Usage:

143H 1AL 160H 2FM 12H ES 2GS 160H ES 2HS 12H

ES 2LR 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H
NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H
NA 4XM 163H NA 5AK 120H 5FM 140H 5HM 12H 5ZM 120H
ES 6NM 120H 6TM 160H
ES 6WM 135H 7MM 140H 8JM 140H ES 8KM 12H
NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H
NA 9TN 120H ES 9YR 140H NA 9ZN
Illustration 1

Schematic of the Circuit of the Shift Lever

Note: Refer to the Electrical System Schematic in the Service

Manual of the machine for the correct schematic.
Problems with the transmission direction and speed control lever
will cause the machine to respond incorrectly to the actions of the
lever. Some problems with the transmission direction and speed
control lever will cause the transmission to remain in the present
speed and direction when a problem is detected. Other problems
with the transmission direction and speed control lever will cause
the transmission to shift to neutral.
1. View the status.
i. Use the Caterpillar Electronic Technician (ET) to view
the status "Group 1 Gear Lever Parameters".
i. Actuate the transmission shift lever through all speeds
in forward and reverse. Verify the positions on the display of
the ET.
i. Operate the machine in all speeds and all directions. All
speeds and all directions may not be available.
Expected Result: The failure is NOT present.
Results:
OK - The failure is NOT present. Suspect an
intermittent failure. STOP.
NOT OK - The failure is still present. Note the
positions that were incorrect on the ET screen.
Proceed to Step 2.
2. Check the harness.
i. Check the harness connectors and the harness from
the transmission direction and speed control lever to the
power train electronic control module (ECM).
i. Thoroughly inspect the connectors for the transmission
direction and speed control lever and the connectors for the
power train ECM.
i. Visually inspect the harness wiring from the
transmission direction and speed control lever to the power
train ECM.
i. Use the ET to view the status "Group 1 Gear Lever
Parameters".
 i. Actuate the transmission direction and speed control
lever through all speeds in forward and reverse. Verify the
positions on the display for the ET.
i. Operate the machine in all speeds and all directions. All
speeds and all directions may not be available.
Expected Result: The harness and harness connectors
are correct. The fault is NOT present.
Results:
OK - The harness and the harness connectors
are correct. The fault is NOT present. Proceed to Step
3.
NOT OK - The harness and/or the harness
connectors are NOT correct and the fault is still
present. Repair the machine harness and/or the
harness connectors. If necessary, replace the machine
harness and/or the harness connectors. Ensure that all
the seals are properly in place. Also, check that the
connectors mate completely. Verify that the repair
eliminates the problem. Clear all diagnostic codes.
STOP.
3. Check the voltage.
i. Disconnect the transmission direction and speed
control lever from the machine harness.
i. Turn the key start switch to the ON position.
i. Measure the voltage between pin 2 and pin 15 of the
24-pin connector for the transmission direction and speed
control lever.
Expected Result: System voltage is present.
Results:
OK - System voltage is present. Proceed to Step
4.
 NOT OK - System voltage is NOT present. There
is a problem with the power supply to the transmission
direction and speed control lever. Check the fuse for
the transmission direction and speed control lever and
the associated harness. STOP.
4. Check the continuity.
i. Ensure that the key start switch is in the OFF position.
i. The transmission direction and speed control lever and
the power train ECM are disconnected from the machine
harness.
i. Check for continuity from pin 2 to all active pins on the
24-pin connector of the transmission direction and speed
control lever.
Expected Result: Continuity is NOT present.
Results:
OK - Continuity is NOT present. Proceed to Step
5.
NOT OK - Continuity is present. The problem is in
the harness. Repair the harness or replace the
harness.
5. Check the continuity.
i. Check for continuity from pin 15 to all active pins on the
24-pin connector of the transmission direction and speed
control lever.
Expected Result: Continuity is NOT present.
Results:
OK - Continuity is NOT present. Proceed to Step
6.
NOT OK - Continuity is present. The problem is in
the harness. Repair the harness or replace the
harness. STOP.
6. Check the transmission direction and speed control
lever.
i. Reconnect the connectors for the power train ECM.
i. Create a jumper wire that can short from pin 2 to two of
the other pins on the connector for the transmission
direction and speed control lever.
i. The key start switch should be in the ON position.
i. Use the ET to display "Group 1 Gear Lever
Parameters". Conduct the following items and view the
parameters on the ET. Refer to Table 1 for the correct
connections of the jumper wire to the harness for the
transmission direction and speed control lever.
Table 1

Check of the Gear Parameters.

