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 the ECAP or ET to access “Read Customer Specified Parameters” from 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 the ECAP or 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, ECAP or ET serial number, Total Tattletale, and Reason Code.
– Leave the ECAP or ET on the Factory Specified Passwords screen and obtain the Factory Passwords. Fill out the “Factory Passwords Worksheet” on page 41.
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. These codes are Full Load Setting (FLS), Full Torque Setting (FTS), Vehicle Speed Calibration (ppm), Rating Number and Engine Serial Number.
– Use the ECAP or 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 the ECAP or ET to access “Read/Change Customer Specified Parameters”. Enter the Customer Specified Parameters and the original Customer Passwords recorded on the worksheet.
– Use the ECAP or 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 159).
8. Install the new ECM on the engine.