Challenger Terra Gator 3244 Chassis. Manual - part 30

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Transmission Troubleshooting

TRANSMISSION TROUBLESHOOTING

GENERAL TROUBLESHOOTING 
INFORMATION

When you are attempting to define a problem with the

transmission, it is necessary to perform the procedures

that are contained in this section.

If a problem is encountered with the planetary

transmission, recalibrate the transmission prior to

proceeding with investigations.

A visual inspection of the system must be carried out in

order to eliminate many of the less complex problems.

Upon completion of a visual inspection, if the cause of

the problem has not been diagnosed, carry out

operational checks of the system.

If both visual inspection and operational checks have

been carried out and there is still no clear indication of

the cause of the problem. Then it will be necessary to

refer to the troubleshooting procedures and the test

procedures that are contained in the engine service

manual.

Troubleshooting a system such as the transmission is a

complex operation. Refer to the various troubleshooting

sections in this manual for specific routines for

troubleshooting.

This list of possible problems and possible corrections

will only, provide an indication of the location of a

problem and the repairs that are required. It is important

to remember that a problem is not necessarily caused

by a single part, but by the relation of one part to a

number of other parts. This information cannot provide

all the possible problems and corrections. It is

necessary for service personnel to define the problem.

Any repairs may then be carried out.

Transmission Troubleshooting

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TROUBLESHOOTING

When a error is active for more than 3 seconds, it will

automatically appear as a code in the transmission

display. Error code will disappear when the error is not

active anymore. The error code will be stored in the

ECU and in the TCU

When errors are shown, first check for visible

malfunctions. For example, broken or loosen

connectors or incorrect battery voltage.

When you cannot find the problem, find the error code

in the display and search the explanation in this manual

or in the recommend manual.

Complete explanation overview of the functions and

troubleshooting of the gearbox can be found the CAT

manuals.

Visual Inspection

Perform a visual inspection at the beginning of

troubleshooting a problem. Perform the inspection

while the engine is turned off. Put the transmission

control in the NEUTRAL position and engage the park

brake.

FIG. 1:

m

WARNING: Never check for leaks in the

hydraulic system with your hands.

Hydraulic fluids under pressure can

cause cuts, burns, eye injuries or skin

irritations. Therefore never use your

hands for finding leaks in lines, always

use a piece of cardboard. 

1. Check for leaks.

Inspect all oil, hoses and connections for damage

or for leaks.

NOTE: If oil can leak out of a fitting or a connection, air

can leak into the system. Air in the system can

be as bad as a low amount of oil.

2. Check the electrical system.

Inspect the harnesses, the electrical connectors

and the fuse(s) for the ECM. Refer to electrical

schematic.

With the engine start switch and the battery

disconnect switch in the OFF position. Check the

20 ampere fuse for the Electronic Control Module.

If the fuse is open, replace the fuse.

Inspect the electrical harnesses for damaged wires

or for broken wires. Disconnect each connector

and look for pins and socket that have been bent,

broken or removed. Look for any foreign material

inside the connectors. The connectors must be

tightened with normal force. The connectors must

be disconnected with the same amount of force.

FIG. 1

P000079

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Transmission Troubleshooting

Operational Checks

Operate the transmission in each direction and in

speeds. Check that the transmission is operating

correctly in all functions. If the transmission is not

operating correctly refer to the troubleshooting

information that is contained in the Engine service

manual. Use in the Engine service manual the

troubleshooting information in order to investigate the

problem.

The checks for troubleshooting that are included in this

manual are designed to guide service personnel in a

correct troubleshooting procedure. The checks and

procedures are set sequence in order to find problems

and causes quickly.

The checks for troubleshooting should be carried out in

order. Do not proceed to the next check until the current

check has been carried out fully. If the correct result for

the check is found, go directly to the next check.

Take note of all warnings and notices in these checks.

You must read the warnings and the notices before you

start a check. before carrying out a procedure, it is

important to read the procedure thoroughly.

The checks that follow can be used to find many of the

problems that may occur during the operation of the

machine. The checks that follow can also give an

indication of the system that has the problem.

Transmission Troubleshooting

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ERROR CODES

NOTE: For the complete explanation of the error code,

see the troubleshooting manual of the

transmission (TA 19 KENR 6678).

NOTE: For the complete troubleshooting maunal (TA

19 KENR 6678) see end of this chapter.

Error Codes 100 - 699

Codes

Description

Possible Cause

117-2

Parking brake pressure switch inputs incorrect.

The signal circuit for sensor has failed.

126-16

Transmission filter plugged.

Filter not renewed on time.

127-1

Low transmission oil pressure warning.

Leakage on transmission.

127-3

Transmission oil pressure open circuited short to 

positive terminal of the battery.

The signal for the sensor is open. 

The signal circuit for the sensor is shorted to the 

+ battery circuit.

The sensor has failed.

The power circuit or the ground circuit has failed.

The ECM has failed. This is unlikely

127-4

Transmission oil pressure sensor short to 

ground.

The signal circuit for the sensor is shorted to 

ground.

The sensor has failed.

The ECM has failed. This is unlikely

161-2

Transmission input speed sensor signal erratic.

The sensor has failed.

Intermittent connections or poor connections.

Mechanical devices are loose.

The ECM has failed. This is unlikely.

177-0

High transmission oil temperature shutdown.

To lowe oil level.

177-3

Transmission oil temperature sensor open 

circuit/short to positive terminal of the battery.

The transmission oil temperature is too high.

The signal circuit for the sensor is open.

The signal circuit for the sensor is shorted to a 

higher voltage.

The sensor has failed.

The power circuit or the ground circuit has failed.

The ECM has failed. This is unlikely.

191-12

Transmission output speed sensor #1 bad 

component.

Sensor or cable failure.

191-16

Transmission over speed.

525-0

Transmission lever position sensor signal out of 

range high.

The sensor has failed.

The signal circuit of the sensor is shorted to the + 

battery circuit.

The sensor needs to be calibrated/

The ECM has failed. This is unlikely.