C-12 TRUCK ENGINE Caterpillar

The Caterpillar Electronic Service Tools are designed to help the service technician analyze and locate faults or problems within the system. They are required to perform calibrations, and to read or change engine parameters.

Caterpillar ET (Electronic Technician) is a software program that runs on a personal computer and requires a Caterpillar Communication Adapter or MPSI Pro-Link with Caterpillar Cartridge to translate information from the ATA Data Link to the computer RS-232 port. Caterpillar ET is the recommended Service Tool.

ET (Electronic Technician) can be used to display the following information:

* Programmable Parameter Settings

* Active and Logged Diagnostic Codes

* Logged Events

* Engine Rating History

* Driver & Fleet Trip Segments

* Histograms

* Custom Data

* ECM Date/Time

* Maintenance Intervals

ET (Electronic Technician) can also be used to perform the following functions:

* Diagnostic Tests

* Sensor Calibrations

* Flash Programming

* Parameter Programming

* Copy Configuration (ECM Replacement)

* Data Logging

* Real Time Graphing

* Snapshot Recorder

The Electronic Control Analyzer Programmer (ECAP) service tool can also be used in a limited capacity but it is no longer supported. ECAP uses small plug-in modules, called Service Program Modules (SPM), to adapt the basic tool to the specific Caterpillar electronic control application.

There are several adapter cables, breakout T cables, probes, etc, that are used in order to access measurements of signals. A heavy duty multimeter is suitable for making the necessary measurements, a multimeter that is capable of measuring Duty Cycle may also be required. Other Special Tools include those needed to measure pressure or temperature.

Required Service Tools

Optional Service Tools

Connecting ET (Electronic Technician)

The Communications Adapter is powered by 12 volts DC from the vehicle battery. This permits operation beside the engine or in the cab of a truck, to allow use during vehicle operation.

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

1. Turn ignition key to the OFF position.

2. The PC (with ET software installed) should be connected to the engine system through the Cab Diagnostics Connector. There are several types of cab connectors used. Determine the necessary Adapter Harness Assembly from the tool list for the vehicle you are working with. Connect the appropriate adapter to the Service Tool Harness Cable.

3. Connect the opposite end of the Service Tool Harness Cable to the Communication Adapter (refer to diagrams for specific type).

4. Connect the Communication Adapter to the PC using the appropriate cable as shown.

5. Turn ignition key to the ON position to begin testing. The Service Tool will operate with the engine running, or with the engine OFF, ignition key ON. If the Tool does not communicate with the ECM, disconnect and reconnect the Cab Diagnostic Connector cable. Check communication, if the problem is still present refer to "PB-21: SAE J1587/1708 (ATA) Data Link Circuit Test" on page 189.

NOTE: The Service Tool may restart during engine cranking due to a voltage dip on the battery line.

NOTE: ET must be configured to communicate with the specific type of Communication Adapter used. Go to the "Preferences" menu located under "Settings" to select the appropriate communications device.

Connecting ET using a 7X-1701 Comm Adapter

Connecting ET using a 171-4400 Comm Adapter

Passwords

Factory Passwords

Factory passwords are required to perform each of the following six 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 Engine Family

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

3. Read Customer Passwords

- If the owner loses his customer passwords, he will not be able to program customer parameters. Using factory passwords, one can read customer passwords, then use those customer passwords to program customer 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 (59) also requires factory passwords. It should be cleared only if you are certain the personality module is for the specific engine.

5. Unlock a "Locked" Customer Parameter

- If a Customer Parameter has been locked out, Factory Passwords are required to either unlock the parameter or change the parameter. Refer to "Customer Parameter Lockout" on page 39.

6. Enable ECM Wireless Communication Enable parameter

- Enabling this feature for the transfer of trip information over the data link through remote communications systems requires Factory Passwords. This feature can only be enabled after the truck has been delivered to the customer.

Certain other codes require customer passwords. The majority of logged codes require no passwords to clear. Since factory passwords contain alphabetic characters, only Electronic Technician (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, Electronic Technician (ET) will request factory passwords and display the information required to obtain the passwords.

NOTE: The Customer Parameter "Parameter Lockout" may restrict changing some Customer Parameters unless Factory Passwords are obtained. If changing a Customer Parameter indicates Factory Passwords are required, it is because the Parameter has been Locked Out. See "Customer Parameter Lockout" on page 39 for a list of parameters available for lockout.

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. See the previous section on "Customer Specified Parameters" for more detail on what parameters are customer programmable.

