Usage:
824G (4SN) Wheel Tractors;
825G (6RN) Soil Compactors;
826G (7LN) Landfill Compactors;
980G (9CM, 2KR, 2SR) Wheel Loaders
Reference: Service Magazine; February 2, 1998; Page 26; "Machine Flash Software (Non-Engine Software) Ordered Through The Parts Distribution System Is Now Available Through The Corporate Mailbox".
Reference: Service Manual Module, SENR5891-02, Electronic Implement Control System, page 38; for the 980G Wheel Loader, 824G Wheel Tractor, 825G Soil Compactor and 826G Landfill Compactor. This module is found in Service Manual SENR5870.
Description of Change: New implement control group (electronic control modules) are now available that incorporate the following improvements:
1. A new calibration mode offers an additional method for manual adjustment of the minimum modulation current starting value. This is the initial current applied to the hydraulic proportional valves when a lever is moved out of the hold position. The value controls the proportional valve modulation current. This is an additional mode that can be used to fine-tune the hydraulics. This mode is neither a replacement for, nor an addition to the existing hydraulic calibration.
2. The lower cushioning feature has been modified to provide a smoother stop (980G only).
3. Option code plug status information is now broadcast over the CAT® Data Link. This information is displayed on the ET service tool.
4. Option code plug status information is now broadcast over the CAT® Data Link. This information is displayed on the ET service tool.
5. When entering the implement calibration mode, if no lift position sensor is installed and configured with an option code plug, "cal 1" mode is not displayed. "Cal 2" is the first mode shown (824G, 825G, 826G and custom 980G).
6. The lever tables have been modified to reflect reduced lever deflection and float detent changes made to the joystick (824G, 825G, 826G only).
7. Current values can be decreased in either Manual Adjustment Of Modulation Current or Manual Adjustment Of Start Of Modulation Current mode. Depress the operator switch to decrease the current while in either of these modes.
Adaptable To: On the 980G, the 164-4868 Software Group can be flashed (via ET) into the machines listed in the following chart to update to the enhancements listed above. The software can be ordered through the parts distribution system on diskette or through the corporate mailbox system. See the service magazine article referenced above for ordering information.
The optional service replacement 167-1336 Control Group is a preprogrammed ECM which directly replaces the former 155-9891, 143-2524, 138-1846, 140-6126, 138-1002, 138-0421, 136-6317, 134-0808, 130-1878, and 109-0584 Control Groups (824G, 825G, 826G only).
The optional service replacement 164-4869 Control Group is a preprogrammed ECM which is a direct replacement for the former 163-5284, 160-4932, 155-9927, 152-6491, 140-8922, 138-1846, 140-6126, 138-1002, 138-0421, 136-6317, 134-0808, 130-1878 and 109-0584 Control Groups. Machines that are currently equipped with the 114-4728 (three lever) implement Control Group must upgrade to the 150-9053 (three lever) Implement Control Group in order for the 164-4868 Software Group to function properly (980G only). The new 164-4868 (Flash) Software Group can be flashed into the 980G Wheel Loaders listed in the following chart. The new 163-6198 (Flash) Software Group is available for the 824G, 825G, and 826G machines with flashable ECMs. See the chart for software and machine compatibility. Two conditions must be met before a flash software file can be loaded.
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- 1. The key start switch must be in the ON position and the engine must be OFF.
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- 2. The implement lockout switch must be in the LOCK position. If the conditions are not met, the message "Inappropriate To Flash At This Time" will be displayed on the Electronic Technician Screen. The flash software can be ordered through the parts distribution system on a diskette or through the corporate mailbox system. Refer to the Service Magazine article referenced at the beginning of this article for ordering information. The new 164-4868 (Flash) Software Group is in production on the 980G Wheel Loader effective with 2KR2449-Up.
If the conditions are not met, the message "Inappropriate To Flash At This Time" will be displayed on the Electronic Technician Screen.
The flash software can be ordered through the parts distribution system on a diskette or through the coporate mailbox system. Refer to the Service Magazine article referenced at the beginning of this article for ordering information. The new 164-4868 (Flash) Software Group is in production on the 980G Wheel Loader effective with 2KR2449-Up.
NOTE: The above chart of serial numbers is based upon how the machine was originally configured from the factory. Earlier machines may have been updated with flashable ECMs. Two methods to check whether the ECM is flashable are by checking the service records (or the P/N on the ECM) and by using the ET service tool to check the serial number on the implement ECM. When using the ET service tool to check the serial number on the ECM, the end of the serial number contains a two letter suffix. The suffix DB is not flashable. All other suffixes can be flashed. The ECMs which are flashable are 138-0425, 142-3363, 145-1885, 147-5108, 150-4661, and 15-5151 Control Groups.
Manual Adjustment Of Start Of Modulation Current To Solenoid Valves
NOTE: The following steps are not necessary to obtain satisfactory implement control operation. The following steps are provided to give a means to customize or finetune control function for a given application.
1. Connect the 4C-8195 Service Tool to the service connector located behind the fuse access door in the right rear corner of the cab.
