Special Instruction - Electronic Control Module (ECM) Reference Information (REHS3400).pdf

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Special InstructionElectronic Control Module (ECM) Reference Information{1901, 7569}

Electronic Control Module (ECM) Reference Information{1901, 7569}

SMCS -1901; 7569

Engine:C15 (S/N: MXS1-UP; NXS1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

The purpose of this Special Instruction is to provide supplemental information on troubleshooting the engine ECM in order to help prevent the unnecessaryreplacement of a good ECM. Information on using a digital multimeter and information on the ECM circuits are provided.

Troubleshooting Guide

For a complete guided troubleshooting procedure on the ECM for the C15 Engine, refer to Component Based Troubleshooting (CBT) https://cbt.cat.com. Refer to the"ECM Procedures and Symptoms". The following procedures and symptoms are available:

ECM Troubleshooting (Validation Procedure)

ECM Will Not Communicate

ECM Will Not Flash

Test ECM Procedure

Required Service Tools

Caterpillar electronic service tools are designed to help the service technician with the diagnosis and with the repair of electronic engines. Several tools are availableto assist the service technician.

Two short jumper wires are needed to check the continuity of some wiring harness circuits. A long extension wire may also be needed to check the continuity of somewiring harness circuits.

Caterpillar Electronic Technician (ET)

Cat ET can display the following information:

Parameters

Diagnostic codes

Engine rating history

Driver and fleet trip segments

Shutdown SIS

Previous Screen

Product: NO EQUIPMENT SELECTEDModel: NO EQUIPMENT SELECTEDConfiguration: NO EQUIPMENT SELECTED

Media Number -REHS3400-00 Publication Date -21/12/2006 Date Updated -21/12/2006

i02624580

Table 1

Part Number Description

N/A 4 mm Allen Wrench

6V-2197 Transducer

7X-1171 Transducer Adapter

7X-1695 Cable As

1U-5804 Crimp Tool (12 to 18 AWG)

1U-5805 Wire Removal Tool

151-6320 Wire Removal Tool

167-9225 Harness (Service Tool Adapter)

140-2266 Cable (70-Pin Breakout)

257-9140or

146-4080

Digital Multimeter

Digital Multimeter (RS-232)

190-8900 Connector Repair Kit

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Histograms

Custom data

ECM date/time clock

Maintenance intervals

Cat ET can also be used to perform the following functions:

Diagnostic tests

Sensor calibrations

Flash programming

Set parameters

Copy the configuration for ECM replacement.

Data logging

Snapshot recorder

The following components are required to use Cat ET to service the engine.

Note: For more information regarding the use of Cat ET and the PC requirements for Cat ET, refer to the documentation that accompanies your Cat ET software.

Connecting Cat ET and the Communication Adapter II

Table 2

Required Electronic Service Tools for the Use of Cat ET


Caterpillar Electronic Technician

JERD2124 "Electronic Technician Program" (Cat ET)

JERD2125 "Electronic Technician Truck Engine Data Subscription"

171-4400 (1) Communication Adapter II Gp

237-7547 (2) Adapter Cable As

( 1 ) The 7X-1700 Communication Adapter Gp may also be used.

( 2 ) The 237-7547 Adapter Cable As is required to connect to the USB port on computers that are not equipped with a RS232 serial port.

Illustration 1 g00647144

(1) Personal computer (PC)




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Note: Items (2), (3), and (4) are part of the 171-4400 Communication Adapter II Gp .

Use the following procedure to connect Cat ET and the Communication Adapter II.

1. Turn the keyswitch to the OFF/RESET position. If the keyswitch is not placed in the OFF/RESET position, the engine may start.

2. Connect cable (2) between the "COMPUTER" end of communication adapter (3) and the RS232 serial port of PC (1) .

3. Connect cable (4) between the "DATA LINK" end of communication adapter (3) and the service tool connector.

4. Turn the keyswitch to the ON position. If Cat ET and the communication adapter do not communicate with the Engine Control Module (ECM), refer toTroubleshooting, "Electronic Service Tool Will Not Communicate With ECM".

Optional Service Tools

Electrical Measurement

This is a brief description on how to perform a voltage or current test with the information provided in the terminal chart for the ECM.

This information covers the basic functions and operation of the digital multimeter. Although an analog multimeter and test light may be used by a service technician,

the digital multimeter performs the more complex measurements on the newer electronic systems. Digital multimeters use the metric system, in order to make iteasier to work with large numbers.

Digital Multimeter

(2) 196-0055 Adapter Cable As

(3) 171-4401 Communication Adapter As

(4) 207-6845 Adapter Cable As

Table 3


7X-6370 Adapter Cable As (3-Pin Breakout)

8T-8726 Adapter Cable As (3-Pin Breakout)

5P-7277 Voltage Tester

9U-5103 Socket (Slotted)

7X-1710 Multimeter Probe

1U-5718 Vacuum Pump

1U-8757 Tube (Fluid Sampling)

169-7372 Fluid Sampling Bottle

9S-9082 Engine Turning Tool

198-4240or1U-5470

Digital Pressure Indicator

Engine Pressure Group

6V-9130 Temperature Adapter

124-5643 Cable As (Service Tool Breakout)

125-3662 Cable As (Sensor Bypass)

157-4829 Cable Adapter

7X-1403 Adapter Cable As

7X-1686 Cable Adapter

139-4166 Data Link Cable As (18 FT)

208-0059 Cable As (70-PIN BREAKOUT)




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The digital multimeter is highly accurate. The digital multimeter is used to find the precise value of any type of voltage, current or resistance. The meter is poweredby a 9 volt alkaline battery. The meter is sealed against dirt, dust, and moisture.

