Procedure to Install Software on Certain AD45B Underground Articulated Trucks Fitted With Ventilation Reduction Package {7600, 7620} Caterpillar

Underground Articulated Truck

AD45B (S/N: CXM1-UP; GXM1-UP)

Introduction

This special instruction covers the procedure to install software and required labels on AD45B Underground Articulated Trucks, which are fitted with the Ventilation Reduction Package. This update of the engine and power-train software will lower ventilation rates, and decrease engine power to approximately 370 kW (500 hp).

Note: This procedure cannot be used in Canadian provinces that require "CANMET" certification. This procedure will invalidate the existing "CANMET" approval for an engine.

This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Reference: Operation and Maintenance Manual, SEBU7335, "AD45B Underground Articulated Truck"

Reference: Operation and Maintenance Manual, SEBU8909, "AD45B Underground Articulated Truck"

Reference: Specifications, SENR9831, "C15 and C18 Engines for Caterpillar Built Machines"

Reference: Systems Operation Testing and Adjusting, SENR9832, "C15 and C18 Engines for Caterpillar Built Machines"

Reference: Troubleshooting, RENR5031, "C15 and C18 Engines for AD30, AD45B, and AD55 Underground Articulated Trucks"

Reference: Systems Operation Testing and Adjusting, RENR8567, "AD45B Underground Articulated Truck Power Train"

Reference: Systems Operation Testing and Adjusting, UENR6109, "AD45B Underground Articulated Truck Power Train"

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

Required Parts

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

Pre-Test and Data Capture

Torque Converter Stall Test (Preliminary)

Complete the following "Torque Converter Stall Test", prior to commencing ECM software updates.

The service brakes must be applied when tests are performed. Make sure that the service brakes are fully operational before you perform any tests. Make sure that the transmission oil is at the normal operating temperature of 82° ± 3°C (180° ± 5°F) during tests.

The drive wheels must not turn during the torque converter stall test. Place the machine in an open area clear of personnel and obstructions. Engage the parking brake.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Using Caterpillar Electronic Technician (ET), set up a data capture for the following channels at a minimum of 4 Hz. Refer "Data Capture - Set Up"to set up the data capture.

   1. Engine

      • Engine Speed

      • Boost Pressure (manifold)

      • Ambient Pressure

      • Inlet Air Temperature

      • Engine Coolant Temperature

      • FRC Fuel Limit

      • Rated Fuel Limit

      • Fuel Position

   2. Transmission

      • Actual Gear

      • Transmission Oil Temp

      • Transmission Output Speed

      • Brake Pedal

      • Torque Converter Outlet Temperature

      Note: Section b. Transmission is optional

4. Start the data collection with Cat ET.
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   Illustration 1	g03117716
   (1) Tachometer (2) Display window for digital tachometer

5. Start the engine, release the parking brake, and apply the service brake.

   Note: To ensure that the transmission oil does not overheat, do not keep the torque converter in a full stall condition for more than 30 seconds. After the torque converter is stalled, shift the transmission direction control to the NEUTRAL position. Operate the engine at 1200 rpm to 1500 rpm to cool the oil.

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   Illustration 2	g03117717
   (3) Transmission control

6. Move transmission control (3) to the FIRST SPEED FORWARD position.

7. Fully depress the throttle pedal for 15 seconds.

8. Allow the engine rpm to stabilize. Observe tachometers (1) and (2).

   Notes regarding preliminary stall speed results.

   • Stall speed of used machines may vary

   • Stall speed of new or reconditioned machines should be in the range of 1920 +/- 20rpm

   • Low stall speeds indicate incorrect engine performance

   • Stall speeds that are high indicate incorrect transmission performance or incorrect performance of the torque converter

9. Once the machine has stalled for 15 seconds, release the throttle and shift the transmission direction and speed control to the NEUTRAL position. Allow the machine to idle at 1200 rpm to 1500 rpm for at least 2 minutes. Continue to hold the service brake.

10. After 2 minutes of idle, perform Steps 6 through 9 two more times for a total of three stalls.

11. Release the service brake.

12. Stop the data collection with Cat ET and save the file. The file should include machine serial number, and the date (year, month, date).

    Example: CXM00123_20140710.sdf

13. After 2 minutes of idle, stop the engine.
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    Illustration 3	g02720498

14. Using Cat ET, establish the machine stall speed by reviewing the data log. The "Settings" tab on the bottom left of Cat ET can be used to change the "X" and "Y" axis. Changing the "X" and "Y" axis will provide a high resolution of the stall speed. Refer to Illustration 24 for examples of stall speed graphs.

