G3520B Industrial Engines Caterpillar

An Electronic Control Module (ECM) contains no moving parts. Replacement of an ECM can be a time consuming task. Before you replace an ECM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ECM will correct the problem.

When an ECM is replaced, the system configuration parameters must be programmed into the new ECM. The new ECM will allow specific parameters to be programmed once without the use of factory passwords. Parameters that require factory passwords on the ECM that is being replaced may require the use of factory passwords in order to configure these parameters on the new ECM.

Note: Factory passwords are only available to service technicians from an authorized Caterpillar Dealer. Customers of Caterpillar do not have access to the Caterpillar Factory Password System (FPS).

Note: Customer versions of Cat ET do not have the capability for flash programming. Contact your Caterpillar Dealership for assistance.

Note: Do not interchange the master ECM with the slave ECM in order to determine if an ECM is faulty. If replacement of both modules is necessary, replace the modules one at a time. Transfer the configuration data from one ECM into the Caterpillar Electronic Technician (ET). Replace the suspect ECM and transfer the configuration data from Cat ET into the new ECM. Repeat the process for the slave ECM. Failure to program each ECM correctly may result in improper engine operation.

Verify that the suspect ECM is the cause of the problem. Install a new ECM in place of the suspect ECM. Transfer the software from the suspect ECM to the new ECM. Program all the parameters for the new ECM in order to match the parameters of the suspect ECM. The parameters must match. Refer to the following test steps for details on programming the parameters.

If the new ECM resolves the problem, reconnect the suspect ECM. Verify that the problem recurs. If the problem recurs, replace the suspect ECM with the new ECM.

Note: If the parameters cannot be read from the suspect ECM, the parameters must be obtained from records or from the factory.

Perform the following procedure to replace the ECM.

1. Use the "Service/Copy Configuration/ECM Replacement" function of Cat ET.

   Save the file. Select "Load from ECM". You may also select the "Print" function in order to obtain a paper copy of the parameter settings.

   Note: Before replacement of the ECM, record all of the logged events.

   1. Connect Cat ET to the service tool connector. Select "Service/Copy Configuration/ECM Replacement" from the drop-down menu on Cat ET.

      Cat ET will load the configuration parameters and the monitoring system parameters of the suspect ECM.

   2. Select "Load from ECM" in the lower left corner of the Cat ET screen. Select the suspect ECM and select "OK".

      After the loading is complete, the Cat ET will display this message: "The data has been successfully loaded from the ECM". Select "OK".

   3. Select "File/Disconnect F8" from the drop-down menu.

Note: Do not terminate Cat ET.

2. Replace the ECM.

   1. Set the engine control switch to the OFF/RESET position.
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   Illustration 1	g01410578
   Terminal box for the master ECM (1) Ground strap (2) ECM connectors

   2. Remove the electrical power from the engine.

   3. Use a 4 mm allen wrench to disconnect the ECM connectors (2) .

   4. Remove the mounting nut in order to disconnect ground strap (1). Remove the three remaining mounting nuts.

   5. Remove the ECM from the terminal box.

Note: The rubber grommets that are used to mount the ECM are held in place by the mounting studs. The grommets help to reduce vibration. Ensure that the rubber grommets are intact before installing the new ECM.

3. Install the replacement ECM.

   1. Use the mounting hardware to install the new ECM. Install the ground strap for the ECM to the upper left mounting stud. Then install the other three mounting nuts.

      Check the mounting hardware and the ECM for correct installation. A correctly installed ECM will move slightly on the rubber grommets. If the ECM cannot move slightly on the grommets, check that the washers, spacers, and grommets are positioned correctly.

   2. Use a 4 mm allen wrench to connect the ECM connectors to the ECM. Tighten the screws to the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the proper torque value.

4. Program the configuration parameters and the monitoring system parameters into the replacement ECM.

   1. Restore the electrical power to the engine.

   2. Set the engine control switch to the STOP position.

   3. On Cat ET, select "File/Select ECM" from the drop-down menu.

   4. Select the appropriate ECM and click "OK".

   5. Select "Service/Copy Configuration/ECM Replacement" from the drop-down menu. Click "OK" on the window.

   6. Select "Program ECM" from the lower left corner of the screen. Select the appropriate ECM and click "OK". Confirm that the correct ECM is shown and select "Yes".

   7. After the loading is complete, a window with the message "Programming Conflict Warning" will appear. Select "OK".

   8. A window with the message "Program ECM Results" will appear. Select "OK".