Newsletter 25 September 2003 Version 1.1
Engine Information for: Instructors Technical Communicators Service Reps Worldwide The world economy is showing signs of revival. This is our chance to show show the world that we - the Dealer / Caterpillar Caterpillar team is indeed the best in the business. Excellence in training is a key success factor in product support and ultimately future sales.
The Editor’s Column New Service Training Manager Incoming Richard Mizanin has replaced Doug Stark as Service Training Manager. Richard comes from the NACD Rental and Used Equipment Services Group. Richard has broad product support experience including 12 years in dealer management with a variety of positions including service management and dealer training. His Caterpillar Caterpillar experience includes time time in Service Training Training and Service Rep. Positions. Positions. He is very customer oriented and with his broad background, comes very well equipped for the job. We welcome Richard to his new position in Service Training.
Outgoing Doug Stark, who was the Service Training Training Manager and regular contributor to this Newsletter has moved on to Moscow, Russia as Product Support Manager for the CIS (Confederation of Independent States) and Mongolia - a vast territory. He is responsib responsible le for Parts, Service, Service Training, and Business Systems. We thank Doug for his many contributions to Service Training.
Confidentiality Please use care in sharing the website content and information in these these Newsletters. Check page two for more on safeguarding our intellectual property.
Feedback A hot topic topic at this time time is Cat ET and Service Service Technician Workbench Workbench training. A new course is in progress and will be available electronically electronically later in the year. Training will follow. There have been many requests for STW/ET STW/ET training and training material. material. In the mean time, we will release material on issues requiring clarification. clarification. For example, there may be communications difficulties difficulties with the program and the interface device, the Communication Communication Adapter Adapter II. These issues like any other, become complicated if the user is not informed, but become relatively easy with the right information being available. available. Subject to this course being published, this Newsletter Newsletter contains some information which will fill that need. At the risk of being repetitive, material on the subject which was previously published has been updated and included to provide more complete information.
Thought for the Day Whether we are teaching our children or Caterpillar students in the classroom, here is a thought.
Example isn't another way to teach, it is the only way to teach Albert Einstein
Training Material Updates SIS Web Training Materials for Download
C-9 / C9 Training Material
The Service Training website has a link to a site which contains SIS Web (Service Information System) training material.
C-9 Material The C-9 (Industrial and Machine) Training Manual with slides and script has been updated and published in CD format. It is available individually and will also be included in both the Machine and Engine Training Material Subscriptions.
Use the following menus to download the training material: E-Learning Activities / Software /
This training material is now available in CD format using the following media number.
Service Information System - SIS Web Presentations
There are presentations in Adobe Acrobat and Microsoft Powerpoint formats.
SERH4050 C-9 Engine - Systems and Controls Engines with ACERT Technology
Feedback
There is also Training Material available for C9 OnHighway Engines with ACERT technology. This material is available on the Service Training website.
Suggestions for articles and subjects are welcome. Also updates and corrections are encouraged. Feedback on the Newsletter can be directed to the following address:
NOTE: The designation "C9" without the hyphen denotes an engine with ACERT technology. For more ACERT information, go to the January 02 Newsletter No. 22, page 6.
Nigel Wilkinson Caterpillar Inc. Service Training, Bldg. LC 1A-D 501 S.W. Jefferson St. Peoria IL 61630-2124 USA
Use the following URL to access the Service Training Website:
Email:
[email protected]
https://psmktg.cat.com/srvtrng
Double click on the URL below (or copy to the web browser) for current and last year's issues of the Tech Tips Newsletter:
Use the following menus for locating presentations on the website for the new engines: Material Downloads / NPI
https://psmktg.cat.com/srvtrng/download/resource/in dex.htm#engmu
NOTE: Information on the use of Injector Trim Files and injector calibration is contained in the C9 presentation.
Confidentiality Please use care in sharing the website content and information in these Newsletters. The Newsletters should be kept within our company/dealer organisation and should not be shared in electronic form outside the organization. If necessary, information can be extracted from the Newsletters with good judgement and shared with our customers.
STW Update Service Technician Workbench Course A Service Technician Workbench (STW) course which includes Electronic Technician (Cat ET) is in progress and will be available by the end of the year. Also training classes will be available at that time in Peoria. A segment of this course is described in the second half of this Newsletter (from page 4).
Newsletter Correction
The information is designed to help our dealer technical/training staff stay ahead of the technology which of necessity is proliferating. Included are the TCs as they are de-facto trainers.
The last Newsletter (No. 24) contained an error on the last page with the article "Rules of Thumb". There were degree symbols that appeared as zeros on the last line. This has been corrected on the web copy.
We need to take all necessary steps to safeguard our intellectual property. This means the entire team; both Caterpillar and Caterpillar Dealer staff. 2
Computers, Software and Web Stuff USB Cables
Cat ET Issues
The last issue (No. 24) contained information on the new USB Serial Adapter for Cat ET (listed below).
Cat ET Communication Diagnostics Cat ET (Electronic Technician) communication problems have arisen with computer Comm Ports being inadvertently disabled. This problem can happen for a variety of reasons. For example a conflict with another device such as a docking station or a Palm Pilot.
