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Special Instruction
Explanation of Common Event Codes, Transmission Shift Matrix and Engine ECM Current Totals{4800}
Media Number -REHS2149-02 Publication Date -01/09/2005 Date Updated -13/09/2005
i02407067
Explanation of Common Event Codes, Transmission Shift Matrix and Engine ECM Current Totals{4800}
SMCS - 4800 Articulated Truck: 725 (S/N: AFX1-UP; B1L1-UP) 730 (S/N: AGF1-UP; B1M1-UP) 735 (S/N: AWR1-UP; B1N1-UP) 740 (S/N: AXM1-UP; B1P1-UP) 740 EJECTOR (S/N: AZZ1-UP) 730 EJECTOR (S/N: B1W1-UP) 740 EJECTOR (S/N: B1R1-UP) D250E Series II (S/N: 4PS1-UP) D300E Series II (S/N: 5KS1-UP) D350E Series II (S/N: 2XW1-UP) D400E Series II (S/N: APF1-UP; 8PS1-UP)
Introduction
This Special Instruction is intended to identify the most common event codes that occur on Articulated Trucks. The Special Instruction will also outline the interpretation of the information that is shown in the transmission shift matrix. The event codes and transmission shift matrix information that is discussed in the Special Instruction can be accessed by using Caterpillar's Electrical Technician. Event codes represent the symptom of operational problems. These event codes indicate the operation of the machine to the service technician. This Special Instruction will identify the event codes, the parameters for tripping the event codes, the possible reasons for the machine operator to trip the event codes, and the possible effects to the machine.
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References
Reference: Caterpillar Service Tool Software, NEHS0679, "Caterpillar Electronic Technician" Reference: Special Instruction, REHS0126, "Diagnostic Code Information for Caterpillar Electronic Control". Reference: Systems Operation, Testing and Adjusting, RENR3442, "725, 730, 735, 740 and 740 Ejector Articulated Trucks Power Train Electronic Control System" Reference: Systems Operation, Testing and Adjusting, RENR8035, "725, 730, 735, 740 and 740 Ejector Articulated Trucks Power Train Electronic Control System"
Event Codes
The event log records the number of different events of all the different types of event that happen on the machine. When such an event happens, the event will be recorded by the ECM as well as the time of the event. When the number of events of one type is above 127, the log is full in regard to recording events of that type. The log cannot record above 127 events, even though it is possible that more events are happening. The time of the first event will always be indicated. When the log is full and an event occurs, the 127 event is replaced by the latest event and the time of the latest event is recorded. The warning category indicator will show the warning level. This can be seen on Caterpillar Electronic Technician. The number in the bracket that follows the event code indicates the warning level. An example is code E047 (2) which indicates a transmission abuse event at level 2. Refer to Operation and Maintenance Manual, "Warning Categories". Table 1 Event Codes EID E047-(1) E047-(2) E049-(2) E106-(2) (1) E107-(2) (1) E108-(2) E155-(2) E190-(1) E326-(3) Description Transmission Abuse Warning Transmission Abuse Warning Coasting in Neutral Warning High Front Brake Oil Temperature High Rear Brake Oil Temperature Machine Upshift to Prevent Engine Overspeed High Torque Converter Oil Temperature Engine Overspeed Warning Low Transmission Latching Pressure (2)
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Low Output Transfer Gear Pressure Output Transfer Gear Filter Plugged Transmission Filter Plugged Transmission Output Speed Mismatch Low Steering Pump Pressure Low Brake Pump Pressure Machine Driven with Parking Brake On
735 and 740 with a continuous audible warning 725, 730 and 735 with latching transmissions only Continuous audible warning
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Possible Causes Selecting an incorrect gear for an incline and then driving down the incline with insufficient retardation or no retardation
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Damaged internal components within the output transfer gear Low oil level High oil temperature Scavenge Pump
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Table 2 shows a normal matrix of changes in the gears that can be expected from a machine that is being operated in the correct manner. The matrix does not exhibit any faults. The vertical axis of the matrix shows the initial gear position of the transmission shift. The horizontal axis of the matrix show the final gear position of the transmission shift. For example, 814 transmission shifts from fourth gear to third gear were performed. All the transmission shifts are from one gear to the next gear. The following examples are correct transmission shifts. A transmission shift from first gear to neutral gear or into reverse gear, A transmission shift from fifth gear to four gear and A transmission shift from sixth gear up to seventh gear. If a transmission shift from first gear to reverse gear is performed and the machine is still moving forward, an event code will be triggered.
