Procedure to Use a Machine Electronic Control Module (ECM) for Machine Testing{7610} Caterpillar

Procedure to Use a Machine Electronic Control Module (ECM) for Machine Testing{7610}

Usage:

525C 525

Articulated Truck:: 725 (S/N: B1L1-UP; AFX1-UP); 730 (S/N: AGF1-UP; B1M1-UP); 730 EJECTOR (S/N: B1W1-UP); 735 (S/N: B1N1-UP; AWR1-UP); 740 (S/N: AXM1-UP; B1P1-UP); 740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)
Backhoe Loader:: 420E (S/N: HLS1-UP; KMW1-UP); 432E (S/N: BXE1-UP)
Excavator:: M313D (S/N: W3H1-UP); M315D (S/N: W5M1-UP); M318D (S/N: W8R1-UP)
Integrated Toolcarrier:: IT62H (S/N: M5G1-UP)
Motor Grader:: 120M (S/N: B9C1-UP); 12M (S/N: B9F1-UP; B9R1-UP); 140M (S/N: B9D1-UP; B9M1-UP); 14M (S/N: B9J1-UP); 16M (S/N: B9H1-UP)
On-Highway Transmission:: CX31 (S/N: B3X1-UP)
Off-Highway Truck/Tractor:: 773F (S/N: EED1-UP); 777F (S/N: JRP1-UP)
Quarry Truck:: 775F (S/N: DLS1-UP)
Petroleum Transmission:: TH48-E80 (S/N: FRT1-UP)
Pipelayer:: 572R Series II (S/N: DSC1-UP); 583T (S/N: CMX1-UP); 587T (S/N: FAT1-UP)
Compact Track Loader:: 279C (S/N: MBT1-UP); 279C2 (S/N: KWB1-UP); 289C (S/N: JMP1-UP); 289C2 (S/N: RTD1-UP); 299C (S/N: JSP1-UP); 299D (S/N: HCL1-UP); 299D XHP (S/N: NLC1-UP)
Multi Terrain Loader:: 287C (S/N: MAS1-UP); 277C (S/N: JWF1-UP); 277C2 (S/N: MET1-UP); 287C2 (S/N: SSB1-UP); 297C (S/N: GCP1-UP)
Skid Steer Loader:: 246C (S/N: JAY1-UP); 256C (S/N: DWS1-UP); 262C (S/N: MST1-UP); 262C2 (S/N: TMW1-UP); 272C (S/N: RED1-UP); 272D (S/N: GSL1-UP); 272D XHP (S/N: SHY1-UP)
Telehandler:: TH220B (S/N: SLA1-UP); TH330B (S/N: SLB1-UP); TH350B (S/N: SLD1-UP); TH360B (S/N: SLE1-UP); TH460B (S/N: SLF1-UP); TH560B (S/N: SLG1-UP); TH580B (S/N: SLH1-UP)
Track-Type Loader:: 953D (S/N: LBP1-UP); 963D (S/N: LCS1-UP)
Track-Type Tractor:: D10T (S/N: RJG1-UP); D11T (S/N: GEB1-UP; TPB1-UP); D3G (S/N: BYR1-UP); D4G (S/N: HYD1-UP); D4K (S/N: MMM1-UP); D5G (S/N: WGB1-UP; RKG1-UP); D6K (S/N: DHA1-UP; NCF1-UP; HMG1-UP; FBH1-UP); D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP); D6T (S/N: JHB1-UP; ZEB1-UP; SMC1-UP; JWD1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; LKJ1-UP; SNK1-UP; KJL1-UP; SKL1-UP; GCT1-UP; RLW1-UP; LAY1-UP; PEZ1-UP); D7R Series II (S/N: AEC1-UP; ABJ1-UP; AGN1-UP); D8T (S/N: J8B1-UP; KPZ1-UP); D9T (S/N: RJS1-UP)
Wheel Loader:: 924G (S/N: DDA1-UP; RBB1-UP; WMB1-UP); 924GZ (S/N: RTA1-UP); 928G (S/N: DJD1-UP; WLG1-UP); 930G (S/N: TWR1-UP; TFW1-UP); 930H (S/N: DHC1-UP); 938H (S/N: JKM1-UP); 950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP); 966H (S/N: A6D1-UP; A6G1-UP; A6J1-UP); 972H (S/N: A7D1-UP; A7G1-UP)
Wheel Skidder:: 525C (S/N: 5251-UP); 545C (S/N: 5451-UP)

Introduction

This Special Instruction will provide the detailed instruction for using an Electronic Control Module (ECM) for a machine test procedure.

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Safety Precautions

Before applying this machine test procedure, make sure that all work tools are lowered to the ground and that all control locks are activated. Read and follow the Operation and Maintenance Manual, "Safety Section" for the machine which is being serviced. This is especially important for this procedure, since the machine ECM may contain some configuration and calibration data from previous machine testing.

