PRODUCT SUPPORT PROGRAM FOR REPLACING THE SOLENOID VALVE (BRAKE CHARGING) ON CERTAIN 924G AND 928G WHEEL LOADERS AND IT28G INTEGRATED TOOLCARRIERS

Usage:

SEBE9099-01

March 7, 2005
(Revised May 2005)
U-75
A-56
D-64
O-64

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*before or* *after failure* *Parts stock action needed*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE SOLENOID VALVE (BRAKE CHARGING) ON CERTAIN 924G AND 928G WHEEL LOADERS AND IT28G INTEGRATED TOOLCARRIERS
5073 4268 5479		PS41753

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41753" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "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 March 7, 2005 Service Letter. Changes have been made to the Rework Procedure.

TERMINATION DATE

March 31, 2006

PROBLEM

NOTE: This program can be completed at the same time PI30690 is being completed. A new Solenoid Valve (Brake Charging) needs to be installed on certain 924G and 928G Wheel Loaders and IT28G Integrated Toolcarriers. The Solenoid Valve (Brake Charging) may malfunction on some machines.

Machines with defective valves may experience problems with the hydraulic brake charging and cooling fan circuit.

The following are known problems associated with a defective Solenoid valve (Brake Charging):

Unable to achieve maximum Brake Accumulator cut-out pressure.
Hydraulic noise in the Fan circuit during Brake charging.
Unable to calibrate or achieve specified hydraulic Fan speed.
Vibration and resonance in the hydraulic Brake and Fan circuit lines.
Structural failure of the Brake/Fan Pump casing.

Machines using part numbers 203-6590, 248-3143 and 2500392/">250-0392 should install the latest part number 255-4311.

AFFECTED PRODUCT

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Model	Identification Number
924G	DDA001-575, 577-702, 704-720, 722-802, 805-813, 815-819, 821-834, 836-890, 892-895, 897-919, 922-953, 955-1002, 1004, 1005, 1007, 1009-1014, 1016-1031, 1033-1040, 1042, 1044-1184, 1186-1194, 1196-1210, 1212-1228, 1230-1255, 1257-1259, 1261-1280, 1282-1284, 1286-1320, 1322-1360, 1365, 1367-1372, 1372-1377, 1385-1387, 1392-1398, 1400-1403, 1408-1411, 1416-1419, 1421-1452, 1455-1464, 1466, 1468-1472, 1474-1479, 1481-1486, 1488-1494, 1496-1499, 1501, 1502, 1504, 1506-1509, 1511-1513, 1515, 1518-1523 DFZ001-462, 464-475, 477-563 RTA001-182, 184-192, 194-211, 213-290 WGX001-461, 463-756 WMB001-405, 407-454, 456-543, 545-568, 570-575, 577-596, 598-784 RBB001-373, 375-528, 530-534, 536-538, 540-545, 547-594, 596-601, 602-644
928G	WLG001-338, 340-394, 396-420, 422-449, 451-491, 493-505, 507-547, 549-699 DJD001-583, 585-588, 590-697, 699-729, 731, 732, 735-743, 745-755, 757-778, 780-804, 806-817, 819-823, 825-913, 915-925, 927-970, 972-975, 975-1049, 1051-1063, 1065-1140, 1142-1156, 1158-1173, 1177-1205, 1207-1247, 1249-1251, 1253-1310, 1312-1318, 1320-1328, 1330-1334, 1336, 1338-1384, 1386-1390, 1392, 1394-1428, 1430, 1434, 1435, 1437-1444, 1446-1449, 1453-1456, 1458, 1459, 1461, 1464, 1466, 1470, 1473-1475
IT28G	DBT001-654, 656-683, 685-726, 728-740, 742-758, 760-825, 827-880, 882-901, 904-906, 908-942, 944-977, 979-992, 994-999, 1001-1022, 1024-1043, 1046-1102, 1104-1132, 1134-1201, 1204-1206, 1208-1257, 1259-1295, 1297-1305, 1307-1373, 1375-1401, 1403-1472, 1474-1492, 1494-1520, 1524-1535, 1537, 1540, 1543, 1548, 1549, 1551-1557, 1559, 1560, 1562, 1565-1569, 1572-1575, 1578-1582, 1584-1590 WAC001-326, 328-332, 334-393, 395-399, 401-415, 417-453, 455-490, 492-558 EWF001-289

PARTS NEEDED

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Qty	Part Number	Description
1	7K1181	STRAP ? CABLE
1	2554311	VALVE GROUP - SOLENOID

ACTION REQUIRED

***** Parts Stock *****

Remove all 2036590, 2483143, and 2500392 VALVE GROUP - SOLENOIDS from parts stock.

***** Affected Product *****

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 2036590, 2483143, and 2500392 VALVE GROUP - SOLENOIDS removed from parts stock.

***** Affected Product *****

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-3000 0-24 mos	100%	1.0
3001-5000 25-36 mos	33.3%	0.5	0	0	50.0%	0.5
NOTE: This is a 1.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Rework Procedure Part 1.

Reference 205-3665 Brake/Fan Pump Engineering change 08.

Reference RENR6428-01 Systems Operations and Test and Adjust Braking and Hydraulic Fan System.

Reference SEBU7645 Operation and Maintenance Manual.

Reference the Safety Section and General Hazard Information in the Operation and Maintenance Manual before starting work.

Open the engine access door on the right side of the machine. Turn the battery disconnect switch to the OFF position.

Disconnect the 2 Pin DT connector at the Valve Group Solenoid.

Loosen the nut securing the Solenoid Coil to the Valve cartridge enough to allow the coil to rotate freely.

Loosen the cartridge at the pump body and unscrew the cartridge and coil assembly.
Follow steps 2 through 5 in reverse order to install the new Valve Group and Solenoid.

Note: The Valve Cartridge to Pump and Solenoid Coil to Valve Cartridge are torque sensitive. Reference torque specifications listed in Table 1. In some cases the Solenoid Coil will still be free to rotate on the Valve Cartridge even when torque is correctly applied. Do not exceed the specified torque if the coil rotates freely. If axial play is present do not use the Valve assembly.
Table 1.

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Description	Torque Value
Valve Cartridge to Pump Housing	45 +/- 5 N.m.
Coil to Valve Cartridge	35 +/- 3 N.m.

After installation perform the Brake Accumulator Charge Test and Fan Speed Calibration listed in the Testing and Adjusting section of the Service Manual module RENR6428.

Rework Procedure Part 2.

Machines using Transmission Software listed in Table 2 should flash the machine controller with the latest Transmission Flash File listed in Table 3.

The new 269-7591 Software eliminates the ramp rate during charging. This change eliminates the noise during the transition from Brake Cut In to Brake Cut Out. The new Software also employs a valve cycling feature. This feature cycles the valve to full current for a duration of 100 ms every 10 seconds while in the Brake charging mode. This cycling characteristic helps to clear any contamination particles off the EBC Edge Filter that may be present.

Table 2.

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Electronics Arrangement	Software Part Number
215-2884	220-7145
	221-3242
	231-7093
	233-9475
	236-0586
	245-8200
	261-8013

Table 3.

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Electronics Arrangement	New Software Part Number
215-2884	269-7591

Note: Flash Programming of the ECM can only be achieved using Caterpillar Electronic Technician ( ET ). ET contains the program WinFlash. WinFlash is used in order to load Software into the ECM. Reference RENR6423 Troubleshooting, Electronic Control Module ? Flash Program for correct procedure.

After flashing the latest Transmission Flash File listed in table 3, you will need to perform the following calibration routines: