3126 HEUI INDUSTRIAL ENGINES ENGINES EQUIPPED WIT Caterpillar

Section 2: Programming Parameters

Usage:

Programmable Parameters

Many programmable parameters affect 3126 HEUI Engine operation. These parameters may be changed using Electronic Service Tools. The parameters are stored in the ECM, not the personality module. Any parameter can be read. However, passwords protect parameters from unauthorized changes.

There are two categories containing various parameters, System Configuration Parameters and Customer Specified Parameters.

System Configuration Parameters can be altered only with the proper factory passwords using an Electronic Control Analyzer Programmer (ECAP) or Caterpillar Electronic Technician (ET).

Customer Specified Parameters can be changed using an Electronic Service Tool only with the proper customer passwords.

NOTE: For details on how to read and change parameters using an Electronic Service Tool, refer to the Caterpillar Electronic Technician, Getting Started Manual, included with the software.

Electronic Technician (ET)

For details on how to read and change parameters using ET, Communication Adapter Tool and the appropriate software, refer to the instructions included with the JERD2129 ET Data Subscription and the JERD2124 ET Software. ET consists of an IBM compatible computer and software. The software allows the laptop to program ECM parameters, read and display sensor values and switches, perform diagnostic tests and calibrate sensors.

Electronic Control Analyzer and Programmer (ECAP)

Refer to Passwords for more details on how to obtain and use passwords.

Updating the ECM Personality Module using FLASH downloading.

Software inside the ECM is contained in a Personality Module. The Personality Module uses a FLASH memory chip. The ECM has the capability to reprogram the FLASH memory chip internally. This process is called FLASH downloading. Flash downloading is accomplished by connecting ET to the engine using the Communication Adapter Tool and transferring data from a disk drive on ET into the ECM.

Connecting an Electronic Service Tool

The Electronic Control Analyzer Programmer (ECAP) and the Communications Adapter are powered by 12 VDC from the vehicle battery. This permits operation near the engine compartment or in the cab, to obtain readings during vehicle operation.

Use the following procedure to connect the service tool to the engine.

1. Turn the keyswitch to the OFF position.

2. The Electronic Service Tool should be connected to the 3126 HEUI system through the data link connector. Determine the necessary Adapter Harness Assembly from the service tool list for the vehicle you are working with. Connect the appropriate adapter to the 8T5275 (or 7X1412) Breakout T harness connector cable.

3. Connect the opposite end of the Breakout T cable to the Electronic Service Tool.

4. Turn the keyswitch to the ON position to begin testing. The Service Tool will operate with the engine running, or with the engine OFF, keyswitch ON. If the Tool does not communicate with the 3126 HEUI ECM, Refer To Section 5: P-513 ECM Personality Module.

System Configuration Parameters

System Configuration Parameters affect emissions or rated power of the engine. They are programmed at the factory and would normally never need to be changed through the life of the engine. System Configuration Parameters must be reprogrammed if an ECM is replaced, but not if the Personality Module is replaced (unless the engine rating changes). Proper values for these parameters are stamped on the Engine Information Plate, located on the valve cover or inlet manifold. Factory Passwords are required to change these parameters. The following is a description of the System Configuration Parameters.

Full Load Setting

Number representing fuel system adjustment made at the factory to "fine tune" the fuel system. The correct value for this parameter is stamped on the Engine Information Plate. A new ECM must have this parameter programmed to avoid generating a Diagnostic Code 253-02 Check Customer Or System Parameters (56).

Full Torque Setting

Similar to Full Load Setting. This parameter must be programmed or a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will be generated.

Personality Module Code

This code prevents use of an incorrect personality module for this engine. Each power rating family and emission certification has a different code associated with it.

When a personality module is replaced (either using a personality module chip or if flash programmed), this code (stored in the ECM) must match the one in the introduced personality module or the engine will only operate at low idle and a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will be generated.

