Using The DDT NEXG4526 Electronic Ignition System Monitor Functions Service Program Module{1900} Caterpillar

Introduction

This Tool Operating Manual describes the available features of the Service Program Module (SPM) when placed in the Digital Diagnostic Tool (DDT).

The features of this SPM are intended for use with an engine equipped with a stand-alone Electronic Ignition System.

A detailed menu chart is given in this manual to assist in using the DDT.

For each specific operation a detail description is given this manual on how to perform the operation on the DDT.

In the event a problem occurs during a specific operation, a troubling shooting guide is available in this manual.

Also provided in this manual are procedures for connecting the DDT to the application to be serviced, procedure for replacing the SPM in the DDT, and a complete description of the DDT.

NEXG4526 Contents

1. NEXG4526 ... Service Program Module

2. NEHS0621-00 ... Operating manual
(Now shown) NEEG2632 ... Case lid label
(Not shown) NEEG2306 ... DDT back label

NOTE: NEEG forms may not be included in automatic updates of NEXG4526.

Disclaimer

The features of this SPM may or may not be functional on some applications.

This may be due to manufacturing design changes.

All information, illustrations, and specifications in this manual are based on current information at the time of printing.

The right is reserved to make changes at any time without notice.

DDT Glossary

Service Program Module Installation

NOTE: Service Program Module updates for the DDT will be available through AVSpare.

The Service Program Modules are packaged in a protective container. Use care when opening to prevent damage to the program module.

1. Place DDT (1) face down on a clean and level surface.

2. Remove six screws (2) holding cover (3) in place and remove cover for access to DDT circuit board (4).

3. Locate Service Program Module socket (5) on circuit board (4).

The use of any mechanical tool can damage the Service Program Module or socket.

4. Install Service Program Module (6) from Conversion Group into empty socket (5).

NOTE: The Service Program Modules and sockets are keyed so that they can only be installed in the correct (seated) position.

5. Reinstall cover panel (3) using six screws (2).

Decal Installation

1. Place the 6V3072 carrying case (1) on a clean surface with the handle toward you as shown.

2. Remove paper backing of the case decal (2) and install on case lid insert with bottom of decal facing handle side of case.

1. Place DDT (1) face down on a clean and level surface.

2. Remove paper backing of the DDT Back Graphic Decal (2) and install on DDT back cover.

Power And Data Link Connector

1. Locate data link connector on Electronic Control Module (ECM) wiring harness.

2. Connect 7X1685 Cable to DDT connector.

3. Connect the remaining end of 7X1685 Cable (1) to Control Port (2) on the DDT (3).

NOTE: for CSA environments a 7X1414 adapter cable is needed to connect to a 10 pin MS connector or a 7X1415 adapter cable is needed to connect to a 4 pin MS connector.

The DDT will turn ON when battery power is supplied to the electronic control module.

DDT Description

1. LCD is the window which all screens are displayed.

2. CONTROL port communicates with the Electronic Control Module (ECM) through the 7X1685 Cable Assembly

3. PWM SENSOR port measures pulse width modulated (PWM) and frequency signals using the 8T5277 Cable (probe)

4. Pressing the CLEAR key will:

* clear a Fault Screen

* clear a Warning Screen

* clear data inputted while displaying a Customer Specified Parameter (CSP) change screen

* will automatically enter the 0 key followed by the 1 key

5. Pressing the SELECT MODE key will scroll to the next available Menu each time the key is pressed

6. Pressing the SELECT FUNC key will scroll to the next available Function each time the key is pressed

7. Pressing the ENTER key will:

* submit data inputted while displaying a Customer Specified Parameter (CSP) change screen

* display the Menu or Function whose 2 digit code number is displayed on the LCD

8. Pressing the ALT1 key will alternate between displaying a Customer Specified Parameter (CSP) and a CSP change screen

9. Pressing the ALT2 key will alternate between displaying the first set of diagnostic codes and the second set of diagnostic codes if present

Power ON Screen

Fig. 1.1

Power ON Screen (Fig. 1.1) appears when power is applied to the DDT.

It will be left on the display momentarily while the DDT performs internal diagnostic checks.