Engine ECM Backup File

An "Engine ECM Backup File" is created, prior to software updates in the procedure.

1. Connect Caterpillar Electronic Technician (ET) to the machine. Refer to Troubleshooting, "Electronic Service Tools".
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   Illustration 4	g03121900
   Typical example

2. Select the Engine ECM.
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   Illustration 5	g03121876
   Typical example

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   Illustration 6	g03121897
   Typical example

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   Illustration 7	g03123776
   Typical example

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   Illustration 8	g03125656
   Typical example

3. Using the "Copy Configuration/ECM Replacement" feature, found under the "Service" menu, save a copy of the configuration parameters. Refer to Illustration 5, Illustration 6, Illustration 7, and Illustration 8.
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   Illustration 9	g03121899
   Typical example

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   Illustration 10	g03121901
   Typical example

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   Illustration 11	g03121904
   Typical example

4. Using the "Calibrations" feature, found under the "Service" menu, copy the injector calibration serial numbers. Refer to Illustration 9, Illustration 10, and Illustration 11.

Data Capture - Set Up

Data capture is required during torque converter stall tests. Follow steps below to capture the necessary data when required.

1. Connect Caterpillar Electronic Technician (ET) to the machine. Refer to Troubleshooting, "Electronic Service Tools".
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   Illustration 12	g03174657
   Typical example

2. Select "Information", "Data Log", "Recorder" (1).
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   Illustration 13	g06226200
   Typical example

3. Select "Hour(s)" (2).

   Note: Ensure "Sample Rate" is set at 240 per minute.

4. Select "Add" (3).
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   Illustration 14	g06226201
   Typical example

5. Highlight "<TEMPORARY GROUP>" (4) and select "New" (5).
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   Illustration 15	g06225790
   Typical example

6. Input a new group file name (6), then select "OK" (7).
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   Illustration 16	g06225798
   Typical example

7. Highlight and transfer the required parameter (8), using arrow (9). When all the required parameters have been transferred, select "OK" (10).
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   Illustration 17	g06225806
   Typical example

8. Highlight the created temporary group (11), then select "OK" (12).
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   Illustration 18	g06225810
   Typical example

9. Select "OK" (13).

   Note: Caterpillar Electronic Technician (ET) is now set up for data capture.

Procedure to Update Software for Machine Power Increase

Preparation

1. Carry out a preliminary "Torque Converter Stall Test". Refer to Section "Torque Converter Stall Test (Preliminary)".

2. Save a copy of the existing Engine ECM configuration parameters, and injector calibration serial numbers. Refer to "Engine ECM Backup File".

   Note: For backup purposes only, prior to installing new software.

3. Obtain "Power Train" and "Engine" Software. Refer Section "Download Software Files".

Download Software Files

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Illustration 19	g06225782

1. Open SIS-Web to download required software. Select "Service Software Files".
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   Illustration 20	g06225783

2. Select "Flash Files - ECM Software Files".
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   Illustration 21	g06225785

3. Insert the software part number into the "Flash Filename" window. Select "Search". The software files will be listed below the "Flash Files Available for Download" heading.

   Note: Refer to Table 1 for required software part numbers.

4. Select the required file.

5. Save the software to a file location that can be accessed during the installation procedure.

6. Repeat Step 3 through Step 5 to obtain all required software.

Flash Engine and Power-Train Software

1. Flash the Engine ECM with 490-8230 Engine Software.

2. Flash the Power Train ECM with 491-1464 Power Train Software Gp.

3. Follow the instruction below to obtain the factory password.

   • Submit a Dealer Solution Network (DSN) ticket

   • Request that the Tier 1 representative, transfer your ticket to an available Tier 2 representative for Caterpillar Underground Mining

   • Request the factory password required to complete the 370 kW (500 hp) engine power upgrade, for AD45B (S/N: CXM) or (S/N: GXM).

4. Repeat the "Torque Converter Stall Test". Refer to Section "Torque Converter Stall Test (Post Software Update)".

Post-Test and Data Capture

Torque Converter Stall Test (Post Software Update)

Follow the steps below to repeat the "Torque Converter Stall Test", after engine and power-train software is updated.

The service brakes must be applied when tests are performed. Make sure that the service brakes are fully operational before you perform any tests. Make sure that the transmission oil is at the normal operating temperature of 82° ± 3°C (180° ± 5°F) during tests.

The drive wheels must not turn during the torque converter stall test. Place the machine in an open area clear of personnel and obstructions. Engage the parking brake.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Using Caterpillar Electronic Technician (ET), set up a data capture for the following channels at a minimum of 4 Hz. Refer "Data Capture - Set Up"to set up the data capture.

