The transmission system must be calibrated if any of the following conditions have occurred:
- A clutch solenoid modulating valve has been replaced or cleaned.
- A different power train ECM has been installed.
- A transmission clutch has been rebuilt.
- Harsh shifting exists.
Reference: For additional information on the clutch solenoid modulating valves, refer to the Service Manual module Systems Operation, "Modulating Valve (Transmission Clutch)" for the machine that is being serviced.
| Error Codes for Transmission Clutch Engagement | |
| E01 | Active Clutch Solenoid or Speed Sensor Fault Correct the Speed Sensor Fault |
| E04 | Transmission Direction Control Switch is Not in the Neutral Position |
| Transmission Direction and Speed Control Lever is Not in the Neutral Position | |
| E05 | Transmission Oil Temperature is Below Threshold ( 40°C (104°F)) |
| E06 | Engine Speed is Below Threshold (1800 RPM) |
| E07 | Parking Brake Is Not Engaged |
| E09 | Machine Speed Is Not Zero |
During the calibration of the pressure for the transmission clutch engagement, error codes EXX can occur. The error codes will appear in the display area of the Caterpillar Monitoring System. The error codes will appear if a problem occurs during the calibration. Check the error codes in Table 1.
Calibration Procedure for Transmission Clutch Engagement
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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Do not connect or disconnect hose fittings to or from the quick disconnect nipples when there is pressure in the system. This will prevent damage to the seals that are in the fitting. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Park the machine on a smooth, level surface.
- Shift the transmission direction switch to the NEUTRAL position. Shift the transmission speed switch to any speed position.
- Lower the blade or the work tool to the ground.
- Engage the parking brake.
- Place blocks in front of the wheels and behind the wheels.
- Install the steering frame lock.
- Shut off the engine.
- Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.
Show/hide table
Table 2 Required Tools Part Number Description Quantity 4C-8195 Control Service Tool 1 1U-5481 (1) Pressure Gauge Group 1 1U-5482 Hoses From the Pressure Adapter Group 6 Show/hide table( 1 ) The 198-4240 Pressure Indicator Tool Gp is also available.
Note: The steps of this procedure must be performed exactly, as described below. This procedure may terminate if any unknown functions or any unexpected functions are activated. This procedure may terminate if a fault (CID FMI) is present. Do not move any switch positions, any levers or any pedals unless you are instructed differently.
- To access the transmission control, tilt the cab forward. Install support bracket (1) .
Reference: For additional information on the installation of cab support bracket (1), refer to the Service Manual module Disassembly and Assembly, "Cab Raise" for the machine that is being serviced.
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| Illustration 1 | g00615171 |
(1) Cab support bracket (2) Transmission control cover (3) Sensor connection for the oil temperature | |
- Disconnect temperature sensor (3) .
- Remove control cover (2) .
- Label both ends of the six hoses that are from 1U-5482 Pressure Adapter Group (10). Install each hose assembly from 1U-5482 Pressure Adapter Group onto the pressure tap of the clutch solenoid modulating valve that is being calibrated.
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| Illustration 2 | g00606938 |
Transmission Clutch Solenoid Modulating Valves (4) Number 6 clutch solenoid modulating valve (First speed) (5) Number 5 clutch solenoid modulating valve (Second speed) (6) Number 3 clutch solenoid modulating valve (Fourth speed) (7) Six pressure taps for the clutch solenoid modulating valves (8) Number 1 clutch solenoid modulating valve (Reverse) (9) Number 2 clutch solenoid modulating valve (Forward) (10) Number 4 clutch solenoid modulating valve (Third speed) | |
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| Illustration 3 | g00615243 |
Transmission Control (11) Labels on the hoses from the 1U-5482 Pressure Adapter Group . | |
- Position clean cardboard (12) over the control valve. This will prevent excess oil from splashing out of the control. The cardboard will also help to block contaminants.
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| Illustration 4 | g00615293 |
- Connect oil temperature sensor (3) .
- Attach the opposite end of the hose assembly to the 0 to 3400 kPa (0 to 580 psi) pressure gauge in the 1U-5481 Pressure Gauge Group .
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| Illustration 5 | g00615380 |
- Make sure that transmission direction switch (15) is in the NEUTRAL position.
