Using The ECAP NEXG4516 Marine/Industrial Engine Functions Service Program Module{0701, 0782} Caterpillar

Introduction

The NEXG4516 Marine/Industrial Engine Functions Dual Service Program Module (SPM) is a service program module for use with the Electronic Control Analyzer Programmer (ECAP). Before this chip set will function, the internal Expansion Board must be installed, and the new Slave SPM must be located in socket U4 of this Expansion Board.

Once installation is complete, this chip set provides service functions for several Caterpillar electronic engine applications including Marine, Oil Well Service, Electric Power Generation, Locomotive, and various Industrial applications.

Reference: Special Instruction SEHS8742, Using the 8C9700 Rechargeable Portable Printer

Special Instruction SEHS8742, Using the 8T8697 Electronic Control Analyzer Programmer (ECAP)

Special Instruction SEHS8833, Installing the 7X1180 Internal Expansion Board in the 8T8697 ECAP Service Tool

Special Instruction SEHS8889, Installing the 8C9995 Mounting Plate Adapter Group on the ECAP

Special Instruction SEHS8746, Using the 9U5219 Tool Group

SENR4646, Electronic Troubleshooting 3412 Industrial Engine

SENR5522, Electronic Troubleshooting 3408 & 3412 High Performance Marine Engine

NEXG4516 Contents

(1) NEXG4516 Marine/Industrial Master Service Program Module, (2) NEXG4516 Marine/Industrial Slave Service Program Module, and (3) Tool Operating Manual SEHS9199. Not Shown NEEG2490 Pocket Card.

NOTE: The NEEG forms may not be included in automatic updates of NEXG4516.

Acronyms/Abbreviations

ASCII ... American Standard Code for Information ... Interchange

Avg ... Average

Batt ... Battery

CSP ... Customer Specified Parameter

CYL ... Cylinder

Deg C ... Degree Centigrade

Deg F ... Degree Fahrenheit

Eng ... Engine

ECM ... Electronic Control Module

EPROM ... Erasable Programmable Read Only Memory

EUI ... Electronic Unit Injector

Fwrd ... Forward

FRC ... Fuel Ratio Control

G ... Gallon

Gal ... Gallon

GPH ... Gallon per Hour

HP ... Horsepower

Hr ... Hour

Hz ... Cycles per Second

ID ... Identification

kPa ... Kilopascal

l ... Liter

l/h ... Liter per Hour

LB FT ... Pounds Foot

LCD ... Liquid Crystal Display

Lim ... Limit

Max ... Maximum

Min ... Minimum or Minute

mm ... Millimeter

Nm ... Newton-Meter

NUM ... Number

Occur ... Occurrence

OWS ... Oil Well Service

Pos ... Position

Eng ... Engine

PPR ... Pulses per Revolution

Pr ... Pressure

PSI ... Pounds Per Square Inch

PW ... Pulse Width

PWM ... Pulse Width Modulated

Qts ... Quarts

RAM ... Random Access Memory

ROM ... Read Only Memory

RPM ... Revolutions Per Minute

Sec ... Seconds

SPC ... Specification (Performance Specification)

S/N ... Serial Number

Spd ... Speed

SPM ... Service Program Module

Sw ... Switch

TEL ... Top Engine RPM Limit

Temp ... Temperature

V ... Volt

Volt ... Voltage

% ... Percent

Specifications

Dual Service Program Module Version: 1.5

NOTE: To check the Service Program Module Version, Release Date, and Literature Form Number, press SHIFT-HELP after moving cursor to Marine/Industrial Engine Functions in the Main Menu.

Refer to Available Parameters in this manual for a detailed list of available Read, Read and Change, and Status Parameters.

Features

* Read and Change Parameters stored in the ECM

* Display Status of the System

* Display Diagnostic Message information sent from the ECM

* Calibrate the Rack Sensor and Boost sensor

For 3176B/3406E Only:

* Calibrate the Engine Fuel Injection Timing and Boost Sensor

* Perform Interactive Diagnosis of injectors by selectively powering or cutting out individual cylinders

* Display Maintenance Status

* Display trip management information stored in the ECM

Changes/Additions

The Marine/Industrial Engine Functions Dual Service Program Module (SPM) is a package of two SPMs called Marine/Industrial Master and Marine/Industrial Slave that now services 3400 and 3176B Marine, the 3400, 3500, and 3600 Industrial, and the 3176B/3406E Industrial engines.

The internal Expansion Board is now required for the new Slave SPM which is located in socket U4 of this Expansion Board.

For 3176B/3406E Only:

New Customer Specified Parameters:

* Trans Oil Temp/Pres Enable

* Vehicle Speed Calibration

* Cruise/Idle/PTO Switch Configuration

* SoftCruise Control

* Top Engine Limit with Droop

* Idle/PTO Vehicle Speed Limit

* Idle RPM Limit

* Idle/PTO RPM Ramp Rate

New Status Parameters & Change Screens

* Vehicle Speed

* Clutch, Brake, Cruise/Idle, & Set/Resume Switches

* Cruise & Idle Set Speeds

* Cruise & Idle Kickout

* A/C Fan and Fan

Read/Change Injector Codes

Service Program Module Installation

Service programs for use with the Electronic Control Analyzer Programmer (ECAP) are provided through Caterpillar Dealers.

The ECAP is delivered with utility programs to select Metric or English display units and basic communication routines.

The NEXG4516 Marine/Industrial Engine Functions Service Program includes both a Master and a Slave chip.

1. Remove eight screws (1) holding cover panel (2) and lift out of case (3).

2. Turn cover panel (2) over for access to the program module sockets on component side (4) of the cover panel (2).

3. Remove ALL NEXG4516 Marine/Industrial Functions SPMs.

To remove a program module from a socket, grip it firmly by tabs (5) and lift it out with a slight rocking motion.

