525C, 535C and 545C Wheel Skidders Power Train Caterpillar

Procedure for Transmission Clutch Fill Calibration

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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.

Illustration 1	g00924608
Location of the Modulating Valves

• (1) Modulating valve for clutch 2 (Forward High)

• (2) Modulating valve for clutch 1 (Forward Low)

• (3) Modulating valve for clutch 3 (Reverse)

• (4) Modulating valve for clutch 4 (Second Speed)

• (5) Modulating valve for clutch 6 (First Speed)

• (6) Modulating valve for clutch 5 (Third Speed)

1. Start the engine.

2. Park the machine on a smooth, level surface.

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Illustration 2	g01284899
(7) Transmission direction control switch

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Illustration 3	g01287011
(8) Transmission speed upshift control switch (9) Transmission speed downshift control switch

3. Shift transmission direction switch (7) to the NEUTRAL position. Use transmission speed upshift control switch (8) or transmission speed downshift control switch (9) to place the transmission in any speed position.

4. Lower the work tool to the ground.

5. Engage the parking brake and stop the engine.

6. Place blocks in front of the wheels and behind the wheels.

7. Install the steering frame lock.

8. Close the doors for the engine enclosure in order to provide proper operation of the cooling system.

9. Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.

10. If a new modulating valve was installed, start the engine and shift the transmission for at least 12 times into a speed or a direction that uses the new clutch solenoid modulating valve. Refer to Table 1 in order to identify the clutches that are engaged for each direction and each gear. If a new modulating valve was not installed, proceed to the next step.
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    Table 1

    	First gear forward	Second gear forward	Third gear forward	Fourth gear forward	Fifth gear forward	Neutral	First gear reverse	Second gear reverse	Third gear reverse
    Clutch 1	X		X
    Clutch 2		X		X	X
    Clutch 3							X	X	X
    Clutch 4			X	X				X
    Clutch 5					X	X			X
    Clutch 6	X	X					X

    Note: The third gear clutch might not engage in neutral during certain conditions.

The software program that will be used for this test procedure is the Caterpillar Electronic Technician (ET). The Caterpillar Electronic Technician is a software program that can be used on an IBM-compatible personal computer. Refer to the Service Manual, JEBD3003 for the requirements in order to install ET.

1. Open the software program (ET). Select the machine control ECM from the ECM list.

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Illustration 4	g01287089

2. Select the "Service" menu in order to begin the calibration procedure. Then select "Calibrations". A second menu will be displayed. Select "Transmission Fill Calibration" from the second menu.

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Illustration 5	g01287106

3. The next screen is the initial calibration screen. Once "Transmission Fill Calibration" has been selected, the screen displays the instructions for calibration. The top display area displays status parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The display area on the bottom will display the conditions for the setup and the display area on the bottom will also display the instructions for the calibration.

4. The display area will show the following conditions for the setup:
   • Warm the transmission oil to a minimum of 75 °C (167 °F).

   • Place the transmission direction control switch in the NEUTRAL position.

   • Engage the parking brake.

   • Operate the engine at high idle.

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   Illustration 6	g01285054
   (7) Transmission direction control switch

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   Illustration 7	g01285056
   (8) Transmission speed upshift control switch (9) Transmission speed downshift control switch

   1. Perform the following procedure in order to warm the transmission oil:
      • Engage the parking brake.

      • Lower the implement.

      • Push transmission speed upshift control switch (8) into the fifth gear position.

      • Place transmission direction control switch (7) in the FORWARD position.

      • Operate the engine at high idle. Monitor the gauge for the torque converter oil temperature that is on the dash panel. Reduce the engine speed and shift the transmission into the NEUTRAL position when the gauge enters the high temperature area. Shift the transmission back into gear once the temperature returns to normal.

   2. Use the ET calibration screen in order to monitor the transmission oil temperature.

   3. Maintain the transmission oil temperature that is displayed by ET between 3 minutes and 5 minutes in order to properly heat up the transmission.

   4. Ensure that the transmission direction control switch is in NEUTRAL.

   5. Ensure that the parking brake is engaged.

   6. Operate the engine at high idle.

6. Press the "Next>" button in order to start the calibration. If the conditions for the setup are not correct, the condition that is not correct will be display in the middle display area. The calibration will not start. When the conditions are correct, press the "Next>" button in order to start the fill calibration.

7. The calibration procedure continues unless the ECM determines that one of the conditions is not met. The middle display area will display a message in order to alert you of the error. You can correct the error that is described in the middle display area or you can cancel the calibration by pressing the "Cancel" button. The Electronic Technician will display a message in the middle display area in order to alert you of the problem.

8. If the fill calibration needs to be restarted, press the "Restart" button.

9. If some of the clutches reach a limit during the calibration, the ECM will make a log. The ECM will then move to the next clutch. The user may press the "Restart" button in order to restart calibration.

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Illustration 8	g01287115

10. Once the calibration has been successfully completed, select "FINISH". Select the "File" menu and then select "Exit".