Most of the tools that are listed in Table 1 are required to enable a service technician to perform the test procedures in this manual. Some of the devices may be specific to the type of Electronic Control Module (ECM) that is being used.
| Service Tools | |
|---|---|
| Part Number | Description |
| 349-4200 | Thermometer |
| 360-0774 | Refractometer |
| 431-7087 | Tool Gp (REFRACTOMETER (DEF)) |
| N/A | 4 mm Allen Wrench |
| 1U-5805 | Wire Removal Tool (14-GA, GREEN) |
| 6V-2197 | Magnetic Transducer As (TIMING CALIBRATION) |
| 121-9588 | Wire Removal Tool (16-GA, BLUE) |
| 147-6456 | Wedge Removal Tool |
| 151-6320 | Wire Removal Tool (14-GA TO 18-GA, RED) |
| 1U-5804 | Crimp Tool (12−AWG TO 18−AWG) |
| 6V-2197 | Transducer |
| 7X-1171 | Transducer Adapter |
| 7X-1695 | Cable As |
| 146-4080 | Digital Multimeter Gp (RS232) |
| 7X-1710 | Multimeter Probes |
| 326-4904 | Adapter Cable As (3-PIN BREAKOUT) |
| 208-0059 | Adapter Cable As (70-PIN BREAKOUT)
(For ADEM 3 ECM (two 70-pin connectors) and for ADEM 4 ECM (one 70-pin connector and one 120-pin connector)) |
| 257-8718 | The 257-8718 Adapter Cable As is not applicable with Tier IV Engines.
Adapter Cable As (120-PIN BREAKOUT) (For ADEM 4 ECM (one 70-pin connector and one 120-pin connector)) |
| N/A | Torque Wrench (capable of applying |
| Repair Kits for Connectors | |
| 362-3555 | Connector Repair Kit (AMPSEAL) |
| 175-3700 | Connector Repair Kit (Deutsch connector) |
| Bypass Harnesses for the ECM | |
| 217-0113 | Wiring Harness (ECM BYPASS)
(The bypass harness connects to the battery. The bypass harness is used with the following harnesses for different types of electronic control modules.) |
| 328-2292 | Harness (ENGINE ECM BYPASS)
(For ADEM 3 ECM and ADEM 4 ECM) |
| 277-4734 | Harness (ENGINE ECM BYPASS)
(For A4:E2 ECM (Two 64-pin connectors)) |
| 276-7273 | Sensor Test Box (1) |
| (1) | Instrument used to test Cylinder Position sensors. |
Two short jumper wires may be needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. A long extension wire may also be needed to check the continuity of some wiring harness circuits.
Except for harness tests, the use of certain test equipment is not recommended for use on modern Caterpillar electrical circuits. Such testers include the following examples: the 8T-0500 Continuity Tester and 5P-7277 Voltage Tester.
Note: A procedure has been developed to test "In Cylinder" Position Sensors. Reference Special Instruction REHS7338, "Procedure to Test the Position Sensor of a Hydraulic Cylinder".
Table 2 lists the optional service tools that may be needed during testing or repair.
| Optional Service Tools | |
|---|---|
| Part Number | Description |
| 198-4240
or 1U-5470 |
Digital Pressure Indicator
or Engine Pressure Group |
| 4C-4075 | Crimp Tool (4−AWG TO 10−AWG) |
| 4C-4911(1) | Battery Load Tester |
| 5P-7277 | Voltage Tester |
| 6V-9130(2) | Temperature Adapter (MULTIMETER) |
| 8T-5319 | Connector Tool Group |
| 349-4199 | AC/DC Current Probe |
| 348-5430 | Multi-Tool Gp |
| 8T-8726 | Adapter Cable As |
| 163-5443 | Adapter Cable As (3-PIN BREAKOUT) |
| 177-2330 | Battery Analyzer (DIGITAL) |
| 190-8900 | Connector Repair Kit |
| 225-5985 | Parallel Port Cable (COMMUNICATION ADAPTER) |
| 391-8170 | EMISSIONS ANALYZER TOOL GP (Bluetooth Module) |
| 393-0673 | EMISSIONS ANALYZER TOOL GP |
| (1) | Refer to Special Instructions, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8, and 12 v Lead Acid Batteries" and Special Instructions, SEHS7633, "Battery Test Procedure". |
| (2) | Refer to Special Instructions, SEHS8382, "Use of the 6V-9130 Temperature Adapter Group". |
Cat Electronic Technician (ET)
Cat ET can be used by the technician to help perform the following procedures:
- Diagnostic testing
- Calibrations
- Flash programming
- Configuration of the ECM
- Print various reports
Cat ET can display the following information:
- Status parameters
- Event codes
- Diagnostic codes
- ECM settings
- Engine configuration
Always use the latest revision of Cat ET. The media is available on CD and the media can also be downloaded from various Caterpillar web sites.
| Software, JEBD3003, "CATERPILLAR ELECTRONIC TECHNICIAN" |
Once you have downloaded Cat ET onto your PC, you will need a license from your Caterpillar dealer to use the software. Various licenses are available for different users with different requirements. Consult your Caterpillar dealer.
Note: For more information regarding the use of Cat ET and PC requirements, refer to the documentation that accompanies your Cat ET program software.
Connecting the Communication Adapter
Note: The 538-5051 is the latest version of the Communication Adapter Group. Older service tool versions can still be used.
