Procedure to Install Ventilation Reduction Package on R1600H Load Haul Dump Machines {1000, 7620} Caterpillar

Load Haul Dump

R1600H (S/N: 9SD1-UP)

Introduction

This special instruction covers the procedure to install the ventilation reduction package on R1600H S/N:9SD1-UP Load Haul Dump Machines

Note: This procedure cannot be used in Canadian provinces that require "CANMET"certification. This procedure will invalidate the existing "CANMET" approval for an engine.

This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Reference: Operation and Maintenance Manual, SEBU8317, "R1600H Load Haul Dump".

Reference: Systems Operation Testing and Adjusting, SENR9888, "C11 and C13 Engines for Caterpillar Built Machines".

Reference: Troubleshooting, RENR9318, "C11 and C13 Engines for Caterpillar Built Machines".

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

Required Parts

Installation Procedure

Torque Converter Stall - Test

Note: A torque converter stall test must be performed before and after the installation procedure to determine engine performance.

Note: Testing should be completed at the same time with as equal conditions as possible. Changes in weather, specifically temperature could affect the results.

Note: A "Before" torque converter stall test may not always be possible. In this instance, engine specifications for the Ventilation Reduction (VR) engine are available through the Technical Marketing Information (TMI) website.

The service brakes must be applied when tests are performed. Make sure that the service brakes are fully operational before you perform any tests. Make sure that the transmission oil is at the normal operating temperature of 82° ± 3°C (180° ± 5°F) when tests are performed.

The drive wheels must not turn during the torque converter stall test. Place the machine in an open area clear of personnel and obstructions. Engage the parking brake.

1. Using Caterpillar Electronic Technician (ET), set up a data capture for the following channels at a minimum of 4 Hz. Refer to "Data Capture - Set Up" to set up the data capture.

   1. Engine

      • Engine Speed

      • Boost Pressure (manifold)

      • Ambient Pressure

      • Inlet Air Temperature

      • Engine Coolant Temperature

      • FRC Fuel Limit

      • Rated Fuel Limit

      • Fuel Position

   2. Transmission

      • Actual Gear

      • Transmission Oil Temp

      • Transmission Output Speed

      • Brake Pedal

      • Torque Converter Outlet Temperature

      Note: Section b. Transmission is optional

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   Illustration 1	g06130935
   (1) Tachometer (2) Display window for digital tachometer (3) Transmission autoshift control switch

2. Start the engine and apply the service brake.

   Note: To ensure that the transmission oil does not overheat, do not keep the torque converter in a full stall condition for more than 30 seconds. After the torque converter is stalled, shift the transmission direction control to the NEUTRAL position. Operate the engine at 1200 rpm to 1500 rpm to cool the oil.

3. Start the data collection with Cat ET.

4. Move transmission autoshift control switch (3) to the MANUAL position to prevent any unexpected shifts during the stall test.

5. Shift the transmission direction and speed control to the FOURTH SPEED FORWARD position.

   Note: Transmission maximum forward gear may require a configuration change if fourth speed cannot be obtained. Use Caterpillar Electronic Technician (ET) in order to enable fourth gear.

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   Illustration 2	g03117636
   Typical example Caterpillar Electronic Technician (ET) indicating fourth gear enabled

6. Fully depress the accelerator pedal for 15 seconds.

7. Allow the engine rpm to stabilize. Observe tachometers (1) and (2). Stall speed should reach 1950 ± 65 rpm for a new or reconditioned machine.

   Note: This specification may vary for a used machine.

   Note: Stall speeds that are low indicate incorrect engine performance. Stall speeds that are high indicate incorrect transmission performance or incorrect performance of the torque converter. Refer to Troubleshooting, Testing and Adjusting, "Torque Converter Troubleshooting" and Troubleshooting, Testing and Adjusting, "Transmission Troubleshooting".

