D7R Series 2 Track-Type Tractor Power Train Caterpillar

Symptoms

Before you follow any procedure, read Troubleshooting, "Troubleshooting Procedures" in this module.

• "The Transmission Does Not Operate in Any Gear"

• "Harsh Shifting of Transmission"

• "The Transmission Does Not Change Gears but the Machine Moves"

• "The Machine Makes an Abrupt Stop When You Shift into The NEUTRAL Position"

• "The Transmission Operates in FORWARD Gears Only"

• "The Transmission Operates in REVERSE Gears Only"

• "The Transmission Does Not Operate in FIRST GEAR FORWARD or in REVERSE"

• "The Transmission Does Not Operate in SECOND GEAR in FORWARD or in REVERSE"

• "The Transmission Does Not Operate in THIRD GEAR FORWARD or in REVERSE"

• ""Transmission Slip Detected""

Transmission Controls

ReferenceRefer to theTesting and Adjusting , KENR5124, "Pressure Charts" section for more information.

Table 1

Transmission Clutch Engagement
Gear		Engaged Clutches
FIRST GEAR FORWARD		No. 2 and No. 5
SECOND GEAR	FORWARD	No. 2 and No. 4
THIRD GEAR FORWARD		No. 2 and No. 3
NEUTRAL		No. 3 (1)
FIRST GEAR	REVERSE	No. 1 and No. 5
SECOND GEAR	REVERSE	No. 1 and No. 4
THIRD GEAR	REVERSE	No. 1 and No. 3

( 1 )

The number 3 clutch may not be engaged in neutral if the neutral default strategy is active in the transmission ECM. Refer to Systems Operation, "Transmission" in this manual for more information about the neutral default strategy.

The Transmission Does Not Operate in Any Gear

1. Operate the machine.

   The two primary causes of this symptom are the transmission and the brakes. This step guides the diagnosis of the problem to the brakes or to the transmission.

   1. Start the engine. Operate the engine at high idle.

   2. Attempt to operate the machine. Shift the transmission into third speed forward. Observe the engine speed during shifts.

      Expected Results

      • The engine speed decreases. The engine is near stall condition during shifts.

      Results

      • NEAR STALL: Proceed to Step 2.

      • NO SIGNIFICANT DECREASE: The engine speed does not decrease significantly. Therefore, check the transmission first. Proceed to Step 3.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

2. Check the brake pressure.

   ReferenceRefer to Testing and Adjusting, "Brake Pressure - Test" in this module.

   1. Expected Results
      • The pressure is correct.

      Results

      • OKAY: The brake pressure is correct but the original problem is not resolved. Therefore, the transmission is the probable cause of the problem. Proceed to Step 5.

      • NOT OKAY: Proceed to Step 4.

3. Check for transmission drag.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Place pressure gauges on all transmission clutches.

      Refer to "Transmission Controls" in this topic. Table 1 shows the clutches that are used for the corresponding gears.

   2. Start the engine. Make sure that the parking brake is disengaged. Shift through all of the transmission gears.

   3. Check that the proper clutches engage for each gear.

   4. Check that the clutches disengage properly for each gear.

      Expected Results

      • The pressure for a clutch that is disengaged is less than 138 kPa (20 psi).

      Results

      • OKAY: Proceed to Step 6.

      • NOT OKAY: Proceed to Step 7.

4. Follow the procedure in this reference.

   Refer to "The Machine Does Not Move or the Machine Moves Slowly" in this module under Troubleshooting, "Machine Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: Proceed to Step 8.

5. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: Proceed to Step 8.

6. Eliminate other possible causes.

   The condition can be caused by several other components. Eliminate the following components as possible causes of the problem.

   1. Torque divider (converter)

   2. Transfer or bevel gears

   3. Final drives

   4. Drive shaft

   5. Axle shafts

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: The cause of the problem is unknown. Use the information from the original problem to troubleshoot.

7. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

8. Inspect the transmission.

   1. Disassemble the transmission. Inspect the transmission for damage.

      ReferenceRefer to Disassembly and Assembly, "Transmission" in the Service Manual for your machine.

   2. Replace components or repair components that are not functioning correctly, if necessary.

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

Harsh Shifting of Transmission

Follow this procedure if harsh shifts occur. Harsh shifting can occur when the transmission shifts into certain gears or when the transmission shifts from certain gears.

