“WinFlash”  Error Messages

If any error messages are displayed during flash

programming, click on the “Cancel” button in order to

stop the process. Access the information about the

“ECM Summary” under the  “Information”  menu.

Ensure that you are programming the correct flash file

for your engine.

If a 630-2 diagnostic trouble code is displayed after

flash programming, a required parameter is missing.

Program the missing parameter.

i05085410

Injector Code - Calibrate

Illustration 21

g02132457

Sequence for recording the injector code

Injector codes are codes that are 30 hexadecimal

characters in length that are supplied with each

injector. The code is on a plate on the top of the

injector and a card is also included in the packaging

for the injector. The code is used by the Electronic

Control Module (ECM) to balance the performance of

the injectors.

The electronic service tool is used to load the injector

codes into the ECM.

The injector codes must be loaded into the ECM if

any of the following conditions occur:

•   An electronic unit injector is replaced.

•   The ECM is replaced.

•   Diagnostic code 630-2 is active.

•   Electronic unit injectors are exchanged between

cylinders.

Note: Diagnostic code 630-2 will also become active

if the engine serial number, FLS or FTS are not

entered into the ECM.

If the ECM is replaced, the injector codes are

normally transferred to the new ECM as part of the

“Copy Configuration” procedure. If the “Copy

Configuration” procedure fails, the injector codes

must be loaded manually.

Installing Injector Codes

Note: The injector code is located on the electronic

unit injector.

1. Record the injector code for each electronic unit

injector.

Illustration 20

g02854936

Label with the injector code

2. Connect the electronic service tool to the

diagnostic connector. Refer to Troubleshooting,

“Electronic Service Tools”.

3. Turn the keyswitch to the ON position.

4. Select the following menu options on the electronic

service tool:

•   Service

•   Calibrations

•   Injector Trim Calibration

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KENR9101

37

Programming Parameters

5. Select the appropriate cylinder.

6. Click on the “Change”   button.

Mode Selection Switch Input 2 and

Mode Selection Switch Input 1

The number of these non-programmable parameters

that are visible depends on the value that is

programmed into the “Number of Switch Inputs”

parameter.  “Open” signifies that the switch is in the

OFF position. “Ground”  signifies that the switch is in

the ON position.

7. Input the applicable injector code that was

recorded in Test Step 1.

8. Click on the “OK”  button.

The injector code is loaded into the ECM.

Rating Enabled

9. Repeat the procedure for each cylinder, as

required.

If  “Yes” is selected on the drop-down menu, the

ECM is programmed to use the values that are

programmed into “Rating Number” ,  “Throttle 1

Droop Percentage” , “Throttle 2 Droop Percentage”

and  “TSC1 Droop Percentage” for the given

combination of switch positions.

Exchanging Electronic Unit Injectors

Exchanging electronic unit injectors can help

determine if a combustion problem is in the electronic

unit injector or in the cylinder. If two electronic unit

injectors that are currently installed in the engine are

exchanged between cylinders, the injector codes

must also be exchanged. Press the “Exchange”

button at the bottom of the “Injector Trim Calibration”

screen on the electronic service tool. Select the two

electronic unit injectors that will be exchanged and

press the “OK”  button. The tattletale for the

electronic unit injectors that were exchanged will

increase by one.

Table 8

Values

Default

Factory Password

Yes

No

No

No

High Idle Speed

The  “High Idle Speed” is the maximum engine rpm.

i03771589

Table 9

Mode Switch Setup

Minimum

Maximum

Default

1800 rpm

2800 rpm

2420 rpm

The Mode Switches can be used to change the

performance characteristics of the engine. The

electronic service tool is used to program the

characteristics. Select the “Service”   drop-down

menu and then select “Engine Operating Mode

Configuration” . A maximum of two switches can be

used.  “Switch 1” is connected to J1:62Mode Switch

1.  “Switch 2” is connected to J1:64Mode Switch 2.

The other contact on both switches is connected to

J1:18Switch Return.

Rating Number

This parameter is the engine rating that is used by the

Electronic Control Module (ECM) for a given

combination of switch positions. There is a maximum

of four ratings in a flash file.

Table 10

Range

Default

Factory

Password

Number of Switch Inputs

1 to the maximum

number of ratings in

the currently installed

Flash File

1

No

This configuration parameter is the total number of

switches that are used. The switches can be

individual switches or a multiple rotary switch.

Table 7

Rated Speed (RPM)

Range

Default

This parameter represents the engine speed that is

selected when the mode switch or the mode switches

are in a particular position.

