Integrated Braking System Software Version II

Requirements Specification for 938G - 980G Series II MWL

E&ES, Aurora WLED - Caterpillar Inc.

Version: 0.2, March 1, 2001
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

Block Diagram
This Block Diagram shows the inputs and outputs of the Integrated Braking
System only. Other inputs and outputs of the Powertrain ECM are shown
in the applicable Powertrain Production System Requirements Documents.

MAC-14
Powertrain ECM
172-0143

CAT Datalink

HMU Shifter Configuration CCS Shifter Configuration

HMU Shifter 2
CCS Shifter
3
166-7820 4
151-7007

Implement Lever
5 position
Mounted Downshift
Transmission Auto/
Switch
Manual Switch
4E-7822
201-7952
3 position
Transmission Auto/ Engine Speed
Manual Switch Sensor
185-6335 Wire from Engine ECM 6V-2455

Neutralizer Torque Converter Output

Disable Lamp Speed Sensor (except 980G)
7N-5876 183-5011
Neutralizer Transmission Output
Disable Switch Speed Sensor 1
188-4804 183-5011
Transmission Output
Left Pedal Speed Sensor 2
Position Sensor (except 980G)
147-1680 183-5011
 CALIBRATED
DEADBAND LEFT BRAKE
INITIAL BRAKE PEDAL POSITIONS
PRESSURE POINT

INITIAL MODE

LEFT
NORMAL BRAKE
CALIBRATED MODE POSITION
NEUTRALIZATION
SENSOR
SET POINT

MAXIMUM BRAKE
PEDAL LAMP
TRAVEL SWITCH
 Transmission Neutralizer Modes

Transmission Direction and Speed

Control Position of the Autoshift Control Switch
Selected
Type Speed Manual 4 3 2 1-4
Truck
Command Control Steering N/A Normal Normal Normal Loading Normal
Conventional Steering 1 Normal Normal Normal
Truck
Conventional Steering 2 Normal Loading Normal
Conventional Steering 3 Normal Normal Normal
Conventional Steering 4 Normal Normal N/A Normal
 First Neutralization Re-Engagement Re-Neutralization Exit IBS Mode
Normal Mode < calibration point > max.- Delta < max. > dead band
Truck Load Mode < calibration point > max.- Delta < current pos.- Delta > calibration point
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

3.1.2 IBS Activation

IBS is active in all Transmission Auto/Manual Switch settings (including
Manual) whenever all of the following are true:

• Engine Speed is below the trigger point listed in the IBS Shift Point
Table

• The Left Pedal is depressed beyond the Left Pedal Deadband listed
in the IBS Shift Point Table

• No faults are detected on the Torque Converter Output Speed

Sensor, the Transmission Output Speed Sensor, or the Left Brake
Pedal Position Sensor. The Left Brake Pedal Position Sensor must
be calibrated.

3.1.3 IBS Initial and Normal Modes

As the operator modulates the Left Brake Pedal between the Left Brake
Pedal Deadband position and the Calibrated Initial Brake Pressure
Point, the IBS function will operate in Initial Mode.

As the operator modulates the Left Brake Pedal between the Calibrated
Initial Brake Pressure Point and the fully depressed position, the IBS
function will operate in Normal Mode.

3.1.3.1 Depressing the Left Brake Pedal in Initial and Normal Modes
The function performs the following steps when the pedal is depressed
in Initial and Normal Modes:

1. Regardless of the position of the Transmission Auto/Manual Switch,

if the transmission is in 3rd or 4th gear, the transmission will
downshift one gear at a time down to 2nd gear. Each downshift will
occur when the Transmission Output Speed decreases to the Initial
or Normal Mode shift point for the current gear listed in the IBS Shift
Point Table.

2. If the Transmission Auto/Manual Switch is in the Auto 1 – 4 position,

the transmission will downshift from 2nd to 1st gear when the
Transmission Output Speed decreases to the 2 – 1 Initial or Normal
Mode shift point listed in the IBS Shift Point Table.

3. If the Transmission Auto/Manual Switch is not in Auto 1 – 4 position,

the transmission will remain in 2nd gear unless the operator manually
requests a downshift to 1st gear by depressing the Downshift Switch
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

one time.