When rerating the engine, programming this code to "0" will prompt the ECM to read and match its stored code to the Personality Module Code. This code does not need to be programmed when a personality module is replaced, as long as the new module is of the same family and emission year.

If the Personality Module is of a different family, then pistons, injectors, ect, may need to be changed and the Engine Information Plate must also be changed to reflect the new rating.

Some vehicle systems, such as the cooling system or transmission may also require changes when uprating an engine. Please contact the local OEM dealer for further information.

Engine Serial Number

This number should be programmed to match the engine serial number stamped on the Engine Information Plate. A new ECM is delivered with the engine serial number programmed to 0XX00000.

Customer Specified Parameters

Customer Specified Parameters allow the Industrial owner to influence how a vehicle can be operated. Some parameters may affect engine operation in ways an inadequately trained operator does not expect. These parameters may lead to power or performance complaints, even when the engine is performing to specification.

Customer parameters may be changed repeatedly as a customer changes his operation or as new operators are assigned. Customer Passwords are required to change these parameters.

The following is a brief description of the Customer Specified Parameters. Along with each are the minimum and maximum values for the parameter and the default value.

NOTE: Parameter value shown in bold is a programmed setting to disable a feature.

The tables show values in U.S. (or English) units (miles, mph, quarts), followed by an approximate range for metric (kilometers, km/h, liters) units. The exact range of the parameter in metric units depends upon the Service Tool used because each Tool may use slightly different conversion factors.

Engine Power Rating Selection Number

Rating number within a power family. The Personality Module defines the power family such as 300 hp (224 kW) and may contain only one or several ratings. The rating number defines which rating is used within the family.

Vehicle ID

Identification of the vehicle assigned by the customer and used only for customer reference. Not required by the ECM.

Vehicle Speed Parameters

Vehicle Speed Calibration

The ECM uses this value to scale the vehicle speed signal into miles per hour. It is programmed in pulses per mile (PPM). This parameter must be programmed or a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will occur. This parameter affects cruise control, progressive shifting, the ECM speedometer signal, and can affect PTO operation. For more information, Refer To Section 5: P-593 Machine/Vehicle Speed.

Vehicle Speed Limit (VSL)

Top vehicle speed the ECM will permit. The ECM will shut off fuel above this speed. An inexperienced operator may think something is wrong with the engine, because the engine will not fuel above this vehicle speed limit.

VSL Protection

Maximum engine rpm when there is an ECM detected vehicle speed signal problem. The ECM limits to this engine rpm when it senses no vehicle speed signal, and the engine is loaded.

NOTE: When this parameter is programmed to 3000 rpm, diagnostic codes 84-01, 84-10 are disabled, and the VSL Protection can be exceeded by disconnecting the Vehicle Speed Sensor.

Tachometer Calibration

The ECM uses this value to scale the engine speed signal into revolutions per minute for a tachometer. It is programmed in pulses per revolution (ppr). Programmable range is from 12.0 to 500.0 in 0.1 ppr increments.

Soft Vehicle Speed Limit

This limit operates in conjunction with the Vehicle Speed Limit. It limits the vehicle speed from 2.5 mph (4 km/h) below the programmed Vehicle Speed Limit at full load, to 2.5 mph (4 km/h) above the selected Vehicle Speed Limit at no load.

Cruise Control Parameters

Low Cruise Control Speed Set Limit

The lowest vehicle speed at which cruise control can be used. Programming this parameter to the maximum value disables cruise control.

High Cruise Control Speed Set Limit

The highest vehicle speed at which cruise control can be set. If a operator attempts to set a vehicle speed higher than this as the cruise set speed, the High Cruise Control Speed Set Limit will be the cruise set speed.

Cruise/Idle/PTO Switch Configuration

The configuration defines the function of Set/Resume for ACCEL and DECEL modes. This parameter applies to cruise control, idle, and PTO modes.

Figure 2.1 - SoftCruise Control and Soft Vehicle Speed Limit

SoftCruise Control

SoftCruise Control provides a 5 mph (8 km/h) operating range around the cruise control set speed to provide a smoother cruise control.