0 to 2

0

Mode Selection Number

Table 11

Range

Default

Factory

Password

This parameter is a non-programmable parameter

that represents the number of possible combinations

of switch positions. This parameter is based on the

value that is programmed into the  “Number of Switch

Inputs”  parameter.

“Programmed Low

Idle” to  “Pro-

grammed High Idle”

2100 rpm

No

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KENR9101

Programming Parameters

Engine High Idle Speed (RPM)

i04105410

Throttle Setup

This parameter represents a maximum of 112% of the

rated speed that is selected when the mode switch or

the mode switches are in a particular position.

Table 12

There are two separate channels for throttle input.

The two channels can have any combination of a

digital throttle that uses a Pulse Width Modulated

(PWM) signal, an analog throttle or a multi-position

switched throttle.

Range

Default

Factory

Password

“1800 to 2800 rpm”   112% of rated speed

No

The Electronic Control Module (ECM) must be

programmed with the type of throttle input that is

being used in either position. From the menu, select

“Services” . On the “Services”  screen, select

“Throttle Configuration” . Select the type of throttle

from the following list:

Governor Type

This parameter represents the mode of operation of

the governor that is installed on the engine.

Table 13

Range

Default

Factory

•   No throttle

Password

•   Analog throttle

“Min/Max speed

(rpm)” or  “All

Speed”

All Speed

No

•   PWM throttle

•   Multi-position throttle switch

Throttle 1 Droop Percentage

The Electronic Control Module (ECM) must be

programmed for throttle arbitration. This parameter

determines which throttle input has priority. From the

menu, select “Services” . On the “Services”   screen,

select  “Throttle Arbitration” . Select the arbitration

method from the following list:

This parameter represents the amount of droop that

is applied to the “Throttle 1” input.

Table 14

Range

Default

Factory

Password

•   Highest Wins

•   Lowest Wins

•   Manual Switch

0 to 10 percent

5.0%

No

Throttle 2 Droop Percentage

The default setting for throttle arbitration is  “Highest

Wins”  .

This parameter represents the amount of droop that

is applied to the “Throttle 2” input.

Table 15

Range

Default

Factory

Password

0 to 10 percent

5.0%

No

TSC1 Droop Percentage

This parameter represents the amount of droop that

is applied to the “Torque Speed Control 1(TSC1)”

input.

Table 16

Range

Default

Factory

Password

0 to 10 percent

5.0%

No

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KENR9101

39

Programming Parameters

Table 18

Range

Default

0 to 100%

10%

Initial Lower Position Limit

This parameter is the maximum throttle percentage

that will be interpreted by the ECM as zero throttle.

This parameter is used with the value of the lower

position limit to make an allowance for manufacturing

tolerances between different pedals.

Table 19

Range

Default

0 to 100%

20%

Idle Validation

All analog throttles and digital throttles can have an

idle validation switch. If this parameter is programmed

to  “Yes” , the ECM will look for this switch input on pin

J1:22 for Idle Validation Switch 1 (IVS1) and J1:40 for

Idle Validation Switch 2 (IVS2).

Illustration 22

g01785156

Typical Range of Throttle

(1) Lower Diagnostic Limit (Default=5)

(2) Lower Position Limit (Default=10)

(3) Initial Lower Position (Default=20)

(4) Idle Validation Minimum Off Threshold (Default=21)

(5) Idle Validation Maximum On Threshold (Default=25)

(6) Lower Dead Zone % (Default=8)

Table 20

Values

Default

No

Yes

No

(7) Upper Dead Zone % (Default=5)

(8) Initial Upper Position (Default=70)

(9) Upper Position Limit (Default=85)

(10) Upper Diagnostic Limit (Default=95)

Idle Validation Minimum Off (Open)

Threshold

Analog throttles and digital throttles require additional

programming. If a multi-position switch is selected,

additional parameters must be programmed. Refer to

the Troubleshooting Guide, “Multiposition Switch

Setup”. If an analog throttle or a digital throttle is

selected, the following parameters can be

This parameter is the minimum throttle percentage

that will be detected by the ECM when the IVS  is ON

(Closed).

If the ECM detects a throttle percentage below this

value with the idle validation switch OFF (Open), a

fault code will be generated and the engine will

remain at idle.

programmed into the ECM.

Lower Diagnostic Limit

This parameter is the minimum throttle percentage

that should be detected by the ECM in normal

operation when the pedal is in the  “off”  position. A

value below this limit will generate a short circuit

diagnostic code. The range of this diagnostic

detection area is from 0 percent to the programmed

value for the lower position limit.

Refer to Table 21 and Table 22 .

Table 17

Range

Default

0 to 100%

5%

Lower Position Limit

This parameter is the minimum throttle percentage

that will be interpreted by the ECM as zero throttle.