Jumper Wire Connections. (1)

Ground Contact Directional Contact Speed Cont

2 11 3

2 11 4

2 11 5

2 11 6

2 11 7

2 11 8

2 11 9

2 11 10

2 12 3

2 12 4
 2 12 5

2 12 6

2 12 7

2 12 8

2 12 9

2 12 10

2 14 10

(1)
All contacts are on the harness for the shift lever.

iii. Expected Result: All the gear parameters read the

proper gear.
iv. Results:
OK - All gear parameters read the proper gear.
Replace the transmission direction and speed control
lever and verify correct operation. STOP.
NOT OK - All gear parameters DO NOT read the
proper gear. It is unlikely that the power train ECM is
faulty. Exit this procedure and perform this CID FMI
again. If the cause of the fault is not found, replace the
power train ECM. Refer to Testing and Adjusting,
"Electronic Control Module (Power Train) - Replace" for
more information on replacing the power train ECM.
STOP.
Usage:

160H 2FM 12H 4ER 120H 5FM 140H 5HM 120H 6TM 135H 7
MM 140H 8JM 135H 8WN 160H 9JM 140H XZH 12H XZJ 160
H XZK
Illustration 1

The transmission direction and speed control (lever) is to the right

of the operator's seat.

Note: You must move the lever from the PARKING BRAKE
ENGAGED position before you can move the lever to the
NEUTRAL position.

Forward (1) - Move the lever to

the left and pull back the lever to
the desired forward speed setting.
The machine will move forward.

1 - First Speed

2 - Second Speed

3 - Third Speed

4 - Fourth Speed

5 - Fifth Speed
6 - Sixth Speed

7 - Seventh Speed

8 - Eighth Speed

Neutral (2) - Move the lever to the

NEUTRAL position when you change
direction or when you are preparing
to park the machine. A stopped
machine on a smooth horizontal
surface should not move when the
lever is in the NEUTRAL position.

Reverse (3) - Move the lever to

the right and pull back the lever to
the desired speed. The machine will
move in reverse.

1 - First Speed

2 - Second Speed

3 - Third Speed

4 - Fourth Speed

5 - Fifth Speed

6 - Sixth Speed
Usage:

143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H
ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 12H
ES 2LR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H
NA 2ZK 140H ES 3AS 140H ES3AS 160H NA 3GM 160H
NA 3GM 135H NA 3YK 135H
NA 3YK 12H 4ER 12H 4ER 120H NA 4MK 120H NA 4MK 12H
NA 4XM 12H NA 4XM 163H NA 5AK 163H
NA 5AK 120H 5FM 120H 5FM 140H 5HM 140H5HM 12H 5ZM
120H ES 6NM 120H ES 6NM 120H 6TM 120H 6TM 160H
ES 6WM 120H NA 6YN 120H
NA 6YN 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H
ES 8KM 12H NA 8MN 12H
NA 8MN 135H8WN 135H 8WN 160H NA 9EJ 160H NA 9EJ
Illustration 1
Illustration 2

View A-A

(1) Spring

Test length ... 160 mm (6.3 inch)

Test force ... 245 15 N (55 3 lb)
Free length after test ... 140 mm (5.5 inch)
Outside diameter ... 31.5 mm (1.24 inch)

(2) Cable assembly

(3) Shim

Outside diameter ... 45.0 mm (1.78 inch)

Thickness ... 0.51 mm (0.020 inch)
(A) Distance from cab floorplate to the bottom edge of the pedal ...
95 6 mm (3.7 0.2 inch)

(B) Distance from centerline to centerline of the rod ends ... 447
3 mm (17.6 0.1 inch)

Illustration 3

Cable Assembly

(4) Final installation torque ... 38 7 Nm (28 5 lb ft)

(5) Final installation torque ... 8 3 Nm (71 27 lb in)

Usage:
143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H
ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 12H
ES 2LR 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H
NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 160H
NA 3GM 160H NA 3GM 135H NA 3YK 135H
NA 3YK 12H 4ER 12H 4ER 120H NA4MK 120H NA 4MK 12H
NA 4XM 12H NA 4XM 163H NA 5AK 163H
NA 5AK 120H 5FM 120H 5FM 140H5HM 140H 5HM 12H 5ZM
12H 5ZM 120H ES 6NM 120H
ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 160H
ES 6WM 120H
NA 6YN 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H
ES 8KM 140H ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN

Adjustment of the clutch pedal may be necessary after

replacement of any of the following items: mechanism for
the clutch pedal, clutch control cable and transmission control
valve for the clutch pedal.
Use the following information for the adjustment of
the clutch pedal.