It controls the cruise speed from 2.5 mph (4 km/h) below the set vehicle speed at full load to 2.5 mph (4 km/h) above the set vehicle speed at no load.

Engine Retarder

Determines operation of the Exhaust Brake while the cruise control On/Off switch is in the ON position, but the engine is not in cruise control. This does not determine, or allow engine retarder operation while the engine is in cruise control.

Allowable options are COAST, LATCH or MANUAL. When programmed to COAST, the retarder is enabled only while the service brakes are being applied. When programmed to LATCH, the retarder stays enabled after the service brakes are released. A direct, immediate pressure on the brake pedal latches the retarder ON.

If programmed to MANUAL, the retarder operates the same with the cruise control switch ON (but not in Cruise) as when it is OFF.

Figure 2.2 - Coast and Latch Engine Retarder Mode

Idle Parameters

Idle/PTO Vehicle Speed Limit

Maximum vehicle speed for setting or maintaining a set engine rpm in either idle or PTO mode. Idle mode is entered if the engine rpm is set using the cruise control On/Off switch along with Set/Resume. PTO mode is entered if the PTO On/Off switch is ON (uses Multi-Function Input #1). If the vehicle speed signal exceeds this value, the engine will not maintain the set engine rpm.

Idle RPM Limit

Maximum engine rpm in idle mode. Idle mode occurs if the engine rpm is set using the cruise control On/Off switch and the Set/Resume switch. The actual high limit of this parameter is determined by the programmed Top Engine Limit. The lower limit is determined by the programmed Low Idle Engine RPM.

Programming this parameter to 600 rpm will prevent the engine from idling at a constant rpm above the programmed Low Idle rpm.

Idle/PTO RPM Ramp Rate

This parameter determines engine rpm rate of increase/decrease. This parameter determines Accel, Decel, and Resume Idle or PTO Engine rpm rates of increase/decrease. The parameter can be set to a value between 5 rpm and 1000 rpm inclusively in one rpm increments.

NOTE: The parameter applies to both idle control (rpm set using cruise control On/Off switch and Set/Resume) and PTO control (rpm set using PTO On/Off switch and Set/Resume).

Idle/PTO Bump RPM

Determines the rpm increment/decrement when the Accel/Decel switches are briefly toggled. It also applies to both dedicated PTO and idle. If a PTO Engine RPM Set Speed has been programmed the Idle/PTO Bump RPM applies only to engine rpm control initiated using the Cruise Control On/Off circuit not the PTO On/Off circuit.

Fast Idle RPM (JAN95 or earlier Personality Module)

Fast Idle RPM determines the preset Fast Idle engine rpm as controlled using the Fast Idle Enable Switch. This rpm can be overridden within its programmable range by the operator. To override, depress the accelerator pedal until the desired rpm is reached, and then depress the Fast Idle Enable Switch. This rpm will be the Fast Idle RPM as long as the ECM is powered up.

Fast Idle RPM #1 (AUG96 or later Personality Module)

Fast Idle RPM #1 determines the first preset Fast Idle engine rpm as controlled using the Fast Idle Enable Switch. This rpm can be overridden within its programmable range by the operator. To override, depress the accelerator pedal until the desired rpm is reached, and then depress the Fast Idle Enable Switch. This rpm will be the Fast Idle RPM #1 as long as the ECM is powered up.

Fast Idle RPM #2 (AUG96 or later Personality Module)

Fast Idle RPM #2 determines the second preset Fast Idle engine rpm as controlled using the Fast Idle Enable Switch. This rpm preset can be disabled by programming it to 0. If disabled Fast Idle RPM #1 functions the same as Fast Idle RPM (JAN95 or earlier Personality Module).

Dedicated PTO Parameters

PTO Installation and Application Manual, SEHS9857 is available to further explain these features and how to install them.

