Adaptive Control System (ACS) Advanced Calibration Procedures {5051, 5063} Caterpillar

Adaptive Control System (ACS) Advanced Calibration Procedures {5051, 5063}

Usage:

Excavator: 336D2 (S/N: MFA1-UP; MEH1-UP; NAH1-UP; LBX1-UP); 336E (S/N: JEA1-UP; RZA1-UP; SSL1-UP; HDW1-UP; GNY1-UP); 336F (S/N: KGH1-UP; YBH1-UP; NAJ1-UP; PFL1-UP; LTP1-UP; MTW1-UP; DFY1-UP); 349F (S/N: SFG1-UP; RAX1-UP); 352F (S/N: SD21-UP; XAJ1-UP; MDR1-UP); 374F (S/N: AT21-UP; AP41-UP; EBF1-UP; NFJ1-UP; MFL1-UP; DNM1-UP); 390F (S/N: HJD1-UP; TYE1-UP; MGF1-UP; HNG1-UP; FEH1-UP; HSM1-UP; GAY1-UP)
Mobile Hydraulic Power Unit: 390F MHPU (S/N: B371-UP)

Introduction

The following instructions explain the procedure to determine the cause of a calibration failure.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not specifically recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Calibration Error Codes

Show/hide table

Table 1
ACS Calibration	Calibration Error Code	Calibration Error Code Description	Reason for Error Code
Bypass	000A	Calibration Failure	Occurs when reaches max attempts
	105F	Calibration Timed Out	Took too long to reach desired stem current threshold
	10F1	Calibration Value Out of Range High	Calibration Value is above a pre-defined range
	10F0	Calibration Value Out of Range Low	Calibration Value is below a pre-defined range
Combiner	000A	Calibration Failure	Occurs when reaches max attempts
	105F	Calibration Timed Out	Took too long to reach desired stem current threshold
	10F1	Calibration Value Out of Range High	Calibration Value is above a pre-defined range
	10F0	Calibration Value Out of Range Low	Calibration Value is below a pre-defined range
Straight Travel	000A	Calibration Failure	Occurs when reaches max attempts
	105F	Calibration Timed Out	Took too long to reach desired stem current threshold
	10F1	Calibration Value Out of Range High	Calibration Value is above a pre-defined range
	10F0	Calibration Value Out of Range Low	Calibration Value is below a pre-defined range
IMV Calibration	104C	Hold Pressure Too High	Bypass control could not reach correct system threshold
	104D	Hold Pressure Too Low	Bypass control could not reach correct system threshold
	000A	Calibration Failure	Occurs when reaches max attempts
	105F	Calibration Timed Out	Took too long to reach desired stem current threshold
	112B	Pump to Cylinder Head End Minimum Current Out of Range High	Calibration Value is above a pre-defined range
	112C	Cylinder Head End to Tank Minimum Current Out of Range High	Calibration Value is above a pre-defined range
	112D	Pump to Cylinder Rod End Minimum Current Out of Range High	Calibration Value is above a pre-defined range
	112E	Cylinder Rod End to Tank Minimum Current Out of Range High	Calibration Value is above a pre-defined range
	112F	Pump to Cylinder Head End Minimum Current Out of Range Low	Calibration Value is below a pre-defined range
	1130	Cylinder Head End to Tank Minimum Current Out of Range Low	Calibration Value is below a pre-defined range
	1131	Pump to Cylinder Rod End Minimum Current Out of Range Low	Calibration Value is below a pre-defined range
	1132	Cylinder Rod End to Tank Minimum Current Out of Range Low	Calibration Value is below a pre-defined range
BLCV/SLCV Calibration	106B	Implement Valve Not Installed	BLCV/SLCV is not installed
	105F	Calibration Timed Out	Took too long to reach desired pressure or current threshold
	000A	Calibration Failure	Occurs when max attempts have been reached
	10F0	Calibration Value Out of Range Low	Calibration Value is below a pre-defined range
	10F1	Calibration Value Out of Range High	Calibration Value is above a pre-defined range

Note: If any calibration failures occur, refer to the appropriate procedure below. The procedure will specify what channels to data log during the calibration process to help determine the root cause of the calibration failure.

ACS IMV Calibration for Boom, Bucket, Stick, Attachment 1, & Swing (for 336E H, 336F XE, 336D2 XE)

IMV calibration is a procedure to determine the valves' minimum current, also known as the valves' cracking current. This value is stored in the ECM configuration, available through the Cat^® Electronic Technician (Cat ET) Service Tool.

