2011/04/01 Calibration (KENR6172)

SMCS - 7610 i04330590

Calibration allows the Machine ECM to determine the correct output level for solenoids and the correct input signal range for position sensors.

Calibration should be performed if the ECM has been removed or replaced and if the applicable components have been removed or replaced.

The solenoids and position sensors that are under the control of the Machine ECM can be calibrated by using the Caterpillar Electronic Technician
(Cat ET).

Illustration 1 g02500239
Cat ET Calibrations Menu

To access the calibration procedures for the Machine ECM, establish the connections of the Cat ET to the Machine ECM. Navigate to the
calibration screen by clicking "Service" on the tool bar and then clicking "Calibrations". Click on the calibration that is needed.

Once the specific calibration is selected, the Cat ET will guide you through the calibration procedure.

The Cat ET will list initial machine conditions that must be satisfied before the ECM will allow the calibration procedure to continue. Follow the
specific instructions on the display in order to complete the calibration procedure successfully.

Note: The "CALIBRATION REQUIRED" diagnostic will be active if either the operator or the ECM aborts any of the calibrations. The ECM will revert to
the previous successful calibrated values. In order to clear the diagnostic, key cycle the machine.

The following list details the calibrations that can be performed for the hystat components on the Machine ECM.

Note: For information on implement calibrations, refer to Testing and Adjusting, , KENR5705, "Calibration".

"Transmission Drive Pump Pressure Override Calibration"

This calibration is used in order to identify the relief pressures in the drive loops of the hydrostatic transmission. Identifying the relief pressures
allows the transmission control to optimize the hydraulic pressure in the drive loops. Hydrostatic pressures that are too low will affect the
performance of the machine and pressures that are too high can damage the components. This calibration determines the maximum pressure that
the ECM should allow the drive pressure to reach. The calibration checks the range of the pressure in order to ensure that the pressure is within the
acceptable range.

Navigate to the Cat ET calibration screen by clicking "Service" the tool bar and then clicking "Calibrations". Click "Transmission Drive Pump
Pressure Override Calibration".
Note: The transmission must be operated in FORWARD and in REVERSE for 5 seconds in each direction between consecutive pressure override
calibrations.

Illustration 2 g02490056
Cat ET Transmission Drive Pump Pressure Override Calibration Sequence

Average pressure is calculated when the following conditions occur:

The pump reaches 50% current

The minimum average of the left and right is determined for the calibration point

See Illustration 2.

If one or both of the average calculations are outside of the calibration range, a calibration error will occur. Refer to Table 1 for additional
information of each error code.

Cat ET Error Codes for Transmission Drive Pump Pressure Override Calibration 
Error ID and Description  Reasons for the Error Code  Recommended Response/Possible Cause  
"10F7 - Hydrostatic Transmission Neutral Motor speed is detected during Pressure Override Parking Brake is not holding machine when
Interlock Active"  calibration  stalling against the brakes. 
Check and adjust the setting for the crossover
One of the "Crossover Relief" pressures was out relief valve.

"0103 - Calibration Value Out-of-Range" 

of range (high or low)  Refer to Crossover Relief Valve - Adjust in this
manual. 
Check and adjust the setting for the crossover
One or both of the "Crossover Relief" pressures relief valve.

"0100 - Out-of-Range Low " 

were out of range low  Refer to Crossover Relief Valve - Adjust in this
manual. 
Check and adjust the setting for the crossover
One or both of the "Crossover Relief" pressures relief valve.

"0101 - Out-of-Range High " 

were out of range high  Refer to Crossover Relief Valve - Adjust in this
manual. 

Table 1

____________________

"Hystat Pump and Motor Solenoid Calibration"

Note: Secure the machine on stands before the calibration is performed. Refer to the lift and support information in Disassembly and Assembly,
"Track Roller - Remove" for your machine.

To prevent injury or death, never work under a machine while a test is

being performed.

The following components are utilized during the "Hystat Pump and Motor Solenoid Calibration":

Forward and Reverse Hystat Pump Solenoids

Motor Solenoids

Navigate to the Cat ET calibration screen by clicking "Service" the tool bar and then clicking "Calibrations". Click "Hystat Pump and Motor Solenoid
Calibration". A "Select Components to Calibrate" popup box will be visible. See Illustration 3.

Illustration 3 g02490096
"Select Components to Calibrate"

Note: Select both the forward and reverse components in order to perform a complete calibration.

The "Forward Pump and Motor Solenoid Calibration"determines the minimum and maximum solenoid currents for the following:

Left forward pump

Right forward pump

 Motor solenoids

The "Reverse Pump Solenoid Calibration" determines the minimum and maximum currents for the left and right reverse pump solenoids.