This parameter is used with the value of initial lower

position limit to make an allowance for manufacturing

tolerances between different pedals.

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KENR9101

Programming Parameters

Table 21

Throttle Position Sensor  Idle Validation Switch (IVS) Throttle Demand Output

(TPS)

Fault Status

Comment

TPS< IVS Min OFF

TPS< IVS Min OFF

OFF

ON

Minimum Position

Throttle Position

Raise IVS fault

No fault

Force throttle demand to

minimum

Normal operation

Table 22

Range

Default

0 to 100%

21%

Idle Validation Maximum On

(Closed) Threshold

This parameter is the maximum throttle percentage

that will be detected by the ECM when the idle

validation switch (IVS) is OFF (Open) . When the idle

validation switch is OFF (Open) and the ECM detects

a signal that is higher than the programmed value for

IVS Max ON , the ECM will generate a fault code and

the engine will remain at idle.

Refer to Table 23 and Table 24 .

Table 23

Throttle Position Sensor  Idle Validation Switch (IVS) Throttle Demand Output

(TPS)

Fault Status

Comment

TPS> IVS Max ON

TPS< IVS Min Off

OFF

ON

Throttle Position

Minimum Position

No fault

Normal operation

Raise IVS fault

Force throttle demand to

minimum

Table 24

Initial Upper Position Limit

Range

Default

This parameter is the minimum throttle percentage

that will be interpreted by the ECM as full throttle.

This parameter is used with the value of the upper

position limit to make an allowance for manufacturing

tolerances between different pedals.

0 to 100%

25%

Lower Dead Zone

Table 27

This parameter is a throttle range above the initial

lower position limit before the engine will increase in

rpm.

Range

Default

0 to 100%

70%

Table 25

Range

Default

Upper Position Limit

0 to 100%

5%

This parameter is the maximum throttle percentage

that will be interpreted by the ECM as full throttle.

This parameter is used with the value of the initial

upper position limit to make an allowance for

Upper Dead Zone

This parameter is a throttle range that is below the

initial upper position limit that does not allow the

engine speed to increase.

manufacturing tolerances between different pedals.

Table 28

Range

Default

Table 26

0 to 100%

85%

Range

Default

0 to 100%

5%

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KENR9101

41

Programming Parameters

Upper Diagnostic Limit

Physical Position Enabled

This parameter is the minimum throttle percentage

that is detected by the ECM in normal operation when

the pedal is in the maximum position. A value above

this limit will generate an open circuit diagnostic code.

The range of this diagnostic detection area is from the

programmed value of the upper position limit to 100

percent.

If  “Yes” is selected from the drop-down menu, the

ECM sets the engine rpm to the value that is

programmed into the “Engine Speed”  for the

configuration of the switches that is defined for that

Physical Position.

Table 31

Value

Default

Table 29

No

Yes

No

Range

Default

0 to 100%

95%

Logical Position

i04105411

The Logical Position is the order that is required by

the user for a unique Physical Position.

Multiposition Switch Setup

Table 32

Range with Four Switches

Default

Note: The multi-position throttle switch can only be

enabled if the optional PTO switches are not installed.

1 to 16

1

The multi-position throttle switch is an optional throttle

input. A maximum of four switches can be used. Four

switches will allow a maximum of 16 speeds to be

selected.

Engine Speed (in RPM)

The  “Engine Speed” is the programmed engine rpm

for a particular position of the multi-position throttle

switch.

If an optional intermediate engine speed switch is

installed, the multi-position throttle switch can have a

maximum of three switches. Three switches will allow

a maximum of eight speeds to be selected.

If the ECM detects a switch combination that has

been configured as “No” , a fault code will be

generated. In this situation, the ECM will ignore the

multi-position switch until the keyswitch is cycled

through OFF and ON.

When the multi-position switch is selected as the

“Throttle Type” on the  “Throttle Configuration

Screen”  of the electronic service tool, additional

information is required.

Table 33

Range

Default

Number of Switch Inputs

Programmed Low Idle to Pro-

grammed High Idle

0

This parameter is the total number of switches that

will be used. The switches may be individual switches

or a ganged rotary switch.

Table 30

Range

Default

1 to 4

0

Physical Position

This parameter is non-programmable. The parameter

is used to signify the position of the rotary switch.

Input 4, Input 3, Input 2, Input 1

The number of these non-programmable parameters

that are visible depends on the value that is

programmed into the “Number of Switch Inputs”

parameter.  “Open” signifies that the switch is in the

OFF position. “Ground”  signifies that the switch is in

the ON position.

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KENR9101

Customer Specified Parameters

Customer Specified

Parameters

Speed Control

Low Idle Speed

The  “Low Idle Speed” is the minimum engine rpm.