Copyright Screen

Fig. 1.2

The Copyright Screen (Fig. 1.2) appears after the Power ON Screen and is displayed only momentarily.

DDT Fault Screens (When Initial Power Is Applied)

If the DDT does not go to the Diagnostic Fault Codes Screen, then a DDT Fault Screen will be displayed (Fig. 1.3 - 1.6).

Fig. 1.3

If FAULT #E0 appears on the display (Fig. 1.3), the DDT has found an internal fault. The fault found will not allow the DDT to operate properly. Refer to Service in this manual for information on how to return the DDT for service.

Fig. 1.4

If FAULT #E1 appears on the display (Fig 1.4), the DDT has found an internal fault. The fault found will not allow the DDT to operate properly. Refer to Troubleshooting the DDT in this manual.

Fig. 1.5

If FAULT #E2 appears on the display (Fig. 1.5), the DDT has found a communication fault. The fault found will not allow the DDT to operate properly. Refer to Troubleshooting the DDT in this manual.

Fig. 1.6

If FAULT #E6 appears on the display (Fig. 1.6), the DDT has found a incompatible fault. The fault found will not allow the DDT to operate properly. Refer to Troubleshooting the DDT in this manual.

How To Access A Menu Or Function Directly

To go quickly to a particular Menu or Function, use the Direct Access method.

Enter the desired Menu or Function two digit code number. The code number will be shown on the LCD display. Pressing the ENTER key will display the desired Menu or Function on the LCD.

Note that a Menu or Function can not be directly accessed if the LCD is displaying a warning screen or a fault screen.

Example of how to directly access the Software Version Screen (the Software Version Screen code number is 00):

* Press SELECT MODE key

* Press 0 key

* Press 0 key

* Press ENTER key

Fig. 1.7

Software Version Screen (Fig. 1.7) displayed on the LCD.

How To Scroll To A Menu

To scroll to the next Menu press the SELECT MODE key.

Repeated pressing of the SELECT MODE key will advance the tool through all available Menus.

When all available Menus have been scroll though, the Menu from which the scrolling had started will reappear and the scrolling process can be repeated.

The Scrolling Access operates in a circular fashion.

An example of scrolling from the current Menu to the next Menu:

Fig. 1.8

Diagnostic Fault Code Screen (Fig. 1.8) displayed on the LCD.

* Press SELECT MODE key

Fig. 1.9

Status Menu Screen (Fig. 1.9) displayed on the LCD.

How To Scroll To A Function

To scroll to the next Function press the SELECT FUNC key.

Repeated pressing of the SELECT FUNC key will advance the tool through all available Functions.

When all available Functions have been scroll though, the Function from which the scrolling had started will reappear and the scrolling process can be repeated.

The Scrolling Access operates in a circular fashion.

An example of scrolling from the current Function to the next Function:

Fig. 1.10

Any Function screen (Fig. 1.10) displayed on the LCD.

* Press SELECT FUNC key

Fig. 1.11

Next Function screen (Fig. 1.11) displayed on the LCD.

Trouble Shooting The DDT

LCD display is blank

* Disconnect and reconnect the 7X1685 cable or

* Replace 7X1685 cable or

* Service is required

LCD display top line is black and bottom line is blank

* Disconnect and reconnect the 7X1685 cable or

* Pull out and reinsert the Service Program Module or

* Service is required

LCD display bottom line shows 'FAULT #E0'

* Service is required

LCD display bottom line shows 'FAULT #E1'

* Pull out and reinsert Service Program Module or

* Service is required

LCD display bottom line shows 'FAULT #E2'

* Press CLEAR key to clear fault condition or

* Check to see that the application is powered or

* Disconnect and reconnect the 7X1685 cable or

* Check for power ON at the electronic control module

LCD display bottom line shows 'FAULT #E4'

* Turn engine off but leave power ON at the electronic control module

* Press CLEAR key to clear fault condition

LCD display bottom line shows 'FAULT #E6'

* Call service to verify that the software version number is the current version for the application

* Check the procedure for a 'FAULT #E2' if the version number is current for the application

LCD display bottom line shows 'SERVICE, KEYPAD'

* Service is required

LCD display bottom line shows 'NO FAULTS'