An 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 ET (factory passwords are required in order to read the customer passwords) by following these steps.

1. Use ET to access the "Utilities" menu. Then access "View Passwords" located under the Utilities menu.

2. When the Factory Passwords screen appears, record the information on the "Factory Passwords Worksheet" on page 35).

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

Programming a New ECM

The Engine Control Module or ECM is the brain of the system. So when a problem occurs, it is easy to jump to the conclusion that the ECM is responsible. That is usually the wrong conclusion.

Most failures occur at the wiring and connectors or a sensor input/output. Follow the troubleshooting guide procedures, and do not replace an ECM on speculation!

However, when your troubleshooting indicates that a failure has occurred in the ECM, the following procedure outlines the steps required to replace a faulty ECM.

NOTE: If an ECM replacement is required, the ECM parameters, injector trim codes, and timing calibration can be transferred from the suspect ECM to the replacement ECM. Timing calibration will NOT be necessary. This feature requires Caterpillar Electronic Technician (ET) and is only possible if the suspect ECM can communicate with ET.

Replacing The ECM Using Caterpillar Electronic Technician (ET) ECM Replacement Feature

1. Ensure the ECM is the problem by first temporarily connecting a test ECM. Do this by hanging it on the side of the engine. Flash Program the identical Personality Module used in the suspect ECM into the test ECM. Use the ET ECM Replacement feature to Copy the parameter configuration of the suspect ECM into the Test ECM. Ensure the parameters in the test ECM are programmed the same as the parameters in the suspect

2. If the test ECM repairs the problem, reconnect the suspect ECM. Verify the problem returns when the suspect ECM is reconnected.

3. Select the ECM Replacement feature under the Service\Copy Configuration menu and load the parameters from the failed ECM.

4. Temporarily connect the new ECM by connecting both ECM Connectors. Do not mount the ECM on the engine yet.

5. Flash program the Personality Module into the new ECM (if not already installed). The new ECM is shipped with a blank Personality Module.

6. Use the ET ECM Replacement feature to program the new ECM.

7. Enter the Rating Number parameter into the new ECM.

8. Check for Active Codes. Program any parameters requiring programming that have not been programmed.

NOTE: On initial power-up of a new ECM, the Rating Number parameter must be programmed to avoid a 253-02 Check Customer Or System Parameters (56) Diagnostic Code.

9. If a 22-13 Check Timing Calibration Diagnostic Code is not Active, install the new ECM on the engine. Otherwise, perform a timing calibration first.

Replacing The ECM (If Caterpillar ET ECM Replacement Feature Cannot be Used)

1. Ensure the test ECM is the problem by first temporarily installing the test ECM. Do this by hanging it on the side of the engine. Flash Program the identical Personality Module used in the suspect ECM into the test ECM. Program any parameters necessary to use the ECM for the test. For example, Vehicle Speed Parameters need to be programmed to check the vehicle speed circuit. Program the parameters exactly the same as they are in the suspect ECM.

2. If the test ECM repairs the problem, reconnect the suspect ECM. Verify the problem returns when the suspect ECM is reconnected.

3. Obtain customer parameters from the failed ECM.

- Obtain and record the Customer Passwords. If the customer (owner) has lost or forgotten their passwords, obtain factory passwords to get them.

- Use ET to access Customer Specified Parameters from the ECM being replaced. If ECM does not communicate with Electronic Service Tool, obtain the required Parameter List from OEM.

- Use the Customer Parameter Worksheet on page 36 to record the customer parameters.

4. Record ECM Current Totals.

- Use the Current Totals Worksheet on page 35 to record the old ECM Current Totals.

5. Temporarily connect the new ECM by connecting both ECM Connectors. Do not mount the ECM to the engine until the timing calibration has been performed.

6. Flash program the Personality Module into the new ECM (if not already installed). The new ECM is shipped with a blank Personality Module.

7. Obtain Factory Passwords (if required).

NOTE: Full Load Setting (FLS), Full Torque Setting (FTS) and engine serial number can be programmed without factory passwords on a new ECM. System Configuration parameters must be entered before the Customer Specified Parameters are entered.

If Customer Parameters are entered before the System Configuration Parameters, the Total Tattletale will change. It will then be necessary to obtain another set of Factory Passwords to access System Configuration Parameters.

8.

- Use the Factory Passwords Worksheet on page 35 to record the following information from the Engine Information Plate: Full Load Setting, Full Torque Setting, and Engine Serial Number.

