2008/12/08 Caterpillar

Articulated Truck:

725 (S/N: B1L1-UP; AFX1-UP)

730 (S/N: AGF1-UP; B1M1-UP)

730 EJECTOR (S/N: B1W1-UP)

735 (S/N: B1N1-UP; AWR1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)

Landfill Compactor:

826GSeries II (S/N: AYH1-UP)

826G (S/N: 7LN1-UP)

826H (S/N: AWF1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

836H (S/N: BXD1-UP)

Soil Compactor:

825G (S/N: 6RN1-UP)

825H (S/N: AZW1-UP)

Motor Grader:

120H (S/N: 4MK1-UP; 6NM1-UP; 6TM1-UP; ALZ1-UP)

120M (S/N: B9C1-UP; B9N1-UP)

12M (S/N: B9F1-UP; B9R1-UP)

135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 8WN1-UP; AMX1-UP)

140H (S/N: 2ZK1-UP; APM1-UP; 8JM1-UP; 8KM1-UP)

140M (S/N: B9D1-UP; B9M1-UP)

143H (S/N: 1AL1-UP; APN1-UP)

14M (S/N: B9J1-UP)

160H (S/N: 9EJ1-UP; 2FM1-UP; CCP1-UP; 2HS1-UP)

160M (S/N: B9E1-UP; B9L1-UP)

163H (S/N: 5AK1-UP; ARL1-UP)

16M (S/N: B9H1-UP)

24M (S/N: B9K1-UP)

Transmission:

TH55FT-E70 (S/N: PCJ1-UP)

Off-Highway Truck/Tractor:

773F (S/N: EED1-UP)

777F (S/N: JRP1-UP)

793F (S/N: SND1-UP; SSP1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP)

Quarry Truck:

775F (S/N: DLS1-UP)

Petroleum Transmission:

TH31-E61 (S/N: LAD1-UP; SKY1-UP)

TH35-E81 (S/N: MSB1-UP; TZM1-UP; PZT1-UP)

TH48-E70 (S/N: JGC1-UP; KSH1-UP)

Paving Compactor:

CS-573C (S/N: 6LN1-UP)

Pipelayer:

561N (S/N: TAD1-UP; CPH1-UP)

572RSeries II (S/N: DSC1-UP)

572R (S/N: AAC1-UP; 2HZ1-UP)

583T (S/N: CMX1-UP)

587T (S/N: FAT1-UP)

Track-Type Tractor:

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D5M (S/N: 6GN1-UP; 3CR1-UP; 3DR1-UP; 4BR1-UP; 7LR1-UP; 4JS1-UP; 5ES1-UP; 5FS1-UP; 6AS1-UP)

D5N (S/N: AKD1-UP; AGG1-UP; CFH1-UP; CKT1-UP)

D6M (S/N: 9ZM1-UP; 2RN1-UP; 3WN1-UP; 4JN1-UP; 5NR1-UP; 5WR1-UP; 6LR1-UP; 2YS1-UP; 4GS1-UP; 4HS1-UP)

D6N (S/N: DJA1-UP; CBF1-UP; CCG1-UP; ALH1-UP; JAH1-UP; CBJ1-UP; CCK1-UP; CBL1-UP; JAL1-UP; AKM1-UP; ALR1-UP; CCS1-UP; ALY1-UP; DJY1-UP)

D6RSeries II (S/N: BNC1-UP; AFD1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6RSeries III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6R (S/N: A6M1-UP; 2HM1-UP; 4FM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 4JR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; S6T1-UP; 1RW1-UP)

D6T (S/N: JHB1-UP; SMC1-UP; DJG1-UP; WCG1-UP; WFH1-UP; SNK1-UP; KJL1-UP; SKL1-UP; GCT1-UP; LAY1-UP)

D7RSeries II (S/N: EEA1-UP; AEC1-UP; AFG1-UP; ABJ1-UP; BPK1-UP; BNM1-UP; BRM1-UP; AGN1-UP; BRP1-UP; ACS1-UP; BPT1-UP; ADW1-UP; BNX1-UP)

D7R (S/N: 9HM1-UP; 2EN1-UP; 3DN1-UP; 2HR1-UP; 3ZR1-UP; 5MR1-UP; 6ER1-UP; CBZ1-UP; 5KZ1-UP)

D8RSeries II (S/N: AKA1-UP; 6YZ1-UP)

D8R (S/N: 7XM1-UP; 9EM1-UP)

D8T (S/N: J8B1-UP; KPZ1-UP)

D9T (S/N: RJS1-UP)

Wheel Dozer:

824G (S/N: 4SN1-UP)

824H (S/N: ASX1-UP)

834G (S/N: BPC1-UP; 6GZ1-UP)

834H (S/N: BTX1-UP)

Wheel Loader:

924G (S/N: DDA1-UP; RBB1-UP; WMB1-UP; AAN1-UP; 9SW1-UP; 3PZ1-UP)