The meter has four main areas: the liquid-crystal-display, push buttons, rotary dial function switch, and inputs for the meter leads.

Liquid Crystal Display

The meter's liquid crystal display, or LCD, uses display segments and indicators. Digital readings are displayed on a 4000 count display with polarity () indicationand automatic decimal point placement. When the meter is turned ON, all display segments and annunciators appear briefly during a self test. The digital displayupdates four times per second. When frequency readings are taken, the display updates three times per second.

The analog display is a 32 segment pointer that updates at 40 times per second. The display segments have a pointer that rolls across the segments indicating ameasurement change. The display also uses indicators to abbreviate various display modes and meter functions.

Push Buttons






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The buttons on the meter are used to perform additional functions. The additional buttons are discussed later as they apply to the type of measurement taken.

When the meter is first switched on and a measurement is taken, the meter automatically selects a range. The meter will display the word "AUTO" in the upper leftcorner. Pressing the range button will put the meter in manual range mode. The range scale will be displayed in the lower right corner of the meter. With eachadditional press of the range button, the next increment will be displayed. Press and hold the range button in order to return to the auto range mode. The yellow buttoncan be used to backlight the meter display.

Rotary Switch

Various meter functions are selected by turning the meter's rotary switch. Each time the rotary switch is moved from OFF to a function setting, all display segmentsand indicators turn on as part of a self test routine. Moving clockwise from the OFF switch, the first three positions on the rotary switch are used for measuring ACvoltage, DC voltage, and DC millivolts. The top position is used for measuring resistance. The next position will allow the meter to check diodes. The last two

positions are used for measuring AC and DC current in amperes, milliamperes, and microamperes.

Meter Lead Inputs






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Depending on the measurement that you wish to take, the meter leads must be placed in the correct terminals. The insides of the input terminals are color coded, redor black. The positive lead can go in any of the red inputs.

The "Com" or common terminal is used for most measurements. The black lead will always remain in the "Com" terminal.

The first input terminal that is on the left side of the meter is for measuring amps. This input is fused at 10 amps continuous (20A for 30 seconds).

The next position to the right is for measuring milliamperes or microamps (mA/A). No more than 400 mA can be measured when the rotary switch is in thisposition. If you are unsure of a circuit's amperage, start out with the red meter lead in the 10 amp input jack (highest range).

The input terminal on the right side of the meter is for measuring voltage, for resistance, and for the diode test.

Overload Display Indicator

While you take some measurements, you may see "OL" displayed. "OL" indicates that the value being measured is outside of the limits for the range selected. Thefollowing conditions can lead to an overload display:

In autorange, a high resistance reading indicates an open circuit.

In manual range, a high resistance reading indicates an open circuit or an incorrect scale that has been selected.

In manual range, a voltage reading that exceeds the range selected.

When you perform a diode check, voltage readings are greater that 3 volts or the test leads are open.

Measuring AC/DC Voltage

When you use the multimeter to take voltage measurements, remember that the voltmeter must always be connected in parallel with the load or with the circuit undertest.

To measure voltage, perform the following tasks:

1. Make sure that the circuit is turned ON.

2. Place the black meter lead in the "Com" input port on the meter and the red lead in the VOLT/OHM input port.

3. Place the rotary switch in the desired position for AC or for DC.

4. Place the black meter lead on the low side or on the ground side of the component or circuit that is being measured.

5. Place the red meter lead on the high side or the positive side of the component or circuit that is being measured.





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Observe the circuit in Illustration 7. The tests leads are connected in parallel across the circuit load. With a 12 volt power source connected to the load, the metershould read a voltage drop equal to the source voltage or to 12 volts.

If the meter reads a voltage drop less than 12 volts, it would indicate that an unwanted resistance was present in the circuit. A logical process would be to measure thevoltage drop across the closed switch contacts. If a voltage reading was present, it would indicate that the switch contacts were corroded. This will require the switchto be replaced.

Note: In actual measurements, the meter reading will not exactly equal the power source voltage because the individual wires will offer some small resistance. Inmost practical applications, a voltage drop of 0.1 volts is acceptable for normal circuit wiring conditions.

The digital multimeter is a high impedance meter. This means the meter will not significantly increase the current flow in the circuit that is being measured. Alwaystake voltage measurements with the circuit under power. The digital multimeter is ideal for use in circuits controlled by solid state devices such as electronic

components, computers, and microprocessors.

Measuring AC/DC Current






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When you use the multimeter to take current measurements, it is necessary for the meter probes to be connected in series with the load or circuit under test. To togglebetween alternating and direct current measurements, use the blue push button.