1. Operate the machine.

   1. Operate the machine. Determine the shift or shifts that are harsh shifts.

   2. Determine the clutches that are used. Refer to Table 1 in "Transmission Controls" in this topic. The table shows the clutches that are used for the corresponding gears.

      Expected Results

      • One clutch is common for all harsh shifts.

      Results

      • YES: Proceed to Step 5.

      • NO: Proceed to Step 2.

2. Check the system pressure.

   ReferenceRefer to Testing and Adjusting, "Main Relief Valve - Adjust" in this module.

   1. Expected Results
      • The system pressure is correct.

      Results

      • OKAY: Proceed to Step 5.

      • NOT OKAY: The cause of the problem may be the adjustment of the main relief valve. The main relief valve maintains the system pressure in the control section of the power train oil pump. Proceed to Step 3.

3. Adjust the main relief valve.

   ReferenceRefer to Testing and Adjusting, "Main Relief Valve - Adjust" in this module.

   Expected Results

   • The pressure setting of the main relief valve is correct.

   Results

   • REPAIRED, OKAY: Proceed to Step 5.

   • NOT OKAY: Proceed to Step 4.

4. Follow the procedure in this reference.

   Refer to "System Pressure Is Low" in this module under Troubleshooting, "Oil Pressure Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: Proceed to Step 5.

5. Check the accumulator charge pressure.

   1. Adjust the accumulator charge pressure.

      ReferenceRefer to Testing and Adjusting, "Accumulator - Test" for more information about the test and adjust of the accumulator charge pressure.

   2. Check the operation of the machine for the original problem.

      Results

      • REPAIRED OKAY: Stop.

      • NOT OKAY: Proceed to Step 6.

6. Calibrate the transmission modulating valves.

   1. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   2. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Proceed to Step 7.

7. Replace the transmission modulating valve.

   1. Replace the modulating valve, or valves, for the shifts that are harsh.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Disassemble the transmission and inspect the transmission for failure. Repair the components and/or replace the components, if necessary. Check the operation of the machine for the original problem.

      ReferenceRefer to Disassembly and Assembly, "Transmission" in the Service Manual for your machine.

The Machine Makes an Abrupt Stop When You Shift into the NEUTRAL Position

The machine functions correctly when the transmission is in gear. However, the machine stops when the transmission is placed in the NEUTRAL position.

1. Check for the symptom.

   1. Determine that the symptom is active.

   2. Follow this procedure only if the symptom is active.

      Results

      • ACTIVE: Proceed to Step 2.

      • NOT ACTIVE: The symptom is intermittent. Follow this procedure when the problem is active. Stop.

2. Check the brake pedal.

   1. Inspect the brake pedal. Determine if the pedal is returning to the original position.

   2. Repair the components or replace the components, if necessary.

      ReferenceRefer to Operation and Maintenance Manual, "Machine Adjustments" in the Service Manual for your machine.

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Proceed to Step 3.

3. Check the brake pressure.

   ReferenceRefer to Testing and Adjusting, "Brake Pressure - Test" in this module.

   Follow this procedure in order to check the hydraulic pressure at the brake control valve.

   1. Start the engine. Operate the engine at low idle.

   2. Select the NEUTRAL position of the transmission.

   3. Disengage the parking brake.

   4. Check the hydraulic pressure for the brake.

      Expected Results

      • The pressure is correct.

      Results

      • OKAY: Proceed to Step 7.

      • NOT OKAY: Proceed to Step 4.

4. Check the system pressure.

   ReferenceRefer to Testing and Adjusting, "Main Relief Valve - Adjust" in this module.

   1. Operate the engine at low idle.

   2. Press down the service brake pedal in order to engage the brakes.

   3. Place the transmission in the NEUTRAL position.

   4. Disengage the parking brake.

   5. Check the system pressure.

      Expected Results

      • The system pressure is correct.

      Results

      • OKAY: Proceed to Step 8.

      • NOT OKAY: The cause of the problem may be the adjustment of the main relief valve. The main relief valve maintains the system pressure in the control section of the power train oil pump. Proceed to Step 5.

5. Adjust the main relief valve.

   ReferenceRefer to Testing and Adjusting, "Main Relief Valve - Adjust" in this module.

   1. Expected Results
      • The pressure setting of the main relief valve is correct.

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Proceed to Step 6.

6. Follow the procedure in this reference.

   Refer to "System Pressure Is Low" in this module under Troubleshooting, "Oil Pressure Troubleshooting".