USB Serial Adapter - Part No: 237-7547 There have also been requests for information about a dedicated USB cable. Such a cable is now in the testing process and will be announced shortly.
The Newsletter No. 22 contained a Cat ET communication troubleshooting list for diagnostic purposes. One of the items listed was to check for a disabled Comm Port. We didn't say how this was to be accomplished, page 4 at the Comm Adapter section addresses this issue. This section can be used as a class handout.
Flash Files There are now Flash Files which are actually larger than a 1.44MB floppy disk can carry. Obviously the floppy disk is no longer convenient for transporting Flash Files such as these. A solution is to copy the file to the computer hard drive or to a CD ROM.
This subject is also being addressed in the Service Technician Workbench course which will be available later in the year.
The Flash Files in question are those which pertain to the new truck engines with ACERT technology.
If a technician is in an isolated location, far from the home base and Cat ET communication problem arises, the customer may incur considerable down time and expense as a result of the technician's inability to troubleshoot the problem.
These ECMs can be flashed over the ATA or CAN data links. The file sizes are in the 1.7MB range. They can be zipped and put on a floppy disk, if a floppy is the only way to move them around. It is better just to download them directly to the PC being used.
It may be advantageous to know ahead of time which Comm Port is in use in case it becomes disabled. However by checking ET, it can be determined from the preferences screen which Comm Port was previously selected.
If an ECM breakout harness is being used, it may speed up the process if the harness is updated to include CAN data link wiring.
It could be argued that the average technician is not authorized to work with Comm Ports. However if the technician is far from base, there may be no alternative, other than an expensive car or plane journey back to base.
Information supplied by Jim Roal, Cat Electronics
Check this latest procedure for enabling the Comm Port. Following this procedure, the Data Link Troubleshooting chart has been updated and reprinted Also the cable diagram has been updated to include the USB Serial Cable Adapter.
The following pages contain training material which can be used as a class handout. This material is titled "Communication Diagnostics with Cat ET".
Communication Diagnostics with Cat ET
3
Communication Diagnostics with Cat Electronic Technician
Nigel Wilkinson
Communications Diagnostics Other Diagnostic Issues
Communication Diagnostics Cat ET Training
ECM Power Supplies
The information on these pages can be used for training, either for the reader or in the classroom as a handout. A separate Lab Assignment to reinforce the training is available on the Service Training website.
The ECM power supply and data link wiring harnesses must be complete in order to communicate. Up to three data link circuits may be in use in a single application as follows:
Diagnostics
1. CAN - J1939 (Controller Area Network)
Initiating communications with Cat ET and the Communication Adapter is normally a simple and straightforward process. However, if a problems arises, there are a number of factors that can cause an interruption to communications. These are summarized below.
2. CDL (Cat Data link) 3. ATA - J1708 (American Trucking Assoc.) PC Communication Port Enabling
A procedure for enabling the Computer Comm Port is included in this publication.
The potential factors are grouped into five categories as follows:
Communication Adapter Cables
Communication Adapter
The last page contains a schematic showing all the cables currently in use of both the Communication Adapter I and II. This schematic has been updated again to reflect new cables.
These issues are confined to the Communication Adapter tool, with the related hardware and software. Communication Adapter Cables
These issues discuss the Communication Adapter cables and associated symptoms.
Communication Adapter I
The previous Communication (7X1700) is mentioned briefly in the diagnostic section. Also many of the diagnostic procedures can also apply to this tool.
PC Software and Hardware
Computer Comm (Communication) Port issues are covered here as it affects checking, enabling and disabling of the port within the PC.
Presentation Material
An electronic slide presentation "Communication Diagnostics with Cat ET", is available for dealers on the Service Training website. This presentation is available in Adobe Acrobat format.
Cat ET Preferences
This section covers setting of Cat ET Preferences and related issues within the program.
A lab worksheet can also be downloaded for class purposes and used in conjunction with the presentation and this text as a handout.
Application Systems
For the Communication Adapter to operate and the machine or engine to communicate with Cat ET, power must come from the Service Tool Connector. Also the ECM must be activated and with a valid Personality Module. 5
Updated Aug 03
Cat ET Tooling Tech Tips Communication Adapter II Lights
Communication Adapter Tech Tips
If the Communication Adapter lights are all on as shown below; this is an indication that the (CA II - Application Firmware) Flash File is either missing or corrupted.
Serial Cable Length
At times the length of the Serial Cable for the Communication Adapter II (25 ft) may be inconvenient. A short cable is available through the Caterpillar parts system. The use of this cable dictates that the computer is equipped with a serial port - unless a USB/Serial adapter cable is used. 160-0142 Serial Cable (Short) 10 ft Communication Adapter Availability
The 171-4401 Communication Adapter II is available without the cables and box. The tool is normally supplied with a serial cable. Various other cables are available, including a parallel cable and a USB adapter cable. These cables are described in a diagram on the last page of this publication. USB Cable
A dedicated USB cable will be available later in this year. This cable can replace the USB to Serial Cable Adapter (Part No. 237-7547). System Information Tech Tip
The Communication Adapter must now be re-flashed with the correct file in order to function.