The following current values are determined during calibration:

"Minimum Pump Current" - minimum current flow to the forward and reverse solenoids on the left and right pumps, to start moving the tracks

"Maximum Pump Current" - maximum current flow to the forward and reverse solenoids on the left and right pumps, required to fully stroke
the pumps

"Minimum Motor Current" - minimum current flow to the left and right motor solenoids, required to start destroking the motor

"Maximum Motor Current" - maximum current flow to the left and right motor solenoids, needed to achieve a predetermined machine speed

"Calibration Sequence and Associated Error Codes"

Illustration 4 g02490117
Cat ET Hystat Pump and Motor Calibration Intervals

Illustration 5 g02490119
Cat ET Hystat Pump Calibration Sequence

1. Hystat pump calibration begins. The pump current steps up to the low end of the "Pump Minimum Calibration Range". Pump current is slowly
increased until a motor speed is detected. Current is then decreased until the motor speed returns to zero. This current is the "Pump
Minimum Calibration Current".
If the motor speed is detected immediately during the start of the calibration, the following error codes may be seen in Cat ET:

"10D4 - Left Pump Minimum Current Out of Range Low"

"10DA – Right Pump Minimum Current Out of Range Low"

If motor speed is not detected to be within the calibration range, the following error codes may be seen in Cat ET:

"10D5 – Left Pump Minimum Current Out of Range High"

"10DB – Right Pump Minimum Current Out of Range High"

Refer to Illustration 7 for a typical example of a Cat ET error code.

Refer to Table 2 for a list of possible reasons and causes of these Cat ET error codes.

2. Pump current is ramped up to full current.

3. "Pump Maximum Gear Ratio" is recorded. "Gear Ratio = Motor Speed / Pump Speed"
If the Pump Maximum Gear Ratio is outside the low end of the calibration range, the following error codes may be seen in Cat ET:

"10D8 - Left Pump Maximum Gear Ratio Out of Range Low"

"10DE – Right Pump Maximum Gear Ratio Out of Range Low"

If the Pump Maximum Gear Ratio is outside the high end of the calibration range, the following error codes may be seen in Cat ET:

"10D9 - Left Pump Maximum Gear Ratio Out of Range High"

"10DF – Right Pump Maximum Gear Ratio Out of Range High"

4. Pump current is slowly decreased until a change in motor speed is detected.

If a change in motor speed is not detected in the calibration range, the following error codes may be seen in Cat ET:

"10D6 - Left Pump Maximum Current Out of Range Low"

"10DC - Right Pump Maximum Current Out of Range Low"

5. Pump calibration is complete. Pump current is quickly ramped to zero.

Illustration 6 g02490126
Cat ET Hystat Motor Calibration Sequence
 6. Motor calibration begins. The pump is ramped up to full current with a reduced engine speed.

7. Motor current steps up to the low end of the "Motor Minimum Calibration Range". Motor current is slowly increased until there is a change in
motor speed.
If motor speed immediately jumps up at the low end of the calibration range, the following error codes may be seen in Cat ET:

"10E0 – Left Motor Minimum Current Out of Range Low"

"10E6 – Right Motor Minimum Current Out of Range Low"

If no change in motor speed is detected by the high end of the calibration range, the following error codes may be seen in Cat ET:

"10E1 – Left Motor Minimum Current Out of Range High"

"10E7 – Right Motor Minimum Current Out of Range High"

8. Motor current is slowly increased until the "Gear Ratio" value equals the target.
If the target "Gear Ratio" is not reached in the "Motor Maximum Calibration Range", the following error codes may be seen in Cat ET:

"10E4 – Left Motor Maximum Gear Ratio Out of Range Low"

"10E3 – Left Motor Maximum Current Out of Range High"

"10EA – Right Motor Maximum Gear Ratio Out of Range Low"

"10E9 – Right Motor Maximum Current Out of Range High"

If the "Gear Ratio" starts out above the target "Gear Ratio", the following error codes may be seen in Cat ET:

"10E2 – Left Motor Maximum Current Out of Range Low"

"10E5 – Left Motor Maximum Gear Ratio Out of Range High"

"10E8 – Right Motor Maximum Current Out of Range Low"

"10EB – Right Motor Maximum Gear Ratio Out of Range High"

9. Motor calibration is complete.

The pump and motor currents are quickly ramped to zero.

Illustration 7 g02490129
Example of Cat ET Error Code
Note: A common root cause of a failed "Hystat Pump and Motor Solenoid Calibration" is contamination of the solenoids, pump, or motor
controllers. Contamination will restrict motion and/or cause hysteresis and will prevent a steady gear ratio to be attained during calibration. If the
calibration fails, do NOT adjust the "Min" or "Max" stops of the forward or reverse pumps. Refer to Table 2 for additional information of each error
code.