4. If the internal expansion board is not being used, install the 7X1180 Internal Expansion Board using the Special Instruction SEHS8833, Installing the 7X1180 Internal Expansion Board in the 8T8697 ECAP Service Tool.

5. Move any SPM in expansion board socket U4 to another empty socket(6).

NOTE: The program modules and sockets are keyed so that they can only be inserted in the correct (seated) position.

6. Install NEXG4516 Marine/Industrial Slave SPM (7) into the Expansion Board socket U4.

7. Install the NEXG4516 Marine/Industrial Master SPM into any empty socket.

8. Reinstall cover panel (2) into case (3) using eight screws (1).

Power And RS-485 Connector

NOTE: Make sure that the engine is STOPPED before performing this procedure.

1. Disconnect the data link connector (1) from wiring harness (2).

2. Connect an 8T5275 cable (3) for an 8T8697 ECAP (or a 7X1412 cable for an 8T8697-A ECAP) between connectors (1) and (2).

3. Connect the other end of the 8T5275(7X1412) Cable (4) to Port #1 on the 8T8697(8T8697-A) ECAP (5).

RS-232C Printer Connector

The ECAP Port #2 can be used to connect a serial interface printer. For Help, refer to SEHS8740, Using the 8C9700 Rechargeable Portable Printer.

The printer interface provides XON/XOFF software handshaking (communication) between the printer and the ECAP.

An ECAP menu item is provided to print a parameter listing, or the F6 key can be used to print a copy of an ECAP screen display. Refer to SEHS8742 for the RS232C Connector Pin definitions, and if necessary, for the procedure to change the ECAP port #2 default settings shown here.

Baud rate ... 1200

Parity ... none

Data bits ... 8

Stop bits ... 1

Using The NEXG4516 Marine/Industrial Engine Functions Service Program

The Marine/Industrial Engine Service Program provides an easy to use method for reading, changing, and displaying parameters in the ECM.

NOTE: Refer to SEHS8742 to become familiar with using the ECAP.

All of the functions related to servicing the ECM are accessed through a series of menu, display, or update routines.

NOTE: Refer to the Industrial Engine, the 3400 Marine Engine, the 3176B Marine Engine, or the 3176B/3406E Industrial Engine Screen Maps, in this manual, for detailed ECAP screens. These maps show how to review and/or access a specified function.

Main Menu

When power is applied to the ECAP an identifying title screen will be displayed, followed by the Main Menu listing the major functions provided by the service program modules installed.

One menu choice will be the Marine/Industrial Engine Functions Service Program.

Select it using the UP arrow key, DOWN arrow key, or item number followed by the RETURN key. For Help, see Selecting Menu Options, in this manual.

NOTE: If the Main Menu does not appear, refer to SEHS8742 for troubleshooting procedures.

If the Main Menu appears but the Marine/Industrial Engine Functions Service Program is not displayed, refer to Service Program Module Installation, in this manual.

Marine/Industrial Functions Menu

This menu provides access to all ECM functions.

NOTE: Options 6 and 7 will appear only when connected to a 3176B or 3406E ECM.

1 Read/Change Parameters: Functions to read and/or change parameters that are stored in the ECM.

2 Display Status: Functions to display the status of the system.

3 Display Diagnostic Messages: Functions to display fault and event messages from the ECM.

4 Calibrate/Monitor Sensors: Functions to calibrate sensors used by the ECM.

5 Interactive Diagnostics: Function to initiate several ECM tests.

6 Display Maintenance Status: Function to display the status of the maintenance indicator.

7 Trip Data: Function to access trip information stored in the ECM.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Read/Change Parameters Menu

This menu provides access to parameters in the ECM.

1 Read Customer Specified Parameters: Functions to read customer specified parameters in the ECM.

2 Read/Change Customer Specified Parameters: Functions to read and/or change customer specified parameters that are stored in the ECM.

NOTE: Access to this set of functions may be protected by customer passwords.

3 Read/Change System Configuration Parameters: Functions to read and/or change system configuration parameters that are stored in the ECM.

4 Print all Parameters: Function to print a formatted list of all parameters.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

NOTE: Read/Change Maintenance Parameters, which was here in previous ECAP versions is now handled within Read/Change Customer Specified Parameters.

Read Customer Specified Parameters

This function displays the entire list of customer specified parameters, and their values grouped according to function.

Changeable parameters have a tattletale number following the parameter value on a line, shown preceded by a #. The tattletale indicates how many times that parameter has been changed.

The LCD can only display six lines from the list at one time.

To view more data, use the UP arrow and DOWN arrow keys to move through the list. For Help, see Scrolling list without Cursor, in this manual.

Because this list can be rather long, it can be moved through faster by using the LEFT arrow key to move backwards by group (i.e. Selected Egine Ratings, ECM Identification Parameters, etc.) and by using the RIGHT arrow key to move forward by group.

Read/Change Customer Specified Parameters

The engine/vehicle owner uses customer Specified Parameters to set up each engine for its most efficient use.

To prevent unauthorized access to these parameters, Customer Passwords can be programmed by the owner. To protect the Customer Specified Parameters, two passwords up to eight characters each can be programmed into the ECM. To program Customer Passwords, see Entering Customer Passwords, in this manual.

If Customer Passwords have been programmed, they must be obtained from the engine owner and be entered at the password prompt. For Help, see Entering Customer Passwords, in this manual.

If no passwords have been programmed, customer password entry is skipped.

Either way, the user will be asked to wait while parameter data is loaded. Then a screen just like that shown for Read Customer Specified Parameters will be displayed. Again, the current value for each parameter is shown along with the tattletale number. This number indicates how many times the parameter has been changed.

To move through the list individually, use the UP or DOWN arrow keys.

To move through the list by group, use the RIGHT or LEFT arrow keys.