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Illustration 1
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The table on illustration 1 shows a matrix of changes in the gears from a machine that is being operated incorrectly. There are four areas of the transmission shift matrix that can indicate abuse or incorrect operation of the machine. Rapid Downshifting Abnormal Shifting Rapid Upshift Upshifting from Neutral or Reverse
Rapid Downshifting
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Illustration 2
g01084272
The table on illustration 2 is an example of heavy braking, rapid downshift which results in transmission abuse. The high numbers 1517 and 420 are generated by the following sequence of events that are carried out by the machine operator. In the worst case, these numbers are generated on the shift matrix. However, the additional numbers that are highlighted in the table are also an indication of transmission abuse. (1) The machine is at high speed in seventh gear and the operator applies the service brake. (2) The transmission rapidly downshifts. Reference: Systems Operation, Testing and Adjusting, RENR3442, " Articulated Trucks Power Train Electronic Control System", "Rapid Downshift Function" Reference: Systems Operation, Testing and Adjusting, RENR8035, " Articulated Trucks Power Train Electronic Control System", "Rapid Downshift Function" (3) At this point, the machine is stationary. The operator then selects neutral gear or reverse gear with the transmission control lever before releasing the service brake. The rapid downshifting of the transmission is seen in the following list: Seventh gear to neutral gear. This occurred on 1517 occasions. Seventh gear to reverse gear. This occurred on 420 occasions. Seventh gear to first gear. This occurred on 4 occasions. Seventh gear to third gear. This occurred on 3 occasions.
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Sixth gear to neutral gear. This occurred on 12 occasions. Sixth gear to reverse gear.This occurred on 4 occasions. Sixth gear to first gear. This occurred on 3 occasions. Sixth gear to second gear.This occurred on 3 occasions. Fifth gear to neutral gear.This occurred on 5 occasions. Fifth gear to reverse gear. This occurred on 8 occasions. These high figures are a result of heavy braking which will result in high brake temperatures, premature brake wear and premature transmission failure.
Abnormal Shifting
Illustration 3
g01084278
The table on illustration 3 is an example of abnormal transmission shifting due to the use of the brakes. The high numbers 4169, 564, 27, 1185, 546, 87, 1649, 141, 28, 267, 38, 152, 23, 92, 1, 48 are generated by the following sequence of events that are carried out by the machine operator. Situation 1 (1) The machine is moving forward in gear and the operator applies the service brake. (2) The transmission rapidly downshifts.
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Reference: Systems Operation, Testing and Adjusting, RENR3442, " Articulated Trucks Power Train Electronic Control System", "Rapid Downshift Function" Reference: Systems Operation, Testing and Adjusting, RENR8035, " Articulated Trucks Power Train Electronic Control System", "Rapid Downshift Function" (3) At this point, the machine is stationary. The operator then selects neutral gear, reverse gear or a low gear with the transmission control lever before releasing the service brake. Situation 2 The down shifting in this case can also be related with the rapid down shifting which has been described. The following actions may be a result of rapid downshifting and braking. (1) The machine is moving forward in gear and the operator applies the service brake. (2) The transmission rapidly downshifts. (3) The operator is moving the transmission control lever to reverse gear, neutral gear or a low gear. At the same time, the operator releases the service brake for more than half of a second. The transmission will now log two shifts on the shift matrix. The first shift is the rapid downshift from a high gear to a point when the brakes are first released. The second shift would be the rapid downshift when the service brakes are reapplied. This would also depend on the position of the lever for the transmission control before the brakes are released for the second time. The rapid shifting of the transmission is seen in the following list: Second gear to neutral gear. This occurred on 4169 occasions. Third gear to neutral gear. This occurred on 564 occasions. Fourth gear to neutral gear. This occurred on 27 occasions. Second gear to reverse gear. This occurred on 1185 occasions. Third gear to reverse gear. This occurred on 546 occasions. Fourth gear to reverse gear. This occurred on 87 occasions. Third gear to first gear. This occurred on 1649 occasions. Fourth gear to first gear. This occurred on 141 occasions. Fifth gear to first gear. This occurred on 28 occasions. Fourth gear to second gear. This occurred on 267 occasions. Fifth gear to second gear. This occurred on 38 occasions. Fifth gear to third gear. This occurred on 152 occasions. Sixth gear to third gear. This occurred on 23 occasions.
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Sixth gear to fourth gear. This occurred on 92 occasions. seventh gear to fourth gear. This occurred on 1 occasion. Seventh gear to fifth gear. This occurred on 48 occasions. These figures are a result of heavy braking which will result in high brake temperatures, premature brake wear and premature transmission failure.