Table 4 lists the standard hardware that is required to connect Cat ET.
| Standard Hardware for Connecting with Cat ET | |
|---|---|
| Part Number | Description |
| N/A | Personal Computer (PC) |
| 538-5051 | Communication Adapter Gp |
| 317-7492 | Radio Kit (NACD only) |
| 349-1206 | Radio Kit (EAME only) |
| Components of the 538-5051 Communication Adapter Gp | |
| 478-0235 | Communication Adapter (3) |
| 370-4617 | Cable As (USB) |
| 457-6114 | Cable As (DATA LINK) |
| Components of the 317-7492 Radio Kit | |
| 317-7493 | Wireless Communication Radio |
| 317-7496 | Computer Cable As |
| 317-7510 | Radio Cable Assembly |
| 326-9606 | Antenna (2) |
| Components of the 349-1206 Radio Kit | |
| 348-9250 | Communication Radio Gp |
| 317-7496 | Computer Cable As |
| 317-7510 | Radio Cable Assembly |
| 326-9606 | Antenna (2) |
| Tool Operating Manual & Software CD ROM, NETG5057, "Communication Adapter 3" | |
Follow the instructions for the communication adapter. Use the following procedure to connect Cat ET and the communication adapter to a PC.
- Remove the electrical power from the ECM.
Show/hide table
Illustration 1 g02051513 (1) PC
(2) 353-5083 Cable As (USB)
(3) 478-0235 Communication Adapter (3)
(4) 327-8981 Cable As (DATA LINK) - Connect cables (2) and (4) to communication adapter (3).
Note: The communication adapter will power up when the adapter is connected to a PC or to an ECM that is powered up.
- Connect cable (2) to the USB port of the PC.
- Connect cable (4) to a service tool connector.
- Restore electrical power to the ECM. Verify that the "POWER" indicator on the communication adapter is illuminated. Make sure that the PC is powered up.
- Establish communication between Cat ET and the ECM. If Cat ET indicates that there is more than one ECM, select the engine ECM.
- If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".
Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if any of the following conditions exist:
- Cat ET displays a message that refers to a communication problem.
- Cat ET displays "Error #142 The interface hardware is not responding".
- Cat ET displays a message that indicates that the firmware in the communications adapter is old.
Dual Data Link Communications (If so equipped)
When the connection of the communication adapter is complete, observe the communication adapter and Cat ET. Certain applications require that dual data link communications be established to perform various test procedures. These tests will be listed in the "Diagnostic Tests" menu, some tests may not be available (grayed out). If there are diagnostic tests that are unavailable in Cat ET, ensure that your service tool is communicating in dual data link mode.
Use the following indicators to confirm that Cat ET is communicating on dual data links:
- "J1939" indicator is flashing
- "Cat Data Link" indicator is flashing
- Cat ET is not displaying "Service tool support is limited"
Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if the "J1939" indicator and the "Cat Data Link" indicator are not flashing. Both indicators will be flashing during dual data link communications with the ECM.
Communicating with the Wireless Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed to connect Cat ET by using a wireless connection.
Note: Some applications cannot use a wireless connection. Also, a dual data link cannot be used with a wireless connection.
| Optional Hardware for the Use of Cat ET | |
| Part Number | Description |
| N/A | Personal Computer (PC) |
| |
| Illustration 2 | g02342942 |
|
(1) Personal computer (PC)
(5) 261-4867 Card (PCMCIA) (6) 239-9955 Communication Radio Gp (7) 259-3183 Data Link Cable As | |
Note: Items (5), (6), and (7) are part of the 261-3363 Wireless Communication Adapter Gp.
Note: The 261-3363 Wireless Communication Adapter Gp was canceled and replaced by the 349-1206 Radio Kit. However, the 261-3363 Wireless Communication Adapter Gp can still be used.
Use the following procedure to connect the wireless communication adapter for use with Cat ET.
- Remove the electrical power from the ECM.
- Ensure that the computer has been correctly configured for the 261-4867 Card. Verify that the PC card is installed in the computer PCMCIA expansion slot.
- Connect cable (9) between communication radio (8) and the service tool connector.
- Restore the electrical power to the ECM. If Cat ET and the communication radio do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".
Communicating with the Wireless Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed to connect Cat ET by using a wireless connection.
Note: Some applications cannot use a wireless connection. Also, a dual data link cannot be used with a wireless connection.
Although changes can be made to the internal settings of the W-CA3 wirelessly. Caterpillar recommends that the radio is connected to a PC via 317-7496 Computer Cable As (USB)Cable Assembly (8) and 317-7510 Radio Cable Assembly (9).
| Optional Hardware for the Use of Cat ET | |
| Part Number | Description |
| N/A | Personal Computer (PC) |
| |
| Illustration 3 | g02151132 |
|
(8) 317-7496 Computer Cable As (USB)
(9) 317-7510 Radio Cable AssemblyC | |
| |
| Illustration 4 | g02596964 |
|
(9) 317-7510 Radio Cable Assembly
(10) W-CA3 | |
Note: Items (8), (9), and (10) are part of the 349-1206 Radio Kit.
Use the following procedure to connect the wireless communication adapter for use with Cat ET.
- Remove the electrical power from the ECM.
- Ensure that the computer has been correctly configured for the 802.11a or 802.11b/g enabled wireless card. Verify that the PC wireless is installed and working correctly.
- Connect cable (9) between communication radio (8) and the service tool connector.
- Restore the electrical power to the ECM. If Cat ET and the communication radio do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".
PL1000E Communication ECM (If so equipped)
| |
| Illustration 5 | g03669868 |
The PL1000E is an ECM that provides the customer with the ability to integrate Caterpillar engines into specific applications. The PL1000E enables communication from a J1939 data link to a device that utilizes a MODBUS communication protocol. A PC with the latest version of Cat ET installed can be connected to the PL1000E through the RS232 serial port of the PC. The PL1000E contains an embedded communications adapter that will allow Cat ET to communicate with the engine over the J1939 data link.
Refer to System Operation/Troubleshooting/Test and Adjust, RENR8091, "PL1000E Communication ECM" for additional information.