   Results

   • REPAIRED OKAY: The system pressure is correct but the original problem exists. Proceed to Step 8.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

7. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

8. Follow the procedure in this reference.

   Refer to "The Machine Does Not Move or the Machine Moves Slowly" in this module under Troubleshooting, "Machine Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Change Gears but the Machine Moves

Follow this procedure if the machine operates in both directions, but the machine only operates in a single gear.

1. Check the lockout control.

   1. Check the configuration of the gear lockout control in order to determine whether the gear is available.

      Using Caterpillar Electronic Technician. The Caterpillar Electronic Technician service tool is used in order to access the configuration screens. For more information, refer to the manual that was provided with the ET.

      Follow these instructions to get to the configuration screen:

      • Connect the communications adapter and the computer to the diagnostic service tool connector.

      • Start the Caterpillar Electronic Technician (ET).

      • Select "File". Go to "Select ECM". Choose the appropriate electronic control module.

      • Go to the "Service" Menu. Select "Configuration". Click "OK". Certain operations or characteristics can be changed for attachments or preferences.

      • Look at the "Max Gear Lockout Status". Check the status of SECOND and THIRD gears for both forward and reverse.

      Using Caterpillar Monitoring System. Service personnel access the configuration modes by using the 4C-8195 Control Service Tool .

      To Enter A Mode - Press the "SCROLL" switch and "CLEAR" switches simultaneously. Release both of the switches when the Mode 6 is shown in the display area.

      To Enter a Submode - Press and hold the "CLEAR" switch.

      To Scroll Through The Submodes - Press and hold the "SERVICE/SELECT" switch. Release the "SCROLL" switch when the correct number for the submode is being shown.

      To Scroll Through The Component Identifiers Of Component Data Display Mode - Use the "+" and "-" positions of "CLEAR" switch in order to move through the component list.

      To Adjust A Value Within A Submode - The "+" and "-" positions of "CLEAR" switch are used to change the value within a submode.

      Access the following submodes and check the status of SECOND and THIRD gears for both forward and reverse.

      • Mode 6 - Submode 20 Set Forward High Speed Lockout

      • Mode 6 - Submode 21 Set Reverse High Speed Lockout

      Expected Results

      • SECOND and THIRD gears are not available.

      Results

      • YES: The transmission does not operate in second or third gear because those gears are locked out.

      • NO: Proceed to Step 2.

2. Follow the procedure in this reference.

   ReferenceRefer to Transmission Clutch Troubleshooting, "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this manual.

   Results

   • REPAIRED OK: Stop.

   • NOT OK: Proceed to Step 3.

3. Identify the operation.

   1. Determine the operation of the machine.

      Results

      • AUTOSHIFT: Proceed to Step 4.

      • AUTO KICKDOWN: Proceed to Step 5.

      • MANUAL SHIFT: Proceed to Step 6.

4. Test the autoshift operation.

   1. Turn the start switch key to the ON position. Do not start the engine.

   2. Fully disengage the parking brake.

   3. Press the button for the autoshift function that is located on the left side of the dash. A LED that shows "1F2R", "2F1R"or "2F2R" lights for the appropriate mode.

   4. Press the button for the autoshift function until the LED for "1F2R" is ON.

   5. Move the transmission control from the FORWARD position to the REVERSE position. Then, move the transmission control back to the FORWARD position. The gear display progresses through the following sequence: "1F", "N", "2R", "N" and "1F".

   6. Press the button for the autoshift function until the LED for "2F1R" is ON.

   7. Move the transmission control from the FORWARD position to the REVERSE position. Then, move the transmission control back to the FORWARD position. The gear display progresses through the following sequence: "2F", "N", "1R", "N" and "2F".

   8. Press the button for the autoshift function until the LED for "2F2R" lights.

   9. Select the FORWARD position. Then select the REVERSE position. Select the FORWARD position. The gear display progresses through the following sequence: "2F", "N", "2R", "N" and "2F".

   10. Press the button for the autoshift function until no LED is "ON".

       Expected Results

       • The autoshift function operates properly.

       Results

       • OKAY: Proceed to Step 6.

       • NOT OKAY: Check these components: the wiring, the electrical connectors, the circuit boards and the electronic control module (ECM). Stop.

5. Auto Kickdown Operation

   1. Turn the key start switch to the ON position. Do not start the engine.

   2. Fully disengage the parking brake.

   3. Shift the transmission into THIRD GEAR FORWARD.

   4. Press the switch in the upper right corner of the dash to turn on the auto kickdown operation. The "AUT" LED lights.

   5. The gear display shows "3F" for 2 seconds. Then, the gear display shows "2F" for 2 seconds. Then, the gear display shows "1F".