Purpose

This procedure describes how to use a machine ECM to assist in machine troubleshooting when an ECM is suspected of being faulty.

This machine test procedure is intended for use after all the appropriate troubleshooting steps have been performed.

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NOTICE

This procedure is not intended for use with Engine ECMs. Use of this procedure with engine ECMs may render the engine ECM unusable.

This procedure should only be used for the following ECM part numbers:

230-7490 Electronic Control Module
252-2422 Electronic Control Module
304-5687 Electronic Control Module
304-5691 Electronic Control Module
314-6935 Electronic Control Module
314-5453 Electronic Control Module
314-5455 Electronic Control Module
325-3316 Electronic Control Module
262-1408 Electronic Control Module

For assistance with troubleshooting machines containing ECM part numbers: 172-9389 Electronic Control Module or 161-2355 Electronic Control Module , reference Service Magazine, SEPD0741 and Service Magazine, SEPD0754 for more detailed information.

Make sure that the part number of the ECM, which will be used in the machine test procedure, is the correct service replacement.

Description

This procedure is to use a new or previously used and blanked ECM to determine if a machine malfunction is caused by the ECM. The definition of "blank ECM" in this document applies to an ECM with no flash file installed.

The ECM can be blanked by interrupting the flashing process on the machine or on a bench. The reason for blanking of an ECM is to remove software interlocks, which could prohibit an ECM from being flashed on the machine. Refer to "Blanking a machine ECM" steps described below.

A new or fully functional used ECM can be utilized for the machine test procedure. There is no need for any special flash file, "ECM test mode", or wash file. The only required conditions are: use a blanked or new ECM, follow the ECM replacement instructions, and run the appropriate calibrations. In addition, as always, all safety steps must be followed as described in the Operation and Maintenance Manual for the machine which is being serviced.

There may be an advantage to flash the ECM with proper flash file on a bench before the machine troubleshooting procedure is started. Flashing the ECM on a bench can avoid some potential machine or harness-related problems.

When an ECM is flashed on a bench, use bypass harness 317-2652 Control Harness As (ECM-specific adapter for Main Harness) and 217-0113 Wiring Harness . Refer to Tool News published on 11July 2008 for more detailed information.

Limitations when Using a Machine ECM for Machine Testing

The ECM, which will be used for the machine test procedure, should not have previously installed premium software features. Because, an ECM with installed premium software features can only be flashed with a flash file containing equivalent premium software. Therefore, using such an ECM for the machine test procedure is not recommended.

When attempting to flash over an ECM with software that does not support equivalent premium features, the following pop-up from the WinFlash will indicate that the ECM cannot be flashed.

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Illustration 1	g02374696

Machine Configuration Data

When the ECM is being used for the machine test procedure, it is critical to follow the ECM replacement procedure and restore the correct machine configuration data for the machine that is being serviced. That includes capturing the ECM replacement file before removing the suspect ECM from the machine.

This step is important because the ECM used for the machine test procedure can contain some old configuration data leftover from a previously tested machine.

Depending on the machine application, the leftover configuration data may or may not be removed from the ECM by interrupting flashing and installing a new flash file. Therefore, restore the current machine configuration data properly to the ECM used for the machine test procedure. ECMs with incorrect configuration data may cause features not to work correctly or may cause false diagnostic codes and may complicate machine troubleshooting procedures.

Machine Calibrations

In the machine test procedure, calibrate all operator controls after the ECM is installed on the machine and before the engine is started. Calibration must be done regardless of diagnostic calibration code indication. This step is important, because the ECM may contain some old calibration data leftover from a previously tested machine. Depending on machine application, the calibration data may or may not be removed from the ECM by interrupting flashing and installing a new flash file. Failure to follow this step may cause some unintentional machine response.

After all operator controls have been calibrated, complete all system calibrations as required for the machine ECM that is being serviced.

Check for active diagnostic and events codes and clear all logged diagnostic and events codes before continuing with the machine test procedure.

Blanking the Machine ECM

The fundamental requirement for reusing the ECM for the machine test procedure is to blank the ECM (remove previously installed flash file) before installing the ECM on a machine. Moreover, if a specific ECM will be used in the machine test procedure in the future, blank that ECM before you remove the ECM from the machine. The ECM can be also blanked on the bench.

As it was mentioned before, installing a non-blanked ECM on a machine may create some problems with software interlocks, which consequently may prohibit this ECM from being flashed on the machine.

In order to blank an ECM, first the ECM flashing process must be started. Refer to Caterpillar Electronic Technician (ET) help screens "Programming the New ECM". For this purpose, previously installed flash file or newer replacement can be used. After flashing begins and the progress bar on the WinFlash screen moves above 5%, the flashing can be interrupted by selecting the "Cancel" button from the WinFlash screen. When that action is performed, the flashing will stop and the ECM will become blanked.

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