924GZ (S/N: RTA1-UP; AAB1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)

924H (S/N: HXC1-UP; JTM1-UP)

924HZ (S/N: PED1-UP)

928G (S/N: DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)

928HZ (S/N: BYD1-UP; CXK1-UP)

930G (S/N: TWR1-UP; TFW1-UP)

930H (S/N: DHC1-UP)

950GSeries II (S/N: AXR1-UP; AXX1-UP)

950G (S/N: 4BS1-UP; 3JW1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962GSeries II (S/N: AXS1-UP; AXY1-UP)

962G (S/N: 5AS1-UP; 4PW1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

966GSeries II (S/N: ANT1-UP; ANZ1-UP)

966G (S/N: HDH1-UP; 3ZS1-UP; 3SW1-UP)

966H (S/N: A6D1-UP; A6G1-UP; A6J1-UP)

972GSeries II (S/N: AWP1-UP; ANY1-UP)

972G (S/N: 7LS1-UP; 8TS1-UP; 4WW1-UP)

972H (S/N: WLA1-UP; A7D1-UP; A7G1-UP; A7J1-UP)

980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: BXY1-UP)

Wheel Skidder:

525C (S/N: 5251-UP)

535C (S/N: 5351-UP)

545C (S/N: 5451-UP)

Service Magazine SEPD0942, 08 December 2008, "Procedure for Cleaning the Power Train". Disregard this article. This article has been replaced by the following article. The only change in this article was the effectivity.

Note: This information applies to previous models of the machines that are listed above if the same transmission control system was used on the prior model.

Modern Caterpillar transmission control systems require clean oil in order to maintain the proper functionality and reliability. The electronic clutch pressure control (ECPC) is sensitive to contamination. A failure in the power train system may generate debris in the oil system and contaminate the transmission control. Replacement and/or cleaning of certain components is important in order to prevent repeat failures during low hours of operation.

Note: Components that use the same oil as the transmission can include torque converters, transfer gear groups, drop boxes, retarders, and brakes on Track-Type Tractors.

There is no practical way of cleaning the ECPC valve. The ECPC valve is also referred to as the transmission modulating valve. Refer to 244-3114 Modulating Valve for an example of an ECPC valve. Internal passages and an edge filter are located inside the valve body that cannot be cleaned by spraying solvent into the valve body. The valves can become contaminated when debris gets past the filter at start-up. The valves can also become contaminated if the filter plugs due to the debris that is generated from failure. If the valves have been exposed to contaminated oil, the valves should be replaced. Replacing the valves is especially important if there are complaints on shifting, which can lead to a clutch failure.

Follow the Steps below when you are repairing a failure for the power train.

1. Remove the transmission.

2. Clean the transmission and repair the transmission if repair is needed.

3. The best option is to use a reusable test set of control valves or the original valves from the transmission while performing the bench test procedure and the machine kidney looping process in Step 9. The use of a reusable test set of control valves or the original valves from the transmission will prevent any contamination in the control valve manifold or power train oil lines from contaminating the new ECPC valves. The other option is to replace the valves when the rebuild procedure and the bench test procedure are performed.

   Note: On some machines, the ECPC valves are easily changed while the transmission is in the machine. When replacing the valves is difficult on some machines, the valves can be replaced while the transmission is being repaired. All oil lines and passages between the filter and control valves must be clean. Cleanliness is important. Cleanliness will help reduce the possible contamination of the new valves after starting the machine.

   Note: The probability of damaging a clutch on the test stand when using the old valves is minimal if all of the clutch pressures are being monitored. The test stand procedure can be aborted if a clutch does not build correct pressure or if a clutch maintains residual pressure.

4. Remove all suction screens and clean all suction screens in the system. Include inlet screens for the pumps, scavenge screens, and torque converter screens.

5. Clean the oil sump for the power train in the system and the hydraulic lines in the system.

6. Replace the cooler core for the power train with a Reman unit and flush the cooler lines.

7. Remove the brake valve and clean the inlet screens on a Track-Type Tractor.

8. Reinstall the transmission.

9. Run the machine in neutral when you are performing the kidney looping process on the machine. The system should be operated in the kidney looping process until particle count is ISO16/13.

10. Replace the filters for the power train.

11. Replace all modulating ECPC valves for the transmission with new valves.

12. Calibrate the new transmission valves.

Clean other components that utilize the same control oil for the transmission if needed. Cleaning other oil-related components will depend on the configuration of the machine. The torque converter and brake modules on Track-Type Tractors may need disassembled. Disassembly of the torque converter and brake modules will depend on the amount of debris generated and the time that is spent in filter bypass. This will facilitate cleaning and reducing the time that is required when you are using the kidney looping process to clean the system.

Contact DSN Tier II Transmission Support for further consultation if any questions arise about proper cleanout of the system after a failure.

Note: Refer to Special Instruction, REHS4331 for more general information that is related to Track-Type Tractors.