Using the Digital Diagnostic Tool (DDT) NEXG4511 Industrial Engine Service Program Module{0781, 0782} Caterpillar

Using the Digital Diagnostic Tool (DDT) NEXG4511 Industrial Engine Service Program Module{0781, 0782}

Usage:

Service Program Module NEXG4528

Introduction

This Tool Operating Manual describes the available features of the Service Program Module (SPM) when placed in the Digital Diagnostic Tool (DDT).

The features of the SPM may include more than one application (i.e. Electronic Control Module and Timing Control).

For each application a detailed menu chart is given in this manual to assist in using the DDT.

For each specific operation in an application a detailed description is given for how to perform the operation on the DDT.

In the event a problem occurs during a specific operation, a trouble-shooting guide is available in this manual.

Also provided in this manual are procedures for connecting the DDT to the application to be serviced, procedure for replacing the SPM in the DDT, and a complete description of the DDT.

DDT Glossary

DDT: Digital Diagnostic Tool
ECM: Electronic Control Module
EPROM: Erasable Programmable Read Only Memory
FUNC: Function
LCD: Liquid Crystal Display
RAM: Random Access Memory
ROM: Read Only Memory
SPM: Service Program Module

NEXG4528 Contents

1. NEXG4528 Service Program Module

2. NEHS1757 Operating Manual

(Not shown) NEEG2300 Case Lid Label

(Not shown) NEEG2850 DDT Black Label

NOTE: NEEG forms may not be included in automatic updates of NEXG4528.

Disclaimer

The features of this SPM may or may not be functional on some applications.

This may be due to manufacturing design changes.

All information, illustrations, and specifications in this manual are based on current information at the time of printing.

The right is reserved to make changes at any time without notice.

Service Program Module Installation

NOTE: Service Program Module updates for the DDT will be available through Caterpillar.

The Service Program Modules are packaged in a protective container. Use care when opening to prevent damage to the program module.

1. Place DDT (1) face down on a clean and level surface.

2. Remove six screws (2) holding cover (3) in place and remove cover for access to DDT circuit board (4).

3. Locate Service Program Module socket (5) on circuit board (4).

Show/hide table

NOTICE

Use only finger pressure to remove or install a Service Program Module.

The use of any mechanical tool can damage the Service Program Module or socket.

4. Install Service Program Module (6) from Conversion Group into empty socket (5).

NOTE: The Service Program Modules and sockets are keyed so that they can only be installed in the correct (seated) position.

5. Reinstall cover panel (3) using six screws (2).

Decal Installation

1. Place the 6V3072 carrying case (1) on a clean surface with the handle toward you as shown.

2. Remove paper backing of the case decal (2) and install on case lid insert with bottom of decal facing handle side of case.

1. Place DDT (1) face down on a clean and level surface.

2. Remove paper backing of the DDT Back Graphic Decal (2) and install on DDT back cover.

Power and Data Link Connector

1. Locate data link connector on Electronic Control Module (ECM) wiring harness.

2. Connect 7X1685 Cable to DDT connector.

3. Connect the remaining end of 7X1685 Cable (1) to Control Port (2) on the DDT (3).

NOTE: For CSA environments a 7X1414 adapter cable is needed to connect to a 10 pin MS connector or a 7X1415 adapter cable is needed to connect to a 4 pin MS connector.

The DDT will turn ON when power is supplied to the electronic control module.

DDT Description

1. LCD is the window which all screens are displayed

2. CONTROL port communicates with the Electronic Control Module (ECM) through the 7X1685 Cable Assembly

3. CLEAR Pressing the CLEAR key will:

* Clear the ECM NOT FOUND display.

* Place 01 in front of the MODE/FUNCTION identifier.

* Reread data that displays as Unavailable.

* Clear the FAULT = display.

* Abort the Crankcase Pressure Calibration if feature found on ECM.

4. Select Mode Pressing the Select Mode key will scroll to the next available Mode each time the key is pressed

5. SELECT FUNC Pressing the SELECT FUNC key will scroll to the next available Function each time the key is pressed

6. ENTER Pressing the ENTER key will:

* Scroll to the next available diagnostic code (01 is shown as the mode on the display).

* Go directly to the Mode or Function whose unique 2-digit number is shown on the display.

7. ALT1 Pressing the ALT1 Key will:

* Will put the displayed Function into its programming mode if the Function is a programmable Function.

* Will put the displayed Function into its calibration mode if the Function is a calibrating Function.

8. ALT2 Pressing the ALT2 key will alternate between displaying the main screen and alternate screen if an alternate screen is available for the displayed Mode or Function.

