Transmission Clutch Calibration
The power train ECM includes two calibration procedures for the transmission clutches on machines that have Electronic Clutch Pressure Control (ECPC).
- The "Calibration of the Transmission Clutch Engagement" sets the electrical current of each clutch solenoid in order to obtain the correct pressure of each transmission clutch.
- The "Transmission Clutch Fill Calibration" sets the parameters for the transmission clutch fill. This calibration will affect the quality of the shifting of the transmission.
Calibration of the Transmission Clutch Engagement
The transmission clutches need to be calibrated if any of the following events have occurred:
- A clutch solenoid valve has been replaced.
- A clutch solenoid valve has been substituted.
- A clutch solenoid valve has been cleaned.
- A different power train ECM has been installed.
- A transmission clutch has been rebuilt.
- Shifting is harsh.
When the calibrations are performed, error codes ("EXX") can occur. The error codes appear in the display area if there is a problem with the conditions or if there is a problem with the results of the calibration. The error codes that can appear are listed below:
E01 - There is a problem with the active clutch solenoid or the speed sensor.
E04 - The transmission direction control lever is not in NEUTRAL.
E05 - The transmission oil temperature is below the threshold of
E06 - The engine speed is below the threshold of 1500 rpm.
E07 - The parking brake is not on.
E08 - CID 0299 (sensor) is active. Correct the problem.
E09 - The machine speed is not zero.
E10 - The service brake pedal is depressed.
The life of the transmission is affected when the pressure for clutch engagement is correct. These calibrations set the pressure for the engagement of each clutch. The mechanic must adjust the electrical current that is sent to each clutch solenoid valve in order to obtain the specified pressure for the engagement of the clutch. This calibration should be performed prior to performing the "Transmission Clutch Fill Calibration" (submode 40).
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| Illustration 1 | g01089423 |
| Required Tools | |||
|---|---|---|---|
| Item | Part Number | Description | Qty |
| 4C-8195 | Control Service Tool | 1 | |
| A | 8T-0855 | Pressure Gauge (0 to 4,000 kPa (0 to 580 psi)) | 1 |
| 6v-3989 | Fitting | 1 | |
| 6V-4143 | Quick Connect Coupler | 2 | |
| 177-7861 | Hose As (0 to 41370 kPa (0 to 6000 psi)) | 1 | |
Note: The steps of this procedure must be performed exactly. The steps of this procedure must be performed in sequence. This procedure can terminate if any unexpected functions are activated or if a diagnostic code is present. DO NOT change any switch positions. DO NOT move any levers. DO 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 ("EXX") will appear in the display area.
- 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.
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Table 2 Position of The Transmission Control Lever Clutch Engagement In The Transmission Neutral 3 First Speed Forward 2 and 5 Second Speed Forward 2 and 4 Third Speed Forward 2 and 3 First Speed Reverse 1 and 5 Second Speed Reverse 1 and 4 Third Speed Reverse 1 and 3 - Warm the transmission oil to at least
40 °C (104 °F) . The "Component Data Display Mode" (Mode Number 8) can be used to monitor the temperature of the transmission oil. The CID number is 0177.Show/hide table
Illustration 3 g00932224 (6) Clutch Pressure for REVERSE
(7) Clutch Pressure for FORWARD
(8) Clutch Pressure for third gear
(9) Clutch Pressure for second gear
(10) Clutch Pressure for first gear - Place pressure gauge (A) on the pressure tap for the clutch that needs to be calibrated.
- Place the transmission direction control lever in the NEUTRAL position.
- Engage the parking brake. The transmission will shift to NEUTRAL. Then, the transmission will shift to First Speed.
- Set the engine speed to HIGH IDLE.
- With the 4C-8195 Control Service Tool, enter "Transmission Calibration Mode" (Mode 7). Then, enter the submode that corresponds to the clutch that is being calibrated.
(Submode 31) Clutch 1 Engagement
(Submode 32) Clutch 2 Engagement
(Submode 33) Clutch 3 Engagement
(Submode 34) Clutch 4 Engagement
(Submode 35) Clutch 5 Engagement
- If all the conditions are correct for calibration, the specified pressure for the engagement for the particular clutch is shown in the display area. The value that is shown is in units of ten kPa. For the actual value, multiply the value that is showing by 10. Record the value. In the remaining steps, adjustments are made so that the pressure is the actual reading for pressure from the pressure gauge.
Note: If the conditions for setup are not correct, the pressure is NOT shown in the display area. An error code ("EXX") 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 FORWARD position. This pressurizes the clutch that is being calibrated.
- The display will change. Now, the display shows a number that corresponds to the electrical current of the particular solenoid valve. The INCREMENT position ("+") and the DECREMENT position ("-") of the "CLEAR" switch can now be used to adjust the electrical current of the solenoid valve. The solenoid valve controls the pressure of the engagement of the clutch.
While 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 Step 8.