   6. Apply the service brake. Upshift to THIRD GEAR FORWARD again. The transmission does not downshift until the service brake is released.

   7. Release the service brake. Then, the transmission downshifts.

   8. Press the button for the auto kickdown operation in order to return the machine to the normal operating mode.

      Expected Results

      • The auto kickdown operation functions properly.

      Results

      • OKAY: Proceed to Step 6.

      • NOT OKAY: Check these components: the wiring, the electrical connectors, the circuit boards and the ECM. Stop.

6. Check the switches.

   1. Check the operation of the up shift switch. Check the operation of the down shift switch.

   2. Repair the components and/or replace the components, if necessary.

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Operates in FORWARD Gears Only

Follow this procedure if the machine shifts freely between all forward gears. However, the machine does not move when the transmission is shifted into any reverse gears.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

1. Check the pressure for the No. 2 transmission clutch.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at low idle.

   2. Disengage the parking brake.

   3. Press down the service brake pedal in order to engage the brakes.

   4. Shift the transmission into REVERSE.

   5. Check the pressure on the No. 2 clutch. The No. 2 clutch is used for forward gears.

      Expected Results

      • The pressure is less than 138 kPa (20 psi).

      Results

      • OKAY: The pressure to the No. 2 clutch is not preventing disengagement of the clutch. Proceed to Step 2.

      • NOT OKAY: The No. 2 clutch is not disengaging correctly. The engagement of the No. 2 clutch may be preventing the reverse movement of the machine when REVERSE is selected. Proceed to Step 5.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

2. Check the pressure at the No. 1 transmission clutch.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at low idle.

   2. Engage the parking brake.

   3. Shift the transmission into a REVERSE gear.

   4. Check the pressure at the modulating valve for the No. 1 clutch. The No. 1 clutch is used for the reverse direction.

      Expected Results

      • The pressure is equal to pressure setting of the main relief valve.

      Results

      • OKAY: The modulating valve is receiving the correct pressure. Proceed to Step 6.

      • NOT OKAY: Proceed to Step 3.

3. Interchange the modulating valves.

   1. Interchange the transmission modulating valve for the No. 1 clutch with the transmission modulating valve for the No. 2 clutch.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS: Proceed to Step 5.

      • DOES NOT FOLLOW: Proceed to Step 4.

4. Restore the modulating valves.

   1. Restore the modulating valves to the original locations.

   2. Note the suspect valve.

   3. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: An obstruction in the control valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valve.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

      • NOT OKAY: Proceed to Step 6.

5. Replace the transmission modulating valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Perform the following tests for the No. 1 clutch only. Proceed to Step 6.

6. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Calibrate the transmission modulating valve.

   ReferenceRefer to "System Calibrations" in Service Manual, RENR9867, "Machine Electronic Control System".

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Operates in REVERSE Gears Only

Follow this procedure if the machine shifts freely between all reverse gears. However, the machine does not move when the transmission is shifted into any forward gears.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

1. Check the pressure at the No. 1 transmission modulating valve.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at low idle.

   2. Disengage the parking brake.

   3. Press down the service brake pedal in order to engage the brakes.

   4. Shift the transmission into a FORWARD gear.

   5. Check the pressure on the No. 1 clutch. The No. 1 clutch is used for the REVERSE direction.

      Expected Results

      • The pressure is less than 138 kPa (20 psi).

      Results

      • OKAY: The pressure to the No. 1 clutch is not preventing disengagement of the clutch. Proceed to Step 2.

      • NOT OKAY: The No. 1 clutch is not disengaging correctly. The engagement of the No. 1 clutch may be preventing the forward movement of the machine when a FORWARD gear is selected. Proceed to Step 5.

2. Check the pressure at the No. 2 transmission modulating valve.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at low idle.

   2. Engage the parking brake.

   3. Shift the transmission into the FORWARD position.

   4. Check the pressure for the No. 2 clutch. The No. 2 clutch is used for FORWARD gears.

      Expected Results

      • The pressure is equal to the pressure setting of the main relief valve.

      Results

      • OKAY: The pressure to the No. 2 clutch is correct. Proceed to Step 6.

      • NOT OKAY: The transmission modulating valve is the probable cause of the problem. Proceed to Step 3.