* Normal, no faults have been received

LCD display bottom line shows 'VALUE TOO LO'

* Press CLEAR key

LCD display bottom line shows 'VALUE TOO HI'

* Press CLEAR key

LCD display top line shows 'INVALID CODE'

* Enter a valid unique 2 digit menu or function number

LCD display does not change when the 0 key is pressed while entering a change to a parameter

* Only one leading zero is allowed while entering a parameter

LCD display does not change when (0 - 9) key is pressed while entering a change to a parameter

* The maximum allowable characters have been entered for the parameter

Specifications

Read Only Storage: 16384 bytes of Read Only Memory (ROM)

Operating Temperature: 0°C (32°F) to 70°C (158°F)

Storage Temperature: -10°C (14°F) to 70°C (158°F)

Service

Use the following list to direct troubleshooting questions or information on service and warranty.

Phone - Toll Free Numbers

Outside Illinois 1-800-542-8665

Inside Illinois ... 1-800-541-8665

Canada ... 1-800-523-8665

U.S. Mail

Telex

Number 404435

Attn: AVSpare Service Technology Group

Unit less than one year old will be repaired under warranty (except for abuse). The cost of out-of-warranty repairs will be charged to the owner. Contact AVSpare Service Technology Group for details.

Servicing The Electronic Ignition System Control

Introduction

This Service Program Module (SPM) will service the Electronic Ignition System (EIS) Control.

NOTE: If a 401 through 416 diagnostic code is displayed with a 12 following it, noisy spark plug or transformer, then ignore all other diagnostic codes until the 401 through 416-12 diagnostic codes have been corrected. Correction of the 401 through 416-12 diagnostic code typically requires removal of spark plug in question.

The following service information can be displayed with the SPM installed in the Digital Diagnostic Tool (DDT):

