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Testing and Adjusting

120K, 12K, 140K and 160K Motor Graders Power Train Electronic Control
Sste!
Fill Time for the Transmission Clutch - Calibrate
Procedure for Transmission Clutch Fill Calibration
Improper calibration of the transmission clutch fill will cause transmission shifting
problems. The automatic calibration procedure for setting the transmission clutch fill
will achieve greater consistency when the transmission is shifted. The main relief valve
must be calibrated.
ReferenceRefer to Testing and Adjusting, "Transmission Charging ump ressure !
Test and Adjust" for information about setting the relief valve.
Note: "o not perform this procedure if software has just been uploaded into the
Transmission #C$. Cycle the power for the Transmission #C$ prior to performing
this procedure.
The transmission system must be calibrated if any of the following conditions have
occurred%
A transmission solenoid valve has been replaced or cleaned.
A different Transmission #C$ has been installed.
&ew flash software has been flashed into the #C$.
A transmission clutch has been rebuilt.
The transmission clutch does not shift correctly.
The oil for the transmission is a different weight from the oil that was previously
used.
The transmission relief valve has been adjusted.
The following conditions must be met before calibration%
The main relief valve must be calibrated.
The calibration of the engagement pressure must be successfully completed.
The machine speed must be 'ero.
The engine must be running at ())) R$ or higher.
The par*ing bra*e must be set.
The transmission filter bypass must not be bypassing.
The transmission oil temperature must be at an operating temperature of +), -
.),C /.0).), - .1.),23.
The inching pedal must be fully released in order to allow the automatic
calibration function to start.
Calibration Procedure
The Caterpillar #lectronic Technician /#T3 is used to access the calibration procedures.
A message on the Cat #T screen will give instructions that guide the user through the
calibration procedure. Refer to the $anual that is provided with the Cat #T for more
information about Cat #T.
.. Connect Cat #T to service connector /43 .
(. 5pen the software program Cat #T. 6elect the transmission #lectronic Control
$odule /#C$3 for the machine that is being calibrated.
7. 6elect "Transmission 2ill Calibration" from the drop!down calibration list. Refer
to Illustration 1. that is located in the "Inching edal ! Calibrate" section of the
manual.
0. If the conditions that are listed above in reparation for Calibration rocedure
are met, the display will inform the technician to press &#8T in order to
advance to the ne9t step.
Note: "uring the calibration of the transmission clutch fill, many transmission
clutch fills are occurring. Remain seated. There will be some vibration and noise
as the clutches are being calibrated. If any of the conditions for calibration are
violated during the calibration, the calibration will be stopped. Do not operate
the air conditioning or hydraulics during the calibration of the solenoids.
During the automatic calibration function, aoid performing steering
moements.
Note: At any time during the calibration, the user can abort the calibration by
pressing the CA&C#: button. "epressing the clutch pedal or depressing the
service bra*e pedal will also abort the calibration.
Note: The engine must achieve the re;uested speed in a ma9imum of five
seconds. If the engine does not reach the re;uested rpm in the given amount of
time, the #C$ will abort calibration due to a incorrect engine speed.
<. The display will continuously display "Calibrating Clutch =.". The #C$ will
fill clutch . and the #C$ will drain clutch . several times. The #C$ will
formulate the optimal hold current and the optimal ramp levels for the solenoid
that operates the modulating valve for clutch .. >hen the #C$ has completed
calibrating this clutch, Cat #T automatically moves to the ne9t step.
+. The display will continuously display "Calibrating Clutch =(". The #C$ will
fill clutch ( and the #C$ will drain clutch ( several times. The #C$ will
formulate the optimal hold current and the optimal ramp levels for the solenoid
that operates the modulating valve for clutch (. >hen the #C$ has completed
calibrating this clutch, Cat #T automatically moves to the ne9t step.
