3176C, 3196 & 3406E MARINE ENGINES Caterpillar

Programmable Parameters

Many programmable parameters affect engine operation. Certain parameters affecting Marine Engine operation may be changed with an Electronic Service Tool. Some parameters may affect engine operation in ways an operator does not expect. Without adequate training, these parameters may lead to power or performance complaints, even when the engine is performing to specification.

The parameters are stored in the ECM, and are protected from unauthorized changes by passwords. These parameters are either System Configuration Parameters or Customer Specified Parameters. Any parameter can be read, however, passwords protect parameters from unauthorized changes.

Two categories contain various parameters, System Configuration Parameters and Customer Specified Parameters. System Configuration Parameters can be changed only with the proper factory passwords using an Electronic Control Analyzer & Programmer (ECAP) or Caterpillar Electronic Technician (ET). Customer Specified Parameters can be changed using an Electronic Service Tool only with the proper customer passwords.

Refer to the topics, Passwords, System Configuration Parameters and Customer Specified Parameters for more details on how to receive and use Factory Passwords and Customer Passwords.

NOTE: For details on how to read and change parameters using an ECAP, refer to Tool Operating Manual SEHS9199 (if using the NEXG4516 Marine Engine Functions Service Program Module set).

System Configuration Parameters are set at the factory and affect emissions or power ratings within a family of engines. Factory passwords must be obtained and used to change System Configuration Parameters.

Customer Specified Parameters are variable and can be used to affect engine rpm limits, rpm/power ratings within the limits set by the factory and Caterpillar Engine Monitoring. Customer passwords are necessary to change Customer Specified Parameters.

System Configuration Parameters

System Configuration Parameters affect emissions or power of the engine. They are programmed at the factory and would normally never need to be changed through the life of the engine. System Configuration Parameters must be reprogrammed if an ECM is replace. Proper values for these parameters are stamped on the Engine Information Plate located on the valve cover or inlet manifold. The following is a description of the System Configuration Parameters.

Full Load Setting

The setting number represents the fuel system adjustment performed at the factory to fine tune the fuel system. A new ECM must have this parameter programmed to avoid generating a Diagnostic Code 253-02 Check Customer Or System Parameters (56).

Full Torque Setting

Similar to Full Load Setting, this parameter must be programmed or a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will be generated.

Personality Module Code

Code which prevents use of incorrect Personality Module for this engine. Each power family has a different code associated with it.

When a Personality Module is replaced (either using a Personality Module chip or if flash programmed), this code (stored in the ECM) must match the one in the introduced Personality Module or the engine will only run at low idle and a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will also be generated.

When rerating the engine, programming this code to "0" will prompt the ECM to read and match its stored code to the Personality Module Code.

Engine Serial Number

The engine serial number should be programmed to match the engine serial number stamped on the Engine Information Plate. A new ECM is delivered with the engine serial number programmed to 0XX00000.

Customer Specified Parameters

Customer Specified Parameters allow the engine owner to influence how a unit operates. Some parameters may affect engine operation in ways an inadequately trained operator does not expect. These parameters may lead to power or performance complaints, even when the engine is performing to specification.

Customer parameters may be changed repeatedly as a customer changes his operation or as new operators are assigned. Customer passwords are required to change these parameters.

The following is a brief description of the Customer Specified Parameters with the minimum and maximum values for the parameter and the default value. The tables show values in metric units followed by an approximate range for its US (or English) units counterpart. The exact range of the parameter in metric units depends upon the Electronic Service Tool used because each tool may use slightly different conversion factors.

Low Idle Engine Speed

The minimum engine rpm (may be programmed to any value between 600 and 750 rpm).

Top Engine Limit (TEL)

TEL is not adjustable. For the 3176C, 3196 & 3406E Marine Engines, TEL is equal to a value of 105 percent of rated engine speed (i.e. 2300 rpm rating would allow a maximum 2410 high idle rpm).

NOTE: TEL is dependent upon the RATING number, with all RATING numbers allowing no variation as specified above.