When you measure current, the meter's internal shunt resistors develop a voltage across the meter's terminals. This is called burden voltage. The burden voltage isvery low, but the voltage could possibly affect precision measurements.

When you measure current flow, the digital multimeter is designed with low resistance to not affect the current flow in the circuit. When you measure current in acircuit, always start with the red lead of the multimeter in the Amp input (10 A fused) of the meter. Only move the red lead into the mA/A input after you havedetermined the current is below the mA/A input maximum current rating (400 mA).

The meter has a buffer which allows it to momentarily measure current flows higher than 10 A. This buffer is designed to handle the surge current when a circuit isfirst turned on. The meter is capable of reading 20 amps for a period not to exceed 30 seconds.

To measure current, perform the following tasks:

1. Place the black multimeter input lead in the "Com" port and the red input lead in the "A" (amp) port.

2. Create an open in the circuit by pulling the fuse, or by opening the switch.

3. Place the leads in series with the circuit so that the circuit amperage is flowing through the meter.

Note: If the current flow exceeds the rating of the fuse in the meter, the fuse will open.

4. Apply power to the circuit.

Measuring Resistance

When you use the multimeter to take resistance measurements, it is necessary to turn off the circuit power and discharge all capacitors before attempting circuitmeasurements. If an external voltage is present across the component being tested, it will be impossible to record an accurate measurement.

The digital multimeter measures resistance by passing a known current through the external circuit or the component. The digital multimeter measures the respectivevoltage drop. The meter then internally calculates the resistance using the Ohm's Law equation R = E/I. It is important to remember that the resistance displayed bythe meter is the total resistance through all possible paths between the two meter probes. To accurately measure most circuits or most components, it is necessary toisolate the circuit or the component from other paths.

The resistance of the test leads can affect the accuracy when the meter is in the lowest (400 Ohm) range. The expected error is approximately 0.1 to 0.2 Ohms for astandard pair of test leads. To determine the actual error, short the test leads together and read the value displayed on the meter. Use the "REL" mode on themultimeter to automatically subtract the lead resistance from the actual measurements.

To accurately measure resistance, perform the following tasks:

1. Make sure that the circuit or the component power is turned OFF.

2. Place the red lead in the jack marked Volt/Ohms and the black lead in the jack marked "Com".

3. Place the rotary selector in the &ohm; position.

4. Place the meter leads across the component or the circuit that is being measured.

Note: It is important that your fingers are not touching the tips of the meter leads when you are performing resistance measurements. Internal body resistance canaffect the measurement.





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Diagnostic Functional Tests

Use the Diagnostic Functional Tests to assist in troubleshooting problems in the circuits.

To perform a diagnostic functional test refer to Troubleshooting, RENR5088, "C15 On-highway Engines ", "Diagnostic Functional Tests".

ECM Hotline

If assistance is needed to troubleshoot a suspected ECM problem always consult with your dealer technical support first. Follow the troubleshooting guides andinvolve your Technical Communicator (TC) when necessary. Forward any questions on Test ECM Mode to your TC. If you have an issue that does not need

immediate attention, have your TC call or send e-mail to the Dealer Solutions Network (DSN).

For further technical assistance when troubleshooting ECM and software issues, or if you are at the point of replacing the ECM, call the ECM Hotline.

The Hotline hours are Monday through Friday, 7:30 AM to 10:00 PM Central Standard time, and Saturday 7:00 AM to 5:00 PM Central Standard time. The Hotlineoffers technical assistance, troubleshooting tips and when necessary, will issue an ECM Authorization Number (if a Caterpillar ECM Phone Analyst determines theengine ECM is faulty). Dealers are responsible in determining if the ECM is still under warranty. Refer to Warranty Update #0221.

Obtain the following information before you call the ECM Hotline:

Engine serial number

Caterpillar dealer code

Personality module part number

Version of Cat ET

Detailed description of the problem (history must include complaint, cause and corrections made)

Troubleshooting performed so far

Any fault codes

Note: You do not need prior authorization to try a test ECM.

ECM Flash Files

Ensure that the correct software (flash file) is properly installed in the ECM. Use WinFlash in Cat ET to check that the correct flash file software program has beendownloaded into the ECM. Use the web to download the latest available flashfile. The latest flash files are found at the following web sites:

TMI Web- Use TMI Web "Flash File" as your first choice for downloading the correct ECM flash file. TMI Web shows flash files for every unique engine serialnumber along with a replaced by progression. Each current flash file listed on TMI Web has a short release description and the related CPI number.

SIS Web- "Service Software Files" - https://sis.cat.com

SIS Web lists the following file types for engines:

ECM flash files

ECM replacement flash files

Injector trim files

Remanufactured injector trim files

Truck.Cat.Com - Another resource is the Truck.cat.com Home Page - Parts & Service - Service Specific Information - https://truck.cat.com

Copyright 1993 - 2007 Caterpillar Inc.All Rights Reserved.Private Network For SIS Licensees.

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Special Instruction - Electronic Control Module (ECM) Reference Information (REHS3400).pdf