- Move the transmission direction control lever to the NEUTRAL position. The calibration is complete.
- Use the "SCROLL" switch to go to the submode that corresponds to the next clutch that needs to be calibrated. The "SCROLL" switch may also be used to go to the "Transmission Clutch Fill Calibration" (submode 40). To exit Transmission Calibration Mode, use the "MODE" switch.
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| Illustration 2 | g00937242 |
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(1) Modulating valve for clutch 1
(2) Modulating valve for clutch 2 (3) Modulating valve for clutch 3 (4) Modulating valve for clutch 4 (5) Modulating valve for clutch 5 | |
Transmission Clutch Fill Calibration
The quality of the shifting of the transmission can be affected by the calibration of the clutch fill. The calibration procedure is automatic. The "Calibration of the Transmission Clutch Engagement" (submodes 31 through 35) should be performed prior to performing the "Transmission Clutch Fill Calibration".
During this calibration, error codes ("EXX") 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:
E01 - There is a problem with the active clutch solenoid or the speed sensor.
E04 - The transmission direction control lever is not in NEUTRAL.
E05 - The transmission oil temperature is below the threshold of
E06 - The engine speed is below the threshold of 1500 rpm.
E07 - The parking brake is not on.
E08 - CID 0299 (sensor) is active. Correct the problem.
E09 - The machine speed is not zero.
E10 - The service brake pedal is pressed.
E21 - Clutch 1 is at a limit.
E22 - Clutch 2 is at a limit.
E23 - Clutch 3 is at a limit.
E24 - Clutch 4 is at a limit.
E25 - Clutch 5 is at a limit.
The calibration software is needed in order to adjust one of the parameters beyond the design specification for error codes E21, E22, E23, E24, or E25. The software will select values that will provide the best performance. An error indicates that something is wrong with either the calibration or the control system. Some objects that need to be checked for E21 through E25 are listed below:
- The oil and the transmission is fully warmed for the calibration.
- The valves are correctly torqued when the machine is cool.
- The seals are not worn.
- The clutch is not worn beyond the allowable range.
- The valve is not damaged.
- If a new valve was installed, shift the transmission at least 12 times into a gear that uses the new valve. This must be done before you begin the procedure.
Once problems are fixed, run the "Transmission Clutch Fill Calibration" (submode 40) again.
| Required Tools | ||
|---|---|---|
| Part Number | Description | Qty |
| 4C-8195 | Control Service Tool | 1 |
Note: The steps of this procedure must be performed exactly. The steps of this procedure must be performed in sequence. This procedure can terminate if any unexpected functions are activated or if a diagnostic code is present. DO NOT change any switch positions. DO NOT move any levers. DO 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 ("EXX") will appear in the display area.
- The "Calibration of the Transmission Clutch Engagement" (submodes 31 through 35) should be performed prior to performing the "Transmission Clutch Fill Calibration".
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Illustration 4 g00937242 (1) Modulating valve for clutch 1
(2) Modulating valve for clutch 2
(3) Modulating valve for clutch 3
(4) Modulating valve for clutch 4
(5) Modulating valve for clutch 5 - 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.
Show/hide table
Table 4 Position of The Transmission Control Lever Clutch Engagement In The Transmission Neutral 3 First Speed Forward 2 and 5 Second Speed Forward 2 and 4 Third Speed Forward 2 and 3 First Speed Reverse 1 and 5 Second Speed Reverse 1 and 4 Third Speed Reverse 1 and 3 - Warm the transmission oil to at least
68 °C (154 °F) . The "Component Data Display Mode" (Mode Number 8) can be used to monitor the temperature of the transmission oil. The CID number is 0177. - Place the transmission direction control lever in the NEUTRAL position.
- Engage the parking brake. The transmission will shift to NEUTRAL and to First Speed.
- Set the engine speed to 1600 rpm.
- With the 4C-8195 Control Service Tool, enter "Transmission Calibration Mode" (Mode 7). Then, enter submode 40.
- If all the conditions are correct for calibration, "0's" will move across the display area.
Note: If the conditions for setup are not correct, "0's" are NOT shown in the display area. An error code ("EXX") appears. The calibration will not run until all error codes are corrected. Correct the error code and restart the procedures.
- When "0's" are moving across the display, move the transmission direction control lever to the FORWARD position. The "clutch fill calibration" will begin.
- The display changes. The display now shows the number of the active clutch (1 through 5). The calibration automatically changes in order to perform the calibration for each clutch.
Note: During the calibration, there are many clutch fills that occur. Remain seated. Vibration 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 ("EXX") will be shown. Correct the error code and restart the procedures.
- When the calibration is completed successfully, "---" will be shown on the display. An error code may also be displayed. The error code indicates that the calibration had a problem.
- Operate the machine in order to check the quality of the shifting of the transmission.
- Exit submode 40 by scrolling to another submode with the "SCROLL" switch. The "MODE" switch can also be used to exit the calibration.