Shutdown SIS Previous Screen Product: NO EQUIPMENT SELECTED Model: NO EQUIPMENT SELECTED Configuration: NO EQUIPMENT SELECTED 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. Page 1 of 16 Service Information System 1/19/2012 https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe...
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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.
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".
Event Codes
EID Description
E047-(1) Transmission Abuse Warning
E047-(2) Transmission Abuse Warning
E049-(2) Coasting in Neutral Warning
E106-(2) (1) High Front Brake Oil Temperature
E107-(2) (1) High Rear Brake Oil Temperature
E108-(2) Machine Upshift to Prevent Engine Overspeed
( 1 ) 735 and 740 with a continuous audible warning( 2 ) 725, 730 and 735 with latching transmissions only( 3 ) Continuous audible warning
E047-1 Transmission Abuse Event
This event is recorded when the operator shifts out of NEUTRAL or through NEUTRAL with the engine speed above the threshold. For the 725 and 730, the threshold for the engine speed is 2000 rpm. For the 735 and 740, the threshold for the engine speed is 1500 rpm.
Note: If the operator shifts the lever for the transmission control from neutral into any speed and the engine rpm is above the threshold, the directional shift management function will be activated. This will decrease the engine speed below 1500 rpm before the transmission is allowed to engage a gear.
Possible Causes
The dump body is being raised and the engine is at high idle. If the operator then moves the transmission control into any gear this will create a event code.
•
Driving the machine forward, stopping the machine and then selecting reverse gear before the engine RPM is below the threshold.
•
When the machine is being driven forward with the engine RPM above the threshold, the operator then moves the transmission control to either the NEUTRAL position or to the REVERSE position.
•
E047-2 Transmission Abuse Event
This event is active when the machine is travelling above 64.5 km/h (40 mph) for 2.5 seconds. This event becomes inactive when the speed of the machine falls below 58 km/h (36 mph).
Possible Causes
The machine is being driven forward down a steep grade in top gear.•
This event is recorded when the machine speed exceeds 19 km/h (12 mph) with the transmission in NEUTRAL (Coasting in Neutral).
Possible Causes
When the machine is being driven at speeds above 19 km/h (12 mph), the transmission control is in the NEUTRAL position and there are no application of the brakes.
•
E106 High Front Brake Oil Temperature Even
This event is recorded when the temperature switch for the front brakes indicates that the oil temperature is above 107° ± 3°C (225° ± 5.4°F).
Possible Causes
Excessive use of the brakes instead of using the retarder•
E107 High Rear Brake Oil Temperature Event
This event is recorded when the temperature switch for the rear indicates that the oil temperature is above 107° ± 3°C (225° ± 5.4°F).
Possible Causes
Excessive use of the brakes instead of using the retarder•
E108 Machine Upshift to Prevent Engine Overspeed Event
This event is recorded when the engine speed increases to a predetermined level which then sends a signal to the transmission ECM in order to upshift the transmission. The transmission will shift one gear position past the operator's selection in order to protect the engine from overspeed. This only applies if the transmission control lever is in the FIRST GEAR position, the SECOND GEAR position or theTHIRD GEAR position.
When the transmission control lever is in the DRIVE position and the operator selects the maximum gear limit with the yellow button, the transmission will only shift one gear past the selected gear. If the operator has selected top gear and the engine speed continues to increase to a predetermined level that is above the engine overspeed, the engine will signal the transmission to disengage the lockup clutch in the torque converter. The event is also recorded when the transmission is forced to upshift past the gear limit for the body up or when the control lever is in the FLOAT position.
If the transmission control lever is in the DRIVE position and the machine down shifts, the transmission hold switch can be activated. This will hold the transmission in the preferred gear until the engine speed reaches a predetermined level. The engine will then send a signal to the transmission ECM in order to upshift the transmission.
Selecting an incorrect gear for an incline and then driving down the incline with insufficient retardation or no retardation
•
E155 High Torque Converter Oil Temperature Event
This event is active if the oil temperature for the torque converter is above 124 °C (255 °F). This event becomes inactive when the oil temperature falls below 115 °C (239 °F).
Possible Causes
Excessive use of the retarder 725 and 730•
Fault in the torque converter•
Excessive operation in torque converter drive•
E190Engine Overspeed Event
This event is activated when the operator triggers a E108 Machine Upshift to Prevent Engine Overspeed Event. The machine has already shifted up one gear and the engine speed has now increased to a higher predetermined level.
Possible Causes
Selecting an incorrect gear for an incline and then driving down the incline with insufficient retardation or no retardation
•
E326 Low Transmission Latching Pressure Event
725 (S/N: AFX1-849), 730 (S/N: AGF1-794) and 735 (S/N: AWR1-454)•
This event is recorded when the transmission pressure for the latching is too low for the corresponding engine speed of the machine. In this case, the ECM will inhibit shifting of the transmission. This will cause the lockup clutch to disengage. The machines log this event if the machines have not been converted to a nonlatching system.