Using Cat ET, select Ctrl I and the following screen will appear, this screen contains much useful system information, and all on one screen.
The presentation available on the Service Training Website (URL below) explains this process in detail (Communication Diagnostics with Cat ET). https://psmktg.cat.com/srvtrng/index.htm CA II Start Up Light Sequence
On start up, the Communication Adapter lights are lit in sequence, starting with the Power light. This function is useful for diagnostic purposes. 6
Communications Diagnostics Data Link Troubleshooting with Communication Adapter II CAT ET will not communicate with the ECM Tool Issues 1. Comm Adapter cable defect (test by substituting new cables) 2. Non standard data link cable, too long for CAN use, standard cable 2 ft long (J1939 standards limit cable length) 3. No power to Comm Adapter (no power light), check keyswitch, master switch, fuse 4. Comm Adapter II - hardware and software: A. Physical or internal damage to Comm Adapter, defect (test by substituting a new Communication Adapter) B. Comm Adapter II Firmware Flash File missing or corrupted (replace the Flash File) All lights ON, indicates no Firmware Flash File installed C. Comm Adapter II (early) software version/operating system conflict (see following page for more details) NOTE: Software updates and compatibility issues on next page
Computer/CAT ET Issues 5. CAT ET preferences not set correctly A. Correct comm port not selected, not matched with computer comm port B. Incorrect Communication Adapter selected C. Computer software (Comm Adapter II driver) not installed or corrupted in computer (re-install) D. Baud rate selection problem (a lower rate can be selected on older computers) 6. Computer comm port not enabled or comm port conflicting with another device
Application System Issues 7. Low or no power to ECM, or ECM not energized from keyswitch (turn on keyswitch) 8. No Flash File in ECM, or Flash File is corrupted (re-flash Personality Module) 9. Machine/engine wiring harness (datalink) open/short between ECM and Service Tool Connector (check cable harness continuity) 10. Power supply to Comm Adapter at Service Tool Connector failed (check cable harness continuity)
Communication Adapter I (7X1700) Many of these checks can also apply to the Comm Adapter I (7X-1701). In place of the Comm Adapter Flash File, there is a removable Service Program Module (SPM). Ref: SEHS9274 Using The 7X1700 Communication Adapter Group. 1. Check for correct installation of SPM 2. Check for blown fuses in Comm Adapter I NOTE: Comm Adapter I will not service the CAN (J1939) Data Link, use Comm Adapter II 7
Updated Aug 03
Communications Diagnostics PC Communication Port Enabling Procedure Select the following items in sequence. Note: All key strokes/selections are in bold.
1.
Select Start
2.
Select Settings (from the "Start Menu")
3.
Control Panel Screen Select System
4.
System Properties Screen Select Hardware
5.
6.
Device Manager Screen a.
Select Ports (Com & LPT)
b.
Select Communications Port (Com 1)
Communications Port (Comm 1) Screen Select Use this device (enable)
7.
Select OK
8.
Device Manager Screen Click X at top of screen to close
9.
System Properties Screen Select OK
The Comm Port should now be enabled.
The port previously used can be identified using the Cat ET Preferences screen. This procedure is for use with the Windows 2000 operating system. The procedure can also be accessed through the "My Computer" icon on the desktop. 8
Updated Aug 03
Communications Diagnostics Communications Adapter II Software Information (Group No. 171-4400) Current STW and Cat ET Software: STW2003A and ET2003A
PC Operating Systems
PC Software Driver
CA II Firmware Flash Files Version
95B, 98, NT, ME, 2000, XP
2.22
2.2
95, 95A
1.2
1.0 or 1.1
Software and Operating System Compatibility
PC Operating Systems
PC Software Driver
CA II Firmware Flash Files Version
95, 95A, 95B, 98, NT, ME
1.0
1.0 or 1.1
95, 95A, 95B, 98, NT, ME
1.1
1.0 or 1.1
95, 95A
1.2 (2001B)
1.0 or 1.1 (current for 95/95A)
2000
1.8 (2001A)
2.2
95B, 98, NT, ME, 2000, XP
1.93 (2001B)
2.2
95B, 98, NT, ME, 2000, XP
2.22 (2003A)
2.2 (current)
Miscellaneous Information Cat ET will no longer function with Windows 95 after 2003. Windows 98 or later must be used with Version 2004A The Boot Firmware is factory installed and cannot be changed in the field. Version 1.0 is currently in use. PC software Version 1.0 software can not flash CA II firmware (instead use PC software version 1.1 or another PC with PC software version 1.93 or above). If the CA II flash routine cannot be accessed, it may be necessary to exit Cat ET and/or reboot the computer. PC software Version 2.22 allows use of the, Serial Port (Com 1-4) or Parallel Port (LPT 1 or 2) USB Serial Adapter (237-7547) requires additional software, supplied with the adapter. (See Newsletter No. 24 for info.) Refer to the Comm Adapter II operating manual or the Readme file for more information. For more information or help with problems, contact the Help Desk Email:
[email protected] Updated Aug 03
Phone: 1-800 765-0999 or (309) 675-4000 9
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Updated September 03