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ECM Replacement Procedures

Replacing The Electronic Control Module With A New ECM

The Electronic Control Module (ECM) is the heart of the Electronic Control System used on the 3126
Industrial Engine. The ECM contains no moving parts, has a very high reliability rating and replacement
can be time consuming. Most problems occur in the connectors, wiring, or sensors. Follow the
troubleshooting procedures outlined in this guide. DO NOT replace an ECM on speculation!

To ensure the suspect ECM is the cause of the problem, temporarily connect a new or test (known good)
ECM, before replacing the old ECM. To temporarily connect a test ECM you must transfer the
Personality Model data from the old ECM to the test ECM and program any necessary parameters
required for testing (the parameters must be programmed exactly as they were in the old ECM.) Refer to
the following test steps for details. If the test ECM resolves the problem, reconnect the old ECM and
verify the problem returns. If the problem returns, replace the old ECM.

The parameters stored in the ECM to be replaced, must be read with an Electronic Service Tool and
recorded. The Personality Module from the old ECM must be FLASH downloaded to the new ECM.
After the new ECM is installed on the engine, the parameters recorded from the old ECM must be
programmed into the new ECM and the injection timing must be recalibrated.

NOTE: If the parameters cannot be read they must be obtained elsewhere. Some parameters are
stamped on the Engine Information Plate, but most parameters must be obtained from the user or dealer
that installed the engine.

The following procedure is a summary of the basic steps necessary to program a replacement ECM.

1: Use a copy of the Read/Change Parameters Worksheet in this manual to record the Parameters from
the ECM being replaced.

NOTE: It is recommended to record any Logged Events also.

(a) Use the Communication Adapter Tool and connect ET to access Parameters from the ECM
being replaced.

(b) Record the Parameters listed on the worksheet.

2: Replace the faulty ECM.

(a) Turn the keyswitch to the OFF position.

(b) Use a 4 mm Allen wrench to disconnect both 40-Pin Deutsch connectors.

(c) Remove the fuel lines, ECM mounting bolts and disconnect the ECM ground strap.

Use caution when removing fuel lines. The fuel may be under pressure

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and can penetrate body tissue.

d) DO NOT lose any of the ECM mounting hardware (i.e. rubber grommets, spacers and
washers).

e) Ensure the old ECM's mounting hardware is free of damage and use it to install the new ECM.
Reconnect the fuel lines. Ensure the ECM mounting hardware is installed correctly. Verify the
fuel lines are not tugging or pulling on the ECM. The rubber grommets are used to protect the
ECM from excessive vibration. When installed correctly, the ECM can drift in the rubber
grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines are not
pulling the ECM against one side of the grommets.

(f) Reconnect the 40-Pin Deutsch connectors and the ground strap to the ECM.

3: Always use FLASH downloading whenever possible. Use ET to FLASH download the Personality
Module information into the ECM (refer to the instructions included with JERD2124 ET Software and
the JERD2129 ET Data Subscription for more information).

(a) Connect ET through the Communication Adapter Tool.

(b) Turn the keyswitch to the ON position.

(C) Select the FLASH Download option from the ET menu.

(d) Select the appropriate file to be downloaded from a disk on the laptop PC. Use an Electronic
Service Tool to program the Read/Change Parameters

(e) Enter all the parameters recorded in Step 1, Full Load Setting, Engine Serial Number, etc.

(f) Due to the ECAP's limited abilities you may not be able to program all the needed parameters.

4: Calibrate the Injection Timing. Use the Electronic Service Tool to select Monitor/Calibrate Timing
option to calibrate the Timing (Refer To P-614: Speed/Timing Sensor Calibration).

Replacing The Electronic Control Module With An Old ECM

In extreme circumstances, (when a new ECM replacement is not available) you may have to remove an
ECM from an engine that is not in service. If the replacement ECM is not from the same application as
the current ECM, the ECM engine application and Personality Module Interlock will have to be
matched.

NOTICE
If the Personality Module and engine application are not matched,
engine damage may result.

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The Electronic Control Module (ECM) is the heart of the Electronic Control System used on the 3126
Industrial Engines. The ECM contains no moving parts, has a very high reliability rating and
replacement can be time consuming. Most problems occur in the connectors, wiring, or sensors. Follow
the troubleshooting procedures outlined in this guide. DO NOT replace an ECM on speculation! Be
certain that replacing the ECM is required to correct the problem.

The parameters stored in the ECM to be replaced, must be read with an Electronic Service Tool and
recorded. The Personality Module from the old ECM must be FLASH downloaded to the new ECM.
After the new ECM is installed on the engine, the parameters recorded from the old ECM must be
programmed into the new ECM and the injection timing must be recalibrated.

NOTE: If the parameters cannot be read they must be obtained elsewhere. Some parameters are
stamped on the Engine Information Plate, but most parameters must be obtained from the user or dealer
that installed the engine.

The following procedure is a summary of the basic steps necessary to program a replacement ECM.

1: Use a copy of the Read/Change Parameters Worksheet in this manual to record the Parameters from
the ECM being replaced.

NOTE: It is recommended that the Logged Events are recorded also.

(a) Use the Communication Adapter Tool and connect ET to access Parameters from the ECM
being replaced.

(b) Record the Parameters listed on the worksheet.

2: Replace the faulty ECM.

(a) Turn the keyswitch to the OFF position.

(b) Use a 4 mm Allen wrench to disconnect both 40-Pin Deutsch connectors.

(c) Remove the fuel lines, ECM mounting bolts and disconnect the ECM ground strap.

Use caution when removing fuel lines. The fuel may be under pressure
and can penetrate body tissue.

(d) DO NOT lose any of the ECM mounting hardware (i.e. rubber grommets, spacers and
washers).

(e) Ensure the old ECM's mounting hardware is free of damage and use it to install the new ECM.
Reconnect the fuel lines. Ensure the ECM mounting hardware is installed correctly. Verify the
fuel lines are not tugging or pulling on the ECM. The rubber grommets are used to protect the
ECM from excessive vibration. When installed correctly, the ECM can drift in the rubber
grommets. If the ECM cannot be moved slightly in the grommets, check that the fuel lines are not

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pulling the ECM against one side of the grommets.

(f) Reconnect the 40-Pin Deutsch connectors and the ground strap to the ECM.

3: Always use FLASH downloading as outlined in this step whenever possible. Use ET to FLASH
download the Personality Module information into the ECM (Refer To The Instructions Included
With JERD2124 ET Software And The JERD2129 ET Data Subscription For More Information).

(a) Connect ET through the Communication Adapter Tool.

(b) Turn the keyswitch to the ON position.

(C) Select the FLASH Download option from the ET menu.

(d) Select the appropriate file to be downloaded from a disk on the laptop PC.

4: Use an Electronic Service Tool and Communication Adapter Tool to match the ECM and Personality
Module Interlock if the replacement ECM was used in a different application.

NOTE: For ET, refer to instructions included with JERD2124 ET Software and the JERD2129 ET Data
Subscription. For ECAP, refer to Special Instruction SEHS9343.

5: Use an Electronic Service Tool to program the Read/Change Parameters. Use the Read/Change
Parameters Menu item to perform the following.

(a) Enter all the parameters recorded in Step 1, Full Load Setting, Engine Serial Number, etc.

(b) Program the Engine Monitoring System, if applicable.

(c) Due to the ECAP's limited abilities you may not be able to program all the needed parameters.

6: Calibrate the Injection Timing. Use the Electronic Service Tool to select Monitor/Calibrate Timing
option to calibrate the Timing (refer to P-614: Speed/Timing Sensor Calibration).

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