631K and 637K Wheel Tractor-Scraper Systems Calibration Procedures Caterpillar

Cat ^® Electronic Technician (Cat ET) Service Tool

Illustration 1	g02618978
Cat ® Electronic Technician (Cat ET) Service Tool

All of the calibration procedures for the Scraper are carried out by using Cat ET.

Cat ET is a software program that runs on a personal computer. Cat ET communicates with the electronic control module through the data link.

Note: Ensure the most recent version of Cat ET is installed.

Engagement Pressure for the Transmission Clutch

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Hot hydraulic oil under high pressure can remain in the components of the hydraulic system or the power train system after the engine has been stopped. The uncontrolled release of the hydraulic oil can cause sudden machine movement and can also result in the following conditions: Burns The penetration of body tissue Other personal injury Death If hydraulic oil penetrates body tissue, the injury must be treated immediately by a doctor who is familiar with this type of injury. Use a board or a piece of cardboard to check for a hydraulic oil leak. Make sure that all of the attachments have been lowered to the ground and that all trapped pressure has been released from the hydraulic system and the power train system. Also, make sure that the hydraulic oil is cool before the removal of any components or lines. Remove the hydraulic 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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Personal injury or death can result from not engaging the parking brake. Transmission engagement alone will not prevent machine from rolling when the engine is stopped.

The calibration procedure calibrates the control of the modulating valves that are used to fill the clutches in the planetary transmission.

Calibrate the transmission if any of the following conditions occur:

• The quality of transmission shifts has degraded.

• Modulating valves for the electronic clutch pressure control have been replaced.

• A new ECM has been installed.

• A new wiring harness has been installed.

• A repair has been carried out to a wire to the modulating valves for the electronic clutch pressure control.

• The transmission has been rebuilt with new clutches.

If any transmission components have been replaced, operate the component at least 12 times prior to calibration.

Calibration of the Transmission Planetary Clutches

Before initiating the calibration of the transmission, check that the parking brake and the service brakes function correctly.

Note: Pressing the service brakes at any time during the calibration procedure will abort the calibration procedure.

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Illustration 2	g02563737
The Cat ET connector is located on the wall of the cab and to the right of the operator seat.

1. Connect the computer to the socket connector for Cat ET by using the communications adapter. The socket connector for Cat ET is located on the panel to right side of the operator.

2. Turn the engine start switch to the ON position. Start the engine.

   Switch on the computer and open the Cat ET software.

3. Check that the computer detects the electronic control modules.
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   Illustration 3	g03479594

4. Click "SERVICE" on the menu at the top of the screen. Click "CALIBRATIONS" when the drop-down appears.
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   Illustration 4	g03479617

5. Expand the "Transmission" section of the menu screen and click "Transmission Clutch Calibration" as shown in Illustration 4.
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   Illustration 5	g03479648

6. The screen for the calibration of the transmission planetary clutches will appear as shown in Illustration 5.

   Note: A gauge valve must be attached to the valve being calibrated. Select one Transmission Clutch to be calibrated from the list above and continue the calibration process until all of the clutch valves have been calibrated.

7. Note the conditions that are listed on the screen to satisfy the calibration requirements:

   • The parking brake must be engaged.

   • The transmission must be in the NEUTRAL position.

   • The engine must be running at low idle.

   • The temperature of the transmission oil must be above 75 °C (150 °F) and not higher than 85° C (185° F).

   If necessary, perform a torque stall of the machine to heat the transmission oil to the required temperature.

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   Illustration 6	g03479759

8. Once all the above conditions are satisfied, select "Next" in the bottom left corner of the screen. The calibration of the transmission planetary clutch will begin automatically.

   Note: You can follow the progress of the calibration by viewing the bar chart at the bottom of the screen.

   Note: The engine speed will fluctuate automatically for approximately 5 minutes. Engine speed fluctuation is normal as the transmission planetary clutch is being calibrated.

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   Illustration 7	g03479766

9. Once the calibration procedure for the transmission planetary clutch has been completed, a message will appear on the screen. The message will state:

   • (a) calibration procedure has been successful. or

   • (b) calibration has reached a limit.
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   Illustration 8	g03479821

   1. If the calibration procedure has been successful, select "Finish".Repeat the calibration procedure for each of the clutches on the machine.

   2. If the calibration procedure has reached a limit, repeat the calibration procedure.

Fill Time for the Transmission Clutch

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.