- Record the mileage from the vehicle odometer. Use ET to access System Configuration Parameters. When the Factory Specified Passwords screen appears, record the following information, ECM serial number, Engine serial number, ET serial number, Total Tattletale, and Reason Code.

- Leave ET on the Factory Specified Passwords screen and obtain the Factory Passwords. Fill out the Factory Passwords Worksheet on page 35.

9. Program the new ECM.

NOTE: On initial power-up of a new ECM, six parameters must be programmed to avoid a 253-02 Check Customer Or System Parameters (56) Diagnostic Code. These codes are Full Load Setting (FLS), Full Torque Setting (FTS), Vehicle Speed Calibration (ppm), Rating Number, Engine Serial Number, and Injector Trim Codes.

- Use ET to access System Configuration Parameters. Enter the Full Load Setting, Full Torque Setting, and Engine serial number recorded on the worksheet.

- Use ET to access Customer Specified Parameters. Enter the Customer Specified Parameters and the original Customer Passwords recorded on the worksheet.

- Use ET to access Current Totals (from the Read/Change Current Totals main menu). Record information using the Factory Passwords Worksheet on page 35 to obtain the Factory Passwords. Enter the Totals recorded on the worksheet from the original ECM.

- Use Service\Calibrations\Timing Calibration and calibrate the timing. Refer to PC-31: Engine Speed/Timing Circuit Test on page 257.

10. Install the new ECM on the engine.

Programming a Personality Module Using Flash Programming

1. Connect the PC to the appropriate Communication Adapter and connect the Communication Adapter to the ECM. Refer to the diagrams in Connecting ET (Electronic Technician) on page 27.

2. Start the WinFlash PC Program.

3. Ensure the Ignition Key Switch is ON, engine OFF.

4. 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.

NOTE: The WinFlash program provides the ECM, Application, and Software part number of the selected file. Make sure this file matches the engine before you begin to Flash the file into the ECM.

5. PC Program Personality Module Messages and Their Meaning.

NOTE: A new ECM comes with a blank (previously unprogrammed) personaly 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).

1. "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 C-10 personality module, and you are attempting to program a 3406E personality module.

- Stop the transfer and access information about ECM Status under the Engine Control Module menu. Ensure the file you are about to transfer matches the engine application.

2. "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 C-12 On-Highway Truck personality module and you are attempting to program a 3508B Marine personality module.

- Stop the transfer and access information about ECM Status under the Engine Control Module menu. Ensure the file you are about to transfer is for an On-Highway Truck personality module.

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

- Meaning- The ECM is not for use with an On-Highway truck application.

- Stop the transfer and access information about ECM Status under the Engine Control Module menu. Ensure the ECM on the engine is for an On-Highway truck application.

NOTE: The time it takes to flash a Personality Module is significantly longer than earlier applications. It can take 10 minutes or longer with a Caterpillar 7X-1701 Communication Adapter, and 20 minutes or longer using a MPSI Pro-Link with the Caterpillar cartridge as a communications adapter.

The 171-4401 Communication Adapter II has the ability to Flash Program using the J1939 data link. This results in much faster flash times. However, the vehicle wiring harness must have J1939 support in order to flash program using the J1939 data link. If J1939 communications are not supported, the 171-4401 Communication Adapter II will use the ATA data link for flash programming, resulting in similar flash times as the 7X-1701 Communication Adapter.

NOTE: If you access the ECM Status under the Engine Control Module menu, but do not program the Personality Module: Turn the vehicle ignition key switch to the OFF position, and then to the ON position before using ET. If the ignition key switch is not cycled after reading the ECM Status, the ECM will not communicate with your Service Tool, or start. Cycling the ignition key switch is not necessary following successful programming of a Personality Module using the WinFlash Program.

4. 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, six 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, Engine Serial Number, and Injector Trim Codes. Refer to Programming a New ECM on page 29.

ECM Snapshot

The ECM can record a "snapshot" of engine/vehicle parameters for a period of 13 seconds surrounding an event. The event is either a diagnostic code or an external trigger.

When to Use a Snapshot

Use Snapshots ONLY to help determine engine/vehicle operating conditions when an intermittent problem occurs. If an intermittent diagnostic code is causing problems, use the snapshot data to determine if the problem seems to occur in specific engine rpm or vehicle speed ranges, coolant temperature ranges, etc. Use this data to attempt to duplicate these conditions with the vehicle and get the code to reoccur.