* 300-03 Primary return shorted high

* 300-04 Primary return shorted to +battery or -battery

* 301-05 Transformer 1, open circuit primary

* 301-06 Transformer 1, short circuit primary

* 301-12 Transformer 1 output shorted to return

* 302-05 Transformer 2, open circuit primary

* 302-06 Transformer 2, short circuit primary

* 302-12 Transformer 2 output shorted to return

* 303-05 Transformer 3, open circuit primary

* 303-06 Transformer 3, short circuit primary

* 303-12 Transformer 3 output shorted to return

* 304-05 Transformer 4, open circuit primary

* 304-06 Transformer 4, short circuit primary

* 304-12 Transformer 4 output shorted to return

* 305-05 Transformer 5, open circuit primary

* 305-06 Transformer 5, short circuit primary

* 305-12 Transformer 5 output shorted to return

* 306-05 Transformer 6, open circuit primary

* 306-06 Transformer 6, short circuit primary

* 306-12 Transformer 6 output shorted to return

* 307-05 Transformer 7, open circuit primary

* 307-06 Transformer 7, short circuit primary

* 307-12 Transformer 7 output shorted to return

* 308-05 Transformer 8, open circuit primary

* 308-06 Transformer 8, short circuit primary

* 308-12 Transformer 8 output shorted to return

* 309-05 Transformer 9, open circuit primary

* 309-06 Transformer 9, short circuit primary

* 309-12 Transformer 9 output shorted to return

* 310-05 Transformer 10, open circuit primary

* 310-06 Transformer 10, short circuit primary

* 310-12 Transformer 10 output shorted to return

* 311-05 Transformer 11, open circuit primary

* 311-06 Transformer 11, short circuit primary

* 311-12 Transformer 11 output shorted to return

* 312-05 Transformer 12, open circuit primary

* 312-06 Transformer 12, short circuit primary

* 312-12 Transformer 12 output shorted to return

* 313-05 Transformer 13, open circuit primary

* 313-06 Transformer 13, short circuit primary

* 313-12 Transformer 13 output shorted to return

* 314-05 Transformer 14, open circuit primary

* 314-06 Transformer 14, short circuit primary

* 314-12 Transformer 14 output shorted to return

* 315-05 Transformer 15, open circuit primary

* 315-06 Transformer 15, short circuit primary

* 315-12 Transformer 15 output shorted to return

* 316-05 Transformer 16, open circuit primary

* 316-06 Transformer 16, short circuit primary

* 316-12 Transformer 16 output shorted to return

* 317-08 Noisy load sensor signal

* 317-11 No load sensor signal

* 318-01 No right bank detonation sensor signal

* 318-03 Right bank detonation sensor output shorted high

* 318-05 Right bank detonation sensor output shorted low or open circuit

* 319-01 No left bank detonation sensor signal

* 319-03 Left bank detonation sensor output shorted high

* 319-05 Left bank detonation sensor output shorted low or open circuit

* 320-05 Speed/timing sensor open or shorted high

* 320-07 Speed/timing wheel reverse rotation

* 320-08 Noisy signal from speed/timing sensor

* 321-04 Diagnostic reset switch shorted

* 322-03 Shutdown relay driver shorted high

* 322-05 Shutdown relay driver open or shorted low

* 323-03 Shutdown lamp driver shorted high

* 323-05 Shutdown lamp driver open or shorted low

* 324-03 Warning lamp driver shorted high

* 324-05 Warning lamp driver open or shorted low

* 325-00 Excessive detonation shutdown

* 326-01 Detonation retarded timing (on at 0.1 degrees retard, off at 0)