3. Interchange the modulating valves.

   1. Interchange the transmission modulating valve for the No. 2 clutch with the transmission modulating valve for the No. 1 clutch.

   2. Determine whether the problem follows the valve.

      Expected Results

      • The original problem is resolved.

      Results

      • FOLLOWS: Note the suspect valve. Proceed to Step 5.

      • DOES NOT FOLLOW: Proceed to Step 4.

4. Restore the modulating valves.

   1. Restore the transmission modulating valves to the original locations.

   2. Note the suspect valve.

   3. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: An obstruction in the valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valve.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

      • NOT OKAY: Proceed to Step 6.

5. Replace the transmission modulating valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Perform the following tests for the No. 2 clutch only. Proceed to Step 6.

6. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Calibrate the transmission modulating valve.

   ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Operate in FIRST GEAR FORWARD or REVERSE

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

1. Operate the machine.

   The following steps guide the diagnosis of the problem to the transmission clutches or to the transmission modulating valves.

   1. Start the engine. Operate the engine at high idle.

   2. Shift the transmission into FIRST GEAR FORWARD.

   3. Attempt to operate the machine.

      Expected Results

      • The engine speed decreases.

      Results

      • YES: First check the transmission clutches. An engaged clutch could be preventing the transmission from operating properly. Proceed to Step 2.

      • NO: Check the pressure at the transmission modulating valve first. Proceed to Step 3.

2. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

3. Check the pressure at the transmission modulating valve.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at high idle.

   2. Disengage the parking brake.

   3. Press down the service brake pedal in order to engage the brakes.

   4. Shift the transmission into FIRST GEAR FORWARD.

   5. Wait at least 5 seconds after you shift the transmission. Then, measure the pressure at the No. 5 clutch.

      Expected Results

      • The pressure is approximately 2240 kPa (325 psi).

      Results

      • OKAY: The pressure to the No. 5 clutch is correct but the No. 5 clutch may not be engaging properly. Perform the following tests for only the No. 5 clutch. Proceed to Step 7.

      • NOT OKAY: Check the transmission modulating valve. Proceed to Step 4.

4. Interchange the modulating valves.

   1. Interchange the transmission modulating valve for the No. 5 clutch (first gear) with the transmission modulating valve for the No. 4 clutch (second gear).

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS VALVE: Proceed to Step 6.

      • DOES NOT FOLLOW: Proceed to Step 5.

5. Restore the modulating valve.

   1. Restore the transmission modulating valves to the original locations.

   2. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: An obstruction in the valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valve.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

      • NOT OKAY: Perform the following tests for only the No. 5 clutch. Proceed to Step 7.

6. Replace the modulating valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Perform the following tests for only the No. 5 clutch. Proceed to Step 7.

7. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Calibrate the transmission modulating valve.

   ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Operate in SECOND GEAR in FORWARD or REVERSE

1. Check the lockout control.

   1. Check the configuration of the gear lockout control in order to determine whether the gear is available.

      Using Caterpillar Electronic Technician. The Caterpillar Electronic Technician service tool is used in order to access the configuration screens. For more information, refer to the manual that was provided with the ET.

      Follow these instructions to get to the configuration screen:

      • Connect the communications adapter and the computer to the diagnostic service tool connector.

      • Start the Caterpillar Electronic Technician (ET).

      • Select "File". Go to "Select ECM". Choose the appropriate electronic control module.

      • Go to the "Service" Menu. Select "Configuration". Click "OK". Certain operations or characteristics can be changed for attachments or preferences.

      • Look at the "Max Gear Lockout Status". Check the status of SECOND and THIRD gears for both forward and reverse.

      Using Caterpillar Monitoring System. Service personnel access the configuration modes by using the 4C-8195 Control Service Tool .

      To Enter A Mode - Press the "SCROLL" switch and "CLEAR" switches simultaneously. Release both of the switches when the Mode 6 is shown in the display area.

      To Enter a Submode - Press and hold the "CLEAR" switch.

      To Scroll Through The Submodes - Press and hold the "SERVICE/SELECT" switch. Release the "SCROLL" switch when the correct number for the submode is being shown.

      To Scroll Through The Component Identifiers Of Component Data Display Mode - Use the "+" and "-" positions of "CLEAR" switch in order to move through the component list.

      To Adjust A Value Within A Submode - The "+" and "-" positions of "CLEAR" switch are used to change the value within a submode.

      Access the following submodes and check the status of SECOND and THIRD gears for both forward and reverse.

