ECM Replacement Procedure on 700 Series Articulated Trucks{7610} Caterpillar

Articulated Truck:

725 (S/N: AFX1098-UP)

730 (S/N: AGF1011-UP)

735 (S/N: AWR625-UP)

740 (S/N: AXM1377-UP; AZZ340-UP)

Introduction

A new transmission/chassis ECM is used on 700 Series Articulated Trucks. This new transmission/chassis ECM is effective with the above-listed serial numbers. The ECM replacement procedure is listed below.

Transmission/Chassis ECM Replacement Procedure

1. Turn the engine start switch to the ON position.

   1. Connect Caterpillar Electronic Technician (ET) to the transmission/chassis ECM.

   2. Verify that the Truck Product ID is programmed in the configuration screen. If the Truck Product ID has not yet been programmed, do so before proceeding.

      Note: The Truck Product ID is the Machine serial number, for example AGFXXXXXX.

2. Ensure that no active diagnostic codes are present before proceeding.

   Note: If any active codes exist, refer to the machine's Systems Operation, Testing and Adjusting, Troubleshooting Manual for troubleshooting procedures.

3. Using the ECM Replacement option within Cat ET, download the required configuration data.

   Note: The ECM Replacement feature is found within the Copy Configuration menu of Cat ET.

   Note: The cycle counters, shift count matrix, and any logged events will not be copied with the ECM Replacement feature in Cat ET. If it is expected that this information may be required for warranty purposed at a later date, the service technician should record this information separately. The service technician should also record the transmission/chassis ECM hours for confirmation later in this procedure.

   Note: If unable to communicate with the machine ECM, the technician will not be able to perform Steps 1 through 3. Once the replacement ECM has been installed, the technician will need to program the Product ID and configuration data into the ECM manually.

4. Turn off the engine start switch and the battery disconnect switch.

   Note: Refer to the machine's Operation and Maintenance Manual for the switch location.

5. Remove the exterior access panel on the right side of the cab.

6. Remove the existing ECM from the machine.

   Note: Refer to Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 730 EJECTOR, 735, 740, and 740 EJECTOR Articulated Trucks Power Train Electronic Control System".

7. Verify that the replacement ECM is the correct part number for the machine.

8. Install the new ECM and connect the machine wiring harness to the ECM connectors.

   Note: Refer to Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 730 EJECTOR, 735, 740, and 740 EJECTOR Articulated Trucks Power Train Electronic Control System".

   1. Ensure that the harness connectors are properly aligned with the mating ECM connector pins. Also ensure that the connector seals and connector sealing plugs are properly seated in place.

9. Turn the battery disconnect switch to the ON position.

10. Turn the engine start switch to the ON position. Do not attempt to start the engine at this point.

11. FLASH the ECM with the appropriate transmission/chassis ECM flash file.

    Note: The FLASH procedure can be found in Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 730 EJECTOR, 735, 740, and 740 EJECTOR Articulated Trucks Power Train Electronic Control System". Refer to SISWEB for the most recent transmission/chassis ECM flash file for the machine.

    Note: Do not use 3.5 inch disks when flashing software. All software to be flashed must be loaded onto the PC hard drive first, and then flashed from the hard drive directory. Disable the PC screensaver before beginning the flash procedure.

12. Once the flashing has been completed, disconnect Cat ET and turn the engine start switch to OFF. To allow the ECM to reset, wait 30 seconds before turning the engine start switch back to ON.

    Note: Certain warning indicators on the instrument cluster will illuminate briefly when the engine start switch is turned to the OFF position. The indicators might stay illuminated for up to 30 seconds after the engine start switch is turned to the OFF position. The following indicators are typical of the indicators that might illuminate: Primary Steering System, Action Light, Parking Brake, and Hoist Control. This is not a fault of the machine. The illumination of the warning indicators is a normal result of the ECM resetting during engine shutdown.

13. Connect Cat ET to the transmission/chassis ECM.

    1. Program the Product ID (Machine Serial Number).

    2. Upload the configuration data recorded from the original ECM (Step 3) into the newly installed ECM.

       Note: To upload the configuration data, use the ECM Replacement option within the Copy Configuration menu of Cat ET. During this upload, two pair of Factory Passwords will be needed. These passwords should be requested on the website "https://fps.cat.com" at the time the passwords are required. The two sets of passwords will be used to allow reprogramming the total hours and total distance into the new ECM.

14. For All 700-Series Articulated Truck Models, perform the electronic system calibration of the transmission shift lever.

    Note: The Transmission Control (Shift Lever) calibration can be found in Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 730 EJECTOR, 735, 740, and 740 EJECTOR Articulated Trucks Power Train Electronic Control System".

15. Check the transmission/chassis ECM for any active diagnostic codes:
    • If there are no active diagnostic codes, reinstall the exterior access panel onto the cab and start the machine.

    • If any active diagnostic codes exist, refer to the troubleshooting section of the machine's Systems Operation, Troubleshooting, Testing and Adjusting Manual.

16. For 725, 730, and 735 Articulated Truck Models, perform the Transmission Fill calibrations.

    Note: The Transmission Fill calibrations can be found in Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 730 EJECTOR, 735, 740, and 740 EJECTOR Articulated Trucks Power Train Electronic Control System".

    Note: The Transmission Fill calibrations are temperature sensitive and require the transmission to be within a specific temperature range. It is recommended that the ECM update and calibrations be performed when the machine is at ambient temperature. Warming the machine to the proper transmission temperature range for transmission calibrations should be more controllable, and will require less time, than waiting for the transmission temperature to decrease to the proper range on a machine that has been operating. When the transmission calibration procedure is initiated, the transmission oil temperature range must be between 70 °C (158.0 °F) and 75 °C (167.0 °F). While the transmission calibration procedure is executing, the transmission oil temperature must remain within the range of 65 °C (149.0 °F) to 85 °C (185.0 °F).

17. For 725 and 730 Articulated Truck Models, perform the Retarder calibration.

    Note: Refer to the Retarder calibration procedure in Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 730 EJECTOR, 735, 740, and 740 EJECTOR Articulated Trucks Power Train Electronic Control System".

    Note: The Retarder calibration is temperature sensitive and requires the transmission oil temperature to be within a specific temperature range. It is recommended that the ECM update and calibrations be performed when the machine is at ambient temperature. Warming the machine to the proper transmission temperature range for the retarder calibration should be more controllable, and will require less time, than waiting for the transmission oil temperature to decrease to the proper range on a machine that has been operating. It is recommended that the retarder calibration be performed after the transmission calibration has been completed. The transmission should then be within the appropriate temperature range to proceed with the retarder calibration. When the retarder calibration procedure is initiated, the transmission oil temperature range must be between 45 °C (113.0 °F) and 80 °C (176.0 °F). While the retarder calibration procedure is executing, the transmission oil temperature must remain within the range of 41 °C (105.8 °F) to 120 °C (248.0 °F).

18. Start the engine. To verify that all machine functions are working properly, observe machine operation for several minutes.