Highlighted instructions will appear at the bottom of the screen as the cursor is moved over each parameter value.

To enter a numeric value, type the new value and press RETURN. To change a choice value, press SPACE until the desired value appears, then press RETURN. For Help, please see Entering Data Values or Selecting Data Values, in this manual.

To insure against accidental programming of parameters in the ECM, the changes must be confirmed. For Help, please see Confirming Changes, in thie manual.

This is how most of the parameters may be changed. There are a few exceptions. Most of the parameters in ECM Identification Parameters and Security Access Parameters either cannot be changed or require Factory Passwords, and must be changed in Read/Change System Configuration Parameters.

Two other groupings, Select Engine Rating and Passwords must be changed in another screen. To enter these screens, move the cursor to the line that reads "Press RETURN to change". Then press RETURN and you will be taken to one of the screens described below. When changes are completed and saved, press PREVIOUS SCREEN to return to the Customer Specified Parameters list.

Engine Power Rating Selection

Use this function to select the engine power rating map code.

NOTE: This function cannot be accessed and the Engine power rating CANNOT be changed while the engine is RUNNING.

The current rating map code and the parameters affected by the rating are shown along with a tattletale number which indicates how many times the rating map has been changed.

Available power rating parameters can be reviewed to determine the proper choice before changing the rating code used by the ECM. To view a specific rating map code and its parameters, enter the code number and press RETURN.

When viewing a different rating code than the one stored in the ECM, an additional message is displayed, describing the displayed rating map code plus the one still stored in the ECM.

To change the rating map code stored in the ECM to the currently displayed map, move the cursor to the 'Change Rating number' message by pressing the UP arrow key once. This message will now be shown in reverse screen characters.

Complete the rating change by pressing RETURN.

To prevent accidental programming of parameters in the ECM, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

Because changes in engine ratings may affect the operation of other systems, such as the transmission, radiator, etc., a message to check the rating for compatibility with those other systems is displayed.

This is only a WARNING message and does NOT indicate any error, and after being displayed for 10 seconds, the message may be cleared by pressing any key. The rating selection display will be restored at this time.

NOTE: Whenever a rating is changed, the Top Engine Limit is automatically changed to the maximum RPM value for that rating.

Read/Change Customer Passwords

This function is used to read and change the customer passwords.

Each parameter is shown along with the tattletale number. This number indicates how many times it has been changed.

To change one of the parameter values, move to the parameter by pressing the UP or DOWN arrow keys, then enter a new value. For Help, see Moving Cursor between Items, and Entering Data Values or Toggling Data Values, in this manual.

To prevent accidental programming of ECM parameters, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

Example:

To change the second password from ARE BEST to RUNGREAT, move to that parameter by pressing the DOWN arrow key once. Change the value by pressing the R, U, N, G, R, E, A, and T keys. Complete the entry by pressing RETURN.

To prevent accidental programming of this parameter, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

System Configuration Parameters Menu

This menu provides a way to read and change System Configuration parameters stored in the ECM.

1 - Read Customer Passwords: Function to read the customer's passwords.

NOTE: Access to this function is protected by factory specified passwords.

2 - Read/Change System Configuration Parameters: Function to read and change System Configuration parameters.

NOTE: Access to this function is protected by factory specified passwords.

NOTE: Read System Configuration Parameters, which was here on earlier ECAP versions, has been removed since all of these parameters can now be read on the Read or Read/Change Customer Specified Parameters menus or on the Read/Change System Configuration Parameters menu.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Read Customer Passwords

If the Customer Passwords from an ECM are lost or forgotten, they can be read using this function.

To protect the Customer Passwords from unauthorized access, factory specified passwords must first be entered. For Help, see Entering Factory Passwords, in this manual.

Once factory specified passwords have been correctly entered, this function is used to read the customer passwords.

This ability is provided for cases where the customer's passwords are forgotten or are otherwise not available.

Customer passwords can only be read using this function. To change them, use the function Read/Change Customer Passwords in the Read/Change Customer Specified Parameters Menu, in this manual.

Read/Change System Configuration Parameters

This function provides a way to read and change parameters associated with ECM configuration. This function cannot be accessed, and the System Configuration Parameters CANNOT be changed while the engine is RUNNING.

System Configuration Parameters are values which are not changed for normal operation, and should not be changed except when an ECM is replaced or when an engine is re-rated to another horsepower family.

The current value for the parameters is shown along with the tattletale number, which indicates how many times the parameter has been changed.

To change one of the parameter values, move to the parameter by pressing the UP or DOWN arrow keys, then enter a new value. For Help, see Moving Cursor between Items, and Entering Data Values, in this manual.

To prevent accidental programming of ECM parameters, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

If factory passwords are required for the requested change, the password prompt will automatically appear. No changes will actually be saved in the ECM until both factory passwords are entered correctly. For Help, see Entering Factory Passwords, in this manual.

Once the correct passwords have been entered, other items with the same reason number can be changed without re-entering passwords until the Read/Change System Configuration Parameters function is exited.

Also, to facilitate ECM replacement, Full Load Setting, Full Torque Setting, and Engine Serial Number can be programmed once without entering factory passwords. If passwords are required, the entry screen will automatically appear.

Print All Parameters

This function is used to print customer specified and ECM system configuration parameters.

The parameters are printed in a format similar to the Read Parameter List functions, in this manual. Printing may be stopped at any time by pressing any key on the keyboard.

Follow the steps shown in RS-232C Printer Connector, in this manual, to connect a printer to the ECAP.

NOTE: To print a currently displayed screen, press the F6 key.

Display Status

This function displays various ECM parameter status.

For 3176B Marine Engines:

For 3176B/3406E Industrial Engines:

For All Other Engines:

All applications have six parameter screens. If a screen is not shown above, then the default for those screens are blank and may be programmed to any setup desired.