      • Mode 6 - Submode 20 Set Forward High Speed Lockout

      • Mode 6 - Submode 21 Set Reverse High Speed Lockout

      Expected Results

      • SECOND and THIRD gears are not available.

      Results

      • YES: The transmission does not operate in second or third gear because those gears are locked out.

      • NO: Proceed to Step 1.

      Expected Results

      • SECOND gear is not available.

      Results

      • YES: The transmission does not operate in second gear because second gear is locked out. Stop.

      • NO: Proceed to Step 2.

2. Operate the machine.

   The probable cause of the problem is the transmission or the brakes. The following step helps you determine a starting point for troubleshooting.

   1. Start the engine. Operate the engine at high idle.

   2. Shift the transmission into SECOND GEAR FORWARD.

   3. Attempt to operate the machine.

      Expected Results

      • The engine speed decreases.

      Results

      • OKAY: Check the brake pressure first. If the brake pressure is low, then the brake does not release. Proceed to Step 3.

      • NOT OKAY: Check the pressure to the transmission modulating valve first. Proceed to Step 4.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

3. Check the brake pressure.

   ReferenceRefer to Testing and Adjusting, "Brake Pressure - Test" in this module.

   1. Start the engine. Operate the engine at low idle.

   2. Select the NEUTRAL position of the transmission.

   3. Disengage the parking brake.

   4. Check the hydraulic pressure for the brake.

      Expected Results

      • The pressure is correct.

      Results

      • OKAY: If the symptom is not resolved, an engaged transmission clutch could be preventing the transmission from operating properly. Proceed to Step 6.

      • NOT OKAY: A brake that is engaged could be preventing the movement of the machine. Proceed to Step 5.

4. Check the pressure at the transmission modulating valve.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at high idle.

   2. Disengage the parking brake.

   3. Shift the transmission into SECOND GEAR FORWARD.

   4. Wait at least 5 seconds after you shift the transmission. Then, measure the pressure at the No. 4 clutch.

      Expected Results

      • The pressure is equal to the pressure setting of the main relief valve.

      Results

      • OKAY: Perform the following tests for only the No. 4 clutch. Proceed to Step 10.

      • NOT OKAY: Proceed to Step 7.

5. Follow the procedure in this reference.

   Refer to "Brake Does Not Release" in this module under Troubleshooting, "Brake Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

6. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Calibrate the transmission modulating valve.

   ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

7. Interchange the modulating valves.

   1. Interchange the transmission modulating valve for the No. 4 clutch with the transmission modulating valve for the No. 5 clutch.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS VALVE: Proceed to Step 9.

      • DOES NOT FOLLOW: Proceed to Step 8.

8. Restore the modulating valve.

   1. Restore the transmission modulating valves to the original locations.

   2. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: An obstruction in the control valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valve.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

      • NOT OKAY: Perform the following tests for only the No. 4 clutch. Proceed to Step 10.

9. Replace the modulating valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Perform the following tests for only the No. 4 clutch. Proceed to Step 10.

10. Follow the procedure in this reference.

    Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

    Results

    • REPAIRED OKAY: Calibrate the transmission modulating valve.

    ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

    • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

The Transmission Does Not Operate in THIRD GEAR FORWARD or REVERSE

1. Check lockout control.

   1. Check the configuration of the gear lockout control in order to determine whether the gear is available.

      Using Caterpillar Electronic Technician. The Caterpillar Electronic Technician service tool is used in order to access the configuration screens. For more information, refer to the manual that was provided with the ET.

      Follow these instructions to get to the configuration screen:

      • Connect the communications adapter and the computer to the diagnostic service tool connector.

      • Start the Caterpillar Electronic Technician (ET).

      • Select "File". Go to "Select ECM". Choose the appropriate electronic control module.

      • Go to the "Service" Menu. Select "Configuration". Click "OK". Certain operations or characteristics can be changed for attachments or preferences.

      • Look at the "Max Gear Lockout Status". Check the status of SECOND and THIRD gears for both forward and reverse.

      Using Caterpillar Monitoring System. Service personnel access the configuration modes by using the 4C-8195 Control Service Tool .

      To Enter A Mode - Press the "SCROLL" switch and "CLEAR" switches simultaneously. Release both of the switches when the Mode 6 is shown in the display area.

      To Enter a Submode - Press and hold the "CLEAR" switch.