?. The display will continuously display "Calibrating Clutch =7". The #C$ will
fill clutch 7 and the #C$ will drain clutch 7 several times. The #C$ will
formulate the optimal hold current and the optimal ramp levels for the solenoid
that operates the modulating valve for clutch 7. >hen the #C$ has completed
calibrating this clutch, Cat #T automatically moves to the ne9t step.
1. 5nce the calibration has been completed successfully, the #C$ will write the
calibration data to memory.
4. 5perate the machinery in order to chec* the ;uality of transmission shift.
Note: If the machine does not shift to the satisfaction of the operator or the
inching pedal is not operating to the satisfaction of the operator, repeat the "2ill
Calibration" procedure.
.). Resume normal operation of the machine.
"+&
Procedure
Note: The steps of this procedure must be performed e9actly. The 6teps of this
procedure must be performed in se;uence. This procedure can terminate if any
une9pected functions are activated or if a diagnostic code is present. "o not change any
switch positions. "o not move any levers. "o not depress any pedals. If there is a
problem with the calibration or if there is a problem with the results of the calibration,
an error code /"#88"3 will appear in the display area.
1. If a new clutch solenoid valve was installed, shift the transmission at least 12
times into a gear that uses the solenoid valve. Allow sufficient time for the
corresponding clutch to be fully pressurized.
2. Warm the transmission oil to at least 4 !" #14 !$%. &he component data
display mode #'ode number (% can be used to monitor the temperature of the
transmission oil. &he "I) number is 1((.
*. +lace a pressure gauge on the clutch that needs to be calibrated. A gauge that
can measure *, -+a #,. psi% is desired.
4. +lace the transmission direction control lever in the /01&2A3 position.
,. +lace the par-ing bra-e switch in the 4/ position. The transmission will shift
to NEUTRAL.
5. 6et the engine speed to high idle.
(. With the 4C-8195 "ontrol 6ervice &ool, enter 7&ransmission "alibration 'ode7
#'ode 5% for the ),', )5', )52 and the )(2. &he mode for the )52 6eries II,
)(2 6eries II, and the ).2 6eries II is mode number (. &hen, enter the
submode that corresponds to the clutch that is being calibrated.
o 6ubmode *1 8 "lutch 1 0ngagement
o 6ubmode *2 8 "lutch 2 0ngagement
o 6ubmode ** 8 "lutch * 0ngagement
o 6ubmode *4 8 "lutch 4 0ngagement
o 6ubmode *, 8 "lutch , 0ngagement
.. If all the conditions are correct for calibration, the specified pressure for the
engagement for the particular clutch is shown in the display area. &he value
that is shown is in units of ten -+a. $or the actual value, multiply the value that
is showing by 1. 2ecord the value. In the remaining 6teps, ad9ustments are
made so that the pressure is the actual reading for pressure from the pressure
gauge. &he pressure that is specified in the procedure is also listed in the
engagement pressure specifications table.
Note: If the conditions for setup are not correct, the pressure is not shown in the
display area. An error code /"#88"3 appears instead of the pressure value. The
calibration will not run until all error codes are corrected. Correct the error code
and restart these procedures.
:. When the pressure is showing on the display, move the transmission direction
control lever to the $42WA2) position. &his pressurizes the clutch that is
being calibrated.
1. &he display will change. /ow, the display shows a number that corresponds to
the electrical current of the particular solenoid valve. &he I/"20'0/& #;%
position and the )0"20'0/& #8% position of the clear switch can now be used
to ad9ust the electrical current of the solenoid valve. &he solenoid valve controls
the pressure of the engagement of the clutch.
>hile the pressure gauge is monitored, use the clear switch in order to adjust the
pressure. Adjust the pressure until the value that is on the pressure gauge
matches the pressure that was specified in 6tep 1.
11. 'ove the transmission direction control lever to the /01&2A3 position. &he
calibration is complete.
12. 1se the scroll switch to go to the submode that corresponds to the ne<t clutch
that needs to be calibrated. &he scroll switch may also be used to go to the
7"lutch $ill "alibration7 # submode 4%. &o e<it transmission calibration mode,
use the mode switch.
Submode 40 - Clutch Fill
&able (
Tools Needed
Part
Nm!er