Reference: Refer to Testing and Adjusting, "Transmission Oil Pump Pressure - Test" for information about setting the relief valve.

Note: Do not perform this procedure if software has been uploaded into the Transmission ECM. Cycle the power for the Transmission ECM 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 ECM has been installed.

• New flash software has been flashed into the ECM.

• 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 modulating control valves are mounted on the rear of the transmission on the left side of the machine. There is one modulating valve for each of the eight transmission clutches. The machine is equipped with seven clutches.

Preparation for Calibration Procedure

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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.

The following conditions must be met before calibration:

• The main relief valve must be calibrated.

• The calibration of the engagement pressure must be completed.

• The machine speed must be zero.

• The engine must be running at low idle.

• The parking brake must be set.

• The transmission oil temperature must be at an operating temperature between 75° C (167° F) and 85° C (185° F).

Reference: Refer to Testing and Adjusting, "Transmission Oil Pump Pressure - Test" for information about setting the relief valve.

Note: 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.

Calibration Procedure

Cat ET is used to access the calibration procedures. A message on the Cat ET screen will give instructions that guide the user through the calibration procedure. Refer to the Manual that is provided with Cat ET for more information about Cat ET.

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Illustration 9	g02563737
The Cat ET connector is located on the wall of the cab and to the right of the operator seat.

1. Connect Cat ET to service connector .

2. Open the Cat ET software program. Click "SERVICE" from the menu bar at the top of the screen.
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   Illustration 10	g03479594

3. When the drop-down appears, click "CALIBRATIONS".
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   Illustration 11	g03479938

4. On the computer screen expand the TRANSMISSION sub menu. Click on "TRANSMISSION FILL CAIBRATION".
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   Illustration 12	g03480137

5. If the conditions that are listed above in Set Up Calibration Conditions are met, the display will inform the technician to press NEXT to advance to the next step.

   Note: During the calibration of the transmission clutch fill, many transmission clutch fills are occurring. 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, avoid performing steering movements.

   Note: At any time during the calibration, the user can abort the calibration by pressing the CANCEL button. Depressing the clutch pedal or depressing the service brake pedal will also abort the calibration.

   Note: During calibration Cat ET will display a requested engine speed for the calibration. The engine must achieve the requested speed in a maximum of 5 seconds. If the engine does not reach the requested rpm in the given amount of time, the ECM will abort calibration due to incorrect engine speed.

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   Illustration 13	g03480162

6. The display will continuously display "Calibrating Clutch #1". The ECM will fill clutch 1 and the ECM will drain "Clutch 1" several times. The ECM will formulate the optimal hold current and the optimal ramp levels for the solenoid that operates the modulating valve for "Clutch 1". When the ECM has completed calibrating this clutch, Cat ET automatically moves to the next calibration.

7. The display will continuously display "Calibrating Clutch 2". The ECM will fill "Clutch 2" and the ECM will drain "Clutch 2" several times. The ECM will formulate the optimal hold current and the optimal ramp levels for the solenoid that operates the modulating valve for "Clutch 2". When the ECM has completed calibrating this clutch, Cat ET automatically moves to the next clutch.

8. The display will continuously display "Calibrating Clutch 3". The ECM will fill "Clutch 3" and the ECM will drain "Clutch 3" several times. The ECM will formulate the optimal hold current and the optimal ramp levels for the solenoid that operates the modulating valve for "Clutch 3". When the ECM has completed calibrating this clutch, Cat ET automatically moves to the next clutch calibration.

   Note: The process described above will continue until all of the transmission clutches have been calibrated.

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   Illustration 14	g03480174

9. Once all calibrations have been calibrated successfully, the ECM will write the calibration data to memory.

10. Next, operate the machinery to check the quality of transmission shift.

11. Resume normal operation of the machine.

Inertial Measurement Sensor Calibration

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Illustration 15	g02563737
The Cat ET connector is located on the wall of the cab and to the right of the operator seat.

1. Connect the computer to the socket connector for Cat ET by using the communications adapter. The socket connector for Cat ET is located on the panel to right side of the operator.

2. Turn the engine start switch to the ON position. Start the engine.

   Switch on the computer and open the Cat ET software.