DO NOT replace electronic components based on Snapshot data alone. The snapshot information is stored in frames every 0.24 seconds (if externally triggered) or every 0.48 seconds (if diagnostic code triggered). Frequently, the parameters are changing faster or slower than 0.24 seconds, the result will be a misdiagnosed problem if too much is interpreted from this information. Also, remember when viewing Diagnostic Triggered Snapshots, the ECM sets a sensor value with an ACTIVE Diagnostic Code to a default value when the code is Active. This is why the Sensor value suddenly jumps to a specific value at the trigger point and remains there for the rest of the snapshot frames. DO NOT attempt to interpret the information and analyze how the engine is operating from this historical information. Looking at this information under a "microscope" will lead to misdiagnoses because some parameters are not what are expected, even though they are completely unrelated to the problem under investigation.

Diagnostic Code Triggered Snapshot

When a diagnostic code occurs the ECM records many of the status parameters available on the Caterpillar ET. The ECM records this information for approximately 9 seconds before the code occurs, and approximately 3 seconds after the code.

External Triggered Snapshot

If desired, a snapshot can be externally triggered using either the Cruise Control Set/Resume Switch, or an Electronic Service Tool. By toggling the Cruise Control Set/Resume Switch quickly from Set to the Resume position, the ECM will take a snapshot of information. For the Electronic Technician (when available), the snapshot can be triggered from the Snapshot Recorder Tool (follow the instructions on the screen or help system).

Quick Stop Snapshot

A snapshot can also be stored for a Quick Stop occurrence if the Customer Parameter is programmed. The ECM stores the number of occurrences of the Quick Stop Event, as well as a snapshot of the latest occurrence.

One data record is kept for the most recent Quick Stop occurrence activation. The record is stored with the most recent record replacing the previous record.

Each Quick Stop record contains 60 frames of information; frame 45 is the Quick Stop occurrence, 44 frames before, 15 frames following the code. Each frame is separated by 1.0 second.

Each frame of the snapshot record stores the following data:

ECM Storage of Snapshots

The ECM can store up to two Diagnostic Code Triggered snapshots, two Externally triggered snapshots, and one Quick Stop Snapshot. Each type is stored in a "circular buffer". When a new snapshot is taken, the oldest one in the buffer will be replaced.

The ECM stores the snapshots in memory maintained through the Unswitched Battery connections. If the Unswitched Battery connections are disconnected, the snapshot data is maintained by the internal ECM battery until the Unswitched Battery connection is restored.

The snapshots can be manually cleared using an Electronic Service Tool. Snapshots, like most Diagnostic Codes are automatically cleared by the ECM after 100 hours of operation.

ECM Date/Time Clock

How to use ECM Date/Time Stamped Information

The ECM date & time can be programmed with an Electronic Service Tool. The Electronic Service Tool will display the programmed Date in Month/Day/Year format and the programmed Time in Hour:Minute:Second format. The Electronic Service Tool has the option to program any date/time or automatically select the date/time stored in the PC real time clock. The date and time will remain programmed in the ECM even if the Unswitched Battery connections are removed.

The ECM Date/Time Clock is used to time stamp the following Critical Event Codes:

* 84-00 Vehicle Overspeed Warning

* 84-14 Quick Stop Occurrence

* 100-11 Very Low Oil Pressure

* 110-11 Very High Coolant Temperature

* 111-11 Very Low Coolant Level

* 190-00 Engine Overspeed Warning

ECM diagnostic snapshots, snapshots triggered using the Set/Resume switch, and Quick Stop snapshots are also date/time stamped.

Before Adjusting the ECM Date/Time Clock

Before adjusting the ECM Date/Time Clock on a truck ask the owner/operator if they want the time stamped information recorded. After it is recorded, clear this information before adjusting the ECM Date/Time Clock. This is very important if the clock adjustment is a big change. This will prevent unnecessary confusion if someone else views the information at a later date.

Determining Time Stamped Information Occurrence

When viewing time stamped information remember the truck may be based in a different time zone, or someone may have incorrectly or never set the clock. Use the time currently set in the ECM to compare any ECM recorded information to the time the ECM indicates to determine how long ago the time stamped event occurred. DO NOT REPLACE AN ECM BECAUSE OF AN INCORRECT TIME. The following example indicates how to use the clock.