Torque Limit

Torque limit of the engine applies when the PTO On/Off circuit is ON (Multi-Function Input #1), and the vehicle speed is less than the programmed Idle/PTO vehicle speed limit. The Torque Limit also applies if ECM Connector J1/P1, pin-32 is connected to Sensor Common with the PTO On/Off circuit OFF regardless of the vehicle speed.

Figure 2.3 - Torque Limit Operation

The maximum value is the Rated Torque of the engine. Programmable to (N·m) lb ft of torque, programming a value higher than the Rated Torque is limited by the ECM to Rated Torque. The torque limit is indicated by the dashed line in figure 3. PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle for the Torque Limit to function.

PTO Configuration

Determines the use of the ECM Multi-Function inputs, if any, for PTO applications. OFF (default) indicates the application does not use PTO. The remaining PTO programmable options require a PTO On/Off circuit connected to ECM Connector J1/P1, pin-8. If programmed to Cab Switches the ECM will use the Cab Set (J1/P1, pin-25) and Resume (J1/P1, pin-15) switch inputs for PTO control as well as Cruise Control.

If programmed to Remote Switches the ECM will monitor J1/P1, pin-32 for PTO Set and J1/P1, pin-31 for PTO Resume, ignoring the Cab Switches when the PTO On/Off circuit is ON.

If programmed to Remote Throttle, the ECM will monitor J1/P1, pin-32 for PTO Set and J1/P1, pin-31 for PTO Resume, ignoring the Cab Switches when the PTO On/Off circuit is ON. The second, remote throttle must be connected to the Throttle Position Input (J1/P1, pin-37), and switched in or out of the circuit with a relay at the same time as the PTO On/Off Switch is ON or OFF.

PTO Top Engine Limit

The top engine limit available using a PTO On/Off circuit connected to pin-8 of ECM Connector J1/P1. This parameter is programmable to 3000 rpm maximum, and is limited by the programmed Top Engine Limit (TEL) parameter.

NOTE: PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle before this parameter can be programmed.

PTO to Set Speed

This parameter causes the ECM to proceed to the programmed PTO Engine RPM Set Speed when the PTO On/Off circuit is ON. PTO Configuration must be programmed to Cab Switches or Remote Switches before this parameter can be programmed.

NOTE: This parameter is not available for Remote Throttle.

PTO Engine RPM Set Speed

The engine rpm the ECM will allow the engine to proceed to when the PTO On/Off circuit is ON and then the Cruise Control Set Switch is toggled.

If the PTO to Set Speed parameter is programmed to YES, the engine will proceed to this speed whenever the PTO On/Off circuit is ON.

NOTE: PTO Configuration must be programmed to Cab Switches or Remote Switches for this parameter to function.

This parameter must be programmed higher than the programmed Low Idle. If programmed to a higher value than the PTO Top Engine Limit, the Set Speed will be limited by the lower PTO Top Engine Limit.

For one rpm set speed operation above low idle, (low idle and PTO Engine RPM Set Speed) the PTO Top Engine Limit should be programmed to the same rpm as the PTO Engine RPM Set Speed.

For two rpm set speeds above low idle, program this parameter to some intermediate value between the low idle and the PTO Top Engine Limit.

Place the PTO On/Off circuit switch to the ON position. Toggle the Set switch once to cause rpm to advance to the PTO Engine RPM Set Speed. Toggle the Set Switch again, and the engine advances to the PTO Top Engine Limit. Toggling the Resume Switch decreases the engine rpm to the previous set speed.

PTO Cab Throttle RPM Limit

Determines the engine rpm limit of the Cab Throttle Position Sensor when PTO Configuration is programmed to Cab Switches and the PTO On/Off circuit is ON.

* If programmed to Low Idle, the Cab Throttle Position Sensor is ignored.

* If programmed to TEL, the engine will operate to the programmed Top Engine Limit.

* If programmed to PTO TEL, the engine will operate to the programmed PTO Top Engine Limit.

