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3412 Generator Set 4BZ00001-UP(SEBP2785 - 27) - Document Structure

Shutdown SIS
Previous Screen
Product: GENER ATO R SET
Mode l: 3412C GENER ATO R SET 4BZ
C onfiguration: 3412 Ge ne rator Se t 4BZ00001-UP

Troubleshooting
3412 GENERATOR SET ENGINE
Media Number -SENR6477-02

Publication Date -11/02/1998

Date Updated -12/10/2004


SENR 64770004

Section 2: Programming Parameters


Programming Parameters
Certain parameters that affect engine operation can be changed with an Electronic Service Tool. The parameters are stored in the ECM, NOT in the
Personality Module. Any parameter can be read, but passwords protect certain parameters from unauthorized changes. Parameters which can be
changed have a tattletale number following the parameter value that indicates how many times that parameter has been changed.
Parameters fall into two categories: System Configuration Parameters and Customer Specified Parameters. System Configuration Parameters are
those that effect emissions or power ratings and can only be changed with the proper Factory Passwords. Customer Specified Parameters affect the
low and high idle engine rpm setting and require Customer Passwords (if installed) to change.

Electronic Technician (ET)


For details on how to read and change parameters using ET, Communication Adapter Tool and the appropriate software, refer to the instructions
included with the JERD2129 ET Data Subscription and the JERD2124 ET Software.

Electronic Control Analyzer Programmer (ECAP)


For details on how to read and change parameters using ECAP, refer to Special Instruction SEHS9199, Using The NEXG4516 Marine/Industrial
Engine Functions Service Program Module and Tool Operating Manual SEHS9264.
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System Configuration Parameters


System Configuration Parameters are those that effect emissions or the power rating of the engine. They are programmed at the factory and normally
would never need to be changed through the life of the engine. Proper values for these parameters are stamped on the engine information ratings plate
located on the valve cover or intake manifold. Factory Passwords are required to change these parameters. An example electronic service tool screen
displaying System Configuration Parameters can be found at the end of this section. Following is a description of the System Configuration Parameters
Full Load Setting
A number representing fuel system adjustment at the factory to fine tune the fuel system. The correct value for this parameter is stamped on the engine
information ratings plate.
Full Torque Setting
Similar to the Full Load Setting. It is a number representing an adjustment made at the factory to fine tune the fuel system. The correct value for this
parameter is stamped on the engine information ratings plate.
Personality Module Code
This code prevents the use of the wrong Personality Module for the engine. Each power rating family and emission certification has a different code
associated with it. The Personality Module Code is stored in the ECM and MUST match the code in the Personality Module or a 252-12 Personality
Module Fault Code (52) will be generated. When rerating an engine or installing a new ECM, programming the Personality Module Code to 0 (zero)
will prompt the ECM to read and match it's stored code to the Personality Module.
NOTE: This parameter DOES NOT need to be reprogrammed when a personality module is replaced with a personality module of the same rating.
If the personality module is replaced with a new power rating, then other mechanical modifications (pistons, nozzles) may also need to be made and
the engine information ratings plate should be updated.
Engine Serial Number
Should be programmed to match the engine serial number stamped on the engine information ratings plate. A new ECM is delivered with the serial
number programmed to 0XX00000.

Customer Specified Parameters


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Customer Specified Parameters allow a customer to program some engine/system related features.
Customer parameters may be changed repeatedly. Customer Passwords are required to change these parameters. The following is a brief description
of the Customer Specified Parameters and their maximum, minimum, and default values.
Low Idle Engine RPM
Programs the engine idle speed.

Passwords
System Configuration Parameters are protected by Factory Passwords and Customer Specified Parameters are specified by Customer Passwords.
Factory Passwords
Factory Passwords are required to perform the following functions:
1. Read Customer Passwords. If the owner losses his Customer Passwords he will no longer be able to program Customer Specified Parameters.
Customer Passwords can be viewed on an electronic service tool with the proper Factory Passwords.
2. Clear certain diagnostic codes. Only diagnostic codes 190-00 (Engine Overspeed Warning) and 23-02 (Excessive Engine Power) require factory
passwords to clear once they are logged. The majority of logged codes require no password to clear.
3. Replace the ECM
4. Change ECM History Data.
5. Rerate an engine.
To obtain factory passwords, proceed as if you already have the password. If a factory password is needed, the electronic service tool will request
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factory passwords and display most of the information required to obtain the passwords.
NOTE: The passwords are only good for one programming or clearing session. A different set of passwords will be required after exiting the
Electronic Service Tool Screen.
Customer Passwords
Customer Passwords may be required to change Customer Specified Parameters. Contact the engine owner to obtain Customer Passwords. If the
owner has lost his passwords, customer passwords can be read as follows:
1. Use an 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.
4. Enter the Factory Passwords at 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.

