3176C ENGINE FOR USE IN CPT372 & Caterpillar

Programmable Parameters

Many programmable parameters affect engine operation. Certain parameters affecting Engine operation may be changed with an Electronic Service Tool. Some parameters may affect engine operation in ways an operator does not expect. Without adequate training, these parameters may lead to power or performance complaints, even when the engine is performing to specification.

The parameters are stored in the ECM, and are protected from unauthorized changes by passwords. These parameters are either System Configuration Parameters or Customer Specified Parameters. Any parameter can be read, however, passwords protect parameters from unauthorized changes.

Two categories contain 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.

Refer to the topics, Passwords, System Configuration Parameters and Customer Specified Parameters for more details on how to receive and use factory passwords and customer passwords.

NOTE: For details on how to read and change parameters using an ECAP, refer to Special Instruction SEHS9199 (if using the NEXG4516 Engine Functions Service Program Module set).

System Configuration Parameters are set at the factory and affect emissions or power ratings within a family of engines. Factory passwords must be obtained and used to change System Configuration Parameters.

Customer Specified Parameters are variable and can be used to affect engine rpm limits, rpm/power ratings within the limits set by the factory and Caterpillar Engine Monitoring. Customer passwords are necessary to change Customer Specified Parameters.

System Configuration Parameters

System Configuration Parameters affect emissions or 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. The following is a description of the System Configuration Parameters.

Customer Specified Parameters

Customer Specified Parameters allow the engine owner to influence how a unit operates. 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 with the minimum and maximum values for the parameter and the default value. The tables show values in metric units followed by an approximate range for its US (or English) units counterpart. The exact range of the parameter in metric units depends upon the Electronic Service Tool used because each tool may use slightly different conversion factors.

Personality Module Mismatch Diagnostic Or Incorrect ECM For Application (253-02)

The ECM stores a code number in permanent memory called an interlock that is associated with each Personality Module part number. The interlock does not allow the engine to run (and potentially cause damage) if the wrong Personality Module is installed or FLASH downloaded into the ECM.

ET will warn you if you are FLASH downloading a file that does not match the last one in the ECM. The interlock must be reprogrammed with ET to allow the engine to run with new software. For instructions on how to reprogram the interlock code, refer to Special Instruction SEHS9343. Installing the incorrect ECM software may void Caterpillar warranty.

Caterpillar ECM's may appear to be the same externally, but are different internally and are not interchangeable. For example, a 3508B ECM can not be used to replace a 3176 ECM. The Interlock Code can not be reset if the wrong ECM is installed. If an incorrect ECM is used, an Incorrect ECM For Application Diagnostic Code (253-02) becomes Active and the fuel injection is disabled to prevent the engine from starting. Verify the correct ECM part number by checking the part number listed in the Parts Manual or by checking the last two characters of the ECM serial number. The correct ECM serial number ends with CA.

ECM Internal Failure Diagnostic (254-12)

The ECM continuously monitors itself internally for problems. If an internal problem develops the Diagnostic Code 254-12 becomes Active. This indicates that the ECM has detected an internal power supply or memory problem that cannot be fixed. The ECM must be replaced. Refer to Replacing The Electronic Control Module in this section.

Programmable Parameters

Engine Power Rating Selection Number

Number of rating within power family. The Personality Module defines the power family [such as 242 kW (325 hp)] and may contain only one or several ratings. The rating number defines which rating is used [such as 242 kW (325 hp) and 1900 rpm or 242 kW (325 hp) and 2100 rpm] within the family.

Equipment ID

Identification of the machine assigned by the customer. Used only for customer reference, not required by the ECM.

Engine Serial Number

The engine serial 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.

Fuel to Air Ratio Control

The control system has full authority over engine fuel delivery. The mechanical fuel to air ratio control is eliminated. Electronic control of the fuel to air ratio provides optimum performance while limiting emissions.

PTO Ramp Rate

Engine rpm rate of increase/decrease. This parameter determines Accel, Decel, and Resume PTO Engine rpm rates of increase/decrease. The parameter can be set to an rpm value between 5 and 1000 rpm/sec.

Torque Limit

Engine torque output is limited to the programmable value when the Torque Limit Switch is activated.

Top Engine Limit (TEL)

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

NOTE: TEL is dependent upon the RATING number with some RATING numbers allowing no or little variation.

Low Idle

Minimum programmable engine rpm that the engine will run with the throttle or PTO switch at minimum position.

High Idle

Maximum programmable engine rpm that the engine will run with the throttle or PTO switch at maximum position.

Intermediate Engine Speed

Programmable parameter that defines minimum desired engine speed.

Auxiliary Pressure

High Auxiliary pressure can be programmed to any value from 0 kPa (0 psi) to 2900 kPa (420 psi). The High Auxiliary Pressure Lamp on the EMS will flash when the auxiliary pressure exceeds the high set point. If Auxiliary Pressure is programmed to 0 kPa (0 psi) the Auxiliary Pressure Sensor diagnostics will be disabled.