Parameters are continuously updated and are displayed in a format called a screen. Each parameter has a text description over a value. For convenience, the screens are predefined displaying all available status parameters.

To view parameters on different screens, enter the screen number using the numeric keys or use the Up and Down arrow keys to increment and decrement the screen number by one.

At the top of the screen on both sides, are two special status areas. Messages will appear in reverse screen characters on the left side for ENGINE SHUTDOWN, TOP ENGINE RPM LIMIT, or COLD MODE conditions. Messages will appear in reverse screen characters on the right side for a LOW OIL PRESSURE condition.

Example:

To view Screen 2, press the DOWN arrow once or enter 2.

Change Display Layout

To change the default display layout, press the 'C' key while in the Display Status function. The screen shown below will appear, or whatever screen was shown while pressing 'C'. The screen may be changed at any time by pressing the number keys 1-6 for the desired screen.

Once on the desired screen, use the arrow keys to move the cursor to the desired parameter to be changed.

Press RETURN.

The screen will display a list of all available parameters for the particular engine connected.

Move the cursor to highlight the desired parameter to be added to the numbered screen.

Press RETURN.

At this point, the cursor and screen may be moved to select more parameters to be changed. If changes are done, press PREVIOUS SCREEN to return to the normal display. The screen number will be the same as the screen shown in Change Display while pressing PREVIOUS screen.

Any layout changes made to the six screens while in 'Change Display' mode are stored in memory AFTER exiting Display Status, and are retained even if power is removed from the ECAP. These changes are recalled each time this function is used.

Display Diagnostic Messages Menu

This menu provides a way to display diagnostic messages received from the ECM. Fault, Event and Snapshot data is logged and retained until cleared by a service tool such as the ECAP.

The contents change depending on the capabilities of each ECM type and version. Refer to Appendix A, in this manual, for other Diagnostic Messages Menus.

1 - Display Active Diagnostic Codes: Function to display active diagnostic codes received from the ECM.

2 - Display/Clear Logged Faults: Function to display and clear logged faults in the ECM.

3 - Display/Clear Logged Events: Function to display and clear logged events in the ECM.

4 - Display/Trigger Snapshot: Function to view snapshot data recorded in the ECM.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Display Active Diagnostic Codes

This function displays active diagnostic codes received from the ECM.

The messages are sent to the ECAP from the ECM as code numbers. When a code number is received, the text for the diagnostic message is added and both are displayed on the LCD. Diagnostic messages disappear when the fault or event no longer exists.

NOTE: The diagnostic message, 253-2 - Check Customer Specified Parameters displays the name of any parameter with a programming fault, in this function ONLY. It will not appear in the Display/Clear Logged Faults function or the Display/Clear Logged Events function.

At the top of the screen on both sides, are two special status areas. Messages will appear in reverse screen characters on the left side for ENGINE SHUTDOWN, TOP ENGINE RPM LIMIT, or COLD MODE conditions. Messages will appear in reverse screen characters on the right side for a LOW OIL PRESSURE condition.

If more than six diagnostic messages are present, use the UP and DOWN arrow keys to move through the entire list. For Help, see Scrolling list without Cursor, in this manual.

Display/Clear Logged Faults

This function is used to display and clear diagnostic fault information logged by the ECM.

The diagnostic information is displayed along with the code number and the message text. In addition, the number of occurrences and the diagnostic clock reading for first and last occurrence of each fault are displayed. If the fault is still occurring, the word ACTIVE is displayed along with for that fault message.

Fault codes may be cleared, one at a time, from the ECM memory by pressing RETURN when then the selected message is highlighted. To prevent accidental clearing of logged events, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

If more than six faults have occurred, use the UP and DOWN arrow keys to move through the entire list. For Help, see Scrolling list without Cursor, in this manual.

Display/Clear Logged Events

This function is used to display and clear diagnostic event information logged by the ECM.

The event information is displayed along with the code number and the message text. In addition, the number of occurrences and the diagnostic clock reading for first and last occurrence of each event are displayed. If the event is still occurring, the word ACTIVE is displayed for that event message.

Event codes may be cleared, one at a time, from the ECM memory by pressing RETURN when then the selected message is highlighted. To prevent accidental clearing of logged events, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

If more than six events have occurred, use the UP and DOWN arrow keys to move through the entire list. For Help, see Scrolling list without Cursor, in this manual.

Password Validation For Logged Diagnostics

Diagnostic messages dealing with improper engine/vehicle operation require customer password entry before the diagnostic will be cleared.

Diagnostic messages dealing with abuse or tampering of the ECM require Caterpillar factory specified password entry before the diagnostic will be cleared.

Press PREVIOUS SCREEN or MAIN MENU keys to exit either password entry screen without clearing the diagnostic message.

If no passwords are needed or passwords have been properly entered, the selected diagnostic message is cleared in the ECM and from the display. Until the Display/Clear Logged Faults or Display/Clear Logged Events function is exited, other diagnostic messages with the same password protection level (or lower) can be cleared without re-entering passwords. For Help entering passwords see Entering Customer Passwords or Entering Factory Passwords in this manual.

Display/Trigger Snapshot

This function is used to display, trigger, and clear snapshot information recorded by the ECM.

The available snapshot data from diagnostic codes and other trigger sources are listed along with the ECM clock time when the snapshot was recorded.

Use the UP and DOWN arrow keys to move through the list of snapshots. For Help, see Scrolling list with Cursor, in this manual.

To view the data for the selected snapshot, press RETURN. The Snapshot Viewer displays the recorded snapshot data in the same format as the Display Status function, except when the parameters are rearranged, the changes are not saved. For Help, see Display Status, in this manual.

To trigger a new snapshot, press SPACE. Once recorded, the data frames can be viewed forward, backward, or one frame at a time, much like a video movie.