Trolling Speed

Maximum trolling speed can be programmed to any value from 900 to 1200 rpm.

Engine Power Rating Selection Number

Number of rating within power family. The Personality Module defines the power family [such as 242 kW (325 hp)] and may contain only one of several ratings. The rating number defines which rating is used [such as 242 kW (325 hp) and 1900 rpm or 242 kW (325 hp) and 2100 rpm] within the family.

Vessel ID

Identification number (or name) of the vessel assigned by the customer and used only for customer reference. Not required by the ECM.

Low Idle

Minimum programmable engine rpm that the engine will run with the throttle or throttle switch at minimum position.

Tachometer Calibration

The ECM engine speed signal is provided by the Engine Speed/Timing Sensor. The ECM converts the signal from the Engine Speed/Timing Sensor into engine speed scaled between 12.0 and 500.0 (113.0 default) pulses per revolution before sending it to the Tachometer. Vessels with an OEM or customer installed Tachometer would need to calibrate the Tachometer.

Fuel to Air Ratio Control

The control system has full authority over engine fuel delivery. The mechanical fuel to air ratio control is eliminated. Electronic control of the fuel to air ratio provides optimum performance while limiting emissions.

Engine Location

Identifies PORT and STARBOARD locations for multiple engine installations. This feature must be programmed for all Caterpillar displays to work properly.

Coolant Level Sensor Enable/Disable

Determines if the ECM monitors the Coolant Level Sensor inputs.

Fuel Correction Factor

The Fuel Correction Factor is available for fine tuning fuel consumption calculations. Altering the Fuel correction Factor does not affect data already stored in the ECM, only data stored after the Fuel Correction Factor is entered. The factor is a percentage, programmable in 0.5 percent increments.

Fuel Temperature Monitoring

The Fuel Temperature Sensor monitors the fuel temperature, adjusting the ECM calculated fuel rate to compensate for fuel temperature changes and to adjust the fuel rate for constant power.

The sensor is also used to warn the operator of excessive fuel temperature with a diagnostic event code because excessive fuel temperatures can adversely affect engine performance.

Transmission Oil Pressure Sensor

Transmission Oil Pressure can be programmed to any value from 700 to 2716 kPa (100 to 338 psi). The oil pressure gauge on the CMS will flash when any of the warning segments are ON.

Transmission Oil Temperature Sensor

Transmission Oil Temperature can be programmed to any value from 50°C to 120°C (122°F to 248°F). The oil temperature gauge on the CMS will flash when any of the warning segments are ON.

Maintenance Indicator Parameters

Maintenance Indicator Mode

The ECM records data related to maintenance. When selected (Manual - Hours or Automatic - Hours), then all maintenance indicators (PM Level 1, PM Level 2, Coolant Flush, Fill) on the Electronic Service Tool will be in hours. The ECM provides PM Level 1 maintenance interval and last maintenance information.

PM Level 1 Interval

Manual Maintenance Indicator Mode

PM Level 1 interval allows a user specified PM1 maintenance interval. This parameter (PM1 Interval) must be programmed only if Maintenance Indicator Mode is programmed to Manual-Hours.

For Manual = Hours

Automatic Maintenance Indicator Mode

PM Level 1 Interval can be determined by the ECM based on fuel usage and the programmed sump capacity in liters (quarts). This parameter must be programmed only if Maintenance Indicator Mode is programmed to Automatic-Hours.

For Automatic = Sump Capacity

Trip Parameters

Fuel Correction Factor

The fuel correction factor is available to fine tune all fuel data stored in the future by the ECM. Caterpillar recommends this factor be changed only after significant operating interval with a comparison of actual tank capacity fuel economy. The operating interval should also reflect a typical operating routine. The factor is a percentage, programmable in one-half (0.5) percent increments.

Calculating Fuel Correction Factor - The following formula should be used to determine the Fuel Correction Factor (FCF).

-new FCF = old FCF + [(100 + old FCF) X error] /100

-where old FCF is the Fuel Correction Factor currently in ECM, and error is calculated as follows.

