CHAMPION ROAD MACHINERY 700 SERIES GRADER Applicable to Grader Serial Number 24260 & up. Model 8400 Transmission Electrical Troubleshooting Guidei Error Code Table | CODE | MALFUNCTION CODE ] MALFUNCTION 1.0 Electric power is below 19.5 Vdc 3.0 | Short circuit, solenoid 2 (B) 3.4 Short circuit, solenoid 3 (R) 2.0 Open circuit, solenoid 2 (B) 3.3 Short circuit, solenoid 6 (L) 24 Open circuit, solenoid 3 (R) 34 ‘Short circuit, solenoid 7 (H) 23 Open circuit, solenoid 6 (L) 35 Short circuit, solenoid 5 (D) 24 Open circuit, solenoid 7 (H) 3.6 ‘Short circuit, solenoid 1 (A) 25 Open circuit, solenoid 5 (D) 26 Open circuit, solenoid 1 (A) 4.0 Forward/Neutral input error 44 Reverse/Neutral input error 27 No power to solenoid circuits 42 Controller restart error 44 Forward/Reverse input error NOTE: The information contained in this 8400 Transmission Electrical Troubleshooting Guide is for reference only. Refer to the Champion 700 Series Shop Manual for proper safety and service procedures BEFORE performing any service procedure. Champion Road Machinery cannotanticipate all circumstances that may arise. Use this chart only as a guide to troubleshooting the 8400 Transmission Electrical System.tt Error Code Explanation Chart CODE SERIES | DESCRIPTION 1.0 Low system voltage Check: Charging system Converter output measured at pin 'F" on 6 terminal connector (red wire 122-1) = For proper grounding of controller -High resistance at circuit breaker (transmission converter) if used Le 2.0-2.6 Open circuit or short to ground in applicable solenoid circuit *Check for continuity at: - Solenoid coil | = Solenoid wiring hamess -Hamess connection 27 No voltage in 5 amp circuit (transmission solenoid) Check for continuity at: - Circuit breaker - Transmission relay = Normally closed terminals on micro switch when in Forward or Reverse - Hamess connector ~ At each solenoid = At Transmission hamess connector to controller ~3 pin connector at microswitch 30-36 Short circuit in applicable solenoid circuit Chee! - Solenoid coil resistance - Solenoid wiring hamess and coil resistance = Controller connection for corrosion 40-44 Forward or Reverse input error Check: = Neutral start micro switch operation = Magnets for proper clearance and adjustment 42 Neutral input error = F-N-R lever was left in gear when unit was shut off, or shifted during start-up sequence, or controller experienced a momentary power or ground loss ~ Shift F-N-R lever to Neutral = Check power supply pin 'F' on flat 6 terminal connector (red wire 122-1) on main supply hamess ~A4.2 error code is normal with the ignition key in the accessory position 44 Internal Forward or Reverse signal switch malfunction - Obtainable only when leaving Neutral ~ Replace controller * When using an ohmmeter, ensure the battery isolation switch is tumed OFF.Electrical Schematic - Gearco Mode! 8400 Transmission moTT3A/A389 ‘waviowinaa 122 PURPLE/ WHITE, HUMA7 aad ear wae veer iy awiaa ‘90¥ Why cars ara WIARS OL 1Solenoid/Clutch Engagement SPEED ‘SOLENOIDS CLUTCH Solenoid/Pressure ENERGIZED ENGAGED Checkpoint Locations 1 1,6 ACL 2 2,6 BCL 3 1,5,6 ADL 4 2.5.6 BDL 5 1,7 ACH 6 2.7 BCH 7 4,5,7 ADH 8 2.5.7 BDH Neutral None c A 3.6 RCL 2 3.5.6 ROL 3 37 RCH 4 3.5.7 RDH Fuse Panel These are the fuses, circuit breakers and relays on the fuse o1o ar) panel that relate to the transmis- sion and starting circuit. ‘The fuse panel is located inside me & the side console and is acces & & (me) secs sible through the removeable 8 & o les fuse access door ory lifting the side console cover. Thumb & © & hea screws allow eas} sy removal of ee off bath, 2 @ © [eee oS & fe Se Shr bbs . So) 0 Ee! inne saat Fo) SO UofT mse me 7 TW “Ea crcl reer, = Fl Zs] ignion och (ge A) dD key a SE 78 A creat breakerGrader will not Operate GRADER WILL NOT OPERATE ‘when either forward or reverse is selected Display Blank 3 Amp Circuit Breaker Tripped Is Green Controller-Status-Light ON Check Circuit Condition Does Controller Start-Up if: 1. Move mode lever to NEUTRAL and 2. Key Switch turned OFF for 15 seconds then ON. Is Red Controller- Status-Light ON Does Controller Main Vottage Supply Start-Up if: To Controller 1. Move mode lever to (3 Amp Circuit) Below Intermittent Problem Replace caused by Controller* NEUTRAL and Operational Range Poor Controller Ground 2. Key Switch tuned 1. Check Voltage to of Loose Connections OFF for 15 seconds Controller then ON. 2. Check Charging System 3. Check Controller Ground Repair Wiring or Clean Connections. Does Controller Start-Up if: 1. Ground Circuit is inspected and cor- rected for continuity and solid connec- tions, 2. Power Supply is inspected and correc- -ted for continuity and solid