Possible Causes
Refer to Systems Operation, Testing and Adjusting, RENR3484, "Power Train Pressures".•
E327 Low Output Transfer Gear Pressure Event
This event is recorded when the oil in the output transfer gear is above 38° ± 3°C (100° ± 5.4°F) and the pressure switch for the output transfer gear indicates low pressure below 70 ± 20 kPa (10 ± 3 psi). The ECM will measure the pressure in the output transfer gear only when the engine speed is above 1500 RPM.
Damaged internal components within the output transfer gear•
Low oil level•
High oil temperature•
Scavenge Pump•
E328 Output Transfer Gear Filter Plugged Event
725 (S/N: AFX1-UP), 730 (S/N: AGF1-UP) and 735 (S/N: AWR1-UP)•
This event is recorded when the oil temperature in the output transfer gear is above 38° ± 3°C (100° ± 5.4°F), and the output bypass switch on the filter for the transfer gear indicates that the filter is bypassing. Consequently without warning the operator, unfiltered oil can be allowed to enter the output transfer gear if the oil is not sufficiently warm and the filter is plugged.
Possible Causes
Internal component failure within the output transfer gear•
Contamination by dirt•
E329 Transmission Filter Plugged Event
This event is recorded when the oil temperature for the transmission has initially risen above 51 °C (123.8 °F). After the initial temperature is reached the temperature can fall to a minimum of 43 °C (109.4 °F) before the ECM stops monitoring the bypass switch. The bypass switch on the filter for the transmission indicates that the filter is bypassing. Consequently without warning the operator, unfiltered oil can be allowed to enter the transmission if the oil is not sufficiently warm and the filter is plugged. The 725, 730, and 735 machines log this event.
Possible Causes
Internal component failure within the transmission•
Contamination by dirt•
E330 Transmission Output Speed Mismatch Event
This event is recorded when the readings of the speeds from TOS1, TOS2, and COS sensors do not match. In this case, the ECM will inhibit shifting of the transmission. This will engage the lockup clutch. The 725, 730, and 735 determines the transmission input speed from the COS. The 740 determines the transmission input speed from the status of the lockup clutch and the EOS.
Possible Causes
Refer to Systems Operation, Testing and Adjusting, RENR3442, "Articulated Trucks Power Train Electronic Control System" and Systems Operation, Testing and Adjusting, RENR8035, " Articulated Trucks Power Train Electronic Control System".
This event is recorded when the secondary steering system is armed and the primary steering pressure switch indicates that the primary steering pressure is low.
Possible Causes
Refer to Systems Operation, Testing and Adjusting, RENR3429, "725AFX1-1178 and 730 AGF1-1091Articulated Trucks steering, Suspension and Body Hoist Hydraulic Systems", Systems Operation, Testing and Adjusting, RENR3429, "725AFX1179-UP and 730 AGF1092-UP Articulated Trucks steering, Suspension and Body Hoist Hydraulic Systems", Systems Operation, Testing and Adjusting, RENR5126, "735 and 740 Articulated Trucks steering, Suspension and Body Hoist Hydraulic Systems" and Systems Operation, Testing and Adjusting, RENR5174, "740 Ejector Articulated Trucks steering, Suspension and Body Hoist Hydraulic Systems".
This event is inhibited for the first 20 seconds of running of the engine. The delay allows the brake system to charge on the initial start-up. This event is recorded when the pressure switch for the braking system indicates that the brake pressure is below 12300 ± 345 kPa (1784 ± 50 psi) on all machines except S/N:AFX1179-UP and ; S/N:AGF1092-UP. The brake pressure on machines ; S/N:AFX1179-UP and ; S/N:AGF1092-UP must fall below 10300 ± 689 kPa (1494 ± 100 psi).
Possible Causes
Refer to Systems Operation, Testing and Adjusting, RENR3488, "725 and 730 Articulated Trucks Braking System" and Systems Operation, Testing and Adjusting, RENR5129, "735, 740 and 740 Ejector Articulated Trucks Braking System".
•
E627 Machine Driven With Parking Brake On Event
This event is recorded when the parking brake is engaged and the machine speed is above 8.05 km/h (5.00 mph). The event is also recorded when the start-up override for the parking brake is still active and the machine speed is above 8.05 km/h (5.00 mph).
The following tables show the transmission shift matrix for a 740 or a 740 Ejector with a seven speed transmission. The same logic should be used when you are reading the table for a 725 and a 730 transmission with six speed and a 735 transmission with eight speeds.
Shifts To
N R 1 2 3 4 5 6 7
Shifts From
N --- 357 1062 0 0 0 0 0 0
R 949 --- 138 0 0 0 0 0 0
1 460 730 --- 1254 0 0 0 0 0
2 0 0 1209 --- 868 0 0 0 0
3 0 0 0 43 --- 631 0 0 0
4 0 0 0 0 814 --- 490 0 0
5 0 0 0 0 0 615 --- 459 0
6 0 0 0 0 0 3 487 --- 370
7 0 0 0 0 0 0 1 369 ---
Table 2
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.
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.•
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.
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.•
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"
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. •
Upshifting from Neutral or Reverse
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" ".
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.•
Engine ECM Current Totals
The following list of totals are supported in the 725 to 740 machines.
Total Fuel (Factory Password) Units - Liters/Gallons
This is calculated as the total gallons/liters of fuel that is used when the engine speed is greater than 400 rpm.
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.
