8. Install plug (1) on hood (2).
9. Close hood (TM 5-3805-291-10).
10. Verify correct operation of hood (TM 5-3805-291-10).
WARNING
Before operating the machine, secure the steering frame lock in the stowed position. DO NOT operate machine with steering frame lock connected. Failure to lock steering frame lock into the stowed position before operating can result in loss of steering and injury or death to personnel.
11. Secure steering frame lock in stowed position (TM 5-3805-291-10).
END OF WORK PACKAGE
427-C0277
0059 00-1
HOOD TILT SWITCH AND WIRING HARNESS REPLACEMENT 0059 00
THIS WORK PACKAGE COVERS
Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00)
Materials/Parts
Rag, wiping (Item 35, WP 0233 00)
Strap, tiedown, electrical components (Item 42, WP 0233 00)
Lockwasher
Personnel Required
MOS 62B, Construction Equipment Repairer References
TM 5-3805-291-10 Equipment Conditions
Control box cover removed (Hood Tilt Relay Removal in WP 0053 00)
Drawings Required
TM 5-3805-291-23P, Figures 56 and 72 Estimated Time to Complete Task
0.5 hr
Ensure battery disconnect switch is in OFF position before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.
WARNING
0059 00-2 REMOVAL
1. Remove nut (4), lockwasher (5), switch cover (1), and toggle switch (3) from control box (2). Discard lock-washer.
2. Cut and remove tiedown strap (6) from wiring har-nesses (7 and 8). Discard tiedown strap.
3. Disconnect chassis wiring harness (7) from tilt switch wiring harness (8).
4. Remove chassis wiring harness (7) from control box (2).
INSTALLATION
1. Position chassis wiring harness (7) in control box (2).
2. Connect chassis wiring harness (7) to tilt switch wiring harness (8).
3. Install new tiedown strap (6) on wiring harnesses (7 and 8).
4. Install toggle switch (3), switch cover (1), new lockwasher (5), and nut (4) on control box (2).
5. Install control box (Hood Tilt Relay Installation in WP 0053 00).
6. Verify system operation (TM 5-3805-291-10).
END OF WORK PACKAGE
483-1530
483-1531
0060 00-1
IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT 0060 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) 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) Lockout switch set (TM 5-3805-291-10) Wheels chocked
Drawings Required
TM 5-3805-291-23P, Figure 53 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 procedure to ensure the configuration parameters match those in the faulty ECM. Be sure to clear any logged codes if you use a substitute ECM.
0060 00-2
SYSTEM CONFIGURATION PARAMETERS 00060 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 Joystick Installation Status or Dump Kick-out Enable Status) may be changed to suit the needs of the specific application. Other parameters (such as Autodig Installation Status or Security System immobilizer Installation Status) 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 package.
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.
Table 1. Configuration Parameters.
Parameter Description
Definition/
location Range of Values Default Value Input
Product ID Registration Number 8 characters Blank Customer Defined
Equipment ID Serial Number 9 characters Blank Customer Defined
ECM Part Number ECM 9 characters From Factory
ECM Serial Number ECM 10 characters From Factory
ECM Software Group
0060 00-3
COPY CONFIGURATION FROM ECM 00060 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).
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 “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.
0060 00-4
REMOVE ECM 00060 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 that all diagnostic codes are noted before removing ECM.
1. Disconnect battery cables from batteries (WP 0096 00).
2. Remove three screws (1) and two screws (2) from interior panel (3).
3. Remove interior panel (3) from machine.
WARNING
0060 00-5