Software Calibration Logic:

Verify proper hydraulic temperature, machine dial setting, and RPM.
Set pump to desired displacement for calibration.
Set bypass control to achieve desired pump pressure for calibration.
Calibrate IMVs in the following order: PCHE (Pump to Cylinder Head End), PCRE (Pump to Cylinder Rod End), CTHE (Cylinder to Tank Head End), CTRE (Cylinder to Tank Rod End).

Note: 336 Hybrid swing will be Pump to Motor (PM) - Right, Pump to Motor (PM) - Left, Motor to Tank (MT) -Right, Motor to Tank (MT) -Left.

Calibration for each IMV consists of applying pump pressure to the valve inlet, tank pressure to the valve outlet, then ramp the valve current until calibration sees pump pressure start to drop off. This process is repeated several times for each valve. Refer to table 2 for the respective valve commands during each calibration.

Show/hide table

Table 2
	Valve Commands
Calibration Order	PCHE	PCRE	CTHE	CTRE
1	Ramp	Closed	Open	Closed
2	Closed	Ramp	Closed	Open
3	Open	Closed	Ramp	Closed
4	Closed	Open	Closed	Ramp

Channels to data log during the calibration process:

Implement ECM

Boom (Bucket, Stick, Swing, or Attachment #1) Cylinder Head End Pressure.
Boom (Bucket, Stick, Swing, or Attachment #1) Cylinder Rod End Pressure.
Boom (Bucket, Stick, Swing, or Attachment #1) Head End to Tank Solenoid Current.
Boom (Bucket, Stick, Swing, or Attachment #1) Rod End to Tank Solenoid Current.
Pump to Boom (Bucket, Stick, Swing, or Attachment #1) Head End Solenoid Current.
Pump to Boom (Bucket, Stick, Swing, or Attachment #1) Rod End Solenoid Current.

Machine ECM

Combining Valve Solenoid Current Status.
Desired Engine Speed (or Engine ECM).
Engine Speed (or Engine ECM).
Hydraulic Oil Temperature.
Hydraulic Pump #1 Bypass Valve Solenoid Current.
Hydraulic Pump #1 Outlet Pressure.
Hydraulic Pump #2 Bypass Valve Solenoid Current.
Hydraulic Pump #2 Outlet Pressure.
Main Hydraulic Pump #1 Displacement.
Main Hydraulic Pump #2 Displacement.
Straight Travel Solenoid Current.

Bypass 1 & 2 Calibration

Bypass calibration determines a pressure/valve command relationship by setting the pump to a fixed displacement and ramping close the bypass while recording pump pressures. The procedure is repeated several times for each bypass.

Software Calibration Logic:

Verify proper hydraulic temperature, machine dial setting, and RPM.
Set pump to desired displacement for calibration.
Calibrate bypass.

Channels to data log during the calibration process:

Machine ECM

Combining Valve Solenoid Current Status.
Desired Engine Speed (or Engine ECM).
Engine Speed (or Engine ECM).
Hydraulic Oil Temperature.
Hydraulic Pump #1 Bypass Valve Solenoid Current.
Hydraulic Pump #1 Outlet Pressure.
Hydraulic Pump #2 Bypass Valve Solenoid Current.
Hydraulic Pump #2 Outlet Pressure.
Main Hydraulic Pump #1 Displacement.
Main Hydraulic Pump #2 Displacement.
Pump to Boom Head End Solenoid Current.
Pump to Boom Rod End Solenoid Current.
Stick Lever Position.
Straight Travel Solenoid Current.

Combiner Calibration

Current calibration determines the required current to set the combiner in the closed position. This is done by applying pump pressure to the Boom/Bucket side of the combiner and drain pressure to the Stick/Swing side of the combiner.

Combiner is ramped to determine the transition from closed to open, and closed to check positions, which are then used to determine the closed calibration value.

Software Calibration Logic:

Set pump to desired displacement for calibration.
Close bypass 1 valve.
Apply a series of ramp commands to the combiner valve.

Channels to data log during the calibration process:

Machine ECM

Combining Valve Solenoid Current Status.
Desired Engine Speed (or Engine ECM).
Engine Speed (or Engine ECM).
Hydraulic Oil Temperature.
Hydraulic Pump #1 Bypass Valve Solenoid Current.
Hydraulic Pump #1 Outlet Pressure.
Hydraulic Pump #2 Bypass Valve Solenoid Current.
Hydraulic Pump #2 Outlet Pressure.
Main Hydraulic Pump #1 Displacement.
Main Hydraulic Pump #2 Displacement.
Straight Travel Solenoid Current.

