PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CHASSIS ECM ON CERTAIN 725, 730, 735, 740, AND 740EJ ARTICULATED TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CHASSIS ECM ON CERTAIN 725, 730, 735, 740, AND 740EJ ARTICULATED TRUCKS

Usage:

SEBE9075-01

February 23, 2005
(Revised March 2005)
U-53
A-39
D-46
O-46

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CHASSIS ECM ON CERTAIN 725, 730, 735, 740, AND 740EJ ARTICULATED TRUCKS
3168 7610		PI10350

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10350" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10350" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the February 23, 2005 Service Letter. Changes have been made to the Tools Needed Section.

PROBLEM

The 230-7490 transmission/chassis ECM on certain Articulated Trucks may experience a reset due to an intermittent connection in an ECM memory chip. An ECM reset can cause the instrument cluster gages to sweep, activation of dash lamps and the action alarm. Unexpected application of the parking brake can also result, which can cause a downshift of the transmission if the truck is in motion.

AFFECTED PRODUCT

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Model	Identification Number
725	AFX1230-1232, 1243-1485
730	AGF1146-1148, 1158-1388
735	AWR625-797
740	AXM1377-1847
74OEJ	AZZ340-374

PARTS NEEDED

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Qty	Part Number	Description
1	2621408	Control Gp
1	257-6822	Software Flash File

*Note: Always use the latest version of software. Refer to SISWEB for the most recent transmission/chassis ECM software Flash file for

the machine.

Tools Needed:

CAT Electronic Technician, ET2004B-SP1 or later
171-4400 Communication Adapter Gp.

Includes:
171-4401 Communication Adapter
207-6845 Adapter Cable
196-0055 Serial Cable

Laptop/PC
Factory passwords will be required for the ECM replacement procedure.

Reference Material:

RENR8035 700 Series Articulated Truck Power Train Electronic Control System Operation, Testing and Adjusting Service Manual

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2.0	0	0	0	0
NOTE: This is a 2.0 - hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CHASSIS ECM

MODELS INVOLVED - 725, 730, 735, 740, AND 740EJ ARTICULATED TRUCKS

Dear Caterpillar Product Owner:

A new electronic control module needs to be installed on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated February 23, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to February 23, 2005 Service Letter

Rework Procedure

Turn engine start switch to the "ON" position. Connect CAT ET to the transmission/chassis ECM, and verify that the Truck Product ID (which is the Machine serial number, for example AGF XXXXXX) is programmed in the configuration screen. If it has not yet been programmed, do so before proceeding.
Check and ensure no active diagnostic codes are present before proceeding. If any active codes exist, troubleshoot as per the Systems Operation, Testing and Adjusting and Troubleshooting manuals.
Using the ECM replacement option within CAT ET, download the required configuration data. The ECM Replacement Feature is found within the Copy Configuration menu of CAT ET. Also note that 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 purposes 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.
Turn off the engine start switch and the battery disconnect switch. Refer to the machine?s Operation & Maintenance Manual for switch location.
Remove exterior access panel on right side of cab.
Remove the 230-7490 ECM from the machine. Procedure can be found in the 700 Series Articulated Truck Power Train Electronic Control System Operation, Testing and Adjusting Service Manual, RENR8035.
Install the 262-1408 ECM and connect the machine wiring harness to the ECM connectors. Procedure for replacing the transmission/chassis ECM can be found in the 700 Series Articulated Truck Power Train Electronic Control System Operation, Testing and Adjusting Service Manual, RENR8035. Ensure 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.
Turn the battery disconnect switch to the ?ON? position. Turn engine start switch to "ON". Do not attempt to start the engine at this stage.
FLASH the ECM with the appropriate transmission/chassis ECM flash file. The FLASH procedure can be found in the 700 Series Articulated Truck Power Train System Operation, Testing & Adjusting Service Manual, RENR8035. Refer to SISWEB for the most recent transmission/chassis ECM software 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 flashed from the hard drive directory. Disable the PC screensaver before beginning the flash procedure.

Upon completion of flashing, disconnect CAT ET and turn the engine start switch to "OFF". Wait for 30 seconds before turning it back to "ON". Doing so will allow the ECM to reset. See Service Article SEPD0751.
Connect CAT ET to the transmission/chassis ECM and program the Product ID (Machine Serial number). Upload the configuration data recorded from the original ECM into the newly installed ECM using the ECM Replacement option within the Copy Configuration menu of CAT ET. During this upload two pairs of Factory Passwords will be needed, which should be requested on the website at the time the passwords are required. The two sets of passwords will be used to allow reprogramming the total hours and total distance in the new ECM.
For all 700 Series Articulated Truck models: Perform the electronic system calibration of the transmission shift lever. The Transmission Control (Shift Lever) calibration can be found in the System Operation, Testing & Adjusting Manual for the 700 Series Articulated Power Train Electronic Control System, RENR8035.
Check the transmission/chassis ECM for any active diagnostic codes. If all is OK, reinstall the exterior access panel onto cab and start the machine. If any active codes exist troubleshoot as per the Systems Operation Troubleshooting Testing and Adjusting manual.
For 725, 730, and 735 Articulated Truck models: Perform the Transmission Fill calibrations. Refer to the transmission calibration procedure, that can be found in the System Operation, Testing & Adjusting Service Manual for the 700 Series Articulated Truck Power Train Electronic Control System, RENR8035. 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 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. The transmission oil temperature range must be between 70^oC and 75^oC when the transmission calibration procedure is initiated. Transmission oil temperature must remain with the range of 65^oC to 85^oC while the transmission calibration procedure is executing.
For 725 and 730 Articulated Truck models: Perform the retarder calibration. Refer to the Retarder calibration procedure, which can be found in the System Operation, Testing & Adjusting Service Manual for the 700 Series Articulated Truck Power Train Electronic Control System, RENR8035. Note: The retarder calibration is temperature sensitive, and requires 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 temperature range for retarder calibration should be more controllable, and will require less time, than waiting for the 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 already be within the appropriate temperature range to proceed with the retarder calibration. The transmission oil temperature range must be between 45^oC and 80^oC when the retarder calibration procedure is initiated. Transmission oil temperature must remain within the range of 41^oC to 120^oC while the retarder calibration procedure is executing.
If possible, observe machine operation for several minutes, to verify all machine functions are working properly.