22/10/2021 17:18 SIS 2.

2020/01/24 Fill Calibration Troubleshooting Guide - Transmission Fill Calibration Has Failed (KENR8394-14)

SMCS - 3030, 4000, 5050 i08024151

Before beginning any procedure, review Troubleshooting, "Machine Preparation For Troubleshooting"

Personal injury can result if the machine moves while testing.

If the machine begins to move during test, reduce the engine

speed immediately and engage the parking brake.

Problem: The Fill Time Calibration Has Failed

Probable Causes
A Cat® ET error code is displayed, as a pop-up, during the fill calibration

Recommended Actions
Refer to the following troubleshooting steps:

If a "fill time" calibration is not successful during any part of the automated procedure, none of the clutch fill settings will be stored to ECM memory.
The "Transmission" ECM will use the last successful calibration settings to control the clutch systems.

If no prior successful calibrations have been stored to the ECM memory, the "Transmission" ECM (AKA - Powertrain ECM) will use the factory
defined values.

Reduced clutch life can be expected if the "Transmission" ECM is not calibrated to the changed or updated powertrain components on the
machine.

A Cat® ET Error Code has Displayed During the Fill Calibration

Refer to Table 1 for Calibration Error Codes related to the "Transmission Fill Time Calibration".

Cat® ET Error Codes For The Transmission Calibrations 

Error Description  Possible Causes / Recommended Actions 
Code 
Problem with the Transmission ECM.

0001  ECM Fault 

Refer to Error Code 0001 troubleshooting steps in the guide. 
Troubleshooting and repair any clutch solenoid active code.

0002  Active Diagnostic Present 

After the problem is resolved, attempt the calibration again. 
Technician stopped calibration or interrupted machine connection in Cat® ET.

0006  Calibration Aborted by Tool 

Refer to Error Code 0006 troubleshooting steps in this guide. 
The ECM identified a problem that will not allow a calibration solution.

0009  Calibration aborted by ECM 

Refer to Error Code 0009 troubleshooting steps in this guide. 
The ECM software does not include calibration logic.

000B  Calibration not supported 

Check that the correct powertrain flash file is loaded into the ECM. 
Engine speed is not at idle when the calibration is started.

1012  Engine rpm incorrect 

Adjust engine speed to low idle before starting calibration. 
The brake or retarder system is active.

1017  Service Brake Pedal Depressed  Do not depress the brake pedal during calibration.

Ensure that the manual retarder lever is at 0% (OFF). 

1018  Parking Brake Disengaged  Place the gear selection lever in PARK or engage the parking brake switch. 
Detected transmission output speed (TOS) is not zero.

101B  Machine Speed Is Not Zero 

Refer to Error Code 101B troubleshooting steps in this guide. 
Direction Lever Is Not In
101F  Place the shift lever in PARK. 
NEUTRAL. 
Transmission Oil Temperature Is
1021  Keep transmission oil temperature within the range indicated by Cat® ET.

Too Low. 
Below 65° C (149° F) is too low for calibration routines.

Transmission Oil Temperature Is Above 105° C (221° F) is too high for calibration routines. 
1022 
Too High. 
1023  Transmission Clutch 1 Limit 

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1024  Transmission Clutch 2 Limit 

1025  Transmission Clutch 3 Limit  The calibration routine cannot find a hold pressure or pulse time solutions within the ECM
programmed acceptable limits.
1026  Transmission Clutch 4 Limit 
1027  Transmission Clutch 5 Limit  Refer to "Clutch Has Reached A Limit" troubleshooting steps in this guide. 
1028  Transmission Clutch 6 Limit 
1029  Transmission Clutch 7 Limit 
102F  Transmission Lockup Clutch Limit 
1049  Torque Converter Speed Is Low  During calibration, the end of the clutch filling time is measured by a drop in the Torque Converter
Output Speed (TCOS).