To PLAY the data in REVERSE, press the (<) key, to PLAY FORWARD press the (>) key; to STEP REVERSE, press the LEFT ARROW key, and to STEP FORWARD press the RIGHT ARROW key. To STOP playing data, press the (-) key, or to GO TO a particular FRAME number, press the (?) key, enter the frame number, and press RETURN.

To clear ALL the recorded snapshots, press the 'C' key. To prevent accidental clearing of snapshots, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

Calibrate/Monitor Sensors Menu

This menu lists the functions used to calibrate and monitor sensors used by the ECM. If the engine is running, sensors cannot be calibrated. Any attempts to access Calibrate functions during this time causes a reminder message to be is displayed.

For 3400 Engines:

1 Calibrate Rack Sensor: Function to calibrate the Rack Sensor used by the ECM.

2 Calibrate Boost Sensor: Function to calibrate the Boost Sensor used by the ECM.

3 Monitor Throttle Position Sensor Signal: Function to monitor the throttle position duty cycle.

For 3176B And 3406E Engines:

1 Calibrate Boost Sensor: Function to calibrate the Boost Sensor used by the ECM.

NOTE: If the engine is running, no access to the Calibrate Boost Sensor function is allowed. A message will be displayed as a reminder.

2 Calibrate/Monitor Timing: Function to monitor and calibrate engine fuel injection timing.

3 Monitor Throttle Position Sensor Signal: Function to monitor the throttle position duty cycle.

4 Read/Change Injector Codes: Function for reading/changing 4-digit numeric codes for each of the injectors.

NOTE: Option 4 is only available when connected to a 3406E engine.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Calibrate Boost Sensor

This function is used to calibrate the boost sensor, and is NOT available for all engine types.

When this function is accessed, the ECM automatically calibrates the boost sensor. The ECAP displays a message indicating the calibration is in progress.

When the automatic calibration is complete, the message CALIBRATED! is displayed confirming the boost sensor is calibrated.

Monitor Throttle Position Sensor Signal

This function displays the duty cycle of the throttle position sensor signal to aid in the adjustment of the sensor, and is NOT available for all engine types.

Calibrate Rack Sensor (3400 only)

This function aids in the calibration of the rack sensor used on an electronic engine.

NOTE: A Zero (0) rack position must be set before the Calibrate Rack Sensor function can be used correctly. Refer to SEHS8746.

When this function is accessed, the ECM is placed into the calibration mode and sends calibration error values to the ECAP.

If there is no error in rack calibration:

CALIBRATED! is displayed on the LCD.

If there is a calibration error:

A bar graph showing the relative amount of calibration error and the direction to turn the sensor, for calibration, is displayed.

Example:

If calibration error is above the calibration point, the bar graph will appear on the left side of the center calibration mark with instructions to Turn Sensor Adjustment In.

If calibration error is below the calibration point, the bar graph will appear on the right side of the center calibration mark with instructions to Turn Sensor Adjustment Out.

Calibrate Timing (3176B And 3406E only)

This function performs an automatic calibration of the timing sensor.

The screen first instructs the user to connect the timing probe. When installation is complete, press the SPACE bar to continue the calibration procedure. Refer to Installing the 6V2197 Timing Probe, in this manual, for installation instructions.

The ECM first takes timing measurements and calculates the timing reference and displays the difference between the two as a bar graph. For convenience, the engine RPM is also displayed. After the timing reference has been calculated, a message appears stating that the ECM is ready to be calibrated.

To calibrate, press the SPACE bar once.

When calibration is complete, the message CALIBRATED! is displayed.

If the calibration is unsuccessful, a message explains the cause of the failure and provides further instructions.

Read/Change Injector Codes (3406E only)

This function is used to read/change a numeric 4-digit code for each injector.

Use the UP and DOWN arrow keys to move through the list of injector codes. For Help, please see Moving Cursor between Items, in this manual.

Enter a new code. For Help, please see Entering Data Values, in this manual.

The default code, when one has not yet been entered, is 1100.

Interactive Diagnostics Menu for 3400 Engines

The Interactive Diagnostics function is used to perform special tests on the engine. When the Interactive Diagnostics function is selected from the main menu, the program enters the Special Tests function.

Special Tests

This function is used to start and stop diagnostic tests on an electronic engine, and is NOT available for all engine types. Also, if the engine is running, tests cannot be activated.

The ECM special tests are:

* Shut Off Solenoid Test

* Rack Actuator Sweep Test

* Warning Lamp Test

To change the current status of a test, move the highlight bar to the desired test using the UP and DOWN arrow keys. For Help, see Scrolling list with Cursor, in this manual.

If the current status is NOT ACTIVE, pressing RETURN will activate the test. If the current status is ACTIVE, pressing RETURN will deactivate the test. If the current status is NOT INSTALLED, pressing RETURN will do nothing, since the ECM is not capable of running that test.

To deactivate all tests at once, press the S or s key.

Interactive Diagnostics Menu For 3176B And 3406E

This Interactive Diagnostics function allows access to the Interactive Diagnostics Menu. This menu provides a way to perform interactive diagnostics on the 3176B and 3406E Engines.

1 Cylinder Cutout: Function to selectively cut out or power individual cylinders.

2 Special Tests: Function to start/stop the Retarder Enable Test.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Cylinder Cutout

This function is used to cutout or power the electrical injection signal to an individual cylinder. This capability allows service personnel to diagnose injector problems.

To change the cylinder status, move the cursor, indicated by reverse screen characters, to the desired cylinder and press RETURN.

If the cylinder was powered, pressing RETURN will cause it to be cutout. If the cylinder was cutout, pressing RETURN will cause it to be powered.

Example:

To cutout cylinder number 3, move to that cylinder by pressing the DOWN arrow key twice.