Table 36

Minimum

Maximum

Default

i04805671

700 rpm

1200 rpm

750 rpm

Customer Specified

Parameters

Engine ConfigurationParameters

Ether Solenoid Configuration

Customer specified parameters allow the engine to

be configured to the exact needs of the application.

The ether solenoid configuration defines the

presence of a solenoid for an ether starting aid.

Customer passwords are required in order to change

this parameter.

Customer parameters may be changed repeatedly as

operational requirements change.

The following information is a brief description of the

customer specified parameters. The following

parameter values are included with the descriptions:

Table 37

Value

Default

Not Installed

Continuous Flow Solenoid

•   Minimum

•   Maximum

•   Default

Not Installed

Engine Idle Shutdown

The Engine Idle Shutdown parameters define the

engine response when the keyswitch is turned to the

OFF position.

ECM IdentificationParameter

Equipment ID

Minimum Ambient Air Temperature

“Equipment ID” is the identification of the equipment

that is assigned by the customer. The  “Equipment ID”

is only for reference by the customer. The

“Equipment ID” is not required by the Electronic

Control Module (ECM).

Table 38

Value

Default

0 to 29 Degrees C

0 Degrees C

Table 34

Value

Default

Maximum Ambient Air Temperature

17 digits

The available characters are de-

pendent on the service tool that

is being used.

Table 39

Not programmed

Value

Default

30 to 100 Degrees C

30 Degrees C

Engine Rating Parameter

Shutdown Enable Status

Rating Number

Table 40

The rating number is the selected rating within a

power rating family. The flash file defines the power

rating family. The flash file can contain one to four

ratings. The rating number defines the power rating

that is used within the power rating family.

Value

Default

Enabled

Disabled

Disabled

Table 35

Shutdown Delay Time

Minimum

Maximum

Default

Table 41

1

4

1

Value

Default

1 to 60 minutes

5 minutes

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KENR9101

43

Customer Specified Parameters

Ambient Temperature Override Enable

Status

Multiple Engines on J1939

Engine Location

Table 42

In a situation where multiple engines communicate on

one J1939 channel, the Engine Location parameter

defines the identity of each engine in the set.

Value

Default

Enabled

Disabled

Disabled

Table 47

Value

Default

Air Shutoff

Engine #1

Engine #2

Engine #3

Engine #4

Engine #5

Air Shutoff

Engine #1

The Air Shutoff parameter defines whether an air

shutoff valve is installed in the air inlet for the engine.

Table 43

PTO and Throttle Lock Parameters

Value

Default

Enabled

Disabled

Throttle Lock Feature InstallationStatus

Disabled

Note: PTO and a multi-position throttle switch cannot

be installed at the same time.

Aftertreatment Configuration

The  “Throttle Lock Feature Installation Status”  is

used to turn on the throttle lock features. When this

parameter is changed to “Installed” , the following

parameters are active and the parameters can be

programmed.

ARD Auto Regeneration Enable Status

The  “ARD Auto Regeneration Enable Status”

parameter determines whether automatic ARD

regeneration is enabled.

•

•

•

“PTO engine Speed Setting”

Table 44

“Throttle Lock Increment Speed Ramp Rate”

“Throttle Lock Engine Set Speed Increment”

Value

Default

Disabled

Enabled

Enabled

Table 48

Value

Default

DPF #1 Soot Loading Sensing System

ConfigurationCode

Not Installed

Installed

Not Installed

The  “DPF 1 Soot Loading Sensing System

Configuration Code” parameter determines the type

of diesel particulate filter #1soot loading sensing

system . This parameter identifies orientation of soot

sensor, and the geometry of the DPF.

PTO Mode

PTO mode can be configured to operate in either Set/

Resume  mode or Ramp up/Ramp down  mode. Set/

Resume  mode allows the engine speed to be

controlled by the operator through switch inputs. This

mode allows two specific speeds to be set and stored

in the ECM. A speed can be selected or the

previously selected speed can be resumed.

Adjustments in engine speed can then be made via

the raise and lower switch inputs. Ramp up/Ramp

down  mode only allows the engine speed to be

raised or lowered via switch inputs at a desired ramp

rate. The “Set”  and  “Resume” functions are

disabled.

Table 45

Value

Default

20(Hex) to 7F(Hex)

0

High Soot Load AftertreatmentProtection

The  “High Soot Load AftertreatmentProtection”

parameter determines whether aftertreatment

protection is enabled .

Table 49

Value

Default

Table 46

Value

Default

Ramp Up/Ramp Down

Set/Resume

Set/Resume

Disabled

Enabled

Disabled

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