-error = [(tank economy - ECM economy/tank economy] X 100

Engine Monitoring Parameters

Engine Monitoring Mode determines the level of action taken by the ECM in response to a potentially engine-damaging condition recognized by the Caterpillar coolant temperature, oil pressure, Inlet Air Manifold temperature, or coolant level (if installed and enabled) sensors.

The control system includes an Engine Monitoring Feature which monitors engine oil pressure, coolant temperature, Inlet Air Manifold temperature, and coolant level. All engines are shipped with the Caterpillar Oil Pressure Sensor, Coolant Temperature Sensor, Coolant Level Sensor and Inlet Air Manifold Temperature Sensor. The Coolant Level Sensor is enabled/disabled through a Customer Programmable Parameter, with a default factory setting of enabled.

Default = WARNING

Alternative = OFF

Alternative = DERATE

Coolant Level Sensor Enable/Disable

Determines if the ECM monitors the Coolant Level Sensor inputs.

Default = ENABLED

Alternative = DISABLED

Engine Monitoring Programmed "OFF"

High coolant temperatures are ignored by the ECM. Coolant temperature is still used for Cold Mode. The ECM will not indicate low oil pressure and coolant levels (if installed). Inlet Air Manifold temperature is used for cold air operation.

Engine Monitoring Programmed to "Warning"

Warning mode monitors for high coolant temperatures. Event Codes 11000 High Coolant Temperature Alarm and 11011 High Coolant Temperature Alarm are enabled for "Warning" mode. The Diagnostic Lamp will flash when the diagnostic code is active.

If Engine Monitoring is programmed to Warning, the ECM monitors oil pressure, coolant temperature, Inlet Air Manifold temperature, and coolant level (if sensor is installed and enabled). The following table indicates the diagnostic event codes (EID) available, and their effect on engine performance when active. The Check Engine/Diagnostic Lamp will flash and the Alarm Lamp will come ON as indicated in the table when the diagnostic code is active.

Engine Monitoring Programmed to "Derate"

If Engine Monitoring is programmed to Derate the ECM will alter engine performance when operating parameters are exceeded to avoid damage and return to normal conditions. Whenever the engine is derated, the Check Engine Lamp (due to active diagnostic codes) and Alarm Lamp will flash. For the DERATE column in the following table, "power" indicates engine power is limited [maximum derate is 119 kW (160 hp)], and rpm indicates engine rpm is limited (maximum derate is 1350 rpm). For operating conditions causing these diagnostic codes, refer to the appropriate section for the sensor under consideration.

Passwords

Factory Passwords

Factory passwords are required to perform each of the following four functions.

1. Program a new ECM.

When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. For a new ECM these parameters can be programmed once without factory passwords, thereafter these parameters are protected by factory passwords.

2. Rerate engine to another power rating.

This requires changing the Personality Module Code, which is protected by factory passwords.

3. Read customer passwords.

If the owner loses the customer passwords, the owner will not be able to program Customer Specified Parameters. Using factory passwords, one can read customer passwords, then use those customer passwords to program Customer Specified Parameters.

4. Clear certain diagnostic codes.

Diagnostic Code 190-00 (Engine Overspeed Warning) requires factory passwords to clear once it is logged. Diagnostic Code 252-11 Incorrect Engine Software (Flash Code 59) also requires factory passwords. It should be cleared only if you are certain the Personality Module is for the specified engine.

Certain other diagnostic codes require customer passwords. The majority of logged codes require no passwords to clear. Since factory passwords contain alphabetic characters, only the ECAP or ET may perform these functions.

To obtain factory passwords, proceed as if you already had the password. At some point, if factory passwords are truly needed, the ECAP or ET will request factory passwords and display most of the information required to obtain the passwords.

Customer Passwords

If customer passwords have been entered, they are then required to change ANY Customer Specified Parameter. Customer Specified Parameters are those that affect engine rpm limits and power rating within a family. Refer to the Customer Specified Parameters for more detail on what parameters are customer programmable.