Change the status by pressing RETURN.

When the engine is in the three cylinder cutout mode, a reverse screen character message THREE CYLINDER CUTOUT will appear at the top left of the screen.

Special Tests

This function is used to start and stop diagnostic tests on an electronic engine. If the engine is running, tests cannot be activated.

The 3176B and 3406E special tests are:

* Warning Lamp Test

* Cooling Fan Driver Test

To change the current status of a test, move the highlight bar to the desired test using the UP and DOWN arrow keys. For Help, see Scrolling list with Cursor, in this manual.

If the current status is NOT ACTIVE, pressing RETURN will activate the test. If the current status is ACTIVE, pressing RETURN will deactivate the test. If the current status is NOT INSTALLED, pressing RETURN will do nothing, since the ECM is not capable of running that test.

To deactivate all tests at once, press the S or s key.

Display Maintenance Status

This function displays the status of Maintenance Indicator data in the ECM.

Values displayed as "due in" a number of hours indicate when maintenance should next be done, and values displayed as "OVERDUE" indicate the number of hours maintenance is overdue.

When maintenance has been performed, use the arrow keys to move the cursor to the correct indicator, then press RETURN to reset the value to the next maintenance point.

To prevent accidental resets, any attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

Trip Data Menu

This menu provides access to all trip information functions.

1 Display Status: Function to display the status of certain trip related parameters.

2 Read/Change Current Totals: Function to read or change values of lifetime engine totals.

3 Read/Change Trip Data: Functions to display or reset trip data.

NOTE: Read/Change Trip Parameters, which was here on earlier ECAP versions, has been removed since all parameters can now be viewed on the Read or Read/Change Customer Specified Parameters Menu.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Display Status

This function displays the instantaneous value of several trip related system parameters.

The parameters can be rearranged, as with other status screens, but the changes WILL NOT BE SAVED.

Read/Change Current Totals

This function displays the current values for the engine lifetime totals, and also allows them to be programmed.

NOTE: The values are only read from the ECM once and are not updated on the screen.

To replace an ECM: (1) read the totals from the old ECM, (2) replace the ECM, (3) program these values into the new ECM.

To change one of the parameter values, move to the parameter by pressing the arrow keys, then enter a new value. For Help, see Moving Cursor between Items and Entering Data Values in this manual.

To prevent accidental programming of parameters in the ECM, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

If factory passwords are required for the requested change, the password prompt will automatically appear. No changes will actually be saved in the ECM until both factory passwords are entered correctly. For Help, see Entering Factory Passwords, in this manual.

Once factory passwords have been entered, other parameters can be changed without re-entering passwords until the Read/Change Current Totals function is exited.

Read/Change Trip Data Menu

This menu provides access to all trip data functions.

1 Display Trip Segment: Function to display the status of the trip segment.

2 Display Histograms: Function to display trip histograms.

3 Reset Trip Data: Function to reset the trip data.

Select the desired menu option. For Help, see Selecting Menu Options, in this manual.

Display Trip Segment

This function is used to display and print trip segment data.

The trip Start Hours is the time, in ECM hours, when the trip data was last reset, and the trip End Hours is the current ECM hours. The displayed data was saved from the Start Hours until the current End Hours.

The LCD can only display six lines from the list at one time, so to view more data, use the UP arrow and DOWN arrow keys to move through the list. For Help, see Scrolling list without Cursor, in this manual.

To print the list, press the 'P' key.

Display Histograms

This function is used to select, display and print a trip histogram.

This histogram selection screen lists available histograms. Use the UP and DOWN arrow keys to move through the list, and press RETURN to view the selected histogram. For Help, see Scrolling list with Cursor, in this manual.

Starting from the left of the screen, and moving right, each histogram displays a list of ranges, the time spent in each range, then the percent of time spent in each range. The percent of time is displayed as a number and also as a bar graph for easier interpretation.

The LCD can only display six lines from the histogram at one time, so to view more data, use the UP arrow and DOWN arrow keys to move through the histogram. For Help, see Scrolling list without Cursor, in this manual.

To print the histogram, press the 'P' key.

Reset Trip Data

This function resets BOTH trip segment and histogram data.

To prevent accidental resetting, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

If Customer Passwords have been programmed, they must be obtained from the engine owner and be entered at the password prompt. For Help, see Entering Customer Passwords, in this manual.

Introduction To The ECAP User Interface

The following topics are examples of typical ECAP functions used with the Service Program Module.

Selecting Menu Option

Each ECAP menu screen option in the menu has a number to the left of the option.

An option can be selected by either typing the number of the option then pressing the RETURN key, or by using the UP or DOWN arrow keys to position the block cursor on the option number and then pressing the RETURN key.

In this example, to select Display Status, item 2, press the DOWN arrow key once, or enter 2. Complete the selection by pressing the RETURN key.

To find out more about a menu item before pressing RETURN, Press the SHIFT-HELP key. A help message will appear on the last line.

Scrolling List With Cursor

Scrolling with a cursor (highlighted bar) is used to select items in a list longer than the ECAP screen display.

The UP and DOWN arrow keys are used to move the cursor through the list. When the cursor reaches the bottom of the screen, and there are more items in the list ...

... pressing the DOWN arrow key again ...

... will move the screen down to the next item in the list, and will scroll the topmost item off the list. The item at the bottom of the screen is now highlighted by the cursor.

Scrolling List Without Cursor

Scrolling without a cursor is used to view lines of data in a list longer than the ECAP screen display.

The UP and DOWN arrow keys are used to move through the list.

pressing the DOWN arrow key five times ...

... will move the screen down five positions in the list. Pressing the UP arrow key twice ...

... will move the screen up two positions in the list.

Moving Cursor Between Items

When a screen has a block cursor and there are several items on the screen, use the arrow keys (UP, DOWN, RIGHT, LEFT) to position the cursor on the desired item.