Trouble Shooting the DDT

LCD display is blank

* Disconnect and reconnect the 7X1685 cable or

* Replace 7X1685 cable or

* Service is required

LCD display top line is black and bottom line is blank

* Disconnect and reconnect the 7X1685 cable or

* Pull out and reinsert the Service Program Module or

* Service is required

LCD display bottom line shows 'NO CODES'

* Normal, no diagnostic faults have been received

LCD display top line shows 'INVALID CODE'

* Enter a valid unique 2 digit menu or function number

LCD display does not change when the 0 key is pressed while entering a change to a parameter

* Only one leading zero is allowed while entering a parameter

LCD display does not change when the (0-9) is pressed while entering a change to a parameter

* The maximum allowable characters have been entered for the parameter

Specifications

Read Only Storage: 16384 bytes of Read Only Memory (ROM)

Operating Temperature: 0°C (32°F) to 70°C (158°F)

Storage Temperature: -10°C (14°F) to 70°C (158°F)

Service

Use the following list to direct troubleshooting questions or information on service and warranty.

Phone - Toll Free Numbers

Outside Illinois 1-800-542-8665

Inside Illinois 1-800-541-8665

Canada 1-800-523-8665

U.S. Mail

Caterpillar Service Technology Group
600 W. Washington Street, LD-180
East Peoria, IL 61630

Telex

Number 404435

Attn: Caterpillar Service Technology Group

Unit less than one year old will be repaired under warranty (except for abuse). The cost of out-of-warranty repairs will be charged to the owner. Contact Caterpillar Service Technology Group for details.

Servicing the 3500 Spark Ignited Timing Control (Slave Configuration)

Introduction

This Service Program Module (SPM) will allow a Timing Control configured to operate with an engine control (Slave Operation) to be reconfigured to operate independently (Standalone Operation) without an engine control present. The following service information is displayed with the SPM installed in the Digital Diagnostic Tool (DDT):

Diagnostic Codes

*01 No Speed Sensor Signal (Open)

*02 No Speed Sensor Signal (Short)

*03 No Crank Angle Sensor Signal (Open)

*04 No Crank Angle Sensor Signal (Short)

*05 No Magneto Interface Signal

*06 No Right Detonation Sensor Signal

*07 No Left Detonation Sensor Signal

*08 Magneto Out Of Calibration

*09 Detonation Engine Shut Down

The rest of this chapter is devoted to instructing the service person on how to display the service information.

Mode/Function Chart

Glossary

DDT: Digital Diagnostic Tool
DIAG: Diagnostic
FUNC: Function
LCD: Liquid Crystal Display
SI: Spark Ignited
SPM: Service Program Module
TC: Timing Control

Menu Code Translation Chart

How To Directly Access The Software Version Screen (Mode 00)

Fig 1.1

* Press Select Mode key

* Press 0 key

* Press ENTER key

The Software Version screen (Fig 1.1) is displayed.

How To View The Service Configuration Screen (Mode 00)

Fig 1.2

* Press Select Mode key

* Press 0 key

* Press ENTER key

* Press ALT1 key

The Service Configuration screen (Fig 1.2) is displayed.

How To Directly Access The Diagnostic Codes Screen (Mode 01)

Fig 1.3

* Press Select Mode key

* Press 0 key

* Press 1 key

* Press ENTER key

The TC Diagnostic Code screen (Fig 1.3) is displayed.

If there are more than 5 diagnostic codes active, then the diagnostic codes are shown on 2 screens. The first diagnostic code screen will display the first set of 5 diagnostic codes. A '+' will appear after the fifth diagnostic code to indicate that there are more diagnostic codes available to view on the second diagnostic code screen. While a '+' follows the fifth diagnostic code, pressing the ENTER key will switch the display to the second diagnostic code screen. A '-' will appear before the first diagnostic code indicating that there are more diagnostic codes available to view on the first diagnostic code screen. Each time the ENTER key is pressed, the display will switch between the first and the second diagnostic code screen.

The 01< must show on the display when pressing the ENTER key to switch diagnostic code screens. If another number other than 01< is displayed, pressing the ENTER key will cause the program to jump directly to the Mode or Function that the number identifies.

How To Directly Access The Standalone Configuration Screen (Mode 02)

Fig 1.4

* Press Select Mode key

* Press 0 key

* Press 2 key

* Press ENTER key

The Standalone Configuration screen (Fig 1.4) is displayed. Press the ENTER key to reconfigure the Timing Control to standalone operation.

Servicing the 3500 Spark Ignited Timing Control (Standalone Configuration)

Introduction

This Service Program Module (SPM) will service the 3500 Spark Ignited (SI) Timing Control. The following service information is displayed with the SPM installed in the Digital Diagnostic Tool (DDT):