Auxiliary Temperature

High Auxiliary temperature can be programmed to any value from 50 to 120°C (122 to 248°F). The High Auxiliary Temperature Lamp on the EMS will flash when the auxiliary temperature exceeds the high set point. If Auxiliary Temperature is programmed to 0°C (32°F) the Auxiliary Temperature Sensor diagnostics will be disabled.

Maintenance Indicator Mode

The ECM records data related to unit maintenance and activated the Maintenance Lamp when scheduled maintenance is due. When selected (Manual - Hours or Automatic - Hours), then all maintenance indications (PM Level 1, PM Level 2, Coolant Flush/Fill) on the service tool will be in hours. The ECM provides PM Level 1 maintenance interval and last maintenance information.

PM1 Interval

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 - Hours.

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 - Fuel.

Engine Monitoring Mode

Determines the level of action taken by the ECM in response to a potentially engine damaging condition. The ECM will respond to inputs from the Coolant Temperature, Inlet Air Manifold Temperature, Oil Pressure, Or Coolant Level (if installed) Sensors. Refer to Troubleshooting With A Diagnostic Code for information regarding diagnostic codes and their effect on engine operation.

Coolant Level Sensor Enable/Disable

Determines if the ECM monitors the Coolant Level Sensor Inputs.

Ether Solenoid Configuration

Parameter allows programming for two settings that effect Ether Solenoid Operation.

Fuel Correction Factor

The fuel correction factor is available to fine tune all fuel data stored in the future by the ECM. Caterpillar recommends this factor be changed only after a significant operating interval with a comparison o factual tank capacity fuel economy compared to ECM recorded fuel economy. The operating interval should also reflect a typical operating routing. The Factor is a percentage, programmable in one-half (0.5) percent increments.

Calculating Fuel Correction Factor

The following formula should be used to determine the Fuel Correction Factor (FCF)

New FCF = Old FCF + [(100 + old FCF) X error] ÷ 100 where old FCF is the Fuel Correction Factor currently in the ECM, and error is calculated as follows error = [(tank economy - ECM economy) ÷ tank economy] X 100.

Example

Tanks capacity fuel economy is 7.1 mpg, ECM economy is 7.0 mpg with an old FCF of -2.5. Therefore error is [7.1 - 7.0) ÷ 7.0] X 100 = 1.4 The new FCF is -2.5 + [(100 + {-2.5}) X 1.4) ÷ 100 = -1.135 rounded off to the nearest 0.5, new FCF = -1.0

Customer Passwords #1

Eight Character programmable password. The customer passwords are programmed by the customer.

Customer Passwords #2

Eight Character programmable password. The customer passwords are programmed by the customer.

Personality Module Code

Code which prevents use of incorrect Personality Module for this engine. Each power family 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 run at low idle and a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will also 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. Requires factory passwords to change.

Full Load Setting

The setting number represents the fuel system adjustment performed at the factory to fine tune the fuel system. The original information 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

The original information is stamped on the engine information plate. this parameter must be programmed or a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will be generated.

Throttle Position Sensor Diagnostics

This parameter allows the customer to turn OFF the diagnostic monitoring for the throttle position sensor.

PTO Mode 1

PTO mode 1 will allow the engine to function with traditional PTO parameters. The parameters below are (default) for the mode 1 selection.

* Ramp UP/Ramp Down

PTO Mode 2

PTO mode 2 will allow the engine to function with the enhanced PTO parameters. The parameters below are (default) for the mode 2 selection.

* Set/Resume

* PTO Interrupt

All Engines

Power Trim

Power Trim allows small amounts of power adjustment within a selected rating.

Intermediate Engine Speed

Programmable parameter that defines minimum desired engine speed.

Customer Lockout

To obtain the Customer Lockout Parameters access the Menu Bar on the Electronic Service Tool and select Service, then Parameter Lockout. This parameter is available to restrict access to changing some available parameters. Locking out a parameter requires customer passwords (if customer passwords have been programmed). Once a parameter is locked out, FACTORY PASSWORDS are required to change the parameter to unlocked.

The parameters that can be locked out are:

* Engine Rating

* Engine Monitoring Mode

* Power Trim

* Top Engine Limit

* High Idle

Passwords

Factory Passwords

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

1. Program a new ECM.

- When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. For a new ECM these parameters can be programmed once without factory passwords, thereafter these parameters are protected by factory passwords.

2. Rerate engine to another power rating.

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

3. Read customer passwords.

- If the owner loses the customer passwords, the owner will not be able to program Customer Specified Parameters. Using factory passwords, one can read customer passwords, then use those customer passwords to program Customer Specified Parameters.

4. 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 (Flash Code 59) also requires factory passwords. It should be cleared only if you are certain the Personality Module is for the specific engine.

Certain other diagnostic codes require customer passwords. The majority of logged 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 display 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 Specified Parameter. Customer Specified Parameters are those that affect engine rpm limits, power rating and PTO operation within a family. Refer to the Customer Specified Parameters for more detail on what parameters are customer programmable.