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| Illustration 6 | g00612687 |
Command Control Steering (14) Upshift/downshift switch. (15) Transmission direction selector. | |
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| Illustration 7 | g00616160 |
STIC Steering Control (14) Upshift/downshift switch. (15) Transmission direction selector. | |
- Make sure that the parking brake is engaged.
- Start the engine.
- Warm the transmission oil to approximately 40 °C (104 °F).
Note: The transmission oil temperature gauge should be at the center position.
- Start the engine and operate the engine at low idle.
- Increase the engine speed to high idle.
Note: You can use the SET/DECEL switch to maintain the high idle. The RESUME/ACCEL switch can be used to resume high idle.
Show/hide tableTable 3 Clutch Engagement Calibration Submodes Submode 31 Number 1 Clutch Engagement
ReverseSubmode 32 Number 2 Clutch Engagement
ForwardSubmode 33 (1) Number 3 Clutch Engagement
Fourth SpeedSubmode 34 (1) Number 4 Clutch Engagement
Third SpeedSubmode 35 Number 5 Clutch Engagement
Second SpeedSubmode 36 Number 6 Clutch Engagement
First SpeedShow/hide table( 1 ) 834G only
Note: If a new clutch solenoid modulating valve was installed, shift the transmission for at least 12 times into a speed or a direction that uses the clutch solenoid modulating valve. Refer to Illustration 2 in order to identify the clutch solenoid modulating valve and the corresponding clutch. Allow sufficient time for the corresponding clutch to be fully pressurized.
- Use the 4C-8195 Control Service Tool to enter Transmission Calibration Mode (6). Then enter the submode that corresponds to the clutch that is being calibrated. Enter the submode by using the "SCROLL" switch.
Show/hide table
Table 4 Pressure Specification for Transmission Clutch Engagement Model Clutch 1 Clutch 2 Clutch 3 Clutch 4 Clutch 5 Clutch 6 834G
2210 ± 70 kPa (320 ± 10 psi)
2210 ± 70 kPa (320 ± 10 psi)
2280 ± 70 kPa (330 ± 10 psi)
2280 ± 70 kPa (330 ± 10 psi)
1720 ± 70 kPa (250 ± 10 psi)
2280 ± 70 kPa (330 ± 10 psi)836G
2210 ± 70 kPa (320 ± 10 psi)
2210 ± 70 kPa (320 ± 10 psi)
1720 ± 70 kPa (250 ± 10 psi)
2280 ± 70 kPa (330 ± 10 psi)
- If all the conditions are correct for calibration, the pressure for the particular clutch is shown in the display area of the Caterpillar Monitoring System. The units of the value that is displayed is shown in one-tenth of kPa. Multiply the value that is shown in the display by 10 to determine the true specified value in kPa. Record the value.
In the remaining steps, adjustments are made so that this pressure is the actual pressure gauge reading. The pressure is also listed in Table 4.
Note: If the conditions are not correct for calibration, the pressure is not shown in the display area. Instead, an error code (EXX) appears. The calibration will not run until all necessary conditions are met. Correct the error code and perform these procedures again. Refer to Table 1 for a list of the error codes and the meaning of the error codes.
- When all conditions are met and the pressure is shown in the display area, shift transmission direction control switch (15) to the FORWARD position. This pressurizes the clutch that is being calibrated.
- The value that is shown in the display area will change and a number that corresponds to the electrical current of the particular clutch solenoid modulating valve is shown. The INCREMENT (+) and DECREMENT (-) positions of the "CLEAR" switch can now be used to adjust the electrical current of the clutch solenoid modulating valve. The electrical current of the clutch solenoid modulating valve controls the pressure.
While you are observing the pressure gauge that was installed in Step 7, use the "CLEAR" switch in order to adjust the pressure of engagement until the pressure gauge reading matches the pressure of engagement from Table 4.
- Shift transmission direction control switch (15) to the NEUTRAL position. This completes the calibration of the selected clutch.
- To exit this submode, use the "SCROLL" switch to scroll to the submode that corresponds to the next clutch that needs to be calibrated, or scroll to submode 40. Refer to Table 3 for a list of the clutch engagement calibration submodes. Submode 40 is used to calibrate the transmission clutch fill. Exit the Transmission Calibration Mode by using the "MODE" switch.
Reference: For more information on submode 40, refer to Testing and Adjusting, "Fill Time for the Transmission Clutch - Calibrate" for the machine that is being serviced.