PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOCKUP CLUTCH VALVE AND THE POWER TRAIN SOFTWARE ON CERTAIN 854G WHEEL DOZERS AND 992G WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOCKUP CLUTCH VALVE AND THE POWER TRAIN SOFTWARE ON CERTAIN 854G WHEEL DOZERS AND 992G WHEEL LOADERS

Usage:

SEBE8241-02

January 3, 2003
(Revised February 2003)
U-3
A-2
D-1
O-2

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOCKUP CLUTCH VALVE AND THE POWER TRAIN SOFTWARE ON CERTAIN 854G WHEEL DOZERS AND 992G WHEEL LOADERS
3139		PI30392

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30392" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30392" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the January 3, 2003 (Revised January 2003) Service Letter. Changes have been made to the SMCS Code.

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COMPLETION DATE	TERMINATION DATE
July 31, 2003	January 31, 2004

PROBLEM

The lockup clutch valve needs to be replaced and the power train software changed to prevent premature torque converter failures and harsh shifts on certain 854 Wheel Dozers and 992G Wheel Loaders. The Rimpull Control System (RCS) selection switch must also be added at the rear of the right hand console (854G only). The 5/8-inch 1832047/">(1832047 Modulating Valve) TC Lock Up Clutch Valve is no longer available and is replaced with the ½ inch valve 2165342/">(2165342 Modulating Valve - TC Lock Up Clutch). When changing to the ½ inch valve, the power train software must also be changed. The software is incompatible with the 5/8-inch valve and can cause premature torque converter failures and harsh shifts when Lock Up is engaged. This requires the rework back to 1^st production of all 854 Wheel Dozers and 992G Wheel Loaders with Lock Up Clutches (reference number 1096886). If the new software is installed on an earlier machine, then the valve must be replaced or the result will be a torque converter failure. Any 992G Wheel Loader with a standard torque converter can operate with either software.

AFFECTED PRODUCT

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Model	Identification Number
854G	AMP1-326 1JW1-Up
992G	ADZ130, 137-138, 140, 164, 166, 172, 180-181, 201, 218, 222, 224, 231, 234, 244, 248-250, 310, 315, 317-320, 323, 336, 344, 348-349, 360, 370, 378, 386, 394-395, 402, 408, 439, 458, 460, 461 7HR35, 41, 54, 56, 69, 83, 89, 132, 134, 137, 150, 157, 180-183, 186-187, 191, 193, 212, 221, 223, 235, 239, 248, 266, 271, 273-274, 293, 296, 306, 314, 322, 326, 345-346, 350, 356, 360-364, 374

PARTS NEEDED

Group 1: 854G

1 - 6D7889 Seal - O-Ring
1 - 2P4339 Nut - Jam
1 - 2V0099 Knob
1 - 1236384 Switch Assembly
1 - 1794964 Wire Assembly - Jumper
1 - 2165342 Modulating Valve - TC Lock Up Clutch
1 ? 2295703 Software

Group 2: 992G

1 ? 6D7889 Seal ? O-Ring

1 - 1794964 Wire Assembly ? Jumper

1 - 2165342 Modulating Valve - TC Lock Up Clutch

1 ? 2208566 Software

ACTION REQUIRED

Replace the 1832047 (5/8 inch) Modulating Valve - TC Lock Up Clutch with the 2165342 (½ inch) Modulating Valve - TC Lock Up Clutch. The power train software must also be changed. The Rimpull Control System (RCS) selection switch must also be added at the rear of the right hand console (854G only).

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2	0	0	0	0
NOTE: This is a 2-hour job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

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

Attach. (1-Owner Notification)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - The Lockup Clutch Valve Needs To Be Replaced And The Power Train Software Changed To Prevent Premature Torque Converter Failures And Harsh Shifts

MODELS INVOLVED - 854 Wheel Dozers and 992G Wheel Loaders

Dear Caterpillar Product Owner:

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 January 3, 2003 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.

Caterpillar Inc.

Identification #(s)

Attached to January 3, 2003 Service Letter