Illustration 1

(1) Clutch control cable

(2) Nut
 (3) Nut
(4) Housing
(5) Nut
(6) Rod end

1. Loosen 9S-1354 Nut (2) and 9S-1354 Nut (3) on 144-

5323 Cable As (1) . The cable end is located in 8D-
9973Housing (4) .
2. Adjust nut (2) in order to show a minimum of two threads
on clutch control cable (1) . Tighten nut (3) .
3. Loosen 6V-8187 Nut (5) that is located on the end
of clutch control cable (1) .
4. Screw 5P-7704 Rod End (6) to the end of cable (1) .
Adjust 5P-7704 Rod End (6) until the rod end is approximately
4.8 mm (0.19 inch) from the end of the cable (1) .
5. Tighten 6V-8187 Nut (5) .
Illustration 2

(7) Bolt
(8) Locknut
(9) Clutch pedal
 Illustration 3

Transmission Control Valve

6. Adjust clutch pedal (9) . Pedal (9) can be adjusted in either

of the following two ways.
i. Procedure (A) .
Block the front wheels. Position the machine on
stands. Ensure that all the driving wheels will rotate
freely.
Loosen locknut (8) and tighten bolt (7) to the
bottom of the adjustment.
Start the engine.
 Depress pedal (9) . Shift the transmission into
First Speed Forward.
Slowly release pedal (9) until the tires start to
rotate. Hold pedal (9) in position.
Unscrew the pedal stop bolt (7) so there is a 9.53
mm (0.375 inch) gap between pedal (9) and bolt (7) .
Depress pedal (9) and shift the transmission into
Neutral. Engage the parking brake.
Release pedal (9) .
Hold bolt (7) in position and tighten locknut (8) .
Shut off the engine and remove the stands.
i. Procedure (B) .
Block the front wheels.
Loosen locknut (8) and tighten bolt (7) to the
bottom of the adjustment.
Connect a pressure gauge on the pressure test
port (B) of the valve assembly for the transmission.
Start the engine.
Engage the service brakes in order to prevent the
machine from moving.
Depress pedal (9) . Shift the transmission into "1st
Forward". Slowly release pedal (9) .
Slowly depress the pedal (9) until the pressure
drops to zero and maintain the pedal position.
Unscrew the pedal stop bolt (7) so there is a 9.53
mm (0.375 inch) gap between pedal (9) and the bolt (7)
.
Fully depress pedal (9) . Shift the transmission
into Neutral and engage the parking brake.
Release pedal (9) .
 Hold bolt (7) in position and tighten locknut (8) .
Shut off the engine.
Usage:
143H 1AL 143H 1AL 120H 2AN 160H 2FM 160H 2FM 12H
ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 12H
ES 2LR 12H ES 2LR 12H NA 2WR 12H NA 2WR 140H
NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 160H
NA 3GM 160H NA 3GM 135H NA 3YK 135H
NA 3YK 12H 4ER 12H 4ER 120H NA4MK 120H NA 4MK 12H
NA 4XM 12H NA 4XM 163H NA 5AK 163H
NA 5AK 120H 5FM 120H 5FM 140H5HM 140H 5HM 12H 5ZM
12H 5ZM 120H ES 6NM 120H
ES 6NM 120H 6TM 120H 6TM 160H ES 6WM 160H
ES 6WM 120H
NA 6YN 135H 7MM 135H 7MM 140H 8JM 140H 8JM 140H
ES 8KM 140H ES 8KM 12H NA 8MN 12H NA 8MN 135H 8WN

and adjusting the transmission and power train, move the machine to an area clear of obstructions, with safe exhaust ven
Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To
y, do the procedure that follows before testing and adjusting the transmission and power train.