Press the RIGHT arrow key once and the DOWN arrow key twice to move the cursor to the High Gears Turn On Speed parameter.

Entering Data Values

The following is an example of how to enter either alphabetic (a-z, A-Z) or numeric (0-9) data values, although some data values are restricted to numeric values only.

When the first key is pressed to enter the new value, the old value will be cleared from the LCD. The first character of the new value will take its place.

Continue entering characters until the new value is complete.

Entries may be edited before RETURN is pressed by pressing the SHIFT-DEL key (the SHIFT and DEL keys at the same time). This will clear one character from the end of the entry each time it is pressed. When finished entering characters, press the RETURN key.

A message will appear on the LCD if the maximum allowed number of characters is exceeded.

Toggling Data Values

For parameters which have only two possible values, (e.g. ON or OFF), toggling is the process of changing the parameter from the current value to its other value (e.g. from ON to OFF).

With the cursor on the parameter to toggle, press the RETURN key.

After confirming changes, the parameter will toggle to the other value.

Selecting Data Values

For parameters which have two or more possible values, (e.g. OFF, MAN-Hour, AUTO-Hour), selecting is the process of changing the parameter from the current value to another value (e.g. from OFF to MAN-Hour).

With the cursor on the data value to be changed ...

Press the SPACE bar one (1) time. The new value is displayed.

To program the new value in the ECM, press RETURN. For Help, see Confirming Changes, in this manual.

Confirming Changes

To prevent accidental programming of parameters, after entering new data values, toggling data values, or deleting diagnostic information, a prompt asks if the requested changes are really desired.

Press the Y or y key (for yes), followed by the RETURN key to confirm the change.

Press any other key, followed by the RETURN key to cancel the change.

Entering Customer Passwords

To protect customer specified parameters and certain diagnostic information from unauthorized changes, customer passwords must be entered before changes can be made.

Enter the two passwords using the ECAP keyboard. Press the RETURN key after entering each password.

The desired change can be made only after the correct passwords have been entered. The password entry prompt reappears if the incorrect passwords are entered. No access to the protected data will be allowed until both passwords are entered correctly. For Help, see Entering Data Values, in this manual.

Example:

Four characters of the first password were entered ...

... The passwords entered were incorrect.

Entering Factory Passwords

To protect certain parameters and diagnostic information from unauthorized changes, factory passwords must be entered before changes can be made.

Factory passwords are obtained by contacting a Caterpillar dealer with the following information which is displayed on the ECAP Factory Password screen:

* ECAP Serial Number.

* Engine Serial Number.

* Electronic Control Module Serial Number.

* Total Tattletale.

* Reason.

* From Interlock (only Personality Module Code).

* To Interlock (only Personality Module Code).

A set of two, eight character passwords will be provided that are valid until a parameter is changed in the ECM, which will be indicated by a changed total tattletale number. These passwords are only valid on the particular ECAP used to display this information.

Enter the two passwords using the ECAP keyboard. Press the RETURN key after entering each password.

If incorrect passwords are entered, the password entry prompt reappears. No access to the protected data is allowed until both passwords are entered correctly. For Help, see Entering Data Values, in this manual.

Example:

Four characters of the first password were entered ...

... The passwords entered were incorrect.

Learn/Do Key Programming

The F5 key can be used to initiate a user-defined sequence of key presses. The sequence is stored even when power is removed from the ECAP.

To store a key press sequence, hold down the SHIFT key and press the F5 key (SHIFT-F5). The bottom line of the ECAP will display the message LEARN = ON. Next, press the keys in the sequence to be stored, one at a time. Press SHIFT-F5 again when finished entering key presses. The ECAP will display LEARN = OFF.

Press the F5 key to execute the stored sequence.

Error Messages

The following chart reflects the possible errors, displayed on the ECAP screen, which may occur during the operation of the NEXG4516 Marine/Industrial Engine Functions Service Program Module. The messages are in alphabetical order, by the first word of the message.

The first column is the error message displayed, the second column is a description of the problem (if not explained in the error message) and the third column is the action which you should take to correct the error.

Available Parameters

Coolant Level SensoCruise/Idle/PTO Switch ConfigurationCustomer PasswordsElectronic Control Module Serial NumberEngine LocationEngine Monitoring ModeEngine Oil CapacityEngine Serial NumberFuel to Air RatioFuel Correction FactorFull Load SettingFull Torque SettingIdle/PTO ROM Ramp RateIdle/PTO Vehicle Speed LimitIdle RPM LimitLast Service tool to change customer parametersLast Service tool to change system parametersLow Idle Engine SpeedMaintenance Indicator ModeMaximum Trolling Engine SpeedPersonality Module CodePersonality Module Part NumberPersonality Module Release DatePM1 IntervalRated Peak TorqueRated Peak Torque RPMRated PowerRated RPMRating Selection CodeSoftCruise ControlTachometer CalibrationTest SpecificationTop Engine Limit RPM RangeTop Engine Limit with DroopTop Engine Speed LimitTotal TattletaleTransmission Oil Pressure High Set PointTransmission Oil Temperature High Set PointTransmission Oil Temp/Pressure EnableVehicle Speed CalibrationVehicle/System Identification

Coolant Level Sensor Enable/DisableCruise/Idle/PTO Switch ConfigurationCustomer PasswordsEngine LocationEngine Monitoring ModeEngine Oil CapacityEngine Serial NumberFuel to Air RatioFuel Correction FactorFull Load SettingFull Torque SettingIdle/PTO ROM Ramp RateIdle/PTO Vehicle Speed LimitIdle RPM LimitLow Idle Engine SpeedMaintenance Indicator ModeMaximum Trolling Engine SpeedPersonality Module CodePM1 IntervalRating Selection CodeSoftCruise ControlTachometer CalibrationTop Engine Limit with DroopTop Engine Speed LimitTransmission Oil Pressure High Set PointTransmission Oil Temperature High Set PointTransmission Oil Temp/Pressure EnableVehicle Speed CalibrationVehicle/System Identification

