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Product: GENERATOR SET
Model: 3412 GENERATOR SET DK6
Configuration: 3412 Generator Set DK600001-UP

Troubleshooting
3412 Generator Set
Media Number -UENR0986-01 Publication Date -01/08/2015 Date Updated -14/06/2016

i06732695

ECM - Replace
SMCS - 1901-510

The Engine Control Module (ECM) contains no moving parts. Replacement of the ECM can be costly. Replacement can also be a time consuming task. Follow
the troubleshooting procedures in this manual to ensure that replacing the ECM will correct the problem. Verify that the suspect ECM is the cause of the
problem.

A test ECM can be used to determine if the ECM is faulty. Refer to Troubleshooting, "Test ECM Mode".

Note: Do not interchange the primary ECM with the secondary ECM to determine if an ECM is faulty. If replacement of both modules is necessary,
replace the modules one at a time. Failure to program each ECM correctly may result in improper engine operation.

NOTICE
If the flash file and engine application are not matched, engine damage
may result.

Perform the following procedure to replace the ECM:

1. Record the configuration data:

a. Try to establish communication between the Cat® Electronic Technician (ET) and the ECM. Proceed to Test Step 2 if Cat ET does not
communicate with the ECM.
 b. Print the parameters from the "Configuration" screen on Cat ET. If a printer is unavailable, record all the parameters.

c. Obtain the customer passwords. Access the customer specified parameters with Cat ET. Record the value of each customer parameter.

Record ECM lifetime totals.________

Record any logged diagnostic codes. ________

Note: If the customer passwords are not available, proceed to Troubleshooting, "Customer Passwords" for details that are related to customer
passwords.

d. Use the "Copy Configuration/ECM Replacement" feature that is found under the "Service" menu on Cat ET. Select "Load from ECM" to copy the
configuration data from the suspect ECM.

Note: If the "Copy Configuration" process fails and the parameters are not obtained in Step 4.f, the parameters must be obtained elsewhere. Some
of the system configuration parameters are stamped on the engine information plate. Most of the parameters must be obtained from the factory.
Parameters that are related to customer specified parameters must be obtained from the customer or from the Original Equipment Manufacturer
(OEM).

2. Remove the ECM:

a. Remove the electrical power from the ECM.

b. Disconnect the P1 and P2 connectors.

NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any
spilled fuel immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.

c. Remove the fuel lines (if equipped) from the ECM.

d. Disconnect the ECM ground strap.

 e. Remove the mounting hardware at each corner of the ECM.

3. Install the replacement ECM:

a. Use the old mounting hardware to install the replacement ECM.

b. Reconnect the fuel lines (if equipped).

Note: Ensure that the ECM mounting hardware is installed correctly. The rubber grommets are used to protect the ECM from excessive vibration.
The ECM must be able to drift in the rubber grommets. If the installation is equipped with fuel lines, the fuel lines must not put tension on the
ECM.

c. Connect the ECM ground strap.

d. Connect the P1 and P2 connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

4. Configure the replacement ECM:

a. Flash program the latest available flash file into the ECM. Refer to Troubleshooting, "ECM Software - Install" for the correct procedure.

b. Use Cat ET to match the engine application and the interlock code if the replacement ECM was used for a different application.

c. If the "Copy Configuration" process from Step 4.f was successful, return to the "Copy Configuration/ECM Replacement" screen on Cat ET and
select "Program ECM". Proceed to Step 4.e when programming is complete.

d. If the "Copy Configuration" process from Step 4.f was unsuccessful, manually program the ECM parameters. The parameters must match the
parameters from Step 4.f.

e. Program the engine monitoring system, if necessary.

f. If necessary, install the injector trim files. Refer to Troubleshooting, "Injector Trim File - Install".

g. Calibrate the engine speed/timing if there is a diagnostic code for speed/timing sensor calibration. The procedure is in Troubleshooting, "Timing -
Calibrate".

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