2. Operate the machine until the hydraulic oil reaches operating temperature.
3. Enter mode 6 (980G) or mode 7 (824G, 825G, and 826G) for the calibration. Press the "SCROLL" switch until any submode of Manual Adjustment of Maximum Modulation Current is displayed. The display will show a number (1 through 6) followed by a dash and three other numbers. An example would be "1-650".
4. Cycle the implement lockout switch ON and OFF one time. This toggles the calibration mode between maximum modulation current and start of modulation current. Any time that a manual adjustment submode is shown, the lockout switch will cause the calibration mode to switch between maximum modulation current and start of modulation current.
5. The start of modulation current is displayed. The format of the display will be "1u###". The three "#" symbols here represent a three digit number. On the actual display the three digit number will be the start of modulation current in milliamperes. The start of modulation current can be increased by momentarily pressing the "CLEAR" switch. Each time the "CLEAR" switch is pressed, the current will immediately increase by 3 or 4 milliamperes. Press and hold the "CLEAR" switch for more than one second and the current reading will scroll quickly until the switch is released.
6. The start of modulation current can be decreased by momentarily pressing the "OPERATOR" switch on the service tool. The operator switch is located on the lower left front dash panel. Each time the "OPERATOR" switch is pressed the current will immediately decrease 3 or 4 milliamperes. Pressing and holding the "OPERATOR" switch for more than one second will scroll the current reading quickly until the "OPERATOR" switch is released.
7. Pressing the "SCROLL" switch while displaying the start of modulation current will cause the next function's start of modulation current to be displayed. Table 10 shows the display and associated adjustable function.
8. If Electronic Technician is being used to perform the adjustment procedure, proceed to Step1 of "Start of Modulation Current Adjustment Using ET". If Electronic Technician is NOT being used to perform the adjustment procedure, proceed to Step 1 of "Start of Modulation Current Adjustment Without ET".
NOTE: If the implement calibration mode is exited to the service hourmeter, the manual adjustment mode will default back to the maximum modulation adjustment mode.
Start Of Modulation Current Adjustment Using ET
The start of modulation current is the minimum current that will be sent by the ECM to a hydraulic solenoid valve when the implement control lever is at 3 degrees of deflection from center. Adjusting this value will affect the ability of the operator to smoothly modulate the hydraulics at slow cylinder speeds.
Although ET is not necessary for adjusting the start of modulation current, it is a valuable tool for this procedure. If ET is available, connect the communications adapter and computer to the diagnostic service tool connector and run the ET program. View the real-time status screen which includes parameters for the lever and function that is being adjusted. For example, if the lift linkage raise function is being adjusted, view a screen with the Lift Lever Sensor and Raise Solenoid #1 parameters.
1. Move the lift arms to approximately one-third of total lift height. This allows room for cylinder movement during the procedure.
2. Raise the engine speed to high idle.
3. Move the lever in the direction to activate the function that is being adjusted. Watch the solenoid current for that function on the ET status screen. When the lever is at three degrees of deflection from the CENTER position, the ECM will deliver a nonzero current to the solenoid. Hold the lever at this position.
4. Decrease the start of modulation current so that the cylinder is not moving. If the cylinder is not moving at this point, proceed to the next step.
5. Slowly increase the start of modulation current until the engine starts to lug, but the cylinder is not yet moving. This is the optimal start of modulation current. If the engine does not lug, but the cylinder starts moving, decrease the start of modulation current until the cylinder stops moving.
Start Of Modulation Current Adjustment Without ET
1. Move the lift arms to approximately one-third of total lift height. This allows room for cylinder movement during this procedure.
2. Increase the start of modulation current shown on the display to 350 milliamperes.
3. Raise the engine speed to high idle.
4. Slowly modulate the lever in the direction that activates the solenoid for which this adjustment is being made. If the start of modulation current is above the optimal value, a bump will be felt as soon as the hydraulics are actuated. Proceed to the next step. If no bump is felt when the lever activates the solenoid, proceed to Step 7.
5. Reduce the start of modulation current slightly and check the lever modulation at the new setting. At the optimum setting, as the lever is moved into three degrees of deflection from center, the engine will start to lug just prior to the actual movement of the cylinder. The initial movement of the implement will be smooth.
6. Exit the calibration mode and try the hydraulic function that was just adjusted. Verify that the hydraulic feel is correct. STOP.
7. Increase the start of modulation current slightly and check the lever modulation at the new setting. An initial increase to try is 10 milliamperes. As the setting gets closer to the optimum setting, reduce the increase to 6 and then 3 milliamperes. This will help fine-tune the implement control. Repeat this step until a bump is felt as soon as the hydraulics are actuated.
8. Reduce the start of modulation current slightly and check the lever modulation at the new setting. At the optimum setting, as the lever is moved into three degrees of deflection from center, the engine will start to lug just prior to the actual movement of the cylinder. The initial movement of the implement will be smooth.
9. Exit the calibration mode and try the hydraulic function that was just adjusted. Verify that the hydraulic feel is correct.