Accel/Decel (3176B/3406E Ind only)A/C Fan (3176B/3406E Ind only)Atmospheric Rack Position (3400 only)Brake Sw (3176B/3406E Ind only)Boost PressureClutch Sw (3176B/3406E Ind only)Coolant LevelCoolant TemperatureCruise/Idle (3176B/3406E Ind only)Cruise/Idle Sw (3176B/3406E Ind only)Cruise Kickout (3176B/3406E Ind only)Cruise Set Spd (3176B/3406E Ind only)Desired Engine RPMDesired Rack Position (3400 only)ECM Hours (3400 only)Engine Droop (3400 only)Engine Hours (3176B/3406E only)Engine Hours (3400 only)Engine LoadEngine RPMEstimated Fuel RateFan (3176B/3406E Ind only)FRC Fuel Position (3176B/3406E only)FRC Rack Position (3400 only)Fuel Position (3176B/3406E only)Fuel Pressure (3176B/3406E only)Fuel Temperature (3176B/3406E only)Idle Kickout (3176B/3406E Ind only)Idle/Rated Switch (3400 only)Idle Set RPM (3176B/3406E Ind only)Inlet Air PressureInlet Manifold Temperature (3176B/3406E only)Maximum Rack Limit (3400 only)Oil PressureRack Position (3400 only)Rated Fuel Position (3176B/3406E only)Rated Rack Position (3400 only)Run/Stop SwitchSet/Resume Sw (3176B/3406E Ind only)Throttle PositionTransmission Oil PressureTransmission Oil TemperatureTrolling ModeVehicle Spd (3176B/3406E Ind only)

Appendix A

Appendix A contains information relating to some industrial engines serviced using the NEXG4516 Marine/Industrial Engine Functions Dual SPM.

Display Diagnostic Messages Menu

This menu provides a way to display diagnostic messages received from the ECM.

NOTE: This menu will have different contents depending upon the engine type and the version of Personality Module connected to the ECAP. This reflects the different capabilities of each version.

1 Display Active Diagnostic Codes: Function to display diagnostic messages sent from the ECM.

2 Display/Clear Logged Diagnostic Messages: Function to display and clear diagnostic messages in logged the ECM.

The ECM logs and retains messages until cleared by the service tool.

Select the desired menu option. For Help, see Selecting Menu Option, in this manual.

Display Active Diagnostic Codes

This function displays active diagnostic messages received from the ECM.

With this function, diagnostic messages appear when the ECM detects an engine fault or problem. The messages disappear when the fault or event no longer exists.

NOTE: In this function ONLY, the diagnostic message, 56 - Check Customer or System Parameters, displays the name of any parameter which has a programming fault. It will not appear in the Display/Clear Logged Faults function or the Display/Clear Logged Events function.

Included on both sides of the top line of the LCD are two special status areas. Messages will appear in reverse screen characters for the following conditions:

The left side of the screen will display ENGINE SHUT DOWN, TOP ENGINE RPM LIMIT or COLD MODE.

The right side of the screen will display LOW OIL PRESSURE.

Six diagnostic messages can be displayed at one time.

If more than six messages are received, use the UP arrow and DOWN arrow keys to move through the list. For Help, see Scrolling list without Cursor, in this manual.

Display/Clear Logged Diagnostic Messages

This function is used to display and clear diagnostic message information logged by an ECM with permanent diagnostic logging capability.

The diagnostic information is displayed along with the code number and the message text. In addition, the number of occurrences and the diagnostic clock reading for first and last occurrence of each fault are displayed. If the fault is still occurring, the word ACTIVE is displayed for that fault message.

Codes can be cleared, one at a time, from ECM memory as faults are corrected.

The message selected for clearing is indicated by reverse screen characters in the fault code and message text.

Use the UP and DOWN arrow keys to move through the list of faults. For Help, see Scrolling list with Cursor, in this manual.

Press RETURN to clear the selected message.

To prevent accidental clearing of logged faults, an attempted change must be confirmed. For Help, see Confirming Changes, in this manual.

NOTE: The diagnostic message 56 - Check Customer or System Parameters displays only the diagnostic message itself and NOT the name of the parameter which has a programming fault.

Refer to Display Active Diagnostic Codes, in this appendix, for viewing the parameter name when diagnostic message 56 is active.

Password Validation For Logged Diagnostics

If the selected diagnostic message is protected by passwords, a password entry screen will be displayed.

Diagnostic messages about the control system itself have no password protection.

Diagnostic messages dealing with improper operation of the engine/vehicle require customer passwords. For Help, see Entering Customer Passwords, in this manual.

Press PREVIOUS SCREEN or MAIN MENU keys to exit the password entry screen without clearing the diagnostic message.

Diagnostic messages dealing with abuse or tampering of the ECM require Caterpillar factory specified passwords. For Help, see Entering Factory Passwords, in this manual.

Press PREVIOUS SCREEN or MAIN MENU keys to exit the password entry screen without clearing the diagnostic message.

If no passwords are needed or the passwords have been properly entered, the selected diagnostic message is cleared in the ECM and from the display.

Once the appropriate passwords have been entered other diagnostic messages with the same password protection level or lower can be cleared without re-entering passwords until the function is exited.

Service

Units 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.

Use the following list to direct troubleshooting questions and/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

Mail

Telex

Number 404435

Attn: Caterpillar Service Technology Group

Industrial Engine Screen Map

3400 Marine Engine Screen Map

3176B Marine Engine Screen Map

3176B/3406E Industrial Engine Screen Map

Trip Data Screen Map