* 327-02 Number of detonation sensors mismatch

* 328-02 Number of cylinders mismatch

* 329-11 Communication fault with A/F ratio control

* 330-11 Propane timing mode requested

* 331-11 Ignition shutdown requested

* 401-00 Cylinder 1, spark plug maintenance needed

* 401-05 Transformer 1, open circuit secondary

* 401-06 Transformer 1, short circuit secondary

* 401-12 Cylinder 1, noisy spark plug or transformer

* 402-00 Cylinder 2, spark plug maintenance needed

* 402-05 Transformer 2, open circuit secondary

* 402-06 Transformer 2, short circuit secondary

* 402-12 Cylinder 2, noisy spark plug or transformer

* 403-00 Cylinder 3, spark plug maintenance needed

* 403-05 Transformer 3, open circuit secondary

* 403-06 Transformer 3, short circuit secondary

* 403-12 Cylinder 3, noisy spark plug or transformer

* 404-00 Cylinder 4, spark plug maintenance needed

* 404-05 Transformer 4, open circuit secondary

* 404-06 Transformer 4, short circuit secondary

* 404-12 Cylinder 4, noisy spark plug or transformer

* 405-00 Cylinder 5, spark plug maintenance needed

* 405-05 Transformer 5, open circuit secondary

* 405-06 Transformer 5, short circuit secondary

* 405-12 Cylinder 5, noisy spark plug or transformer

* 406-00 Cylinder 6, spark plug maintenance needed

* 406-05 Transformer 6, open circuit secondary

* 406-06 Transformer 6, short circuit secondary

* 406-12 Cylinder 6, noisy spark plug or transformer

* 407-00 Cylinder 7, spark plug maintenance needed

* 407-05 Transformer 7, open circuit secondary

* 407-06 Transformer 7, short circuit secondary

* 407-12 Cylinder 7, noisy spark plug or transformer

* 408-00 Cylinder 8, spark plug maintenance needed

* 408-05 Transformer 8, open circuit secondary

* 408-06 Transformer 8, short circuit secondary

* 408-12 Cylinder 8, noisy spark plug or transformer

* 409-00 Cylinder 9, spark plug maintenance needed

* 409-05 Transformer 9, open circuit secondary

* 409-06 Transformer 9, short circuit secondary

* 409-12 Cylinder 9, noisy spark plug or Transformer

* 410-00 Cylinder 10, spark plug maintenance needed

* 410-05 Transformer 10, open circuit secondary

* 410-06 Transformer 10, short circuit secondary

* 410-12 Cylinder 10, noisy spark plug or Transformer

* 411-00 Cylinder 11, spark plug maintenance needed

* 411-05 Transformer 11, open circuit secondary

* 411-06 Transformer 11, short circuit secondary

* 411-12 Cylinder 11, noisy spark plug or Transformer

* 412-00 Cylinder 12, spark plug maintenance needed

* 412-05 Transformer 12, open circuit secondary

* 412-06 Transformer 12, short circuit secondary

* 412-12 Cylinder 12, noisy spark plug or Transformer

* 413-00 Cylinder 13, spark plug maintenance needed

* 413-05 Transformer 13, open circuit secondary

* 413-06 Transformer 13, short circuit secondary

* 413-12 Cylinder 13, noisy spark plug or Transformer

* 414-00 Cylinder 14, spark plug maintenance needed

* 414-05 Transformer 14, open circuit secondary

* 414-06 Transformer 14, short circuit secondary

* 414-12 Cylinder 14, noisy spark plug or Transformer

* 415-00 Cylinder 15, spark plug maintenance needed

* 415-05 Transformer 15, open circuit secondary

* 415-06 Transformer 15, short circuit secondary

* 415-12 Cylinder 15, noisy spark plug or Transformer

* 416-00 Cylinder 16, spark plug maintenance needed

* 416-05 Transformer 16, open circuit secondary

* 416-06 Transformer 16, short circuit secondary

* 416-12 Cylinder 16, noisy spark plug or Transformer

* 591-12 Control Failure

* Engine RPM

* Actual and Desired Engine Timing

* Detonation Level

* Inlet Manifold Pressure

Glossary

ACT Actual

DEG Degree

DES Desired

DET Detonation

DDT Digital Diagnostic Tool

EIS Electronic Ignition System

ENG Engine

FUNC Function

kPa Kilopascal

hi High

LCD Liquid Crystal Display

lo Low

MAN Manifold

PR Pressure

RPM Revolutions Per Minute

SPM Service Program Module

TIM Timing

Menu Code Translation Chart

Function Code Translation Chart

Menu/Function Chart

How To Directly Access The Software Version Screen (Menu 00)

Fig. 2.1

* Press SELECT MODE key

* Press 0 key

* Press 0 key

* Press ENTER key

The Software Version screen (Fig. 2.1) will be displayed

How To View The Service Configuration Screen

Fig. 2.2

* Press SELECT MODE key

* Press 0 key

* Press 0 key

* Press ENTER key

* Press ALT2 key

The service configuration screen (Fig. 2.2) will be displayed

How To Directly Access The Diagnostic Fault Codes Screen (Menu 01)

Fig. 2.3

* Press SELECT MODE key

* Press 0 key

* Press 1 key

* Press ENTER key

The diagnostic fault code screen (Fig. 2.3) will be displayed

The method of displaying fault codes is called a circular display. Fault codes are displayed on the LCD one code per screen. Other fault codes maybe viewed by pressing the ENTER key. Each time the ENTER key is pressed, the next fault code is displayed. When all fault codes have been displayed, pressing the ENTER key will redisplay the first fault code. The circular display process continues as long as the ENTER key is pressed.

NOTE: If a 401 through 416 diagnostic code is displayed with a 12 following it, noisy spark plug or transformer, then ignore all other diagnostic codes until the 401 through 416-12 diagnostic codes have been corrected. Correction of the 401 through 416-12 diagnostic code typically requires removal of spark plug in question.

How To View The Status Menu Screen (Menu 02)

Fig. 2.4

* Press SELECT MODE key

* Press 0 key

* Press 2 key

* Press ENTER key

The status menu screen (Fig. 2.4) will be displayed

How To View The Actual Engine RPM Screen (Function 10)

Fig. 2.7

* Press SELECT MODE key

* Press 1 key

* Press 0 key

* Press ENTER key

The actual engine RPM screen (Fig. 2.7) will be displayed

How To View The Actual And Desired Engine Timing Screen (Function 11)

Fig. 2.8

* Press SELECT MODE key

* Press 1 key

* Press 1 key

* Press ENTER key

The actual and desired engine timing screen (Fig. 2.8) will be displayed

How To View The Detonation Level Bar Graph Screen (Function 12)

Fig. 2.9

* Press SELECT MODE key

* Press 1 key

* Press 2 key

* Press ENTER key

The detonation level bar graph screen (Fig. 2.9) will be displayed

How To View The Inlet Manifold Pressure Screen (Function 13)

Fig. 2.10

* Press SELECT MODE key

* Press 1 key

* Press 3 key

* Press ENTER key

The inlet manifold pressure screen (Fig. 2.10) will be displayed