This parameter is intended to prevent engine overspeed while using dedicated PTO.

NOTE: PTO Configuration must be programmed to Cab Switches for this parameter to take effect.

If PTO Configuration is programmed to Remote Switches or Remote Throttle, the ECM will always ignore the Cab Throttle Position Sensor when the PTO On/Off circuit is ON.

Engine/Gear Parameters

Top Engine Limit (TEL)

Maximum engine rpm when the engine is under load. The engine will still achieve Rated RPM under no load conditions.

Low Idle Engine RPM

Minimum engine rpm.

Timer Parameters

Idle Shutdown Time

Time (in minutes) that engine will idle before shutting down. Engine will only shut down if 3126 HEUI senses low engine load and no vehicle speed. The Idle Shutdown Timer will not begin counting if the engine is in Cold Mode. If this parameter is programmed to zero, this feature is disabled and the engine will idle until the keyswitch switch is in the OFF position.

NOTE: This feature does not shut down vehicle power. The ECM and vehicle remain powered.

Allow Idle Shutdown Override

Determines if the clutch or service brake can be used to override the idle shutdown timer during the operator alert (in the last 90 seconds when the Check Engine Lamp begins flashing). Requires Idle Shutdown Time to be programmed in the 3 to 60 minute range to function (0=OFF).

Transmission Style

Indicates to the ECM the type of transmission installed in the vehicle. It is also used by the ECM to determine how to read inputs (brake switch #2, clutch, and neutral switches) and whether the Allison AT/MT/HT transmission driver is used.

If an Allison Automatic Transmission is installed, this parameter must be programmed to either MT/AT w/ 2 Brake Sw or MT/AT w/o 2 Brake Sw.

If any other automatic transmission is installed, this parameter should be programmed to either Auto w/ 2 Brake Sw or Auto w/o 2 Brake Sw.

The Manual selection requires a clutch switch connected to ECM Connector J1/P1 pin-24. Any of the automatic transmission selections (MT/AT w/ 2 Brake Sw, MT/AT w/o 2 Brake Sw, Auto w/ 2 Brake Sw, or Auto w/o 2 Brake Sw) require a neutral switch.

The selections with two brake switches require a second brake switch connected to ECM Connector J1/P1 pin-23.

Engine Monitoring Parameters

Engine Monitoring Mode

Determines the level of action taken by the ECM in response to a potential engine damaging condition. The ECM reads the Caterpillar Coolant Temperature Sensor only.

Maintenance Indicator Parameters

Maintenance Indicator Mode

The ECM records data related to vehicle maintenance. If Distance is selected (Manual - Distance or Automatic - Distance), then all maintenance indications (PM1, PM2, Coolant Flush/Fill) on the service tool will be displayed in Distance.

If Hours is selected (Manual - Hours or Automatic - Hours), then all maintenance indications (PM1, PM2, Coolant Flush/Fill) on the service tool will be in Hours. The ECM provides PM1 maintenance interval and last maintenance information.

PM1 Interval (for Manual Maintenance Indicator Mode)

PM1 Interval allows a user-specified PM1 maintenance interval. This parameter (PM1 Interval) must be programmed only if Maintenance Indicator Mode is programmed to Manual - Distance or Manual - Hours.

PM1 Engine Oil Capacity (for Automatic Maintenance Indicator Mode)

PM1 Interval can be determined by the ECM based on fuel usage. This parameter must be programmed only if Maintenance Indicator Mode is programmed to Automatic - Distance or Automatic - Hours. Sump Capacity influences the Maintenance Interval.

Passwords

Factory Passwords

Factory passwords are required to perform each of the following four functions.

Program a New ECM

When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. These parameters are protected by factory passwords.

Rerate Engine to Another Power Family

This requires changing the Personality Module Code, which is protected by factory passwords. Includes changing from a standard to a multi-torque personality module.