Cat ET Error Codes for Hystat Pump and Motor Solenoid Calibration 
Error ID and Description  Reasons for the Error Codes  Possible Causes 
· "Pump Null"
"10D4 - Left Pump Minimum adjustment may be off

Current Out of Range Low " · Contamination in the

Pump starts to stroke or is always on stroke at a current outside the lower end of the pump control

"10DA - Right Pump calibration range.  · Motor speed sensor

Minimum Current Out of is disconnected

Range Low"  · Malfunctioning or

sticking solenoid 
· "Pump Null"
"10D5 - Left Pump Minimum adjustment may be off

Current Out of Range High" · Contamination in

pump control
Pump does not start to stroke at a current outside the upper end of the calibration range. 
"10DB - Right Pump · Motor speed sensor
Minimum Current Out of is disconnected

Range High"  · Malfunctioning or

sticking solenoid 
"10D6 - Left Pump Maximum
Current Out of Range Low"
Current is not detected when the pump reaches maximum displacement. Occurs · Contamination in
because the pump does not destroke from the maximum displacement within the pump control

"10DC - Right Pump

calibration range.  · Sticking solenoid 
Maximum Current Out of
Range Low" 
"10E0 - Left Motor Minimum
Current Out of Range Low" · Contamination in
Motor begins to destroke and the stroke value is less than the "Max Displacement".
motor control

Occurs while the motor current is outside the lower end of the calibration range. 
"10E6 - Right Motor Minimum · Sticking solenoid 
Current Out of Range Low" 
"10E1 - Left Motor Minimum
· Contamination in
Current Out of Range High"
Motor does not start to destroke off the "Max Displacement ". Occurs while the motor motor control

current is outside the upper end of the calibration range.  · Sticking solenoid
"10E7 - Right Motor Minimum
· Low charge pressure 
Current Out of Range High" 
"10E2 - Left Motor Maximum
Current Out of Range Low"
Motor is destroked and the displacement is smaller than the expected result. Occurs · Contamination in
"10E8 - Right Motor while the motor current is outside the lower end of the calibration range.  motor control 
Maximum Current Out of
Range Low" 
· Contamination in
motor control
"10E3 - Left Motor Maximum · "Motor Min
Current Out of Range High" Displacement" stop is
Motor does not destroke to a displacement that is small enough to reach the target. set too high.

"10E9 - Right Motor Occurs while the motor current is outside the upper end of the calibration range.  · Pump is not at
Maximum Current Out of maximum
Range High"  displacement

· Sticking solenoid
· Low charge pressure 
· Contamination in
motor control
"10E4 - Left Motor Maximum · "Motor Min
Gear Ratio Out of Range Low" Displacement" stop is
Motor does not destroke to a displacement that is small enough to reach the target. set too high.

"10EA - Right Motor Occurs while the motor current is outside the upper end of the calibration range.  · Pump is not at
Maximum Gear Ratio Out of maximum
Range Low"  displacement

· Sticking solenoid
· Low charge pressure 
"10E5 - Left Motor Maximum
Gear Ratio Out of Range
· Contamination in
High"
motor control

Motor is destroked to a smaller displacement than expected range. 

· Motor stuck at min
"10EB - Right Motor
displacement 
Maximum Gear Ratio Out of
Range High" 
"10D8 - Left Pump Maximum
Gear Ratio Out of Range Low" · Contamination in
pump control

Pump did not reach maximum displacement. 

"10DE - Right Pump · Sticking solenoid
Maximum Gear Ratio Out of · Low charge pressure 
Range Low" 
"10D9 - Left Pump Maximum
Gear Ratio Out of Range · Contamination in
High" motor control

Motor is at a displacement which is much lower than the maximum displacement.  · "Motor Min
"10DF - Right Pump Displacement" stop is
Maximum Gear Ratio Out of set too low 
Range High" 

Table 2

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"Operator Control Calibrations (Hystat)"

This calibration associates the working range of the sensors that are associated with the following controls.

Forward and Reverse Joystick

 Left and Right Joystick

Brake/Decel Pedal

Power Train Speed Range Control Rocker

Navigate to the Cat ET calibration screen by clicking "Service" the tool bar and then clicking "Calibrations". Click "Hystat Operator Control
Calibrations".

Note: If a "103 - Calibration Out of Range" error code occurs during calibration, check the PWM signal to ensure that communication is working
correctly.

FFF1-UP, JLF1-UP, JTD1-UP, LLL1-UP, MMM1-UP, RRR1-UP, WWW1-UP, YYY1-UP

PPT-01014C1D
2021/06/21
10:50:54+08:00
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