   1. Engine

      • Engine Speed

      • Boost Pressure (manifold)

      • Ambient Pressure

      • Inlet Air Temperature

      • Engine Coolant Temperature

      • FRC Fuel Limit

      • Rated Fuel Limit

      • Fuel Position

   2. Transmission

      • Actual Gear

      • Transmission Oil Temp

      • Transmission Output Speed

      • Brake Pedal

      • Torque Converter Outlet Temperature

      Note: Section b. Transmission is optional

4. Start the data collection with Cat ET.
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   Illustration 22	g03117716
   (1) Tachometer (2) Display window for digital tachometer

5. Start the engine, release the parking brake, and apply the service brake.

   Note: To ensure that the transmission oil does not overheat, do not keep the torque converter in a full stall condition for more than 30 seconds. After the torque converter is stalled, shift the transmission direction control to the NEUTRAL position. Operate the engine at 1200 rpm to 1500 rpm to cool the oil.

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   Illustration 23	g03117717
   (3) Transmission control

6. Move transmission control (3) to the FIRST SPEED FORWARD position.

7. Fully depress the throttle pedal for 15 seconds.

8. Allow the engine rpm to stabilize. Observe tachometers (1) and (2).

   Notes regarding final stall speed results.

   • Stall speed rpm should be lower than in the pre-test

   • Expected stall speed range is 1840 +/-30 rpm

   • Low stall speeds indicate incorrect engine performance

   • Stall speeds that are high indicate incorrect transmission performance or incorrect performance of the torque converter

   Note: Refer to Troubleshooting, and Testing and Adjusting, for maintenance of torque converter and transmission.

9. Once the machine has stalled for 15 seconds, release the throttle and shift the transmission direction and speed control to the NEUTRAL position. Allow the machine to idle at 1200 rpm to 1500 rpm for at least 2 minutes. Continue to hold the service brake.

10. After 2 minutes of idle, perform Steps 6 through 9 two more times for a total of three stalls.

11. Release the service brake.

12. Stop the data collection with Cat ET and save the file. The file should include machine serial number, and the date (year, month, date).

    Example: CXM00123_20140710.sdf

13. After 2 minutes of idle, stop the engine.
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    Illustration 24	g02720498

14. Using Cat ET, establish the machine stall speed by reviewing the data log. The "Settings" tab on the bottom left of Cat ET can be used to change the "X" and "Y" axis. Changing the "X" and "Y" axis will provide a high resolution of the stall speed. Refer to Illustration 24 for examples of stall speed graphs.

15. If the torque converter stall test is not within specifications, the FLS/FTS must be adjusted.

16. Submit a Dealer Solution Network (DSN) ticket. Attach torque converter stall pre-test report, and post-test report, to the Dealer Solution Network (DSN) ticket for review. Based on the specification, the technician will provide a new FLS/FTS number and factory password for changing. Failure to adjust FLS/FTS if not within specification may cause reduced engine performance or reduced machine life.

17. Order and install a new engine emissions certification film and a new engine serial number plate. Refer to "Label Rework Procedure".

Label Rework Procedure

1. Open Service Information System (SIS) web. The address is https://sis.cat.com.
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   Illustration 25	g03157737

2. Select "Engine Technical Marketing Information - TMI Web" under the "Additional Service Information" heading.

   Note: If "Engine Technical Marketing Information - TMI Web" is not visible, select "View More".

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   Illustration 26	g03817877

3. Input the serial number of the engine in "Reference Number" box (1).

4. Select "Serial Number" in drop-down menu (2).

5. Select "Retrieve Data" (3).
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   Illustration 27	g03817327

6. Select "Emissions Data" (4).

7. Select "Need emissions replacement label? Click here!" (5).

   Note: "Large Power Systems Division" window will now open.

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   Illustration 28	g03817878

8. Select "Recon Replacement Request".
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   Illustration 29	g03817906
   Typical example - "Emissions/Certification Replacement" window

9. Fill in the required details:
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   Table 2

   Emissions/Certification Replacement Window
   Item	Description
   2	Enter the dealer name (code)
   3	Enter "Machine"
   4	Enter "C18" under Engine Sales Model
   5	Enter the Engine Serial Number
   6	Enter the media number of the Special Instruction

10. When all details are filled in, select "Submit".

    Note: Two labels and a serial number plate will be sent to the dealer address. If two labels are not received, contact Global_Engine_Marking@cat.com.

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    Illustration 30	g03159376

11. Install the new emissions certification film (6), information label (7), and serial number plate on the cylinder block. Follow installation instructions received with the labels and plate.

    Note: Destroy the old emissions certification film and serial number plate.