Replacing The Personality Module


The Personality Module is the software which controls how the ECM behaves. The Personality Module consists of all of the software, or instructions
for the ECM to operate correctly. When troubleshooting indicates that a failure has occurred in the ECM or Personality Module then temporarily
install a new part and thoroughly retest.
NOTE: Updating the Personality Module to a different version may cause some engine functions to behave in a different manner.
1. Remove the Personality Module Access Cover.

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2. Firmly grasp the release clips on the old Personality Module and detach the module from the ECM.
3. Install the new Personality Module into the ECM making sure it seats properly into the Personality Module socket. NOTE: The socket is keyed to
accept the Personality Module in one position only. A "Click" can be felt when the module is pushed in correctly.
4. Install the Personality Module Access cover. Ensure the O-Ring is seated properly. NOTE: Improper O-Ring placement could result in moisture
damage form improper sealing.
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, customer and system parameters must be programmed to avoid a 253-02 Check Customer
Or System Parameters (56) code.

Replacing The ECM


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The Electronic Control Module (ECM) is the center of the engine control system and it is easy to come to the conclusion that the ECM is responsible
when a problem occurs. That is usually a wrong conclusion. The ECM has no moving parts inside and therefore seldom fails.
Around 70-90 percent of electronic failures occur in the wiring and connectors. Follow the troubleshooting procedures and do not replace an ECM
on speculation!
However, when troubleshooting indicates that an ECM failure has occurred, temporarily mount a new ECM on the side of the engine and thoroughly
retest. If the problem is no longer present, proceed with the following steps to permanently replace a faulty ECM.
ECM Replacement Procedure
1. Record Customer Specified Parameters from the failed ECM. If the electronic service tool is unable to communicate with the ECM, refer to P-310:
Service Tool Will Not Communicate With ECM. If problem is not resolved, proceed to step 2.
A) Obtain and record the Customer Passwords. Refer to Customer Passwords if the owner has lost them.
B) Use an electronic service tool to access Read Customer Specified Parameters from the ECM being replaced.
C) Use the Customer Specified Parameters Worksheet to record customer parameters.
2. Replace the faulty ECM
3. Obtain Factory Passwords
A) Record Engine Hours from the engine hourmeter
B) Use an electronic service tool to access Read/Change System Configuration Parameters. When the Factory Passwords Screen appears, record
the following information on the Factory Passwords Worksheet: ECM Serial Number, Engine Serial Number, Service Tool Serial Number, and Total
Tattletales.
C) Leave the electronic service tool on the Factory Passwords screen and obtain the passwords by providing the information on the Factory
Passwords Worksheet.
4. Program the new ECM.
A) Enter the Factory Passwords at the Factory Passwords Screen.
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B) Enter the Full Load Setting, Full Torque Setting, and Engine Serial Number recorded on the worksheet. Program the Personality Module
Diagnostic Code to 0 (zero) before leaving the screen. All the necessary System Configuration Parameters MUST be programmed before exiting this
screen or a new set of passwords will be required.
NOTE: If the Customer Specified Parameters are entered before System Configuration Parameters, the Total Tattletales will change. It will then be
necessary to obtain another set of Factory Passwords to access the System Configuration Parameters.
C) Access the Read/Change Customer Specified Parameters and enter the original values recorded on the worksheet.
D) Use the electronic service tool to access Calibrate/Monitor Sensors and calibrate the Boost Pressure Sensor and Rack Position Sensor. Refer to
P-527: Inlet Manifold (Boost) Pressure Sensor and P-317: Rack Position Sensor Calibration.

Factory Passwords Worksheet

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Customer Specified Parameter Worksheet

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C opyright 1993 - 2016 C ate rpillar Inc.


All R ights R e se rve d.
Private Ne twork For SIS Lice nse e s.

3412 Generator Set 4BZ00001-UP(SEBP2785 - 27) - Document Structure

Sun Mar 13 2016 12:33:50 GMT+0200 (Egypt Standard Tim e )

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