8. Once the machine has stalled for 15 seconds, release the throttle and shift the transmission direction and speed control to the NEUTRAL position. Allow the machine to idle at 1200 rpm to 1500 rpm for at least 2 minutes. Continue to hold the service brake.

9. After 2 minutes of idle, perform Steps 5 through 8 two more times for a total of three stalls.

10. Release the service brake.

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

    Example: 9SD00123_BeforeVR_20120614.sdf

12. After 2 minutes of idle, stop the engine.
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    Illustration 3	g02720498

13. 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 3 for examples of stall speed graphs.

Engine Software

1. Prior to flashing the Engine ECM with the latest software, save a copy of the Engine ECM configuration parameters and injector calibration serial numbers. Refer to "Engine ECM Backup File".

   Note: For backup purposes only.

2. Flash the Engine ECM with 455-9274 Engine Ratings Electronic Software Gp.

   Note: The correct software must be installed to complete this instruction.

3. Follow the instruction below to obtain the factory password.

   • Submit a Dealer Solution Network (DSN) ticket

   • Request that the Tier 1 representative, transfer your ticket to an available Tier 2 representative for Caterpillar Underground Mining

   • Request the factory password required to complete the installation of the ventilation reduction package for R1600H (S/N: 9SD)

4. Where a "Before" and "After" torque converter stall test is possible, proceed to ""Before" and "After" Torque Converter Stall Test Possible".

5. Where a "Before" and "After" torque converter stall test is not possible, proceed to "Torque Converter Stall Test Not Possible".

"Before" and "After" Torque Converter Stall Test Possible

1. Perform the torque converter stall test. Refer to "Torque Converter Stall - Test".

2. Compare the "Before VR" stall speed to the "After VR" stall speed.

3. The engine is within specification if the "After VR" stall speed is within specifications shown in Table 2
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   Table 2

   Machine	Specifications
   (S/N: 9SD1-UP)	1950 ± 65 rpm

4. Submit a Dealer Solution Network (DSN) ticket. Attach both stall test files from Cat ET to the Dealer Solution Network (DSN) ticket for review.

5. If the "After VR" stall speed is not within the specifications mentioned in Step 3, the FLS/FTS must be adjusted to comply with specifications.

6. Submit a Dealer Solution Network (DSN) ticket. Attach both stall test files from Cat ET to the Dealer Solution Network (DSN) ticket for review. Based on the difference, the technician 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.

7. Order and install a new engine emissions certification film and a new engine serial number plate. Refer to "Label Rework Procedure".

Torque Converter Stall Test Not Possible

1. Dyno test the Ventilation Reduction (VR) engine.

2. Open Technical Marketing Information (TMI) to retrieve the Ventilation Reduction (VR) engine specifications. The address is http://tmiweb.cat.com.
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   Illustration 4	g03395116

3. Select "Engine/Parts Data".
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   Illustration 5	g03395124

4. Enter the new Ventilation Reduction (VR) engine part number 418-7784 Complete Engine Ar into the "Reference Number" field.

5. Select "Part Number" in the drop-down box.

6. Select "Retrieve Data".
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   Illustration 6	g06130924

7. Select "Spec Compare".
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   Illustration 7	g06130925

8. Select the spec number.

9. A new window will open with the Ventilation Reduction (VR) engine specifications.

10. The engine dyno test should comply with the Ventilation Reduction (VR) engine specifications.

11. Submit a Dealer Solution Network (DSN) ticket. Attach the engine dyno test report to the Dealer Solution Network (DSN) ticket for review.

12. If the engine dyno test is outside the Ventilation Reduction (VR) engine specifications, the FLS/FTS must be adjusted to comply with specifications.

13. Submit a Dealer Solution Network (DSN) ticket. Attach the engine dyno test report to the Dealer Solution Network (DSN) ticket for review. Based on the difference, the technician will provide a new FLS/FTS number and factory password for changing. Failure to adjust FLS/FTS if not within specification may cause reduced engine performance or reduced machine life.