Mono Spool Swing Calibration (374F/390F, 349F XE)

Swing calibration will apply pump pressure to the swing spool inlet, then ramp the swing valve command until pump pressure starts to drop off. This process is repeated several times for both swing directions.

Software Calibration Logic:

Verify proper hydraulic temperature, machine dial setting, and RPM.
Set pump to desired displacement for calibration.
Set bypass control to achieve desired pump pressure for calibration.
Calibrate swing.

Channels to data log during the calibration process:

Machine ECM

Combining Valve Solenoid Current Status.
Desired Engine Speed (or Engine ECM).
Engine Speed (or Engine ECM).
Hydraulic Oil Temperature.
Hydraulic Pump #1 Bypass Valve Solenoid Current.
Hydraulic Pump #1 Outlet Pressure.
Hydraulic Pump #2 Bypass Valve Solenoid Current.
Hydraulic Pump #2 Outlet Pressure.
Swing Pressure.
Main Hydraulic Pump #1 Displacement.
Main Hydraulic Pump #2 Displacement.
Pump to Swing Motor Left Solenoid Current.
Pump to Swing Motor Right Solenoid Current.
Straight Travel Solenoid Current.

Straight Travel Calibration

Straight travel calibration determines the valve current command to achieve the desired displacement. This is determined by applying pressure to the Stick/Swing port and low pressure to the Boom/Bucket port. As the valve command is ramped it will drain Stick/Swing pressure when in the center position, but maintain Stick/Swing pump pressure when in the two end positions.

Software Calibration Logic:

Verify proper hydraulic temperature, machine dial setting, and RPM.
Set pump to desired displacement for calibration.
Open bypass 1.
Close bypass 2 to maintain desired pump 2 pressure.
Ramp current to straight travel valve several times.

Channels to data log during the calibration process:

Machine ECM

Combining Valve Solenoid Current Status.
Desired Engine Speed (or Engine ECM).
Engine Speed (or Engine ECM).
Hydraulic Oil Temperature.
Hydraulic Pump #1 Bypass Valve Solenoid Current.
Hydraulic Pump #1 Outlet Pressure.
Hydraulic Pump #2 Bypass Valve Solenoid Current.
Hydraulic Pump #2 Outlet Pressure.
Main Hydraulic Pump #1 Displacement.
Main Hydraulic Pump #2 Displacement.
Straight Travel Solenoid Current.

Boom Lowering Check Valve (BLCV) Calibration

BLCV calibration determines the current for the valve to crack open and release pressure from the cylinder to the work port.

Software Calibration Logic:

Pressurize the cylinder.
Close all valves.
Open CT to drain the work port pressure. (Cylinder still holds pressure because of the BLCV)
Close the CT and open Boom Drift Reduction Valve.
Ramp current to the BLCV and monitor work port pressure. When the BLCV cracks open, the cylinder pressure will start to drain off and the work port pressure will start to rise.

Channels to data log during the calibration process:

Implement ECM

Boom Cylinder Head End Pressure.
Boom Cylinder Rod End Pressure.
Boom Head End to Tank Solenoid Current.
Boom Rod End to Tank Solenoid Current.
Pump to Boom Head End Solenoid Current.
Pump to Boom Rod End Solenoid Current.

Machine ECM

Boom Anti Drift Solenoid.
Boom Cylinder Head End Pressure.
Boom Lowering Check/Modulation Valve Solenoid Current.
Combining Valve Solenoid Current Status.
Desired Engine Speed (or Engine ECM).
Engine Speed (or Engine ECM).
Hydraulic Oil Temperature.
Hydraulic Pump #1 Bypass Valve Solenoid Current.
Hydraulic Pump #1 Outlet Pressure.
Hydraulic Pump #2 Bypass Valve Solenoid Current.
Hydraulic Pump #2 Outlet Pressure.
Main Hydraulic Pump #1 Displacement.
Main Hydraulic Pump #2 Displacement.
Straight Travel Solenoid Current.

Stick Lowering Check Valve (SLCV) Calibration

BLCV calibration determines the current for the valve to crack open and release pressure from the cylinder to the work port.

Software Calibration Logic:

Pressurize the cylinder.
Close all valves.
Open CT to drain the work port pressure. (Cylinder still holds pressure because of the SLCV)
Close the CT and open Stick Drift Reduction Valve.
Ramp current to the SLCV and monitor work port pressure. When the SLCV cracks open, the cylinder pressure will start to drain off and the work port pressure will start to rise.

Channels to data log during the calibration process:

Implement ECM