The ECAP or ET Electronic Service Tools may change Customer Specified Parameters. To obtain customer passwords, contact the owner of the unit. If the owner has lost the passwords, customer passwords may be read using an Electronic Service Tool (factory passwords are required in order to read the customer passwords). Follow the procedure below.

1. Use the Electronic Service Tool to access Read/Change System Configuration Parameters, then read customer parameters.

2. When the Factory Passwords screen appears, record the information listed on the Factory Passwords Worksheet.

3. Obtain the factory passwords. The information recorded above must be provided, and generates a permanent record at Caterpillar of the access.

4. Enter the factory passwords from the Factory Passwords screen.

5. When the Read Customer Passwords screen appears, record the customer passwords. The customer passwords may then be used to change Customer Specified Parameters.

System Configuration Parameters are protected by Factory Passwords. Factory passwords are calculated on a computer system available only to Caterpillar dealers. Since factory passwords contain alphabetic characters, only an ECAP or ET Electronic Service tool may change System Configuration Parameters. System Configuration Parameters affect power family or emissions.

Customer Specified Parameters are protected by Customer Passwords. The customer passwords are programmed by the customer. Refer to Programmable Parameters, for more details when passwords are needed and how to obtain them.

ECM Replacement Procedure

The Electronic Control Module (ECM) is the heart of the Electronic Control System used on the 3176C/3196 and 3406E Marine Engines. The ECM contains no moving parts, has a very high reliability rating and replacement can be time consuming. Most problems occur in the connectors, wiring, or sensors. Follow the troubleshooting procedures outlined in this guide. DO NOT replace an ECM on speculation! To ensure the suspect ECM is the cause of the problem, temporarily connect a new or test (known good) ECM, before replacing the old ECM. To temporarily connect a test ECM you must transfer the Personality Model data from the old ECM to the test ECM and program any necessary parameters required for testing. Refer to the following test steps for details. If the test ECM resolves the problem, reconnect the old ECM and verify the problem returns. If the problem returns, replace the ECM.

The operating information from the old ECM MUST be transferred to the new ECM with the Electronic Service Tool. The parameters file can be copied with the Electronic Service Tool and the Personality Module can be downloaded. After the new ECM is installed on the engine, the parameters and the personality module recorded from the old ECM must be programmed into the new ECM and the injection timing must be recalibrated.

NOTE: If the parameters cannot be read they must be obtained elsewhere. Some parameters are stamped on the Engine Information Plate, but most parameters must be obtained from the user or dealer that installed the engine.

The following procedure is a summary of the basic steps necessary to program a replacement ECM.

Step 1: Use a copy of the Read/Change Parameters. Worksheet in this manual to record the Parameters from the ECM being replaced.

NOTE: It is recommended to record any Logged Events also.

(a) Use the Communication Adapter Tool and connect ET to access Parameters from the ECM being replaced.

(b) Record the Parameters listed on the worksheet.

Step 2: Replace the faulty ECM.

(a) Turn the keyswitch to the OFF position.

(b) Use a 4 mm Allen wrench to disconnect both 40-pin Deutsch connectors.

(c) Remove the fuel lines, ECM mounting bolts and disconnect the ECM ground strap.

Show/hide table

Use caution when removing fuel lines. The fuel may be under pressure and can penetrate body tissue.

d) DO NOT lose any of the ECM mounting hardware (i.e. rubber grommets, spacers and washers).

e) Ensure the old ECM's mounting hardware is free of damage and use it to install the new ECM. Reconnect the fuel lines. Ensure the ECM mounting hardware is installed correctly. Verify the fuel lines are not tugging or pulling on the ECM. The rubber grommets are used to protect the ECM from excessive vibration. When installed correctly, the ECM can drift in the rubber grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines are not pulling the ECM against one side of the grommets.

(f) Reconnect the 40-Pin Deutsch connectors and the ground strap to the ECM.