"es#ri$tion
%antit&

4"8.1:,

"ontrol 6ervice &ool

1
The ;uality of the shifting of the transmission can be affected by the calibration of the
clutch fill. The calibration procedure is automatic. The clutch engagement calibration
/submodes 7. through 7<3 should be performed prior to performing the clutch fill
calibration.
"uring this calibration, error codes /"#88"3 can occur. The error codes appear in the
display area if there is a problem with the calibration or if there is a problem with the
results of the calibration. The error codes that can appear are listed below%
!"# ! There is a problem with an active clutch solenoid or a speed sensor.
!"$ ! The transmission direction control lever is not in neutral.
!"% ! The transmission oil temperature is below the threshold of +1 ,C /.<0 ,23 or the
transmission oil temperature sensor is faulty.
!"& ! The engine speed is below the threshold of .<)) rpm.
!"' ! The par*ing bra*e is not on.
!"( ! CI" )(44 /sensor3 is active. Correct the problem.
!") ! The machine speed is not 'ero.
!#" ! The service bra*e pedal is pressed.
!*# ! Clutch . is at A limit.
!** ! Clutch ( is at A limit.
!*+ ! Clutch 7 is at A limit.
!*$ ! Clutch 0 is at A limit.
!*% ! Clutch < is at A limit.
2or error codes #(., #((, #(7, #(0, or #(< the calibration software will select values
that do the best job possible, but the error indicates something is wrong with either the
calibration conditions or the control system. Things to chec* for #(. through #(< are%
&he oil and the transmission is fully warmed for the calibration.
&he valves are correctly tor=ued when the machine is cool.
&he seals are not worn.
&he clutch is not worn beyond the allowable range.
&he valve is not damaged.
If a new valve was installed, shift the tractor into a gear that uses the new valve
at least 12 times before beginning the procedure.
"hec- that the priority valve solenoid is off.
5nce problems are fi9ed, run the clutch fill calibration /submode 0)3 again.
Procedure
Note: The steps of this procedure must be performed e9actly. The 6teps of this
procedure must be performed in se;uence. This procedure can terminate if any
une9pected functions are activated or if a diagnostic code is present. "o not change any
switch positions. "o not move any levers. "o not depress any pedals. If there is a
problem with the calibration or if there is a problem with the results of the calibration,
an error code /"#88"3 will appear in the display area.
1. &he clutch engagement calibration #submodes *1 through *,% should be
performed prior to performing the clutch fill calibration.
2. If a new clutch solenoid valve was installed, shift the transmission at least 12
times into a gear that uses the solenoid valve. Allow sufficient time for the
corresponding clutch to be fully pressurized.
*. Warm the transmission oil to at least 5. !" #1,4 !$%. &he component data
display mode can be used to monitor the temperature of the transmission oil.
&he mode for the )52 6eries II, )(2 6eries II, and the ).2 6eries II is mode
number .. &he mode for the ),', )5', )52, and the )(2 is mode number (.
&he "I) number is 1((. 4perate the machine or allow the transmission to spin
in /01&2A3 in order to ensure that the transmission is fully warmed.
4. +lace the transmission direction control lever in the /01&2A3 position.
,. +lace the par-ing bra-e switch in the 4/ position. &he transmission will shift to
/01&2A3 and to first speed.
5. 4n machines that have the power shift tor=ue converter, set the engine speed
to 15 rpm. 4n machines that have the power shift direct drive, set the engine
speed to 2 rpm.
(. With the 4C-8195 "ontrol 6ervice &ool, enter the transmission calibration mode
#'ode 5%. &hen, enter submode 4.
.. If all the conditions are correct for calibration, 7>s7 will move across the display
area.
Note: If the conditions for setup are not correct, ")@s" are not shown in the
display area. An error code /"#88"3 appears. The calibration will not run until
all error codes are corrected. Correct the error code and restart the procedures.
:. When 7>s7 are moving across the display, move the transmission direction
control lever to the $42WA2) position. &he clutch fill calibration will begin.
1. &he display changes. &he display now shows the number of the active clutch #1
through ,%. &he calibration automatically changes in order to perform the
calibration for each clutch.
Note: "uring the calibration, there are many clutch fills occurring. Remain
seated. Aibration and noise will be present . If any of the conditions for setup are
not followed during the calibration, then the calibration will be stopped and a
corresponding error code /"#88"3 will be shown. Correct the error code and
restart the procedures.
11. When the calibration is completed successfully, 78887 will be shown on the
display. An error code may also be displayed. &he error code indicates that the
calibration had a problem.
12. 4perate the machine in order to chec- the =uality of the shifting of the
transmission.
1*. 0<it submode 4 by scrolling to another submode with the scroll switch. &he
mode switch can also be used to e<it the calibration.