      To Scroll Through The Submodes - Press and hold the "SERVICE/SELECT" switch. Release the "SCROLL" switch when the correct number for the submode is being shown.

      To Scroll Through The Component Identifiers Of Component Data Display Mode - Use the "+" and "-" positions of "CLEAR" switch in order to move through the component list.

      To Adjust A Value Within A Submode - The "+" and "-" positions of "CLEAR" switch are used to change the value within a submode.

      Access the following submodes and check the status of SECOND and THIRD gears for both forward and reverse.

      • Mode 6 - Submode 20 Set Forward High Speed Lockout

      • Mode 6 - Submode 21 Set Reverse High Speed Lockout

      Expected Results

      • THIRD gear is not available.

      Results

      • YES: The transmission does not operate in third gear because third gear is locked out.

      • NO: Proceed to Step 2.

2. Operate the machine.

   The probable cause of the problem is the transmission or the brakes. The following step helps you determine a starting point for troubleshooting.

   1. Start the engine. Operate the engine at high idle.

   2. Shift the transmission into THIRD GEAR FORWARD.

   3. Attempt to operate the machine.

      Expected Results

      • The engine speed decreases.

      Results

      • OKAY: Check the brake pressure first. If the brake pressure is low, then the brake does not release. Proceed to Step 3.

      • NOT OKAY: Check the pressure to the transmission modulating valve first. Proceed to Step 4.

3. Check the brake pressure.

   ReferenceRefer to Testing and Adjusting, "Brake Pressure - Test" C in this module.

   1. Start the engine. Operate the engine at low idle.

   2. Select the NEUTRAL position of the transmission.

   3. Disengage the parking brake.

   4. Check the hydraulic pressure for the brake.

      Expected Results

      • The pressure is correct.

      Results

      • REPAIRED OKAY: If the symptom is not resolved, an engaged transmission clutch could be preventing the transmission from operating properly. Proceed to Step 6.

      • NOT OKAY: A brake that is engaged could be an interference in the movement of the machine. Proceed to Step 5.

Show/hide table

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

4. Check the pressure at the transmission modulating valve.

   ReferenceRefer to Testing and Adjusting, "Transmission Controls" in this module.

   1. Start the engine. Operate the engine at high idle.

   2. Disengage the parking brake.

   3. Depress the brake pedal in order to engage the brakes.

   4. Shift the transmission into THIRD GEAR FORWARD.

   5. Wait at least 5 seconds after you shift the transmission. Then, measure the pressure at the No. 3 clutch.

      Expected Results

      • The pressure is equal to the pressure setting of the main relief valve.

      Results

      • OKAY: Perform the following tests for only the No. 3 clutch. Proceed to Step 10.

      • NOT OKAY: Proceed to Step 7.

5. Follow the procedure in this reference.

   Refer to "The Brake Does Not Release" in this module under Troubleshooting, "Brake Troubleshooting".

   Results

   • REPAIRED OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

6. Follow the procedure in this reference.

   Refer to "The Transmission Clutch Is Engaged and the Clutch Does Not Release" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

   Results

   • REPAIRED OKAY: Calibrate the transmission modulating valve.

   ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

7. Interchange the modulating valves.

   1. Interchange the transmission modulating valve for the No. 3 clutch with the transmission modulating valve for the No. 5 clutch.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS VALVE: Proceed to Step 9.

      • DOES NOT FOLLOW: Proceed to Step 8.

8. Restore the modulating valve.

   1. Restore the transmission modulating valves to the original locations.

   2. Operate the machine under normal conditions.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: An obstruction in the valve may have been displaced during the procedure. Change the oil. Change the oil filter elements and clean the screens. Calibrate the transmission modulating valve.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

      • NOT OKAY: Perform the following tests for only the No. 3 clutch. Proceed to Step 10.

9. Replace the modulating valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

   3. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Perform the following tests for only the No. 3 clutch. Proceed to Step 10.

10. Follow the procedure in this reference.

    Refer to "The Transmission Clutch Does Not Engage" in this module under Troubleshooting, "Transmission Clutch Troubleshooting".

    Results

    • REPAIRED OKAY: Calibrate the transmission modulating valve.

    ReferenceRefer to Machine Electronic Control System, RENR9867, "System Calibrations".

    • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

"Transmission Slip Detected"

Follow this procedure if EID 564 ("Transmission Slip Detected") occurs. When the transmission output speed is lower than the expected value, the ECM activates EID564 ("Transmission Slip Detected"). This event indicates that the clutches are not fully engaged. The ECM will command the clutches to disengage in order to prevent damage to the transmission. The ECM will also apply the brakes. When the shift control lever is moved to the Neutral position, the ECM will release the brakes. The ECM will then allow the machine to be operated in another gear.

1. Operate the machine.

   1. Operate the machine.

   2. Determine the active gears that result in an active event.

      Note: The machine may need to be put under load in order to duplicate the event.

   3. Determine the clutches that are used.

      ReferenceRefer to Table 1 in "Transmission Controls" in this topic. The table shows the clutches that are used for the corresponding gears.

      Note: The slippage could be caused by the engagement or the disengagement of a clutch.

      Expected Results

      • More than one clutch slipping causes theEID 564 to activate.

      Results

      • YES: Proceed to Step 2.

      • NO: Proceed to Step 6.

2. Check the transmission output speed sensors and the wire harness.

   Note: Fault codes for the sensors will NOT be active. The ECM diagnoses two missing sensors as clutch slippage in the transmission.

   1. Disconnect the machine harness connectors J1 and J2 from the ECM.

   2. Measure the resistance from J1-2 sensor signal to J1-3 return circuit.

   3. Measure the resistance from J1-4 sensor signal to J1-5 return circuit.

      Expected Results

      • Both resistance measurements should be between 900 ohms and 1300 ohms.

      Results

      • OKAY: Proceed to Step 4.

      • NOT OKAY: Proceed to Step 3.

3. Follow the procedure in this reference.

   ReferenceSystems Operation and Troubleshooting, RENR9867, " D6T, D6R Series III, and D7R Series II Track-Type Tractor Machine Electronic Control System", "MID113-CID0585-FMI02"

   ReferenceSystems Operation and Troubleshooting, RENR9867, " D6T, D6R Series III, and D7R Series II Track-Type Tractor Machine Electronic Control System", "MID113-CID0673-FMI02"

   Note: These fault codes will not be active. The ECM diagnoses two missing sensors as clutch slippage in the transmission.

   Expected Results

   • The original problem is resolved.

   Results

   • OKAY: Stop.

   • NOT OKAY: Proceed to Step 4.

4. Check the main relief pressure.

   Expected Results

   • The system pressure is correct.

   Results

   • OKAY: Proceed to Step 6.

   • NOT OKAY: Proceed to Step 5.

5. Follow the procedure in this reference.

   ReferenceRefer to the section "System Pressure is Low" that is found in Specifications, Systems Operation/Testing and Adjusting, "Oil Pressure Troubleshooting" in this manual.

   Results

   • OKAY Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

6. Check the pressure at the clutch.

   ReferenceRefer to Specifications, Systems Operation/Testing and Adjusting, "Transmission Controls" in this manual.

   Expected Results

   • The pressures are equal to main relief for clutches 1 to 4. The pressure on clutch 5 is approximately2240 kPa (325 psi).

   Results

   • OKAY: Proceed to Step 9.

   • NOT OKAY: Proceed to Step 7.

7. Interchange the modulating valves.

   1. Interchange the transmission modulating valve.

   2. Determine whether the problem follows the valve.

      Results

      • FOLLOWS: Proceed to Step 8.

      • DOES NOT FOLLOW: Proceed to Step 9.

8. Replace the transmission modulating valve.

   1. Replace the suspect transmission modulating valve.

   2. Calibrate the transmission modulating valves.

      ReferenceRefer to Systems Operation and Troubleshooting, RENR9867, " D6T, D6R Series III, and D7R Series II Track-Type Tractor Machine Electronic Control System", "System Calibrations".

   3. Check the operation of the machine for the original problem. Expected Results

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: Proceed to Step 9.

9. Inspect the transmission.

   1. Disassemble the transmission.

      ReferenceFor the D6T, refer to Disassembly and Assembly, KENR5126, "Transmission - Disassemble" for the appropriate procedure.

      ReferenceFor the D6R Series III, refer to Disassembly and Assembly, RENR8173, "Transmission - Disassemble" for the appropriate procedure.

      ReferenceFor the D7R Series II, refer to Disassembly and Assembly, RENR5626, "Transmission - Disassemble" for the appropriate procedure.

   2. Inspect the transmission for damage.

   3. Replace components or repair components that are not functioning correctly, if necessary.

   4. Check the operation of the machine for the original problem.

      Expected Results

      • The original problem is resolved.

      Results

      • OKAY: Stop.

      • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.