Engine Software Power Set Procedure for Tier 0 Software on 24M Motor Graders{1901, 1920, 7610, 7620} Caterpillar

Motor Grader:

24M (S/N: B9K1-UP)

Introduction

The following Special Instruction must be used to perform the torque converter stall, flash the Tier 0 software, and achieve the power setting procedure.

Torque Converter Stall and Power Setting Procedure

A torque converter stall will be used to check that the Tier 0 software is performing the same as the Tier 3 software. The machine should be located on level ground, below 6000 ft (if above 6000 ft contact the DSN for assistance). Room must be provided to operate the Motor Grader. Testing of both software should be completed at the same time with as equal conditions as possible. Changes in weather, specifically temperature could affect the results.

1. With the Tier 3 366-6155 Engine Ratings Electronic Software Gp installed, operate the Motor Grader until all fluids have reached standard operating temperature.

2. Stop the machine with a blade load and ground the ripper.

   Note: Do not place the blade in float mode.

3. Stop the machine and unplug the fan pump solenoid control from the wiring harness. Unplugging the solenoid control will cause the pump to go to max stroke and increase fan speed for the testing.

4. Restart the machine.

5. Using Caterpillar Electronic Technician (ET), set up a data capture for the following channels at a minimum of 4 Hz.

   1. Engine
      • Engine Speed

      • Throttle Position

      • Boost Pressure (manifold)

      • Ambient Pressure

      • Inlet Air Temperature

      • Engine Coolant Temperature

      • Engine Load Factor

      • Engine Power Derate

      • FRC Fuel Limit

      • Rated Fuel Limit

      • Fuel Position

      • Fuel Pressure

   2. Transmission
      • Actual Gear

      • Transmission Oil Temp

      • Transmission Input Speed

      • Transmission Output Speed

      • Brake Pedal

      • Torque Converter Outlet Temperature

6. Start the data collection with Cat ET.

7. Fully depress the service brakes and turn off the parking brake. Hold the service brakes for the entire stall testing.

8. Select "F" from the "FNR" switch and select "3F" using the gear selection.

9. Apply full throttle using the throttle pedal for 15 seconds.

10. Machine rpm should increase and stabilize during testing. Engine speed should reach 1825 rpm ± 50 rpm.

11. Once the machine has stalled for 15 seconds, release the throttle and allow the machine to idle at 800 rpm for at least 30 seconds. Continue to hold service brakes.

12. After 30 seconds of idle, perform Steps 9 through 11 two more times for a total of three stalls.

13. Once at idle, select "N" from the "FNR" switch and turn on the parking brake. The service brakes can be released.

14. Stop the data collection with Cat ET and save the file. The file should include the following: machine serial number, T3 and the date (year, month, date).

    Example: B9K00123_T3_20110917.sdf

15. After machine has run for at least 2 minutes after testing, the machine can be turned off. Once shut down, reconnect the fan pump solenoid to the wiring harness.

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Illustration 1	g02720498
Stall speed shown is approximately 1870 rpm.

Note: Fan pump solenoid was not unplugged for the example above. Therefore, stall speed is on the high side of the 1825 ± 50 rpm range. Testing is performed with pump solenoid unplugged as described.

16. Using Cat ET, establish the machine stall speed by reviewing the data log. The "Settings" tab on the bottom left of Cat ET can be used to change the "X" and "Y" axis. Changing the "X" and "Y" axis will provide a high resolution of the stall speed. Refer to Illustration 1 for examples of stall speed graphs.

17. Flash the engine software to the Tier 0 flash file.

18. Start the machine and perform a fan calibration using Cat ET. Maximum fan speed should be set to 1325 rpm.

19. Operate the machine until the fluids are at standard operating temperature.

20. Repeat Steps 2 through 13 as described above. Remember to disconnect fan solenoid as instructed during testing.

21. Stop data collection with Cat ET and save file. The file should include the following: machine serial number, T3 and the date (year, month, date).

    Example: B9K00123_T3_20110917.sdf

22. Using Cat ET, establish the machine stall speed by averaging the steady state rpm of all three runs. The "Settings" tab on the bottom left of Cat ET can be used to change the "X" and "Y" axis. Changing the "X" and "Y" axis will provide a high resolution of the stall speed. Refer to Illustration 1 for examples of stall speed graphs.

23. Compare the Tier 0 stall speed to the Tier 3 stall speed.

24. If the Tier 0 stall rpm is within ±15 rpm of the Tier 3 stall speed, performance is equivalent. Attach both stall test files from Cat ET to the Dealer Solution Network (DSN) ticket for review and closure.

25. If Tier 0 stall speed is not within ±15 rpm, the FLS/FTS must be adjusted to bring within specification. Attach both files to the DSN ticket and the support engineer for review. Based on the difference, the support engineer will provide a new FLS/FTS number and factory password for changing. Failure to adjust FLS/FTS if stall speeds are not within specification may cause reduced engine performance or reduced machine life. DSN can be closed once FLS/FTS has been adjusted.