3126 TRUCK ENGINE MILITARY Caterpillar

Many programmable parameters affect 3100 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 authorized changes.

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

System Configuration Parameters can be altered only with the proper factory passwordsusing Caterpillar Electronic Technician (ET).

Customer Specified Parameters can be changed using an Electronic Service Tool only with the proper customer passwords.Refer to "Passwords" on page 33 for more details on how to receive and use factor and customer passwords.

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

Connecting an Electronic Service Tool

ET and the Communications Adapter are powered by 12 volts DC 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 ignition key to the OFF position.

2. The Electronic Service Tool should be connected to the 3100 HEUI system through the Cab 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 139-4166 Breakout T harness connector cable.

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

4. Turn the 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 3100 HEUI ECM, refer to "PB-21: ATA (SAE J1587/1708) Data Link Circuit Test" on page 145.

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

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 mustbe reprogrammed if an ECM is replaced. Proper values for these parameters are stamped on the Engine Information Plate, located on the valve cover or intake manifold. Factory Passwordsare 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 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 flashed the code (stored in the ECM) mustmatch 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 notneed 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, etc 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 vehicle owner to influence how a driver operates the vehicle. Some parameters may affect engine operation in ways an inadequately trained driver 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 drivers are assigned to a vehicle. Customer Passwordsare 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 boldis 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.

Customer Parameter Lockout

Locking out a parameter requires Customer Passwords (if used). Once a parameter is locked out, Factory Passwords are required to change the parameter or unlock the parameter.

If a "lockable" parameter is not locked out, Factory Passwords are not required. A locked out parameter restricts the parameter from being changed directly by the customer. This helps vehicle owners encountering problems with operators obtaining Customer Passwords and altering some of these parameters.

It also provides a trail to determine who changed the parameter and when. The following Customer Parameters are available for Lockout.

* Vehicle Speed Limit

* Vehicle Speed Limit Protection

* Vehicle Speed Calibration

* High Cruise Control Speed Set Limit

* Soft Vehicle Speed Limit

* Transmission Style

When an attempt to change a locked out parameter occurs, the Factory Password screen will come up. Follow the instructions on the Service Tool screen if changing the parameter is required.

Factory Passwords are also required to change a parameter from "locked" to "unlocked". If more than one parameter is locked out, and each one needs to be unlocked, one Factory Password is required.

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 "PB-14: Vehicle Speed Circuit Test" on page 89.

Vehicle Speed Limit (VSL)

Top vehicle speed the ECM will permit. The ECM will shut off fuel above this speed. An inexperienced driver 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. This is a feature to deter tampering by running without a Vehicle Speed input to the ECM.

NOTE: When this parameter is programmed to 3000 rpm, Diagnostic Codes 84-01 Loss Of vehicle Speed Signal (31) and 84-10 Vehicle Speed Rate of Change (36) 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. Some applications may only offer a NO option.

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 driver 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 3 - 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. Some applications may only offer a NO option.

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.

Refer to "PB-18: Exhaust Brake And Transmission Interface Circuits Test" on page 132 for details on operation of the engine retarder and auxiliary engine retarder.

Figure 4 - 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.

The Idle/PTO Vehicle Speed Limit has been separated into two parameters, Idle Vehicle Speed Limit (with range as below) and PTO Vehicle Speed Limit (refer to "PTO Vehicle Speed Limit" on page 27).

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 to 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

Fast Idle RPM determines the preset Fast Idle engine rpm as controlled suing 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 #2

Fast Idle RPM #2 determines the second preset Fast Idle engine rpm as controlled using the Fast Idle Enable Switch. This rpm preset is disabled by programming it to 0.

The Fast Idle RPM Customer Parameter range is 700 - TEL rpm. The Fast Idle RPM #2 Customer Parameter range is 700 - TEL rpm with 0 rpm as the default. Following engine start up, depressing/toggling the Fast Idle Enable switch ramps the engine to the programmed Fast Idle RPM. If Fast Idle RPM #2 is programmed to 0 depressing/toggling the Fast Idle Enable switch will cause the engine to return to Low Idle. Depressing/toggling the Fast Idle Enable switch with Fast Idle RPM #2 programmed to a value greater than 0 will cause the engine to ramp to the programmed Fast Idle RPM #2. Depressing/toggling the Fast Idle Enable switch a third time will cause the engine to return to low idle. The engine ramps to the Fast Idle RPM, Fast Idle RPM #2, and Low Idle independent of the programmed Idle/PTO Ramp Rate.

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 supplies 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 5 - Torque Limit Operation

The maximum value is the Rated Torque of the engine. Programmable to lb ft (N·m) 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 5. 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/Of 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 Configurations 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.

PTO Vehicle Speed Limit

This parameter determines the maximum vehicle speed for setting or maintaining a set engine rpm in PTO mode. 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 no longer maintain the set engine rpm. For MAR96 and earlier Personality Modules the Idle/PTO Vehicle Speed Limit determines the maximum PTO Vehicle Speed (refer to "Idle/PTO Vehicle Speed Limit" on page 24).