Read Customer Passwords

If the owner loses his customer passwords, he will not be able to program customer parameters. Using factory passwords, enables the ability to read customer passwords, then allows use of customer passwords to program customer parameters.

Clear Certain Diagnostic Codes

Diagnostic Code 190-00 (Engine Overspeed Warning) requires factory passwords to clear once it is logged. Diagnostic Code 252-11 Incorrect Engine Software (59) also requires factory passwords. It should be cleared only if you are certain the personality module is correct for the engine.

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NOTICE

Installing a incorrect HEUI Personality Module in the wrong engine will damage the engine. Be sure the personality module is correct for the specific engine.

Certain other diagnostic codes require customer passwords. The majority of logged diagnostic codes require no passwords to clear.

Since factory passwords contain alphabetic characters, only the ECAP or ET may perform these functions.

To obtain factory passwords, proceed as if you already had the password. At some point, if factory passwords are truly needed, the ECAP or ET will request factory passwords and provide most of the information required to obtain the passwords.

Customer Passwords

If Customer Passwords have been entered, they are then required to change ANY customer parameter. Customer Parameters are those that affect vehicle speed limits, power rating within a family, and PTO operation. Refer to the previous section on "Customer Specified Parameters" for details on parameters that are customer programmable.

The ECAP, ET, or MPSI Pro-Link with the Caterpillar Cartridge may change Customer Parameters. To obtain customer passwords, contact the owner of the vehicle. If the owner has lost his passwords, customer passwords may be read using an ECAP or ET (factory passwords are required in order to read the customer passwords) by following these steps.

1. Use the ECAP or ET to access "Read/Change System Configuration Parameters", then "Read Customer Parameters".

2. When the Factory Passwords screen appears, record the information listed on the "3126 HEUI Factory Passwords Worksheet".

3. Obtain the factory passwords. The information recorded above must be provided, and generates a permanent record at Caterpillar of the access.

4. From the Factory Passwords screen, enter the Factory Passwords.

5. When the "Read Customer Passwords" screen appears, record the Customer Passwords. The Customer Passwords may then be used to change Customer Parameters.

ECM Replacement Procedures

Replacing The Electronic Control Module With A New ECM

The Electronic Control Module (ECM) is the heart of the Electronic Control System used on the 3126 Industrial Engine. The ECM contains no moving parts, has a very high reliability rating and replacement can be time consuming. Most problems occur in the connectors, wiring, or sensors. Follow the troubleshooting procedures outlined in this guide. DO NOT replace an ECM on speculation!

To ensure the suspect ECM is the cause of the problem, temporarily connect a new or test (known good) ECM, before replacing the old ECM. To temporarily connect a test ECM you must transfer the Personality Model data from the old ECM to the test ECM and program any necessary parameters required for testing (the parameters must be programmed exactly as they were in the old ECM.) Refer to the following test steps for details. If the test ECM resolves the problem, reconnect the old ECM and verify the problem returns. If the problem returns, replace the old ECM.

The parameters stored in the ECM to be replaced, must be read with an Electronic Service Tool and recorded. The Personality Module from the old ECM must be FLASH downloaded to the new ECM. After the new ECM is installed on the engine, the parameters recorded from the old ECM must be programmed into the new ECM and the injection timing must be recalibrated.

NOTE: If the parameters cannot be read they must be obtained elsewhere. Some parameters are stamped on the Engine Information Plate, but most parameters must be obtained from the user or dealer that installed the engine.

The following procedure is a summary of the basic steps necessary to program a replacement ECM.

1: Use a copy of the Read/Change Parameters Worksheet in this manual to record the Parameters from the ECM being replaced.

NOTE: It is recommended to record any Logged Events also.

(a) Use the Communication Adapter Tool and connect ET to access Parameters from the ECM being replaced.

(b) Record the Parameters listed on the worksheet.

2: Replace the faulty ECM.

(a) Turn the keyswitch to the OFF position.

(b) Use a 4 mm Allen wrench to disconnect both 40-Pin Deutsch connectors.