3.1.3.2 Releasing the Left Brake Pedal in Initial and Normal Modes
The function performs the following steps when the pedal is released
past the Left Pedal Deadband minus the Left Pedal Hysteresis in Initial
and Normal Modes:

1. On a HMU configured machine, if the Transmission Auto/Manual

Switch is in the Manual position, the IBS function will terminate and
the transmission shift control logic will shift the transmission
sequentially to the gear selected by the shift handle regardless of
Transmission Output Speed.

2. On a CCS configured machine, if the Transmission Auto/Manual

Switch is in the Manual position, the IBS function will terminate and
the gear will not change.

3. For both HMU and CCS configured machines, if the Transmission

Auto/Manual Switch is in the Auto 4, Auto 3, Auto 2, or Auto 1 – 4
position, IBS will terminate and return transmission shift control to
the Autoshift function.

3.1.3.3 Direction Changes with IBS Active

IBS does not inhibit or change the normal directional shift control logic.

3.1.4 IBS Safe Mode

When IBS is active, excessive Engine Speed or Torque Converter
Output Speed will cause the IBS function to enter Safe Mode.

3.1.4.1 Entering Safe Mode

The following condition causes the IBS function to enter Safe Mode:

1. The Torque Converter Output Speed exceeds the Torque Converter

Output Speed Safe Mode Trigger listed in the IBS Shift Point Table
or the Engine Speed exceeds the Engine Speed Safe Mode Trigger
listed in the IBS Shift Point Table.

3.1.4.2 IBS Function during Safe Mode

The IBS function performs the following steps when Safe Mode has
been entered:
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

1. The IBS function commands an upshift if the transmission is not

already in the maximum allowed gear based on the lowest gear as
defined by the configuration parameter and Transmission
Auto/Manual Switch position.

2. The IBS function waits to command a downshift until the

Transmission Output Speed falls below the corresponding Safe
Mode shift point listed in the IBS Shift Point Table.

3.1.4.3 Exiting Safe Mode

When the Transmission Output Speed falls to the corresponding Safe
Mode shift point listed in the IBS Shift Point Table, the following
conditions occur and the IBS function exits Safe Mode:

1. The IBS function commands a downshift.

2. The IBS function returns to Initial Mode or Normal Mode based on

the position of the Left Brake Pedal.

Note: If the Left Brake Pedal is released enough to deactivate IBS

during Safe Mode, the IBS function will terminate and return control to
the shift control logic.

3.1.5 Neutralizer Enable Control

The Neutralizer Disable Switch is the only input to the Neutralizer
Enable Control Function. The function works as follows:

• Upon powerup, the Neutralizer Enable Control function defaults to

“Neutralizer Enabled.”

• Whenever the Neutralizer Enable Control function is in the

“Neutralizer Enabled” state, the Neutralizer Disable Lamp is not
illuminated.

• Each time the momentary Neutralizer Disable Switch is depressed

and released, the Neutralizer Enable Control function changes
between “Neutralizer Enabled” and “Neutralizer Disabled.”

• Whenever the Neutralizer Enable Control function is in the

“Neutralizer Disabled” state, the Neutralizer Disable Lamp is
illuminated.

• The Neutralizer Enable Control function is in the “Neutralizer

Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

Disabled” state whenever there is a fault on the Left Brake Pedal

sensor. The Neutralizer Disable Lamp is not illuminated in this case.

3.1.6 Neutralizer Control

The Neutralizer Control function is based on the following inputs:

• Left Brake Pedal Position

• Transmission Auto/Manual Switch Position

• Actual Transmission Gear

• Calibrated Neutralization Point

• Neutralizer Enable Control Status

• Ground Speed

There are five Neutralization Counters available through the ET

Configuration Screen, one for each position of the Transmission
Auto/Manual Switch. The values shown in ET must be multiplied by
100 to calculate the actual Neutralization Count. These counters only
represent neutralizations caused by the Left Brake Pedal. These
counters may be reset by changing the value to 0.

Note: If the Neutralizer Enable Control function changes state due to

the Neutralizer Disable Switch at any time that the conditions for
neutralization are satisfied, the neutralization state will change.