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.

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

Timer Parameters

Idle Shutdown Time

Time (in minutes) that engine will idle before shutting down. Engine will only shut down if 3100 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 ignition key 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 driver 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).

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 with 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.

Dash Display Access Parameters

Adjust Customer Parameters

When programmed to YES, four parameters can be accessed and changed through a CAT ID Dash Display. These parameters are:

* SoftCruise

* Fast Idle RPM #1

* Fast Idle RPM #2

* Low Idle

Each parameter listed has a YES/NO option with NO as the default. In addition the CAT ID must have the EEPROM chip capable of supporting communication with 3100 HEUI engines, software version 1.3 or later. The version number is displayed initially on powerup of CAT ID.

PM1 Reset

Determines access for the driver to reset the PM1 Maintenance, when performed. Maintenance Indicator Mode cannot be programmed to OFF for the PM1 Reset parameter to take effect.

Theft Deterrent System Control

When used with a Theft Deterrent Password prevents the engine from starting unless the password has been entered via the CAT ID dash display. The operator must first enter the password before the engine shuts off in order to enable the system, preventing engine starting without reentering the password on the next attempted start.

Theft Deterrent Password

The password required by the ECM before the Theft Deterrent failure is enabled or prevents engine starting.

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 These parameters are protected by factory passwords.

2. 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.

3. 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.

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 onlyif you are certain the personality module is correct for the 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 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, 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 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 ET (factory passwords are required in order to read the customer passwords) by following these steps.

1. Use 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 "3100 HEUI Factory Passwords Worksheet" (refer to "Factory Passwords Worksheet" on page 36).

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.

Programming a New ECM

The 3100 HEUI Electronic Control Module (ECM) is the heart 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 a sensor input/output, or in the wiring and connectors. Follow the troubleshooting procedures in this manual, and do not replace an ECM on speculation!

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

ECM Replacement Procedure

1. Ensure the new ECM repairs the problem by first temporarily installing the new ECM. Do this by hanging it on the side of the engine. Flash Program the same Personality Module from the suspect ECM to the new ECM. Program any parameters necessary to check 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 were in the suspect ECM. Check out the new ECM. If it repairs the problem, reconnect the old ECM using the same Personality Module as the new ECM. Recheck the old ECM to verify the problem stays with the ECM.

2. Record customer parameters from the failed ECM.

- Obtain and record the Customer Passwords. If the customer (owner) has lost or forgotten his passwords, proceed to "Customer Passwords" in this section.

- Use ET to access "Rear Customer Specified Parameters" form the ECM being replaced.

- Use the "3100 HEUI Customer Specified Parameters Worksheet" (in this section), to record the customer parameters.

NOTE: If an ECM replacement is required and both the suspect ECM and replacement ECM have AUG96 or later Personality Module Release Dates, the ECM parameters 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 existing ECM can communicate with Caterpillar Electronic Technician (ET).

3. Record ECM lifetime Totals. - Use the "3100 HEUI Lifetime Totals Worksheet" (in this section), to record the old ECM Lifetime Totals.

4. Replace the faulty ECM, temporarily connect the new one by connecting both ECM Connectors. Do not mount the ECM to the engine until the timing calibration has been performed.

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. Obtain Factory Passwords.

- Using the "3100 HEUI Factory Passwords Worksheet" (in this section), record the following information from the Engine Information Plate, Full Load Setting, Full Torque Setting, Engine Serial Number.

- Record the mileage from the vehicle odometer. Use ET to access "Read/Change 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 36.

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 should 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 "Read/Change System Configuration Parameters".

7. Program the new ECM.

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

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

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

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

- Use the Electronic Service Tool to access "Calibrate Sensors", and calibrate the Engine Speed/Timing Sensor (refer to procedure "PC-31: Engine Speed/Timing Circuit Test" on page 155).

8. Install the new ECM on the engine.

Programming a Personality Module Using Flash Programming

1. Connect components as shown below.

2. Start the WinFlash PC Program.

3. Ensure that the ignition key switch is ON and ensure that the engine is 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.

5. 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 On-Highway Truck 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 vehicle application.

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

- Meaning - The ECM is not for use in the 3100 HEUI On-Highway truck 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 3100 HEUI On-Highway truck 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 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 Flash Designer Program.

6. 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 powerup 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.

Factory Passwords Worksheet

Customer Parameter Worksheet

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 39. Include comments for the Customer's Complaint section of the report indicating if the Check Engine Lamp was ON continuously or intermittently,if symptomssuch as low power are present, indicate this.

Failure Cause

Comments on Failure Cause should include the number of diagnostic codes loggedand 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, and dynamometer testing showed power below specification @ 1700 rpm and above due to loss of cylinder 4 injector. Please be specific.

How Your 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.