connections. No ] Replace Controlier* Check Controller Ground CircuitDisplay Functional Controller Ignoring Shift Commands See Attached Error Code Explanation Charts is Displayed in only Certain Gears Replace Controller* Display does not Change Display Indicates Shift But it does not Occur ‘Check Magnet on the Check all Ground Connections from Batteries to Controller Erratic Display of Error Codes. Controller Clears Error Code if Returned to NEUTRAL ‘Check pin'A’ on 6 pin connector (pink ‘wire 121-1) of the Controller for Voltage when in NEUTRAL only eprops Lave earn cnx || Stee, Treramsion Operation of Pperaute | | Cero Sytem Cartridges Check pin ‘A’ on 6 pin connector (pink wire 121-1) of the Controller| for Voltage when in NEUTRAL only (Continuity to Battery Ground), 44. Check Magnets for Adjustment IO.K, Replace Controller “Replace Controller only after making the following checks 41. Check for 12 Volt supply at pin Fon the Flat 6 Terminal Connector. 2. Check for Ground on Pins ‘C’ and’ on the Flat 6 Terminal Connector '3. Check Micro Switch for Operation, Adjustment, and Proper Connections. Replace Controller”“Smart Shift” Memory Gear Feature - sin 24736 « uP The “smart shift" memory gear feature allows the operator to customize the shift pattems of the transmission in the lowest gears to the job at hand. Table A shows the default shift pattern before the ‘operator uses the memory gear function. To obtain different shift pattems, such as FOR- WARD 2 and REVERSE Table A 4, you must manually Forward | Reverse | shift the transmission to Gear | “Gear | that gear. The memory 1 2 feature remembers the 2 2 selected gear that was 5 5 last used in either FOR- WARD or REVERSE, 4 2 and upon returning to 5 =3___| that direction the contro!- 6 3 ler automatically selects 7 3 that gear. You only have 8 4 to select the required gears in either FOR- WARD or REVERSE, no other programming action is needed. Refer to Table B for the allowable memory gear selections. Once you have obtained a valid memory gear combination, you can ‘shuttle-shift’ between FOR- WARD and REVERSE without moving the PULSER lever. However, you must still use the engine clutch. From a gear in column A, you can access a gear in column B using the memory gear function. Table B Forward to Reverse Reverse to Forward a 8 a 5 7 a a 7 2 a 2 a 3 2 a 2 7 2 2 3 4 5 3 a 3 3 2 3 4 3 3 5 7 2 4 5 3 = z 3 & 3 7 3 & 4 If @ selected combination of FORWARD and REVERSE gears is not valid (see Table B), the transmission controller automatically selects the closest appropriate gear. When the controller is in NEUTRAL, the LCD display always indicates the FORWARD and RE- VERSE gears available. Operating the PULSER lever while in NEUTRAL cancels the memory gear function and returns the transmission shift pattem to the default settings. You must make a complete shift sequence (Le... F-N-R or R-N-F) to use the memory gear function. If you make an incomplete shift sequence F-N-F or R-N-R), the transmission retums to the previous FORWARD and REVERSE gear selec- tion,i Actuator Magnet Adjustment ‘These adjustments apply to both, the Mode Lever and the Pulser Lever. Magnet Clearance Adjustment Adjust the magnet clearance if an error code or the Locknut diagnostic flow chart indicate a need. The magnet clearance is adjustable by loosening the lock nut and ‘tuming the adjustment nut in or out. Tighten the lock nut. . Washer Adjustment Nut \_— Actuator Magnet MAGNET CLEARANCE Min. 0,38 mm ((0.015 inch) Max. 1,78 mm (0.070 inch) Position Adjustment Adjust the magnet in the slot if the shift response does not match the strokes evenly from centre position. Adjustment is necessary if a lever reacts very early in its stroke moving one way and very late in its stroke moving the opposite way. Move the magnet in the slot until the shift reaction strokes are ap- proximately equal. Loosen the lock nut to adjust the magnet's, position. Tighten the lock nut.a Solenoid Coil Resistance Values SOLENOID PART RESISTANCE VALUE col NUMBER 24 Volt I 58728 28.8 (Q) = 5% Resistance at a temperature of 20°C (68°F). = Torque Specifications APPLICATION Ibf-ft Nm ‘Solenoid Cartridges. 25 33.9 Solenoid Retaining Nut 5 68 Grader will Operate GRADER WILL OPERATE Backup Alarm does not sound Shift Steps Display incorrect, Display not Affected ae otae Check for Correct Hamess Connections Replace Controller if: Rae esr benl to Solenoids Backup Alarm does not Operate Backup Alarm ‘Open Circuit Locate and Repair| 1. Backup Alarm Short ‘Segments of Display Memory Gear Circuit not lit Fails to retain data 2. Locate and Repair 0Notesin Road Machinery Limited Printed in Canada Goderich, Ontario, Canada, N7A 3Y6 - (519) 524-2601