(c) Remove the fuel lines, ECM mounting bolts and disconnect the ECM ground strap.

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Use caution when removing fuel lines. The fuel may be under pressure and can penetrate body tissue.

d) DO NOT lose any of the ECM mounting hardware (i.e. rubber grommets, spacers and washers).

e) Ensure the old ECM's mounting hardware is free of damage and use it to install the new ECM. Reconnect the fuel lines. Ensure the ECM mounting hardware is installed correctly. Verify the fuel lines are not tugging or pulling on the ECM. The rubber grommets are used to protect the ECM from excessive vibration. When installed correctly, the ECM can drift in the rubber grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines are not pulling the ECM against one side of the grommets.

(f) Reconnect the 40-Pin Deutsch connectors and the ground strap to the ECM.

3: Always use FLASH downloading whenever possible. Use ET to FLASH download the Personality Module information into the ECM (refer to the instructions included with JERD2124 ET Software and the JERD2129 ET Data Subscription for more information).

(a) Connect ET through the Communication Adapter Tool.

(b) Turn the keyswitch to the ON position.

(C) Select the FLASH Download option from the ET menu.

(d) Select the appropriate file to be downloaded from a disk on the laptop PC. Use an Electronic Service Tool to program the Read/Change Parameters

(e) Enter all the parameters recorded in Step 1, Full Load Setting, Engine Serial Number, etc.

(f) Due to the ECAP's limited abilities you may not be able to program all the needed parameters.

4: Calibrate the Injection Timing. Use the Electronic Service Tool to select Monitor/Calibrate Timing option to calibrate the Timing (Refer To P-614: Speed/Timing Sensor Calibration).

Replacing The Electronic Control Module With An Old ECM

In extreme circumstances, (when a new ECM replacement is not available) you may have to remove an ECM from an engine that is not in service. If the replacement ECM is not from the same application as the current ECM, the ECM engine application and Personality Module Interlock will have to be matched.

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NOTICE

If the Personality Module and engine application are not matched, engine damage may result.

The Electronic Control Module (ECM) is the heart of the Electronic Control System used on the 3126 Industrial Engines. The ECM contains no moving parts, has a very high reliability rating and replacement can be time consuming. Most problems occur in the connectors, wiring, or sensors. Follow the troubleshooting procedures outlined in this guide. DO NOT replace an ECM on speculation! Be certain that replacing the ECM is required to correct the problem.

The following procedure is a summary of the basic steps necessary to program a replacement ECM.

1: Use a copy of the Read/Change Parameters Worksheet in this manual to record the Parameters from the ECM being replaced.

NOTE: It is recommended that the Logged Events are recorded also.

(a) Use the Communication Adapter Tool and connect ET to access Parameters from the ECM being replaced.

(b) Record the Parameters listed on the worksheet.

2: Replace the faulty ECM.

(a) Turn the keyswitch to the OFF position.

(b) Use a 4 mm Allen wrench to disconnect both 40-Pin Deutsch connectors.

(c) Remove the fuel lines, ECM mounting bolts and disconnect the ECM ground strap.

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Use caution when removing fuel lines. The fuel may be under pressure and can penetrate body tissue.

(d) DO NOT lose any of the ECM mounting hardware (i.e. rubber grommets, spacers and washers).

(e) Ensure the old ECM's mounting hardware is free of damage and use it to install the new ECM. Reconnect the fuel lines. Ensure the ECM mounting hardware is installed correctly. Verify the fuel lines are not tugging or pulling on the ECM. The rubber grommets are used to protect the ECM from excessive vibration. When installed correctly, the ECM can drift in the rubber grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines are not pulling the ECM against one side of the grommets.

(f) Reconnect the 40-Pin Deutsch connectors and the ground strap to the ECM.

3: Always use FLASH downloading as outlined in this step whenever possible. Use ET to FLASH download the Personality Module information into the ECM (Refer To The Instructions Included With JERD2124 ET Software And The JERD2129 ET Data Subscription For More Information).