14. Order and install a new engine emissions certification film and a new engine serial number plate. Refer to "Label Rework Procedure".

Data Capture - Set Up

1. Connect Caterpillar Electronic Technician (ET) to the machine. Refer to Troubleshooting, "Electronic Service Tools".
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   Illustration 8	g03174657
   Typical example

2. Select "Information", "Data Log", "Recorder" (1).
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   Illustration 9	g06130927
   Typical example

3. Select "Hour(s)" (2).

   Note: Ensure "Sample Rate" is set at 240 per minute.

4. Select "Add" (3).
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   Illustration 10	g06130928
   Typical example

5. Highlight "<TEMPORARY GROUP>" (4) and select "New" (5).
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   Illustration 11	g03176810
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6. Input a new group file name (6), then select "OK" (7).
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   Illustration 12	g06130929
   Typical example

7. Highlight and transfer the required parameter (8), using arrow (9). When all the required parameters have been transferred, select "OK" (10).
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   Illustration 13	g06130931
   Typical example

8. Highlight the created temporary group (11), then select "OK" (12).
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   Illustration 14	g06130932
   Typical example

9. Select "OK" (13).

   Note: Caterpillar Electronic Technician (ET) is now set up for data capture.

Engine ECM Backup File

1. Connect Caterpillar Electronic Technician (ET) to the machine. Refer to Troubleshooting, "Electronic Service Tools".
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   Illustration 15	g03121900
   Typical example

2. Select the Engine ECM.
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   Illustration 16	g03121876
   Typical example

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   Illustration 17	g03121897
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   Illustration 18	g03123776
   Typical example

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   Illustration 19	g03125656
   Typical example

3. Using the "Copy Configuration/ECM Replacement" feature, found under the "Service" menu, save a copy of the configuration parameters. Refer to Illustration 16, Illustration 17, Illustration 18, and Illustration 19.
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   Illustration 20	g03121899
   Typical example

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   Illustration 21	g03121901
   Typical example

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   Illustration 22	g03121904
   Typical example

4. Using the "Calibrations" feature, found under the "Service" menu, copy the injector calibration serial numbers. Refer to Illustration 20, Illustration 21, and Illustration 22.

Label Rework Procedure

1. Open the login page of Emissions Regulations and Conformance. The website address is https://ercrequestspilotprogram.atlassian.net/servicedesk/customer/portal/2
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   Illustration 23	g06046648

2. If you have an account, proceed to Step 4. If you do not have an account select "Sign up for an account" (1).
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   Illustration 24	g06046650

3. Input your email address, a password, and you full name. Select "Sign Up" (2).
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   Illustration 25	g06046652

4. Return to login page of "Emissions Regulations and Conformance" . Refer to Step 1. Input your username and password and select Log In (3).
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   Illustration 26	g06046653

5. Select "Dealer Conformance" (4). Select "Emissions/Certification/Replacement/Supplementary" (5).
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   Illustration 27	g06046654
   Top view of webpage form

6. View instruction at top of the webpage, then scroll down to the form.
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   Illustration 28	g06046656
   Label request form

7. Select all Label Types Required (6). Include "Certification Label", "Engine Info Label, and Metal Engine Plate."

8. Input all required details into the label request form. Include information listed on Table 3. Provide optional detail which may be of assistance.
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   Table 3

   Additional Information for "Label Request Form"
   Item	Title	Input
   7	Reason for the replacement label required	Enter the media number of the Special Instruction
   8	Engine Sales Model	C11

9. Select "Create" (9).

   Note: Two labels and a serial number plate will be sent to the nominated dealer address. If two labels are not received, contact Global_Engine_Marking@cat.com.

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   Illustration 29	g06047218

10. Install the new emissions certification film (10), information label (11), and serial number plate on the cylinder block according to the installation instructions received with the labels and plate.

    Note: Destroy the old emissions certification film and serial number plate.