The Neutralizer Mode is determined by the following table:

Shifter Transmission Auto/Manual Switch Position

Type Selected Manual Auto 4 Auto 3 Auto 2 Auto 1 – 4

Gear
CCS N/A Normal Normal Normal Truck Normal
Loading
HMU 1 Normal Normal Normal

HMU 2 Normal Truck Normal

Loading
HMU 3 Normal Normal Normal

HMU 4 Normal Normal Normal

Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

3.1.6.1 Normal Mode Neutralization

3.1.6.1.1 Transmission Neutralization Conditions

The following conditions must be met to cause Neutralization:

• The transmission must be in 1st or 2nd gear unless the

Transmission Auto/Manual Switch is in the Auto 1 – 4
position, in which case the transmission must be in 1st gear.

• The Left Brake Pedal must be depressed at or beyond the

Calibrated Neutralization Point.

• The Ground Speed must be below the Neutralization Speed

value listed in the IBS Shift Point Table for the current gear.

• The Neutralizer Enable Control function must be in the

“Neutralization Enabled” state.

Note: The Neutralization Control will remain in effect until the

Left Brake Pedal is released to the Left Brake Pedal
Deadband minus the Left Brake Pedal Hysteresis.

Note: The maximum depressed Left Brake Pedal position is

retained until the pedal is fully released.

3.1.6.1.2 Transmission Re-Engagement Conditions

Transmission re-engagement occurs when any of the
following conditions occur:

• Left Brake Pedal is released by the Left Brake Pedal Inch

Delta listed in the IBS Shift Point Table from the maximum
depressed Left Brake Pedal position.

• The Neutralizer Enable Control function is set to the

“Neutralization Disabled” state.

3.1.6.1.3 Transmission Re-Neutralization Conditions

The operator may re-neutralize the transmission before the
Left Brake Pedal is fully released as follows:
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

• The Left Brake Pedal must again be depressed to the

maximum depressed Left Brake Pedal position. If the
Neutralization conditions are met, the transmission will be
neutralized. If the operator depresses the Left Brake
Pedal past the current maximum depressed Left Brake
Pedal position, the new pedal position will replace the
current maximum depressed Left Brake Pedal position.

3.1.6.1.4 Exiting Neutralization Control

The Neutralization Control function will exit when the operator
releases the Left Brake Pedal to the Left Brake Pedal
Deadband minus the Left Brake Pedal Hysteresis. At this
time, the maximum depressed Left Brake Pedal position is
reset to prepare for the next Neutralization cycle.

3.1.6.2 Truck Loading Mode Neutralization

3.1.6.2.1 Transmission Neutralization Conditions

The following conditions must be met to cause Neutralization:

• The transmission must be in 1st or 2nd gear.

• The Left Brake Pedal must be depressed beyond the

Calibrated Neutralization Point.

• The Neutralizer Enable Control function must be in the

“Neutralization Enabled” state.

The maximum depressed Left Brake Pedal position is stored.

3.1.6.2.2 Transmission Re-Engagement Conditions

Transmission re-engagement occurs when the any of the
following conditions occur:

• Left Brake Pedal is released by the Left Brake Pedal Inch

Delta listed in the IBS Shift Point Table from the maximum
depressed Left Brake Pedal position.

• The Neutralizer Enable Control function is set to the

“Neutralization Disabled” state.
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

The minimum Left Brake Pedal position is stored.

3.1.6.2.3 Transmission Re-Neutralization Conditions

The operator may re-neutralize the transmission before the
Left Brake Pedal is fully released as follows:

• The Left Brake Pedal must again be depressed by the Left

Brake Pedal Inch Delta listed in the IBS Shift Point Table
and the Neutralization conditions must be met.

The new maximum depressed Left Brake Pedal position is

stored.

3.1.6.2.4 Exiting Neutralization Control

The Neutralization Control function will exit when the operator
releases the Left Brake Pedal to a position above the
Calibrated Neutralization Point the Left Brake Pedal Inch
Delta listed in the IBS Shift Point Table. At this time, the
maximum depressed Left Brake Pedal position is reset to
prepare for the next Neutralization cycle.

3.1.7 Neutralization Setpoint Calibration

The Neutralization Setpoint Calibration is used to set the Neutralization
Setpoint and the point of Left Brake Pedal travel where brake pressure
begins to be generated on the highest pressure axle. The
Neutralization Setpoint is offset by Neutralization Offset value.