3. Check that the computer detects the electronic control modules.
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   Illustration 16	g03479594

4. Click "SERVICE" on the menu at the top of the screen. Click "CALIBRATIONS" when the drop-down appears.
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   Illustration 17	g03482097

5. Expand the "Transmission" section of the menu screen and click "Inertial Measurement Sensor Calibration". (See Illustration 17.)
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   Illustration 18	g03482103

6. Once all the above conditions are satisfied, select "Next" in the bottom left corner of the screen. The calibration of the inertial measurement sensor will begin automatically.

7. Follow the on screen instructions in order to perform the calibration procedure for the inertial measurement sensor.

Implement Solenoid Valve

This calibration is used to determine the minimum amount of solenoid valve current needed to initiate movement in an implement cylinder. This current is referred to as the minimum modulation current, or start current. The start current can be affected by engine/pump speed, oil temperature, valve and pump tolerances, and much more. This valve calibration is designed to provide a procedure that reduces deadband related to these factors.

Before starting the calibration, install the Load Sense Pressure Service Tool ( 369-4187 Calibration Kit).

1. Ensure that machine is safely shut down and locked out.
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   Illustration 19	g02623416
   Load Sense Pressure Port

2. Locate the Load Sense Pressure Port at the Implement Pump and the electrical connector to the ECM for the calibration.
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   Illustration 20	g02623517
   Pressure Sensor

3. Using the Calibration Kit, snap the Pressure Sensor in place and connect the electrical connectors.

4. After Calibration Kit is installed, turn the machine battery disconnect switch back to the ON position.
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   Illustration 21	g02618978
   Cat ET

5. Use Cat ET to access the Implement Control Lever Calibration.

   1. Connect a laptop to the machine. A communication adapter must be used. The laptop must have the latest Cat ET software version. Refer to the "Service Tools" section of this document.
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      Illustration 22	g03479594

   2. Select "Implement" ECM.

   3. Press "OK".

   4. Go to "Service".

   5. Select "Calibrations".
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   Illustration 23	g03480323

6. Select "Implement Solenoid Calibrations" under the "Implement" ECM.
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   Illustration 24	g02623588
   Components to Calibrate Selection Screen

7. Select which components to calibrate and press "Begin".
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   Illustration 25	g03480338
   Bowl Up Solenoid Calibration

8. Ensure that the Parking Brake is ON and press the "Next >" button. Once the calibration procedure begins, errors may occur that will abort the calibration. The errors must be corrected to perform the calibration.
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   Table 3

   ERROR CODE	ISSUE DESCRIPTION	CAUSES	ACTION TO TAKE
   0x0002	Active Diagnostic Code Present.	The Calibration Pressure Sensor is not connected or is faulted. A related component fault is active	Check the Calibration Pressure Sensor. Ensure that sensor is connected properly and the circuit components are in good working condition. Troubleshoot, repair, and clear active fault codes.
   0x104D	Hold Pressure is too Low Minimum measured hold pressure is below the valid range.	The Calibration Pressure Sensor is not connected properly to the hydraulic system or not sensing pressure properly. Hydraulic system issues may be preventing proper pressure response when the valve is deactivated.	Check / replace the Calibration Pressure Sensor. Troubleshoot the Hydraulic system low hold pressure symptom.
   0x10FC	Hold Pressure is too High Minimum measured hold pressure is above the valid range.	The Calibration Pressure Sensor is not connected properly to the hydraulic system or not sensing pressure properly. Hydraulic system issues may be preventing proper pressure response when the valve is deactivated.	Check / replace the Calibration Pressure Sensor. Troubleshoot the Hydraulic system High hold pressure symptom.
   0x105F	Calibration Timed Out Pre-charge pressure is not reached in the specified amount of time.	The implement / linkage was not set at the proper location during this step of the calibration. The Calibration Pressure Sensor is not connected properly to the hydraulic system or not sensing pressure properly. The component being calibrated is too far out of range to pre-charge the cylinder. Hydraulic system issues may be preventing proper pressure response of the valve during activation.	Retry calibration, setting component in the proper position. Check / replace the Calibration Pressure Sensor. Check / replace the solenoid being calibrated Troubleshoot / repair the hydraulic system issue.
   0x10F0	Calibration Value Out of Range Low Recorded cracking current is below the valid range.	Component was not set at proper position during this step of the calibration. Hydraulic system issues may be preventing proper pressure response of the valve during activation.	Retry calibration, setting component in the proper position. Troubleshoot / repair the hydraulic system issue.
   0x10F1	Calibration Value Out of Range High Recorded cracking current is above the valid range. Current was ramped all the way through the range, but the pressure never increased higher than the cracking threshold.	Component was not set at proper position during this step of the calibration. Hydraulic system issues may be preventing proper pressure response of the valve during activation.	Retry calibration, setting component in the proper position. Troubleshoot / repair the hydraulic system issue.

9. Follow instructions from the Cat ET calibration procedure screens to complete component calibration.

Implement Control Lever

Calibrations for operator implement controls are designed to provide consistent implement system operation. This calibration helps reduce deadband by recording the sensor duty cycle associated with full rearward (or full left) and full forward (or full right) control positions. These two points can then be used to convert a PWM Duty Cycle (%) into a normalized position.

Illustration 26	g02618978
AVSpare Electronic Technician

1. Use AVSpare Electronic Technician (Cat ET) in order to access the Implement Control Lever Calibration.

   1. Connect a laptop to the machine. A communication adapter must be used. The laptop must have the latest Cat ET software version. Refer to the "Service Tools" section of this document.
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      Illustration 27	g03479594

   2. Select "Implement" ECM.

   3. Press "OK".

   4. Go to "Service".

   5. Select "Calibrations".
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   Illustration 28	g03480397

2. Select "Implement Control Lever Calibrations" under the "Implement" ECM.
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   Illustration 29	g02622289
   Components to Calibrate Selection Screen

3. Select which components to calibrate and press "Begin".
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   Illustration 30	g03480438
   Bowl lever sensor calibration

4. Set the Parking Brake and press the "Next >" button. Once the calibration procedure begins, errors may occur that will abort the calibration. The errors must be corrected to perform the calibration.
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   Table 4

   ERROR CODE	ISSUE DESCRIPTION	CAUSES	ACTION TO TAKE
   0x0002	Active Diagnostic Code Present.	A related component fault is active	Troubleshoot, repair, and clear active fault codes
   0x10F0	Calibration Value Out of Range Low	Component was not set at proper position during this step of the calibration. Component is too far out of range to calibrate.	Retry calibration, setting component in the proper position. If Error code still present, replace component.
   0x10F1	Calibration Value Out of Range High	Component was not set at proper position during this step of the calibration. Component is too far out of range to calibrate.	Retry calibration, setting component in the proper position. If Error code still present, replace component.

5. Follow instructions from the Cat ET calibration procedure screens to complete component calibration.

Cylinder Position Sensor

Calibrations for cylinder position sensors are designed to provide consistent implement system operation on machines. Without the sensors, there would be no way to achieve the calculation accuracy needed for many of the related E/H system features.

Illustration 31	g02618978
AVSpare Electronic Technician

1. Use AVSpare Electronic Technician (Cat ET) in order to access the cylinder position sensor calibration.

   1. Connect a laptop to the machine. A communication adapter must be used. The laptop must have the latest Cat ET software version. Refer to the "Service Tools" section of this document.
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      Illustration 32	g03479594

   2. Select "Implement" ECM.

   3. Press "OK".

   4. Go to "Service".

   5. Select "Calibrations".
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   Illustration 33	g03480537

2. Select "Cylinder Position Sensor Calibration" under the "Implement" ECM.
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   Illustration 34	g02619136
   Components to Calibrate Selection Screen

3. Select which components to calibrate and press "Begin".
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   Illustration 35	g03481577
   Apron cylinder position sensor calibration

4. Set the Parking Brake and press the "Next >" button. Once the calibration procedure begins, errors may occur that will abort the calibration. The errors must be corrected to perform the calibration.
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   Table 5

   ERROR CODE	ISSUE DESCRIPTION	CAUSES	ACTION TO TAKE
   0x0002	Active Diagnostic Code Present.	A related component fault is active	Troubleshoot, repair, and clear active fault codes
   0x10F0	Calibration Value Out of Range Low	Component was not set at proper position during this step of the calibration. Component is too far out of range to calibrate.	Retry calibration, setting component in the proper position. If Error code still present, replace component.
   0x10F1	Calibration Value Out of Range High	Component was not set at proper position during this step of the calibration. Component is too far out of range to calibrate.	Retry calibration, setting component in the proper position. If Error code still present, replace component.

5. Follow instructions from the Cat ET calibration procedure screens to complete component calibration.