(a) Connect ET through the Communication Adapter Tool.

(b) Turn the keyswitch to the ON position.

(C) Select the FLASH Download option from the ET menu.

(d) Select the appropriate file to be downloaded from a disk on the laptop PC.

4: Use an Electronic Service Tool and Communication Adapter Tool to match the ECM and Personality Module Interlock if the replacement ECM was used in a different application.

NOTE: For ET, refer to instructions included with JERD2124 ET Software and the JERD2129 ET Data Subscription. For ECAP, refer to Special Instruction SEHS9343.

5: Use an Electronic Service Tool to program the Read/Change Parameters. Use the Read/Change Parameters Menu item to perform the following.

(a) Enter all the parameters recorded in Step 1, Full Load Setting, Engine Serial Number, etc.

(b) Program the Engine Monitoring System, if applicable.

(c) Due to the ECAP's limited abilities you may not be able to program all the needed parameters.

6: Calibrate the Injection Timing. Use the Electronic Service Tool to select Monitor/Calibrate Timing option to calibrate the Timing (refer to P-614: Speed/Timing Sensor Calibration).

Programming a Personality Module Using Flash Programming

NOTE: Operation of the engine following programming of the Personality Module is identical to operation following replacement of the Personality Module chip. The only difference is the software was already programmed into the chip for you when you replaced the chip. Now you are actually performing the programming function. For example, if rerating an engine, there is still a need for Factory Passwords to change the Personality Module Code.

1. Connect components as shown below.

2. Start the LEXT3037 PC Program.

3. Select the engine Personality Module part number to be programmed into the ECM, and proceed with programming the Personality Module. A new ECM is shipped with a blank Personality Module.

4. PC Program Personality Module Messages and Their Meaning.

NOTE: A new ECM comes with a blank (previously unprogrammed) personality module. A blank personality module will prompt you for all three of the following messages. The information contained in the "ECM Status" will be scrambled and meaningless if the module has not been previously programmed (this is normal).

- Message - "The engine ID in the flash file does not match the engine ID in the ECM."

- Meaning - The ECM has a personality module for a different engine. For example, the ECM has a 3116 personality module, and you are attempting to program a 3126 personality module.

- What you should do. Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Ensure the file you are about to transfer is for the same engine it will be installed.

- Message- "The application ID in the flash file does not match the application ID in the ECM."

- Meaning- The ECM has a personality module for a different application. For example, the ECM has a 3126 Industrial personality module and you are attempting to program a 3126 Marine personality module.

- What you should do. Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Ensure the file you are about to transfer is for the Industrial.

- Message- "The ECM ID in the flash file does not match the ECM ID in the ECM."

- Meaning- The ECM is not for use in the 3126 HEUI Industrial application.

- What you should do. Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Ensure the ECM on the engine is for a 3126 HEUI Industrial application.

NOTE: If you access the "ECM Status" under the "Electronic Control Module" menu of the PC Program, but do not follow this information access by programming the Personality Module, turn the vehicle keyswitch switch to the OFF position, and then to the ON position before using an ECAP or ET. If the keyswitch switch is not cycled after reading the "ECM Status", the ECM will not communicate with your Service Tool, or start. Cycling the keyswitch switch is not necessary following successful programming of a Personality Module using the Flash Designer Program.

5. Start the engine and check for proper operation.

- Program any parameters not previously in the old personality module if 253-02 Check Customer Or System Parameters (56) diagnostic code is active. Read the diagnostic code from the Service Tool Active Diagnostic code screen to determine the parameter(s) requiring programming.

- Remember, on initial power-up of a new ECM, five parameters must be programmed to avoid a 253-02 Check Customer Or System Parameters (56) diagnostic code, Full Load Setting (FLS), Full Torque Setting (FTS), Vehicle Speed Calibration (ppm), Rating Number and Engine Serial Number. Refer to the topic on programming a new ECM.