Rapid Upshift
Illustration 4
g01084279
The table on illustration 4 is an example of rapid downshifting of the transmission which is caused by heavy braking. This is followed by a rapid upshifting of the transmission. Note: The transmission shift matrix will indicate a shift from neutral to top gear and back to neutral when you are carrying out a transmission stall test. The numbers 2, 430, 1455 and 54 are generated by the following sequence of events that are carried out by the machine operator. (1) The machine is at high speed and the operator applies the service brake. The wheels at this point may be locked. (2) The transmission rapidly downshifts. Reference: Systems Operation, Testing and Adjusting, RENR3442, " Articulated Trucks Power Train Electronic Control System", "Rapid Downshift Function"
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Reference: Systems Operation, Testing and Adjusting, RENR8035, " Articulated Trucks Power Train Electronic Control System", "Rapid Downshift Function" (3) The operator then releases the service brake. (4) At this point, the machine is still moving forward at speed. The transmission has downshifted to a gear which is below the gear that is indicated by the ground speed sensor. Therefore, the transmission rapidly upshifts to seventh gear. The rapid shifting of the transmission is seen in the following list: Rapid downshift to first gear back to seventh gear. This occurred on 2 occasions. Rapid downshift to second gear back to seventh gear. This occurred on 430 occasions. Rapid downshift to third gear back to seventh gear. This occurred on 1455 occasions. Rapid downshift to fourth gear back to seventh gear. This occurred on 54 occasions.
Illustration 5
g01084280
The table on illustration 5 is an example of abnormal upshifting from neutral gear. The numbers 5, 1, 2 are generated by the following sequence of events that are carried out by the machine operator. Situation 1 (1) The machine is moving and coasting in neutral. Refer to ""E049 Coasting in Neutral" ".
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Note: An event code may not be recorded in certain cases. (2) The operator moves the lever for the transmission control to the DRIVE position. (3) Because the ground speed is greater than first gear, the transmission will upshift to a gear which is appropriate to the machine ground speed. There could also be two situations when the machine is being loaded. Situation 2 (1) The machine is being loaded on a steep slope. (2) The operator selects the DRIVE position with the lever for the transmission control. (3) When the parking brake is released the severity of the grade allows the machine to accelerate at a higher speed that is above an appropriate upshift. This causes the machine to miss a gear. Situation 3 (1) The machine is being loaded on a steep slope. (2) The operator releases the parking brake without engaging the service brake. The machine then starts to move down the grade. Note: An event code may not be recorded in certain cases. (3) The operator selects the DRIVE position with the lever for the transmission control. (4) The severity of the grade allows the machine to accelerate at a higher speed that is above an appropriate upshift. This causes the transmission to go directly from neutral gear to a higher gear. The transmission will select the appropriate gear for the ground speed of the machine. The upshifting from neutral of the transmission is seen in the following list: Neutral to second gear. This occurred on 5 occasions. Neutral to third gear. This occurred on 1 occasion. Neutral to fourth gear. This occurred on 2 occasions. Reverse to second gear. This occurred on 1 occasion.
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Engine Starts (Factory Password) Unit - Start This increments once for each time when the speed of the engine goes from 0 rpm to above 600 rpm. Lifetime Total Engine Revolutions (Factory Password) Unit - Revolutions This increment is based on the engine speed when the engine speed is greater than 400 rpm. Total Idle Time (Factory Password) Unit - Hours This increments time when the speed of the engine is between 550 rpm and 1150 rpm. Total Idle Fuel(Factory Password) Unit - Gallons/Liters This increments time when the speed of the engine is between 550 rpm and 1150 rpm. Total Max Fuel (Factory Password) Unit - Gallons/Liters This is calculated as the total gallons/liters of fuel that would be used if the engine was at the rated speed of full load. The speed of the engine must be greater than 400 rpm. Total Operating Hours (Read Only) Units - Hours This increments time when the speed of the engine is greater than 400 rpm. The following totals are calculated by using the previous totals. Percentage Idle Time (Read Only) Units - Percent This is calculated as the total idle time which is divided by the total operating hours. Average RPM (Read Only) Units - Revoplutions Per Minute This is calculated as the lifetime total revolutions which is divided by the total operating hours then is divided by 60 mins/hr. Average Fuel Rate (Read Only) Units - Gallons/Hour or Liters/Hour This is calculated as the total fuel which is divided by the total operating hours. Overall Load Factor (Read Only) Units - Percent This is calculated as the total fuel which is divided by the total max fuel.
Copyright 1993 - 2012 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Jan 19 12:36:19 CST 2012
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