104A  Torque Converter Speed Is High  Refer to "Torque Converter Speed Is Incorrect" troubleshooting steps in this guide. 
10B3  Retarder Lever Is Engaged  Ensure that the manual retarder lever is in the OFF (full upward) position. 

Table 1

Personal injury can result if the machine moves while testing.

If the machine begins to move during test, reduce the engine

speed immediately and engage the parking brake.

Calibration Error Code 0001 - ECM Fault

1. Check the "Transmission" ECM

a. Check that the correct flash file is loaded for the "Transmission" ECM.

b. Check for any active error codes that identify an issue with the ECM.

c. Check for circuit continuity, voltage, and current between the "Transmission" ECM and the transmission solenoids.

Under normal operation conditions the following conditions are expected:

While in NEUTRAL/PARK, the 793F Clutch #3 solenoid is energized.

While in NEUTRAL/PARK, the 797F Clutch #2 solenoid is energized.

If a problem is detected, refer to Troubleshooting, KENR8394, Troubleshooting for Transmission Engagement Calibration - Powertrain Electronic
Module.

Expected Results

The Transmission Control Module is functioning and is providing a signal to the clutch solenoid.

Results

OK: Repeat the Fill Time Calibration Routine.

NOT OK: Replace the "Transmission" ECM.

Calibration Error Code 0006 - Calibration Aborted By Tool

1. Check Cat® ET connection and restart calibration procedure.

a. Confirm that "Cancel" or Alt-C button is not pressed during calibration.

b. Check the connection between the machinery and Cat® ET.

Note: Error Code 0009 - A calibration that is aborted by the ECM may also trigger with code 0006 - Calibration aborted by tool. The ECM does not
require troubleshooting for this occurrence.

Expected Results

No issues with machine connectivity or Cat® ET.

Results

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OK: Repeat the Fill Calibration Routine.

NOT OK: Diagnose and correct the machine service tool.

Calibration Error Code 0009 - Calibration Aborted By The ECM

1. Check the "Transmission" ECM, sensors, and solenoid circuit.

a. Check for another active error code that indicates a problem. A communication problem between the "Transmission" ECM and the
"Engine" ECMs or between Cat® ET and the "Transmission" ECM can also cause this error.

b. Check the transmission speed sensors (including engine output speed).

Error Code 0009 can occur when the ECM detects that the difference in speed between the engine and torque converter output
("Transmission" input) does not meet certain stability criteria.

Intermediate engine, converter, transmission input, or transmission output speed sensors can cause this error.

c. Make sure that the engine speed is unaffected by parasitic loads.

Error Code 0009 can be caused by unstable engine speeds during the calibration process or other intermediate loads being applied to
the engine during the calibration process (brake accumulators charging, and so forth)

d. This error can also occur when the maximum number of attempts to calibrate a clutch has been reached without a successful calibration
solution.
The following factors (internal and external) to the transmission can cause this error:

Excessive backlash in the drivetrain, measured by powertrain speed sensors.

An issue with the ECPC valve or the physical clutch assembly.

If this error reoccurs at the same clutch after several attempts, troubleshoot the individual ECPC valve and clutch assembly.

Expected Results

The Powertrain systems are functioning correctly.

Results

OK: Repeat the "Fill Time Calibration Routine".

NOT OK: Diagnose and correct the issues that are identified.

Calibration Error Code 101B - Machine Speed Not Zero

1. Check the Transmission Output Speed Sensors (TOS)

a. Ensure that the truck is not physically moving through the park brake during "Fill Time Calibration". Truck movement typically identifies
an ECPC valve or valves functioning outside of calibration acceptance limit.
Reference: Refer to "Clutch Has Reached A Limit" in this troubleshooting guide.

b. Check TOS status in Cat®ET and troubleshoot TOS circuit if not zero when the machine is stationary.

Before service work is begun, park the machine on a hard level

surface. Block the wheels of the machine so unexpected
movement will not occur. Unexpected movement of the machine
can cause personal injury or death.

