchronizer #3 Not Responding to Command
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| Illustration 3 | g03695906 |
Machine Response:
The XMSN will not shift into AUXILIARY range or will not remain in AUXILIARY range.
Note: XMSN Synchronizer #3 is associated with XMSN AUXILIARY range.
Note: Troubleshoot all related electrical diagnostics prior to starting this troubleshooting procedure. Related diagnostics include: (CID 2836) XMSN Synchronizer #3 Solenoid #1. (CID 2819) XMSN Synchronizer #3 Position Sensor.
- Confirm the XMSN Synchronizer #3 Position Sensor is properly seated in the XMSN case and the bolts are torqued to specification. Check the Synchronizer #3 valve for any visible leaks.
- Check the coil resistance for the XMSN Synchronizer #3 Solenoid. Resistance will vary with coil temperature. If the coil resistance is out of specification, replace the coil.
Show/hide table
Table 7 312-8629 Coil Temperature Resistance (Ohms) 25 °C (77 °F) 5.0 ± 1.0 -40.0 °C (-40 °F) 3.7 ± 1.0 100 °C (212 °F) 6.5 ± 1.0 - Prepare to record ET data channels while requesting the machine to operate in the AUXILIARY range. Add current measurement for XMSN Synchronizer #3 Solenoid. Add
3500 kPa (508 psi) gauges for XMSN Synchronizer #3 valve pressure. Reference the XMSN control valve service literature for valve and pressure port locations. Record the ET synchronizer totals information prior to running the test. Warm up the XMSN to 60 °C (140 °F) XMSN inlet oil temperature. - Record ET data (XMSN Synchronizer #3 position, XMSN Synchronizer #3 Solenoid command, XMSN Output Speed, XMSN Input Speed, XMSN Solenoid #1, XMSN Solenoid #2, XMSN Hydrostatic Ratio) while requesting the machine to operate in the AUXILIARY range. Record the measurements noted in the previous step along with information captured in the ET recording. Fill out the following table during the noted conditions (expected results are shown in the table).
Note: If the test results & visual inspection yield results within specification, contact product support for further information.
Show/hide tableTable 8 XMSN Synchronizer #3 Modulation Solenoid Current (A) XMSN Synchronizer #3 Valve Pressure (kPa) XMSN Synchronizer #3 Position (% Duty Cycle) XMSN Synchronizer #3 not engaged. ~ 0.0 A ~ 0 kPa (~ 0 psi) 50 ± 5 XMSN Synchronizer #3 engaged or engaging ~ 1.2 A ~ 1550 ± 200 kPa (225 ± 29 psi) 71 ± 5 Result 1: If the XMSN will go into AUXILIARY range but will not remain in gear due to the synchronizer backing out of position (walk out totals incremented during the test run), check the XMSN Synchronizer #3 solenoid current and valve pressure while in AUXILIARY range are within specification. If the current is incorrect, troubleshoot the XMSN harness and ECM. If the valve pressure is incorrect, replace the Synchronizer #3 valve.
Result 2: If the XMSN will not complete the shift into AUXILIARY range, review the Synchronizer #3 position data during the shift event. If the position does not change toward the engaged specification, replace the Synchronizer #3 valve.
Result 3: Pull the XMSN suction screen. If considerable material is found, contact product support. Some metal shavings are expected with normal XMSN operation.
- Check the synchronizer #3 position sensor PWM duty cycle. Ensure that the duty cycle reading is 50% ± 40%. If outside this range, replace the synchronizer #3 position sensor.
- Check the synchronizer #3 position sensor frequency. Ensure that the frequency reading is 250 Hz ± 50 Hz. If outside this range, replace the synchronizer #3 position sensor.
- Check accumulator precharge pressure.
- Check transmission suction screen for debris.
Note: If not able to resolve, contact CAT product support and provide EDT and PSRT file from CatET.
E1292 Transmission System Failed to Synchronize
Machine Response:
XMSN unable to engage in either FORWARD or REVERSE from NEUTRAL.