NOTICE
taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair o
prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component co

fluids according to local regulations and mandates.

Before you begin the test, refer to Systems Operation, Testing and
Adjusting, "Machine Preparation for Troubleshooting".
Table 1

Required Tools

Part Number Description

1U-5482 Pressure Adapter Group

8T-0855 Pressure Gauge (0 to 4,000 kPa (0 to 580 psi))

1. Operate the machine until the transmission oil is at operating

temperature of 51 C (124 F).
2. Stop the machine on a hard level surface. Engage the
parking brake. Turn off the engine. Place blocks in front of the
wheels and place blocks behind the wheels.
Illustration 1
 (1) Cover for the transmission control valve

3. Remove cover (1) from the transmission . Remove the

differential drive shaft.
Illustration 2
 Transmission control valve
(2) Test port

4. Remove the cover on test port (2) . Connect 8T-

0855 Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) to test
port (2) .

Illustration 3

Side view of clutch pedal

(3) Clutch pedal
(4) Pedal stop bolt
 (5) Locknut

Illustration 4

Side view of clutch control cable assembly.

(3) Clutch pedal
(6) Clutch control cable
(7) Valve spool

5. Press clutch pedal (3) against pedal stop bolt (4) . Move the
transmission control lever to FIRST GEAR FORWARD
position and operate at half throttle.
6. Depress clutch pedal (3) . The transmission should be
turning. The pressure at test port (2) should read a minimum
of 2125 kPa (310 psi) . Press down clutch pedal (3) . Adjust
pedal stop bolt (4) in order to touch clutch pedal (3) when
pressure at test port (2) reaches 0.00 kPa (0.00 psi). Tighten
locknut (5) .
 7. If the pressure is correct in Step 6, the modulation is working
correctly. If the pressure is not correct in Step 6, follow Step 8.
8. Disconnect clutch control cable (6) from valve spool (7) .
i. Operate the machine in FIRST GEAR FORWARD at
half throttle.
i. Manually pull out valve spool (7) . The pressure gauge
should read 0.00 kPa (0.00 psi).
i. Push valve spool (7) into the valve body. The spool
should move freely. The spool should also be firm because
of the spring. The transmission drive shaft should start to
turn in the range of 0.00 kPa (0.00 psi) to 834 kPa (120
psi).
i. The spool may need to be cleaned if the spool does not
move freely.
9. If the spool moves freely and modulation occurs in Step
8, clutch control cable (6) may need to be replaced.
10. For more information on the clutch pedal, refer to
theSystems Operation, Testing and Adjusting, "Clutch Pedal -
Adjust".
Usage:
143H 1AL 143H 1AL 143H 1AL 120H 2AN 120H 2AN 120H 2A
N 160H 2FM 160H 2FM 160H 2FM 12H ES 2GS 12H
ES 2GS 12H ES 2GS 160H ES 2HS 160H ES 2HS 160H
ES 2HS 12H ES 2LR 12H ES 2LR 12H ES 2LR 12H
NA 2WR 12H NA 2WR 12H NA 2WR 140H NA 2ZK 140H
NA 2ZK 140H NA 2ZK 140H ES 3AS 140H ES 3AS 140H
ES 3AS 140H NA 3FR 140H NA 3FR 140H NA 3FR 160H
NA 3GM 160H NA3GM 160H NA 3GM 135H NA 3YK 135H
NA 3YK 135H NA 3YK 12H 4ER 12H 4ER 12H 4ER 120H
NA4MK 120H NA 4MK 120H NA 4MK 12H NA 4XM 12H
NA 4XM 12H NA 4XM 163H NA 5AK 163H NA 5AK 163H
NA 5AK 120H 5FM 120H 5FM 120H 5FM
Motor Grader:

120H (S/N: 2AN1-UP; 4MK1-UP; 3GR1-UP; 5FM1-UP; 6NM1-

UP; 6TM1-UP; 9FN1-UP; 9YR1-UP)
135H (S/N: 3YK1-UP; 7MM1-UP; 8WN1-UP)
12H (S/N: 2GS1-UP; 4ER1-UP; 5ZM1-UP; 2LR1-UP; 2WR1-UP;
4XM1-UP; 8MN1-UP)
140H (S/N: 2ZK1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP;
9ZN1-UP; 3FR1-UP; 3AS1-UP)
143H (S/N: 1AL1-UP)
160H (S/N: 2HS1-UP; 3GM1-UP; 9EJ1-UP; 2FM1-UP; 6WM1-
UP; 9JM1-UP)
163H (S/N: 5AK1-UP)
Service Magazine SEPD0805, 10 October 2005, "Adjustment
Procedure for the Inching Pedal". Disregard this article. Refer to
the information below.
Adjustment of the inching pedal may be necessary after
replacement of any of the following items: mechanism for the
inching pedal, inching cable and transmission control valve for the
inching pedal.
Use the following information for the adjustment of the inching
pedal.
 Illustration 1

(1) Inching cable

(2) Nut
(3) Nut
(4) Housing
(5) Nut
(6) Rod end

1. Loosen 9S-1354 Nut (2) and 9S-1354 Nut (3) on 144-

5323 Cable (1). The cable end is located in 8D-
9973Housing (4).
2. Adjust nut (2) in order to show a minimum of two threads on
inching cable (1). Tighten nut (3) .
3. Loosen 6V-8187 Nut (5) that is located on the end of inching
cable (1) .
4. Screw 5P-7704 Rod End (6) to the end of cable (1).
Adjust 5P-7704 Rod End (6) until the rod end is approximately
4.8 mm (0.19 inch) from the end of the cable (1) .
5. Tighten 6V-8187 Nut (5) .

Illustration 2

(7) Bolt
(8) Locknut
 (9) Inching pedal

Illustration 3

Transmission Control Valve

6. Adjust inching pedal (9). Pedal (9) can be adjusted in either

of the following two ways.
i. Procedure (A) .
Block the front wheels. Position the machine on
stands. Ensure that all the driving wheels will rotate
freely.
 Loosen locknut (8) and tighten bolt (7) to the
bottom of the adjustment.
Start the engine.
Depress pedal (9). Shift the transmission into First
Speed Forward.
Slowly release pedal (9) until the tires start to
rotate. Hold pedal (9) in position.
Unscrew the pedal stop bolt (7) so there is a 9.53
mm (0.375 inch) gap between pedal (9) and bolt (7) .
Depress pedal (9) and shift the transmission into
Neutral. Engage the parking brake.
Release pedal (9) .
Hold bolt (7) in position and tighten locknut (8) .
Shut off the engine and remove the stands.
i. Procedure (B) .
Block the front wheels.
Loosen locknut (8) and tighten bolt (7) to the
bottom of the adjustment.
Connect a pressure gauge on the pressure test
port (B) of the valve assembly for the transmission.
Start the engine.
Engage the service brakes in order to prevent the
machine from moving.
Depress pedal (9). Shift the transmission into "1st
Forward". Slowly release pedal (9) .
Slowly depress the pedal (9) until the pressure
drops to zero and maintain the pedal position.
Unscrew the pedal stop bolt (7) so there is a 9.53
mm (0.375 inch) gap between pedal (9) and the bolt (7)
.
 Fully depress pedal (9). Shift the transmission into
Neutral and engage the parking brake.
Release pedal (9) .
Hold bolt (7) in position and tighten locknut (8) .
Shut off the engine.
Usage:

143H 1AL 120H 2AN 160H 2FM 12H ES 2GS 160H

ES 2HS 12H NA 2WR 140H NA 2ZK 140H ES 3AS 160H
NA 3GM 135H NA 3YK 12H 4ER 120H NA 4MK 12H
NA 4XM 163H NA 5AK 120H 5FM 140H 5HM 120H 6TM 120H
NA 6YN 16H NA 6ZJ 135H 7MM 14H NA 7WJ 140H 8JM 12H
NA 8MN 135H 8WN 160H NA 9EJ 160H 9JM 140H
NA 9TN 120H ES 9YR 140H
NA 9ZN 135H BDJ 140H XZH 12H XZJ 160H XZK

Illustration 1
The transmission modulator control (pedal) is on the floor of the
operator compartment and to the left of the steering console.

The transmission modulator pedal disengages the power to the

wheels.

Depress the transmission modulator pedal when you start the

machine and when you stop the machine. Also, depress the
transmission modulator pedal when you change the direction of
the machine.

Release the transmission modulator pedal in order to re-engage

the power to the wheels.

Note: Use the transmission modulator pedal to inch the machine.