This article introduces how Replacing the Caterpillar Truck EngineECM withou the Use of the ECM Replacement Feature
1. Ensure that the ECM is the problem by first connecting a test ECM. This is a temporary connection. Hang the test ECM on the side of the engine. Flash program the identical personality module that was used in the suspect ECM into the test ECM. Program any parameters that are necessary to use the ÉCM for the test. For example, vehicle speed parameters need to be programmed to check the vehicle speed circuit.
Program the parameters in the test ECM to be equal to the parameters in the suspect ECM.
2. If the test ECM repairs the problem, reconnect the suspect ECM. Verify that the problem returns when the suspect ECM is reconnected.
3. Obtain customer parameters from the failed ECM.
a. Obtain the customer passwords and record the customer passwords. If the customer
(owner) has lost the passwords or if the customer (owner) has forgotten thepasswords, proceed to Troubleshooting,"Customer Passwords"for more details.
b. Access the "Configuration"screen on Cat ET and record the customer parameters from the ECM that is being replaced. If the ECM does not communicate with Cat ET, obtain the required parameter list from the OEM.
c. Use the Troubleshooting, "Customer Specified Parameters Worksheet"to record the customer parameters.
d. Record the injector codes. The injector codes can be found in the "Injector Codes Calibration"in "Calibrations"under the "Service"menu on Cat ET. Refer to Troubleshooting, "Injector Code -Calibrate"
for more information.
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4. Record ECM lifetime totals.
a. Use the Troubleshooting, "Customer Specified Parameters Worksheet (Current Totals Worksheet)"in order 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 thenew ECM if the personality module is not already installed. The new ECM is shipped with a blank personality module.
7. Obtain factory passwords when the passwords are required.
specified parameters are entered. If customer parameters are entered before the system configuration parameters, the Total Tattletale willchange. It will then be necessary to obtain another set of factory passwords in order to change system configuration parameters.
Note: The following parameters can be programmed on a new ECM without factory passwords: "Full Load Setting (FLS)", "Full Torque Setting (FTS)", and "Engine Serial Number". Šystem configuration parameters must be entered before the customer
8. Perform the following operations.
a. Use the Troubleshooting, "Factory PasswordsWorksheet"to record the following information from the engine information plate: "Full Load Setting (FLS)", "Full Torque Setting (FTS)", and "Engine Serial Number".
b. Record the mileage from the vehicle odometer. Access the "Configuration"screenon Cat ET. When the screen for the "Factory Passwords"appears, record the following information: "ÉCM Serial Number", "Engine Serial Number", "ET Serial Number", "Total Tattletale", and "Reason Code".
c. Leave Cat ET on the screen for the "Factory Passwords"and obtain the factory passwords.
Complete the Troubleshooting, "Factory Passwords Worksheet".
9. Program the new ECM.
Note: On initial powerup of a new ECM, the following parameters must be programmed to avoid activating 253-02 Check Customer Or System Parameters: "Full Load Setting (FLS)", "Full Torque Setting (FTS)", "Vehicle Speed Calibration"(ppm),
"Rating Number", "Engine Serial Number", and
"Injector Codes Calibration".
a. Access the "Configuration"screen on CatET. Enter the following parameters that are recorded on the worksheet: "Full Load Setting
(FLS)", "Full Torque Setting (FTS)", and
"Engine Serial Number".
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b. Enter the customer specified parameters and the original customer passwords that are recorded on the worksheet.
c. Use Cat ET to access current totals from the
"Read/Change Current Totals"main menu.
Record the information on the Troubleshooting,
"Factory Passwords Worksheet"in order to obtain the factory passwords. Enter the totals from the original ECM that are recorded on the worksheet.
d. Program the injector codes on Cat ET. Select the following screens in order: "Service",
"Calibrations", "Injector Codes Calibration".
Refer to Troubleshooting, "Injector Code-
Calibrate"for more information.
e. Select the following screens in order to calibrate the engine timing: "Service",
"Calibrations", and "Timing Calibration".
Calibrate the timing. Refer to Troubleshooting,
"Engine Speed/Timing Sensor -Calibrate"for the proper procedure.
10. Install the new ECM on the engine.