The ECAP or ET Electronic Service Tools may change Customer Specified Parameters. To obtain customer passwords, contact the owner of the unit. If the owner has lost the passwords, customer passwords may be read using an Electronic Service Tool (factory passwords are required in order to read the customer passwords). Follow the procedure below.

1. Use the Electronic Service Tool to access Read/Change System Configuration Parameters, then read customer parameters.

2. When the Factory Passwords screen appears, record the information listed on the 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. Enter the factory passwords from the Factory Passwords screen.

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

System Configuration Parameters are protected by Factory Passwords. Factory passwords are calculated on a computer system available only to Caterpillar dealers. Since factory passwords contain alphabetic characters, only an ECAP or ET Electronic Service Tool may change System Configuration Parameters. System Configuration Parameters affect power family or emissions.

Customer Specified Parameters are protected by Customer Passwords. The customer passwords are programmed by the customer. Refer to Programmable Parameters, for more details when passwords are needed and how to obtain them.

ECM Replacement Procedure

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 6 Cylinder 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!

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 operating information from the old ECM MUST be transferred to the new ECM with the Electronic Service Tool. The parameters file can be copied with the Electronic Service Tool and the Personality Module can be downloaded. After the new ECM is installed on the engine, the parameters and the personality module 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.

Show/hide table

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: Engine 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 in the chip for you when you replaced the chip, now you are actually performing the programming function.

For example, if you are rerating an engine, you will still need factory passwords to change the Personality Module Code.

1. Connect hardware as shown.

2. Start the LEXT3037 PC Program, or Flash from the Electronic Technician (ET) Service Tool.

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

4. PC Program Personality Module Messages and their meanings are discussed in the following procedure.

NOTE: A new ECM has 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 installed for a different engine. For example, the ECM has a 3176C Personality Module and you are attempting to program another Personality Module into it.

- 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 in.

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

- Meaning - The ECM has a Personality Module installed for a different application.

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

- 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 3176C application.

- What you should do - Stop the transfer and access information about ECM Status in the Electronic Control Module menu. Ensure the ECM on the engine is for a 3176C application.

NOTE: If you access the ECM Status under the Electronic Control Module menu of the PC Program, but do not follow (or have not followed) this procedure by programming the Personality Module, you must turn the keyswitch to the OFF position, and then to the ON position before using an Electronic Service Tool. If you do not cycle the keyswitch after reading the ECM Status, the ECM will not communicate with your service tool or start the engine. Cycling the keyswitch 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) code is active. Read the code from the Active diagnostic code screen of the Electronic Service Tool to determine the parameter(s) requiring programming.

- Remember, on initial powerup of a new ECM, five parameters must be programmed to avoid a 253-02 Check Customer Or System Parameters (56) code. They are Full Load Setting (FLS), Full Torque Setting (FTS), Rating Number and Engine Serial Number and Output Shaft Speed Calibration (ppm).

Factory Passwords Worksheet

NOTE: A mistake in recording these parameters will result in incorrect passwords.

Dealer Code

Customer name ____________________

Address ____________________

Phone Number ____________________

From Engine Information Plate

Engine S/N ____________________

Full Load Setting ____________________

Full Torque Setting ____________________

From Unit Hour Meter

Engine Hours ____________________

From Factory Passwords Screen on Electronic Service Tool

Electronic Service Tool S/N ____________________

Engine Serial Number ____________________

Electronic Control Module S/N ____________________

Total Tattletale ____________________

Reason Code ____________________

NOTE: The following two parameters are necessary, and therefore only displayed, when re-rating an engine.

From Interlock ____________________

To Interlock ____________________

Factory Passwords

Factory Password #1 ____________________

Factory Password #2 ____________________

Customer Parameter Worksheet

Customer Passwords

Customer Password #1 ____________________

Customer Password #2 ____________________

Selected Engine Rating

Rating # ____________________

ECM Identification Parameters

Equipment ID ____________________

Engine Parameters

Engine Serial Number ____________________

Fuel to Air Ratio Control ____________________

Torque Limit ____________________

Top Engine Limit ____________________

Low Idle ____________________

High Idle ____________________

Intermediate Idle Engine Speed ____________________

Auxiliary Pressure ____________________

Auxiliary Temperature ____________________

PTO Governor Parameters

PTO Ramp Rate ____________________

PTO Engine Speed Ramp Rate ____________________

PTO Mode ____________________

Engine Monitoring Parameters

Engine Monitoring Mode ____________________

Coolant Level Sensor ____________________

Either Solenoid Configuration ____________________

Fuel Correction Factor ____________________

Engine Monitoring Mode ____________________

Coolant Level Sensor ____________________

Ether Solenoid Configuration ____________________

Fuel Correction Factor ____________________

Trip Parameters

Fuel Correction Factor ____________________

Maintenance Indicator Parameters

Maintenance Indicator Mode ____________________

PM1 Interval (Hours) ____________________

PM1 Reset ____________________

Lifetime Totals Worksheet

Total Hours ____________________

Total Idle Hours ____________________

Average Load Factor (%) ____________________

Total Fuel ____________________

Total Idle Fuel ____________________

Total Max Fuel ____________________