Example use of ECM Date/Time Stamped Information

The Electronic Service Tool indicates a 190-00 Engine Overspeed Warning occurred on NOV 19 1998 10:30:46. The Service Tool also indicates the current ECM time is NOV 24 1998 11:20:58. This indicates the problem occurred approximately one week, 50 minutes ago. Do not compare it to the current time at your location because the truck may be based in a different time zone, or someone may have incorrectly or never set the clock. If the ECM time is significantly different than your current time, for example the wrong month is programmed, make sure you have recorded the time stamped information if it is important. After recording the information, clear the code or snapshot, and then adjust the clock.

ECM Diagnostic Clock

The Diagnostic Clock should not be confused with the ECM Date/Time clock. The Diagnostic Clock records actual hours the ECM has been powered (ignition key switch ON). This information is maintained even if the Unswitched Battery connections are removed. The diagnostic clock information is used to log diagnostic code and event code occurrences. Logged diagnostic codes and event codes display the diagnostic clock hour of the first and last occurrence and the total number of occurrences. The Diagnostic Clock does not represent actual Engine Hours, it increments any time the ECM is powered regardless of whether the engine is running or not. Actual Engine Running hours (Total Time) can be obtained from the Current Totals menu of ET (Electronic Technician).

Injector Codes

Injector Codes are etched on each injector The Injector Codes can be viewed/changed with ET (Electronic Technician) by selecting the Calibrations Screen under the Service menu. The Injector Codes Calibration is located under the Calibrations menu. The injector code must match the code on the corresponding injector. When replacing an injector, reprogram the new code for the new injector.

ET Automated Cylinder Cutout Test

The C-10, C-12, 3406E, C-15 and C-16 engines use electronic fuel injectors. These injectors are mechanically actuated and electronically energized. The Cylinder Cutout tests are used to confirm that the cylinders are functioning properly.

ET (Electronic Technician) provides three automated test options: One, Four, or Five Cylinder Cutout Test. The Four Cylinder Cutout Test is the default test and therefore the recommended starting point. The automated tests shut off the flow of fuel to a cylinder or cylinders while the fuel position is monitored for the remaining cylinders. The fuel position of the remaining cylinders should increase. If it does not, the cylinder that was cutout is not functioning properly. These tests gather and analyze the Fuel Position data. The test runs twice and averages the two sets of data. When the test concludes an OK or NOT OK result is displayed for each cylinder.

The Manual Cylinder Cutout Test is also available. It allows a specific cylinder to be cutout while the fuel position is monitored for the remaining cylinders.

To perform a cylinder cutout test, connect ET to the Cab Diagnostic Connector as described in Connecting ET (Electronic Technician) on page 27. Access the Cylinder Cutout Test located under Diagnostics.

The Cylinder Cutout Test opens with the Manual test. At the bottom of the ET Screen there is a row of buttons that function as follows:

* "Change" toggles the highlighted cylinder between powered and not powered.

* "Power All" returns all cylinders to a the normal operating state.

* "Start" initiates the automated cylinder cutout test.

* "Stop" terminates the automated test.

* "Results" displays the test results.

* "Print" allows the contents of the screen to be previewed, or sent to a file or printer

The following conditions must be met to perform one of the automated tests:

* No Active Diagnostic Codes

* Correct Engine Speed:

- 1 Cylinder Cutout Test = 980 to 1020 rpm

- 4 Cylinder Cutout Test = 980 to 1020 rpm

- 5 Cylinder Cutout Test = 780 to 820 rpm

* Coolant Temp = 77°C (171°F) or higher

* Cooling Fan Enabled (ECM controlled cooling fan will be automatically enabled during test)

Follow the instructions provided in the test procedure.

Service Information Report

After verifying the correct repair has been performed on the vehicle it is critical to provide concise, detailed information. This information helps Caterpillar better serve you and the Customer.

Recommendations

Customer's Complaint

Provide a copy of the "PA-10:Driver Questionnaire" on page 62. Include comments for the Customer's Complaint section of the report indicating if the Check Engine Lamp was ON continuously or intermittently, if symptoms such as the truck had low power are present, indicate this.

Failure Cause

Comments on Failure Cause should include the number of diagnostic codes logged and if the code was Active. Indicate the source of the problem and how it was discovered, such as followed Procedure PC-31, or a visual inspection indicated wire abrasion on the engine harness, or truck dynamometer testing showed power below specification @ 1700 rpm and above due to loss of cylinder 4 injector. Please be specific.

How You Repaired It

Comments on How You Repaired It should include information such as repaired the wiring harness, changed FLS/FTS as per factory instructions, etc.

Factory Passwords Worksheet

Current Totals Worksheet

Customer Parameter Worksheet