Retrofitting the 136-7822 Transmission Control for the 109-3664 Transmission Control {3065} Caterpillar

Wheel Loader:

918F PS (PIN: 2CK1-UP; 3TJ1-UP; 5DL1-UP)

924F (PIN: 4YN1-545; 6MN1-574; 7PN1-UP; 5NN1-741)

928F PS (PIN: 2XL1-2021; 8AK1-973)

928F (PIN: 7YM1-UP)

Integrated Toolcarrier:

IT18F PS (PIN: 5EJ1-UP; 6ZF1-UP)

IT24F (PIN: 4NN1-631; 6KN1-207)

IT28F PS (PIN: 1JL1-366; 3CL1-2043)

Introduction

The 136-7822 Transmission Control is available to replace the former 109-3664 Transmission Control . The new 136-7822 Transmission Control features an electronic shifter. The electronic shifter has no mechanical contacts and improves service life.

The 136-7822 Transmission Control is applicable to the machines that are listed above with autoshift transmission control. Details for installing the 136-7822 Transmission Control are provided in this instruction.

Do not perform the procedure that is outlined in this publication or do not order any parts until you understand the information that is contained in this instruction.

Reference: Service Manual, SENR5760, "918F Wheel Loader," Service Manual Module, SENR5775, "918F Wheel Loader - Electrical System Schematic."

Reference: Service Manual, SENR5900, "IT18F Integrated Toolcarrier," Service Manual Module, SENR5915, "IT18F Integrated Toolcarrier - Electrical System Schematic."

Reference: Service Manual, SENR6720, "924F Wheel Loader and IT24F Integrated Toolcarrier," Service Manual Module, SENR6735, "924F Wheel Loader - Electrical System Schematic."

Reference: Service Manual, SENR6720, "924F Wheel Loader and IT24F Integrated Toolcarrier," Service Manual Module, SENR6737, "IT24F Integrated Toolcarrier - Electrical System Schematic."

Reference: Service Manual, SENR5990, "928F Wheel Loader,"Service Manual Module, SENR5969, "928F Wheel Loader - Electrical System Schematic."

Reference: Service Manual, SENR5970, "IT28F Intergrated Toolcarrier"Service Manual Module, SENR5985-01, "IT28F Integrated Toolcarrier - Electrical System Schematic."

Reference: Special Instruction, SEHS9615, "Servicing DT Connectors."

Parts and Tools Needed

Fabricating the Adapter Harness Assembly

The adapter harness assembly is required for machines with the 4E-0599 Harness . The adapter harness assembly provides power to the electronic shifter.

Note: The adapter harness assembly is not required for machines that have been upgraded with the 122-6078 Harness .

Illustration 1	g00567809
Adapter Harness Assembly See Table 2 and Table 3 for parts and tools needed.

1. Cut the 5P-5623 Wire (7) into 3 equal lengths. See Illustration 1.

   Note: Dimension (A) is 150 mm (6.0 inches).

2. Splice the 3 wires together as shown in Illustration 1.

   Note: Solder the splice with the 9U-7561 Field Soldering Iron .

3. Insulate the splice by wrapping the splice with the 1P-0810 Electrical Tape (12) .

4. Install the 8T-8729 Connector Pin (10) on the end of one wire. This wire is designated as Wire (164A). Use the 1U-5804 Crimp Tool to install connector pin (10) .

   Note: Refer to Special Instruction, SEHS9615, "Servicing DT Connectors".

5. Install connector pin (10) in Position 1 of the 102-8802 Receptacle Kit (8) .

6. Install the 8T-8737 Seal Plug (11) in Position 2 of receptacle (8) .

7. Install the wedge in order to secure the connector pin in the receptacle.

8. Install the two 8T-8730 Connector Sockets (9) on the end of the remaining 2 wires.

Removing the Autoshift Transmission Control

1. Disconnect the existing 109-3664 Transmission Control from the 4E-0599 Harness .

2. Remove the shift cover.

3. Remove the 109-3664 Transmission Control .

Installing the Electronic Transmission Control

Note: Omit Step 1 through Step 14 of this procedure if the machine has been upgraded with the 122-6078 Harness .

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Illustration 2	g00569201
Inside view of the right console service compartment showing location of components: (13) 4E-0599 Transmission Harness , (14) 24-Pin Connector Plug, (15) 24-Pin Connector Receptacle, and (16) Main Cab Harness.

1. Locate the 24-Pin Connector Plug (14), which is a part of the 4E-0599 Harness (13). See Illustration 2.

   Note: The 4E-0599 Harness (13) connects the transmission shifter to main cab harness (16). The 24-Pin connector is located in the service compartment of the right console.

   Note: The 24-Pin connector is not the connector that is bolted to the cab floor.

2. Unplug connector plug (14) from connector receptacle (15) .

3. Remove the wedge from connector plug (14) .

4. Remove the socket terminal and wire (164A) from Position 20 of connector plug (14). Use the 151-6320 Removal Tool to remove the socket terminal and wire (164A) .

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Illustration 3	g00569200
102-8807 Connection Plug Kit (3)

5. Install the socket terminal and wire (164A) in Position 1 of the 102-8807 Connecting Plug Kit (3). See Illustration 3.

6. Install the 8T-8737 Seal Plug (4) in Position 2 of connector plug (3) .

7. Install the wedge in connector plug (3) in order to secure the socket terminal.

8. Plug connector plug (3) into connector receptacle (8) .

   Note: Receptacle (8) is part of the adapter harness assembly.

9. Insert the 8T-8730 Connector Socket (9) and wire (164C) into Position 20 of connector plug (14)

   Note: The 8T-8730 Connector Socket (9) and wire (164C) are part of the adapter harness assembly.

10. Remove the seal plug from Position 19 of connector plug (14) .

11. Insert the remaining 8T-8730 Connector Socket (9) and wire (164D) into Position 19 of connector plug (14) .

    Note: 8T-8730 Connector Socket (9) and wire (164D) are part of the adapter harness assembly,

12. Replace the wedge in connector plug (14) .

13. Plug connector plug (14) into connector receptacle (15) .

14. Tie the adapter harness assembly to transmission harness assembly (13) with the 1S-9593 Cable Straps (5) .

15. Mount the 136-7822 Transmission Control (1) .

16. Connect the 136-7822 Transmission Control (1) to the 4E-0599 Harness (13) .

17. Install the new 108-2556 Shift Cover (6) .