Note: Troubleshoot all related electrical diagnostics prior to starting this troubleshooting procedure. Related diagnostics include: (CID 1761 XMSN Pump A Solenoid (CID 1762) XMSN Pump B Solenoid (CID 669) XMSN Input Speed Sensor (CID 2820) XMSN Planetary Speed Sensor
- Check the coil resistance for the XMSN Pump A Solenoid and XMSN Pump B Solenoid . Resistance will vary with coil temperature. If the coil resistance is out of specification, replace the coil. Otherwise, continue to the next step.
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Table 9 312-8629 Coil Temperature Resistance (Ohms) 25 °C (77 °F) 5.0 ± 1.0 -40.0 °C (-40 °F) 3.7 ± 1.0 100 °C (248 °F) 6.5 ± 1.0 - Prepare to run the ET Variator Actuation service test procedure. Add current measurement for XMSN Pump Solenoid #1 and XMSN Pump Solenoid #2. Add pressure gauges (3500 kPa (508 psi) range for charge pressure XMSN Pump Valve #1, and XMSN Pump Valve #2. Warm up the XMSN to 70 °C (158 °F) hydrostatic outlet oil temperature.
- Run the ET Variator Actuation service test procedure. Record the measurements noted in the previous step along with information provided on the ET service test screen. Fill out the following table during the noted conditions (expected results are shown in the table).
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Table 10 XMSN Pump Solenoid #1 Current (A) XMSN Pump Solenoid #2 Current (A) XMSN Charge Pressure (kPa) Pump Actuator Valve #1 Pressure (kPa) Pump Actuator Valve #2 Pressure (kPa) XMSN Hydrostatic Ratio XMSN Loop A Pressure (kPa) XMSN Loop B Pressure (kPa) Both pump actuator valves commanded OFF ~ 0 A ~ 0 A 2500 ± 200 kPa (363 ± 29 psi) ~ 0 kPa (~ 0 psi) ~ 0 kPa (~ 0 psi) ~ 0.0 2650 ± 200 kPa (384 ± 29 psi) 2650 ± 200 kPa (384 ± 29 psi) Pump Actuator A command sweep. Sweep to ~ 2A ~ 0 A 2500 ± 200 kPa (363 ± 29 psi) Sweep to 2400 ± 200 kPa (348 ± 29 psi) ~ 0 kPa (~ 0 psi) ~ -1.35 > 2650 ± 200 kPa (384 ± 29 psi) 2650 ± 200 kPa (384 ± 29 psi) Pump Actuator B command sweep. ~ 0 A Sweep to ~ 2A 2500 ± 200 kPa (363 ± 29 psi) ~ 0 kPa (~ 0 psi) Sweep to 2400 ± 200 kPa (348 ± 29 psi) ~ 1.35 2650 ± 200 kPa (384 ± 29 psi) > 2650 ± 200 kPa (384 ± 29 psi) Pump Actuator A and B command sweep. Sweep to ~ 2A Sweep to ~ 2A 2500 ± 200 kPa (363 ± 29 psi) Sweep to 2400 ± 200 kPa (348 ± 29 psi) Sweep to 2400 ± 200 kPa (348 ± 29 psi) ~ 0.0 2650 ± 200 kPa (384 ± 29 psi) 2650 ± 200 kPa (384 ± 29 psi) Result 1: The XMSN Pump Actuator Solenoid current is incorrect. Troubleshoot the XMSN harness and ECM.
Result 2: The XMSN charge pressure is low during the test procedure. Check the variator make-up tube seals. Troubleshoot the XMSN charge pump and hydraulic circuit.
Result 3: The XMSN Pump Actuator Valve pressure is incorrect. If unable to build actuator pressure in one direction, swap the pump actuator valves to see if the low actuator pressure problem follows the valve. If it does follow the valve, replace the valve for the corresponding low actuator pressure. If the issue does not follow the valve when swapped, remove the valve manifold and inspect the actuator tube seals.
Result 4: The XMSN pump actuator valve pressure is correct, but the loop pressure is low or the hydrostatic ratio remains near zero. Remove the XMSN cover plate to confirm that the loop pressure sensors, the hydrostatic outlet oil temperature sensor, and the flushing spool caps are torqued to specification.
Note: If the above doesn’t resolve the issue, please check the following items:
- Transmission accumulator precharge pressure
- Transmission suction screen
Note: If unable to resolve, contact CAT product support and provide EDT and PSRT file from CatET