NOTE
If flash programming the ECM as directed by troubleshooting, proceed to step 12. If replacing an ECM, proceed to Copy Configuration (Program ECM) in this work package.
12. Start engine. Run until operating temperature is reached and verify proper operation of all components (TM 5-3805-291-10). Check for active diagnostic codes (WP 0006 00).
COPY CONFIGURATION (PROGRAM ECM) 0056 00
1. Highlight the ECM, then click “OK”.
2. Ensure the correct ECM is highlighted. Select “Copy Configuration” from the “Service” menu, then select “ECM replacement” from the sub-menu.
3. Highlight configuration file that was saved earlier and double click to open. “The current ECM Replacement data came from...” dialogue box opens. Select “OK”.
4. Select “Program ECM” push-button, then highlight the ECM to be programmed and click “OK”.
5. Read the “Warning! This configuration is for the control...” message and verify that the Equipment ID appears, then select “Yes” to “Program the ECM”.
6. If the “Programming parameter cannot be programmed...” message appears, select “OK”.
7. Close the “Programming complete...” dialogue box by selecting “OK”.
8. The “Programming parameter cannot be programmed...” message will reappear. Then select “OK”.
9. Start engine. Run until operating temperature is reached and verify proper operation of all components (TM 5-3805-291-10). Check for active diagnostic codes by selecting “Active Diagnostic Codes” from the “Diagnostics” menu (WP 0006 00).
10. Disconnect ET (WP 0005 00).
END OF WORK PACKAGE
0057 00-1
ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT 0057 00
THIS WORK PACKAGE COVERS
System Configuration Parameters, Copy Configuration from ECM, Remove ECM, Install ECM, Flash Programming, Copy Configuration (Program ECM)
INITIAL SETUP Maintenance Level
Unit
Tools and Special Tools
Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00)
Adapter, test (Item 3, WP 0232 00) Software kit (Item 75, WP 0232 00)
Test set, electronic systems (MSD) (Item 86, WP 0232 00)
Wrench, torque, dial, 3/8” drive, 300 lb-in. (Item 97, WP 0232 00)
Materials/Parts
Rag, wiping (Item 35, WP 0233 00)
Strap, tiedown, electrical components (Item 42, WP 0233 00)
Personnel Required
MOS 62B, Construction Equipment Repairer
References WP 0005 00 WP 0006 00 WP 0096 00 Equipment Conditions
Machine parked on level ground (TM 5-3805-291-10)
Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked
Hood opened (TM 5-3805-291-10) Drawings Required
TM 5-3805-291-23P, Figure 52 Estimated Time to Complete Task
2.0 hr
CAUTION
• Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened compo-nent life.
• The replacement ECM must have the same serial number suffix or damage to the engine may result.
NOTE
If mission dictates, you may need to remove an ECM from an engine that is not in service. Refer to the fol-lowing procedures to ensure that the configuration parameters match those in the faulty ECM. Be sure to clear any logged codes if you use a substitute ECM.
0057 00-2
SYSTEM CONFIGURATION PARAMETERS 00057 00
System configuration parameters are parameters that affect emissions, engine power, and machine applications. Default values for the parameters are programmed at the factory. Some parameters (such as Engine Fan Control or Ether Solenoid Configuration) may be changed to suit the needs of the specific application. Other parameters, such as Full Load Setting (FLS) or Full Torque Setting (FTS), should not be changed unless the engine is rerated or a new ECM is installed. FLS and FTS are stamped on the engine information ratings plate located on the engine (TM 5-3805-291-10). These parameters are protected from unauthorized change by passwords.
View and/or change parameters using the Configuration Tool on the toolbar or by selecting “Configuration” from the
“Service” menu in ET. The Configuration display area in ET has four columns: Description, Value, Unit, and TT. The Descrip-tion column gives the name of the parameter. The Unit column displays the configuraDescrip-tion parameter units. The TT column dis-plays the list of the total tattletales, which represent the number of times the configuration parameter value has changed.
The push-buttons in the Configuration screen are “Change” or “Print”. The “Change” push-buttons allow you to change the configuration values. This is only enabled if the parameter’s configuration can be changed. Parameters that cannot be changed have a yellow key symbol on the left. The ECM Replacement function in ET copies the relevant configuration param-eters from one ECM to the other. Table 1 lists the system configuration paramparam-eters, data range, default value, and unit for the 966H Wheel Loader.
To replace the ECM, perform the following steps, which are explained in more detail in the sections identified below.
a. Record all diagnostic codes before replacing ECM (WP 0006 00).
b. Copy configuration of the existing ECM to the MSD. Refer to Copy Configuration from ECM in this work pack-age.
c. Remove the ECM. Refer to Remove ECM in this work package.
d. Install the new ECM. Refer to Install ECM in this work package.
e. Flash program ECM. Refer to Flash Programming in this work package.
f. Copy the configuration of the old ECM to the new ECM. Refer to Copy Configuration (Program ECM) in this work package.
Product ID Registration Number 8 characters Blank Customer Defined
Equipment ID Serial Number/VIN 4 characters Blank Customer Defined
Engine Serial Number Engine Data Plate 8 characters Blank Customer Defined
ECM Part Number ECM 9 characters From Factory
ECM Serial Number ECM 10 characters From Factory
ECM Software Group
Full Load Setting Engine Data Plate 2 characters COPY CONFIG
Full Torque Setting Engine Data Plate 2 characters COPY CONFIG
0057 00-3
COPY CONFIGURATION FROM ECM 00057 00
CAUTION
You must copy the configuration of the existing ECM prior to replacing it with a substitute ECM or new ECM to avoid damage to the engine.
1. Connect ET to MSD and start ET (WP 0005 00).
NOTE
ET lists Engine ECM as “C11-966H”.
2. After ET establishes a connection with the ECMs, highlight the ECM and click “OK”.
3. Ensure the correct ECM is highlighted. Select “Copy Configuration” from the “Service” menu, then select “ECM Replacement” from the sub-menu.
4. The screen will display any previously saved configuration files. Close the dialogue box to load the current configura-tion.
5. The “No data is available” dialogue box is displayed. Press “Yes” to “Load the data from the ECM”.
6. Highlight the ECM that is being replaced and click “OK”.
NOTE
As the data is loading from the ECM, the “Please wait...” message displays, Then the “Loading data from the ECM...” progress bar is displayed. You may cancel the process at any time by pressing the “Cancel”
push-button. The “Are you sure...” dialogue box is displayed. Press “Yes” to cancel loading the data or
“No” not to cancel.
7. “The current ECM Replacement data...Load from...” message appears. Click the “OK” button.
NOTE
The display area lists the configuration parameters that were loaded from the ECM.
8. Save all parameters on the “Configuration” screen by selecting “Save To File” from the bottom toolbar, then click
“OK”. Note the file name, then click “Save”.
9. Wait for the message “ECM Replacement data saved successfully”, then click “OK”.
10. Select “Disconnect” from the “File” menu or click the “Disconnect Tool” button on the toolbar.
11. Proceed to Remove ECM in this work package.
0057 00-4
REMOVE ECM 00057 00
Ensure battery cables are disconnected before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.
NOTE
• Follow troubleshooting procedures in this manual to ensure replacing the ECM will correct the prob-lem.
• Ensure all diagnostic codes are noted before removing ECM.
1. Disconnect battery cables from batteries (WP 0096 00).
2. Remove bolt (1), nut (2), two washers (3), and clamps (4 and 5) from hydraulic hoses (6 and 7).
WARNING
427-C2022
0057 00-5