Step 3: Always use FLASH downloading whenever possible. Use ET to FLASH download the Personality Module information into the ECM (refer to the instructions included with JERD2124 ET Software and the JERD2129 ET Data Subscription for more information).

(a) Connect ET through the Communication Adapter Tool.

(b) Turn the keyswitch to the ON position.

(c) Select the FLASH Download option from the ET menu.

(d) Select the appropriate file to be downloaded from a disk on the laptop PC. Use an Electronic Service Tool to program the Read/Change Parameters

(e) Enter all the parameters recorded in Step 1, Full Load Setting, Engine Serial Number, etc.

(f) Due to ECAP's limited abilities you may not be able to program all the needed parameters.

Step 4: Calibrate the Injection Timing. Use the Electronic Service Tool to select Monitor/Calibrate Timing option to calibrate the Timing Refer To P-614: Engine Speed/Timing Sensor Calibration.

Programming a Personality Module Using Flash Programming

NOTE: Operation of the engine following programming of the Personality Module is identical to operation following replacement of the Personality Module chip. The only difference is the software was already programmed in the chip for you when you replaced the chip, now you are actually performing the programming function.

For example, if you are rerating an engine, you will still need factory passwords to change the Personality Module Code.

1. Connect hardware as shown.

2. Start the LEXT3037 PC Program, or Flash from the Electronic Technician (ET) Service Tool.

3. Select the engine Personality Module part number to be programmed into the ECM, and proceed with programming the Personality Module. The new ECM is shipped with a blank Personality Module.

4. PC Program Personality Module Messages and their meanings are discussed in the following procedure.

NOTE: A new ECM has a blank (previously unprogrammed) Personality Module. A blank Personality Module will prompt you for all three of the following messages.

The information contained in the "ECM Status" will be scrambled and meaningless if the module has not been previously programmed (this is normal).

- Message- "The engine ID in the flash file does not match the engine ID in the ECM."

- Meaning- The ECM has a Personality Module installed for a different engine. For example, the ECM has a 3176C/3196 and 3406E Marine Engines Marine Personality Module and you are attempting to program another Personality Module into it.

- What you should do - Stop the transfer and access information about "ECM Status" under the "Electronic Control Module" menu. Ensure the file you are about to transfer is for the same engine it will be installed in.

- Message- "The application ID in the flash file does not match the application ID in the ECM."

- Meaning- The ECM has a Personality Module installed for a different application.

- What you should do - Stop the transfer and access information about ECM Status under the Electronic Control Module menu. Make sure the file you are about to transfer is for the Marine application.

- Message- "The ECM ID in the flash file does not match the ECM ID in the ECM."

- Meaning- The ECM is not for use in the 3176C/3196 Marine application.

- What you should do - Stop the transfer and access information about ECM Status in the Electronic Control Module menu. Ensure the ECM on the engine is for a 3176C/3196 Marine application.

NOTE: If you access the ECM Status under the Electronic Control Module menu of the PC Program, but do not follow (or have not followed) this procedure by programming the Personality Module, you must turn the keyswitch to the OFF position, and then to the ON position before using an Electronic Service Tool. If you do not cycle the keyswitch after reading the ECM Status, the ECM will not communicate with you service tool or start the engine. Cycling the keyswitch is not necessary following successful programming of a Personality Module using the Flash Designer Program.

5. Start the engine and check for proper operation.

- Program any parameters not previously in the old Personality Module if 253-02 Check Customer Or System Parameters (56) code is active. Read the code from the Active diagnostic code screen of the Electronic Service Tool to determine the parameter(s) requiring programming.

- Remember, on initial powerup of a new ECM, five parameters must be programmed to avoid a 253-02 Check Customer Or System Parameters (56) code. They are Full Load Setting (FLS), Full Torque Setting (FTS), Rating Number and Engine Serial Number and Injector Codes.

Factory Passwords Worksheet

NOTE: A mistake in recording these parameters will result in incorrect passwords.

Lifetime Totals Worksheet

Customer Parameter Worksheet