PRODUCT IMPROVEMENT PROGRAM FOR RESETTING THE TRANSMISSION CLUTCH ENGAGEMENT PRESSURES ON CERTAIN 824G II WHEEL DOZERS, 825G II SOIL COMPACTORS AND 826G II LF COMPACTORS Caterpillar

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
        (2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

PRIORITY - The Transmission Clutch Engagement Pressures Need To Be Reset

MODELS INVOLVED - 824G II Wheel Dozers, 825G II Soil Compactors and 826G II LF Compactors

Dear Caterpillar Product Owner:

The transmission clutch engagement pressures need to be reset on certain 824G II Wheel Dozers, 825G II Soil Compactors and 826G II LF Compactors. The transmission clutch engagement pressures were set incorrectly at the factory. The transmission clutch engagement pressures need to be reset on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated November 15, 2002 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Identification #(s)

Attached to November 15, 2002 Service Letter
 
 

Note: The steps of this procedure must be performed exactly as described below. The procedure may terminate if any unknown functions or any unexpected functions are activated. This procedure may terminate if a fault (CID FMI) is present. Do not move any switch positions, any levers or any pedals unless instructed to do so.
 

Use the Electronic Technician to set the transmission clutch engagement value of each clutch. In this process, the service technician adjusts the electrical current that is sent to each clutch solenoid modulating valve in order to match the calibration value that is specified in Table 3. The current flash files for the Power Train and Caterpillar Monitoring System are required to perform this procedure. The transmission clutch fill calibration should be performed after adjusting the engagement calibration values.

Machine Preparation

1. Park the machine on a smooth, level surface.

 

 
 
 
 

Show/hide table

Illustration 1
(1) Transmission upshift switch  (2) Transmission downshift switch  (3) Transmission direction control switch

2. Shift the transmission direction control switch (3) to the NEUTRAL position.
3. Lower the work tool to the ground.
4. Engage the parking brake.
5. Shut off the engine.
6. Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.

Reference: Service Magazine, SEPD0676 "New Flash Software Allows Calibrations of the Power Train to be Performed by Using the Caterpillar Electronic Technician".
 
 

Note: Both of the software files are required in order for the transmission clutch engagement values to be adjusted with the Caterpillar Electronic Technician. The new flash files were effective with 824G Series II (S/N: AWW366-UP) Wheel Dozers, 825G Series II (S/N: AXB430-UP) Soil Compactors and 826G Series II (S/N: AYH512-UP) Landfill Compactors.
 

1. Determine the flash file part numbers for the Power Train and Caterpillar Monitoring (ECM) System, currently on the machine. These are listed as the Software Group Part Number on the ECM Summary screen for each ECM in the Electronic Technician.
2. Use Winflash in order to load the software flash files described in Table 2 if they are not already on the machine.

Reference: Testing and Adjusting, 824G Series II Wheel Tractor, 825G Series II Soil Compactor and 826G Series II Landfill Compactor Power Train, RENR6028 "Engagement Pressure for the Transmission Clutch (Electronic Technician) - Calibrate".
 
 

1. Make sure that the transmission direction control switch (3) is in the NEUTRAL position.
2. Make sure that the parking brake is engaged.
3. Start the engine.
4. Warm the transmission oil to approximately 40 °C (104 °F).


Note: The transmission oil temperature gauge should be at the center position.

5. Increase the engine speed to high idle.


Note: You can use the SET/DECEL switch to maintain the high idle. The RESUME/ACCEL switch can be used to resume high idle.

Note: The software program that will be used for this test procedure is the Caterpillar Electronic Technician (ET). The Caterpillar Electronic Technician is a software program that can be used on an IBM-compatible personal computer.

Reference: For more information about the use of Electronic Technician, refer to Testing and Adjusting, "Using Caterpillar Electronic Technician (ET) to Determine Diagnostic Codes" for the machine that is being serviced.

6. Open the software program (ET). Select the "Transmission 824G II", "Transmission 825G II", or "Transmission 826G II" menu item (as required).
7. Select the "Service" menu in order to begin the calibration procedure. Then select "Calibrations". A second menu will be displayed. Select "Transmission Clutch Engagement Pressure Calibrations" from the second menu.
8. Once "Transmission Clutch Engagement Pressure Calibrations" has been selected, the screen displays a dialog box in order to select the clutch or the clutches for calibration. All of the clutches should be selected. Once the clutches for calibrations are selected press the "Begin" button.
9. The next screen is the initial calibration screen. The calibration screen displays the incremental instructions for calibration. The top display area displays status parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The bottom display area displays incremental instructions for the calibration. The step that currently needs to be carried out is in bold text. All other steps are displayed in gray text.
10. Press the "Next>" button in order to start the calibration. The "Next>" button is disabled, until the current step has been successfully completed. A check will be placed in the box that is left of the step, after the current step is complete.

With the direction switch in the forward position, a current (%) will appear at the bottom of the screen. Use the increment and decrement buttons below the current display to adjust the current value to match that in Table 3 of this procedure for the machine and clutch that is being adjusted. When the desired calibration value is displayed, move the direction switch to the neutral position.

11. A dialog box will appear after the calibration of the clutch is complete. The dialog box displays the selected calibrations and the status. After viewing the status, select the "Continue" button. The Electronic Technician will display the instructions for the calibration of the next clutch. Continue this procedure to adjust the calibration value for every clutch. The entire calibration procedure will end if the "Cancel" button is pressed.
12. To exit the calibration, select the "File" menu and then select "Exit".


Note: The transmission clutch fill calibration should be performed after adjusting the engagement calibration values. Perform the "Fill Time for the Transmission Clutch (Electronic Technician) ? Calibrate" procedure as described below.

Reference: Testing and Adjusting, 824G Series II Wheel Tractor, 825G Series II Soil Compactor and 826G Series II Landfill Compactor Power Train, RENR6028 " Fill Time for the Transmission Clutch (Electronic Technician) - Calibrate

1. Select the "Service" menu in order to begin the calibration procedure. Then select "Calibrations". A second menu will be displayed. Select "Transmission Fill Calibration" from the second menu.
2. The next screen is the initial calibration screen. Once "Transmission Fill Calibration" has been selected, the screen displays the incremental instructions for calibration. The top display area displays status parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The bottom display area displays incremental instructions for the calibration. The step that currently needs to be carried out is in bold text. All other steps are displayed in gray text.
3. Press the "Next>" button in order to start the calibration. The "Next>" button is disabled, until the current step has been successfully completed. A check will be placed in the box that is left of the step, after the current step is complete. After the successful completion of a step, press the "Next>" button in order to begin the following step. Continue this process in order to complete the calibration procedure.
4. The calibration procedure continues until the ECM determines that one of the steps is not met. The middle display area will display a message in order to alert you of the error. You can correct the error that is described in the middle display area or you can cancel the calibration by pressing the "Cancel" button. The Electronic Technician will display a message in the middle display area in order to alert you of the problem.
5. After correcting any problems that may occur, the calibration will proceed. After a brief initialization, each clutch is calibrated in sequence without any input from the user. The middle display area will inform the user of the progress of the calibration. The calibration of each clutch is approximately 90 seconds.
6. If some of the clutches reach a limit during the calibration, the ECM will make a log. The ECM will then move to the next clutch. When the calibration has been performed on all of the clutches a dialog box will display the results for each clutch. There are only two possible results: "Success" and "At a limit". The dialog box only appears if one or more of the clutches returns an "At a limit" error. The status of the individual clutches is displayed in the dialog box. The user may press the "Restart" button in order to begin calibration.
7. To exit the calibration, select the "File" menu and then select "Exit".