The Neutralization Setpoint Point Calibration must be done after any of

the following:

• Installation of new Powertrain Production System software

• Installation or adjustment of the Left Brake Pedal Sensor

• Adjustment of the cab floor mounted Brake Valve

The Initial Brake Point Calibration must be performed using the EMS-II
Sub-Mode 29 Calibration Procedure explained in Appendix A of this
document.

If there is no valid calibration data in the ECM memory, there will be an

active fault on the Left Brake Pedal sensor.
Integrated Braking System Version II Software Requirements Spec. Version 0.2 03/01/01

4.1.5 Neutralization Setpoint Calibration - Sub-mode 29

2 9 _ _ _ _ Beginning display for

Left Brake Pedal Sensor Calibration

EXX = E03 = Active Left Brake Pedal Fault

EXX = E04 = Transmission Direction Lever Not In Neutral
2 9 _ E X X EXX = E07 = Parking Brake is not On

2 9 _ C 0 0
Increment
Depress Left Brake pedal to desired neutralization

2 9 _ C 0 1 point and press increment

Increment

2 9 _ - - -
Increment

Mode: Move to next Mode at any time during calibration

Scroll: Move to next Sub-mode at any time during calibration

4.1.6 Neutralization Setpoint Calibration Adjustment – Sub-mode 30

Beginning display for
3 0 _ _ _ _ left brake pedal calibration
adjustment

’x x x’ = current left brake pedal

3 0 _ x x x neutralization point
(valid range is 10 - 70)

Increment/
Decrement
to change ’x x x’

Mode: Move to next Mode at any time during calibration

Scroll: Move to next Sub-mode at any time during calibration
Service Magazine

Media Number - SEPD0664-00 Publication Date - 2003/01/27 Date Updated - 2003/01/27

New Software is Available for Machines that are

Equipped with the Integrated Braking System.
Integrated Toolcarriers:
IT62G (S/N: AKP513-UP)
Wheel Loaders:
950G Series II (S/N: AYB1-UP; AYL1-UP; AXX1-UP; AXR1-UP)
950G (S/N: 2JS1500-UP; 4BS707-UP; 6NS400-UP; 3JW2154-UP; 5FW2000-UP; 5MW1078-UP;
8JW407-UP)
962G Series II (S/N: BAB1-UP; AYE1-UP; AXY1-UP; AXS1-UP)
962G (S/N: BDP202-UP; 3BS800-UP; 5AS401-UP; 5RS403-UP; 4PW504-UP; 6EW415-UP;
6HW624-UP; 7BW800-UP)
966G Series II (S/N: AXJ1-UP; AWY1-UP; ANZ1-UP; ANT1-UP)
966G (S/N: AAH511-UP; 3ZS709-UP; 9RS1400-UP; 3PW1100-UP; 3SW1225-UP; 8XW756-UP)
972G Series II (S/N: TLA1-UP; AXC1-UP; AXN1-UP; AWP1-UP; ANY1-UP)
972G (S/N: 7LS405-UP; AAW402-UP; 1EW700-UP; 4WW720-UP; 6AW500-UP; 9GW508-UP)
980G Series II (S/N: AXG1-UP; AWH1-UP)
980G (S/N: 9CM2034-UP; 2KR4553-UP; 2SR821-UP)

Description of Change: The software for the transmission has been changed for
machines that are equipped with the Integrated Braking System. The truck-loading
mode will apply to all of the gears of the transmission when the new software is used.
The truck-loading mode was formerly used in second gear only.

The new software will engage the transmission if the left service brake pedal is released
at least four degrees upward from the maximum depressed position. The former
software engaged the transmission if the left service brake pedal was released two
degrees upward from the maximum depressed position.

The new software allows the disabling of the Integrated Braking System (“automatic
downshifting”) in manual mode. The default within the Caterpillar Electronic
Technician is enabled. To disable the Integrated Braking System, it will be necessary to
change the Integrated Braking System Manual Mode Enable Status from Enabled to
Disabled in the Transmission Configuration Screen. This can be accomplished by using
the Caterpillar Electronic Technician. This should be done only after consultation
between the dealer and the customer in order to ensure that the change will not cause a
heating problem with the brakes.
Adaptable To:

Table 1

Model Part Number of New Software

980G 229-4986

950G, 966G and 972G 229-4976

980G Series II 229-4981

950G Series II, 966G Series II and 972G Series II 226-7156

The new software was effective with 980G Series II (S/N: AXG539-UP; AWH760-UP)
Wheel Loaders, 972G Series II (S/N: TLA50-UP; AXC564-UP; AXN263-UP; AWP1-
UP; ANY1-UP) Wheel Loaders, 966G Series II (S/N: AXJ832-UP; AWY538-UP;
ANZ1-UP; ANT1-UP) Wheel Loaders, 962G Series II (S/N: BAB317-UP; AYE444-
UP; AXY1-UP; AXS1-UP) Wheel Loaders and 950G Series II (S/N: AYL517-UP;
AYB441-UP; AXX1-UP; AXR1-UP) Wheel Loaders. The new software is adaptable to
first production of the machines that are listed.

The new software cannot be installed on 980G S/N:2KR1-894

Wheel Loaders that were equipped with a non-flashable ECM for the Transmission.

The Integrated Braking System portion of the software will only work the machines that
were listed above or on machines that have had an Integrated Braking System retrofit kit
installed.

Table 2

Model Part Number of the Retrofit Kit

980G 204-7669

950G and 962G machines that are equipped with Command Control
204-7668
Steering

966G and 972G machines that are equipped with Command Control
204-7700
Steering

950G and 962G machines that are equipped with HMU Steering 204-7667

966G and 972G machines that are equipped with HMU Steering 204-7669

When the new software is installed on the 972G (S/N: 7LS405-440; 4WW720-785)
Wheel Loaders, 966G (S/N: 3SW1225-1472; 3ZS709-769) Wheel Loaders, 962G (S/N:
4PW504-563; 5AS401-408; 6EW415-470) Wheel Loaders Wheel Loaders, 950G (S/N:
3JW2154-2499; 4BS707-740; 8JW407-465) Wheel Loaders and IT62G (S/N: AKP513-
541) Integrated Toolcarriers an additional change will be made that will cause
downshifting of the transmission when the parking brake is applied.
 Issue # 44968 Neutralizer Pedal Sensor Find It
left pedal deadband
Affected Model (s) P/N Name Initial mode

all GII 147-1680 Sensor Gp-Pos (old) Calibrated initial brake pressure point

all GII 214-4863 Sensor Gp-Pos (after July 2002) Calibrated Neutralization Setpoint

Normal mode

Maximum pedal travel

z Description:
Intermittent minimum range fault codes on the left brake pedal position sensor (CID
1327) in the transmission ECM during initial startup. This does not allow the
machine to be calibrated.

z Root Cause:
It is not due to a faulty sensor, but to the mechanical tolerance stack up of the
pedal mechanism. The current pedal design does not allow an adjustment of the
mechanical stop integrated in the casting. In some cases, the tolerance stack-up
allows the sensor to rotate beyond the minimum range set in the transmission
software.

GOSSELIES MWL HI-C MEETING

28-29 OCT 2003
SERIES II
Project # 44968 Neutralizer Pedal Sensor Fix It

z Corrective actions:
Transmission Neutralizer Software improvement to set the pedal
diagnostic at 10% duty cycle instead of the former 15%.

Production Field
P/N Part Name Model S/N break Date Publication Date

238-9015 software 938GII PHN00461 June 2003 SEPD0704 29 / 09 / 03

240-9693 software 950GII AYL01044; AYB00693 August 2003 (*)
962GII BAB00438; AYE00530
966GII AXJ01354; AWY00835
972GII AXN00336; AXC00705
980GII AXG00704

(*) Corrected article, disregard SEPD0702

GOSSELIES MWL HI-C MEETING

28-29 OCT 2003
SERIES II
 Project # 44968 Neutralizer Pedal Sensor More Info

The left pedal sensor is recalibrated every time the machine powers up.
However, The pedal will not recalibrate on power-up if it's "close enough"
to the previous saved value.
Due to some hysteresis, some machines may experience a problem where
the transmission ECM detects an IBS activation although the pedal is in the
released position.
It is recommended to press the pedal while powering up to force the ECM
to record a new zero position value, and then bang the pedal up to record
the right zero position value.
left pedal deadband
Initial mode

Calibrated initial brake pressure point

Calibrated Neutralization Setpoint

Normal mode

Maximum pedal travel

GOSSELIES MWL HI-C MEETING

28-29 OCT 2003
SERIES II