NOTICE
Personal injury can result if the machine moves while testing.
Ground speed is sensed by the Transmission Output Speed
sensors, the movement automatically cancels the Transmission
Fill Time Calibration procedure. The truck transmission is also
neutralized and the engine speed is reduced to low idle.
Removal of the speed sensors during the Transmission Fill Time
Calibration is not recommended.

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Clutch Has Reached A Limit

During the "Fill Time Calibration", each clutch is configured for the optimum hold pressure (pressure to fill the clutch) and pulse time (time to end-of-
fill). Limits for hold pressure control and pulse time control are set in the software programming to identify physical problems with the clutch system.

A clutch at limit error identifies the commands to the clutch solenoid that the clutch solenoid has reached one of the pre-programmed limits before
achieving a calibration solution.

1. Check the Transmission Serial Number in the "Transmission" ECM.

The correct transmission serial number must be entered through Cat® ET for use by the ECM.

The transmission utilizes different calibration acceptance limits depending on the serial number prefix (combination of three letters and/or
numbers) entered into the "Transmission" ECM.

793F: "PJT", "LHT", "JA5", or "AS6".

797F: "R1N", "JH5", or "MNY".

If the first three digits of the transmission serial number for the "Transmission" ECM is configured to anything other than one of the above:

The 793F Transmission ECM will use the "PJT" Clutch Calibration Logic.

The 797F Transmission ECM will use the "JH5" Clutch Calibration Logic.

Expected Results

The transmission serial number is correct.

Results

OK: Continue to Step 2.

NOT OK: Correct the serial number prefix.

2. Check the 793F Transmission Torque Shift Mode Feature Installation Status (APECS).
Verify that the 793F transmission hardware and ECM configuration match. A 793F APECS transmission requires that the transmission torque
shift mode feature be enabled.

Expected Results

The shift mode matches the transmission arrangement.

Results

OK: Continue to Step 3.

NOT OK: Correct the main relief pressure.

3. Check the "Main Relief" pressure.

a. Confirm that the "Main Relief" pressure is within spec for the low and high idle. System pressure that is too high or two low can cause
clutch limit errors.

b. Rerun the fill calibration three times before swapping or replacing any suspect ECPC valve.
Expected Results

The main relief pressure is acceptable.

Results

OK:

Rerun the "Fill Calibration" three time sbefore swapping or replacing any suspect ECPC valve.

Continue to Test Step 4.

NOT OK:

Correct the "Main Relief" pressure.

Conduct Engagement and Fill Time calibrations.

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4. Swap or Replace the modulating (ECPC) valve.

a. Swap the ECPC valve with another clutch position or otherwise replace the ECPC valve with a new part. Determine of the ECPC part is
the cause of the original issue.

b. While the ECPC is removed fro the control body, check for debris in the transmission control group.

c. Check for debris in the "Transmission Charge Filter" and "Transmission Scavenge Screens". Fine debris can cause the ECPC valve to
malfunction.

d. Rerun the "Engagement and Fill Calibration" after the ECPC valve swap or change.
Expected Results

The swapped or new ECPC resolves the clutch at limit issue.

Results

OK: STOP

NOT OK: Continue to Step 5.

5. If the same fault persists, document the fault and contact the Technical Communicator (TC) at your dealership for possible consultation with
Caterpillar.

Torque Converter Speed Is Low and/or High

1. Check the Torque Converter Output Speed (TCOS) sensor harness.
Reference: Refer to Troubleshooting, "MID 081 - CID 0672 - FMI 02" in this manual.

Expected Results

Diagnosis of the TCOS sensor and harness resolved the original issue.

Results

OK: STOP

NOT OK:

Rerun the calibration at least three times to check for a repair of this fault.

Document the fault and contact the Technical Communicator (TC) at your dealership for possible consultation with Caterpillar.

D3T1-UP, LAJ1-UP, LTZ1-UP, SND1-UP, SSP1-UP, SXP1-UP, WSP1-UP

PPI-0005A569
2021/10/22
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i08024151
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