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The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
The Electronic Control Module (ECM) contains no moving parts. Replacement of the ECM can be costly. Replacement can also be a time consuming task. Follow the troubleshooting procedures in this manual in order to be sure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem.
Note: Ensure that the ECM is receiving power and that the ECM is properly wired to the negative battery circuit before a replacement of the ECM is attempted. Refer to Troubleshooting, "Electrical Power Supply Circuit - Test".
A test ECM can be used to determine if the ECM is faulty. Install a test ECM in place of the suspect ECM. Flash program the correct personality module (flash file) into the test ECM. Program the parameters for normal operation. The parameters must match the parameters in the suspect ECM. Refer to the following test steps for details. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem returns. Replace the ECM only if the test ECM resolves the problem and the problem returns with the suspect ECM.
Note: When a new ECM is not available, you may need to remove an ECM from an engine that is not in service. The interlock code for the replacement ECM must match the interlock code for the suspect ECM. Be sure to record the parameters from the replacement ECM on the "Parameters Worksheet". Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on the Caterpillar Electronic Technician (ET).
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If the personality module and engine application are not matched, engine damage may result. |
Perform the following procedure in order to replace the ECM:
- Record the configuration data:
- Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
- Print the parameters from the "Configuration" screen on Cat ET. If a printer is unavailable, record all of the parameters. Record any logged diagnostic codes and logged event codes for your records.
- Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on Cat ET. Select "Load from ECM" in order to copy the configuration data from the suspect ECM.
Note: If the "Copy Configuration" process fails and the parameters were not obtained in Step 1.b, the parameters must be obtained elsewhere. Some of the parameters are stamped on the engine information plate. Most of the parameters must be obtained from the factory.
- Remove the ECM:
- Turn off the electrical power from the ECM.
- Disconnect the P1 and P2 connectors from the ECM.
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NOTICE Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
Show/hide tableNOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
- Remove the fuel lines (if equipped) from the ECM.
- Disconnect the ECM ground strap.
- Remove the mounting bolts from the ECM.
- Install the replacement ECM:
- Use the old mounting hardware to install the replacement ECM.
- Connect the fuel lines (if equipped).
- Verify that the fuel lines are installed correctly. The fuel lines must not put tension on the ECM. Rubber grommets are used to protect the ECM from excessive vibration. The ECM should move slightly in the rubber grommets. If the ECM cannot be moved slightly, check that the fuel lines are not pulling the ECM against one side of the grommets.
- Connect the ECM ground strap.
- Connect the P1 and P2 connectors. Tighten the allen head screws on each ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
- Configure the replacement ECM:
- Turn on the electrical power to the ECM.
- Flash program the personality module into the ECM. Refer to Troubleshooting, "Flash Programming" for the correct procedure.
- Use Cat ET to match the engine application and the interlock code if the replacement ECM was used for a different application.
- If the "Copy Configuration" process from Step 1.b was successful, return to the "Copy Configuration/ECM Replacement" screen on Cat ET and select "Program ECM". Proceed to Step 4.f when programming is complete.
- If the "Copy Configuration" process from Step 1.b was unsuccessful, manually program the ECM parameters. The parameters must match the parameters from Step 1.b.
- Program the engine monitoring system, if necessary.
- Calibrate the timing. Refer to Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".