Cat Electronic Technician Course 2-2-1 Module Two

01/04 Lesson Two

2-1

Lesson Two: Communication Diagnostics with Cat ET

Introduction

• Troubleshooting When Cat ET is connected to and ECM, a message may appear indicating
communication that there is no communication between ET and the application.
failures
The question is "how to troubleshoot the problem?" It may be that the
key switch is off or the PC Communication Port is disabled. This could
be caused by a classroom Smart Board or a Palm Pilot software conflict.
Sometimes a competitor's software (Cat ET equivalent) may interfere
with Cat ET (not uncommon with TEPS dealers).

This presentation addresses those questions.

The diagnostic handout is included for student use. A Lab assignment

worksheet covering Lesson One and Two is available for use with this
presentation at the end of this lesson.
Cat Electronic Technician Course 2-2-2 Module Two
01/04 Lesson Two

2-2

Presentation Objective

Given the necessary tooling and the handout, perform the following task:

• Presentation Identify and correct all causes of system communication failures

Objective between Cat ET and the application.
Cat Electronic Technician Course 2-2-3 Module Two
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2-3

Troubleshooting Communication failures

• Troubleshooting The communication problem sources can be grouped into 5 areas, as

- 5 groups follows:

Communication Adapter Hardware or software

Cables Open or short circuits

PC Computer problem, hardware or software

Cat ET Preferences Preferences not set correctly

Application System Power supply, data link wiring, connectors

fuses, ECM problems, flash file
Cat Electronic Technician Course 2-2-4 Module Two
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2-4

• T/S Communication The PC driver is installed automatically with the Cat ET software.
Adapter
The flash file (firmware) is also loaded in the PC with the Cat ET
• Software software, however a prompt will ask whether it is to be included with the
- PC driver
installation.
- Flash file
NOTE: Do not confuse storage of the flash file software (firmware) with
the flash process.

• Handout explains The handout explains the various software combinations and possible
software software conflicts.
combinations
• All lights on - no flash If a Communication Adapter flash file is missing, all the lights will come
file on as shown above (arrow).
Cat Electronic Technician Course 2-2-5 Module Two
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2-5

• Communication Look for obvious damage at the connectors and the body. Substitute with
Adapter physical another tool if possible to verify a problem.
damage
Examine the tool for physical damage, look for damaged pins and
connectors.
Cat Electronic Technician Course 2-2-6 Module Two
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2-6

• Check power to Check that power is available to the Communication Adapter II, check the
Communication power light (arrow).
Adapter
The most common problem is with the keyswitch. The keyswitch should
• Check the keyswitch
be on with the panel warning lights showing that there is power to the
system.
Cat Electronic Technician Course 2-2-7 Module Two
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2-7

• T/S cables The current data link cable overcomes a possible weakness with the
previous braided type. This type has reinforcing around the connector
• Improved data link
(arrow) cable entry.
cable

• Damaged cable A damaged cable can cause two basic problems: no power to the
problem Communication Adapter, leading to no communications, or a data link
problem likewise leading to no communications.

• T/S by substitution The simplest method to troubleshoot cables is by substitution.

• Non standard data link If a non standard data link cable is used with the CAN data link, and it is
cable problem longer than the normal specification, a CAN communication problem may
occur.

NOTE: The longer Communication Adapter I data link cable can be used
with the Communication Adapter II. However, there will not be any
CAN functionality because the CAN connections are not included with
this cable.
Cat Electronic Technician Course 2-2-8 Module Two
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2-8

• T/S PC software and The comm port can become disabled from a variety of causes. For
hardware example a Palm Pilot computer or Smart Board software when loaded on
the Laptop computer can cause the comm port to become disabled for Cat
ET communication. An infrared port can also conflict with the comm
port. Alternatively comm port may not have been enabled previously.

• USB Adapter driver The USB / Serial Adapter driver is supplied with the adapter. This
software must be installed before using the adapter. Also check the comm
port selection for the adapter in Cat ET preferences. The USB adapter
will take a different port to that previously used with the serial cable.

• Dataview driver Occasionally when using Dataview there may be a subsequent Cat ET
conflict conflict with the PC Comm Port. If the correct current Dataview driver is
used, this issue should not arise.

There is more Dataview driver information in the Knowledge Network

under Cat Tools and Supplies. The information is located under the title:
"Dataview Patch for Windows NT, 2000, and XP."

• Student Handout Instructor Note: The procedure for enabling the comm port is laid out in
- PC Comm Port the Student Handout as "PC Comm Port Enabling Procedure" (following
Enabling Procedure this Lesson). The procedure can be demonstrated using the classroom
computer.
Cat Electronic Technician Course 2-2-9 Module Two
01/04 Lesson One

2-9

• System Information It can be useful when troubleshooting PC and Cat ET communication

screen problems to use the this information screen. The screen provides one
source of information for the PC and the application systems.

Use the keystroke: Ctrl + I to access the screen.

Cat Electronic Technician Course 2 - 2 - 10 Module Two
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2-10

• T/S Cat ET The wrong Communication Adapter or the wrong comm port may be
preferences selected in error.

NOTE: If a USB adapter is installed on the serial cable, a change to the

preferences must be made for the new comm port selection. Also the
baud rate will need to be changed if a Communication Adapter I is used
with the USB adapter.

The preferences can also be selected through the Communication Adapter

Tool kit menu possibly avoiding the need to re-enter Cat ET when
troubleshooting.
Cat Electronic Technician Course 2 - 2 - 11 Module Two
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2-11

• T/S application If the keyswitch is not on, the ECM will not be energized and no
system communication will be possible, in addition the Service Tool Connector
may not have power for the Communication Adapter (this varies with
different application wiring arrangements).

• Check battery master Also check that the battery master switch is on.
switch
In summary, the ECM and the Service Tool Connector (for the
Communication Adapter) must have power to communicate.

• Check the flash file The ECM must have a valid flash file to communicate. Use Winflash to
verify that this file is present and not corrupted.

If there is excessive voltage in the power supply circuit in excess of

40 Volts, the ECM will switch off for protection. This condition could be
caused by a faulty alternator voltage regulator.

A high supply circuit voltage (>40 volts) will cause an engine shutdown
and a communication failure with Cat ET.
Cat Electronic Technician Course 2 - 2 - 12 Module Two
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• Check application There may be a wiring harness problem in the machine or engine.
system wiring and
fuses Check the wiring, connectors and fuses for continuity. Check for opens
and shorts.

• Communication Pin numbers A and B on the Service Tool Connector are used for the
Adapter power supply power supply to the Communication Adapter. This power supply may, or
may not be wired through the ignition switch which should be on for
communication. Voltage can be checked at this point (pin A and B).

Termination resistors are not shown in this diagram but are described on
the next visual.

Data link cables should be in twisted pairs to prevent RFI (Radio

Frequency Interference).
Cat Electronic Technician Course 2 - 2 - 13 Module Two
01/04 Lesson Two

CAN Termination Resistors

Service Tool
Connector Engine ECM
A 70 Bat + (switched)
B 65 Bat -
C 42 Shield
D 8 CAT Data Link +
E 9 CAT Data Link -
F 34 CAN Data Link -
G 50 CAN Data Link +

A 120 Ohm
B Termination
C Resistor

2-13

• CAN data link circuit Termination resistors are normally installed in CAN data link circuits. If
terminating resistors terminating resistors are not installed, it will not be possible to flash a new
file to the ECM over the CAN data link. If a CAN data link is wired in
• Flash programming any engine or machine, it is necessary to install termination resistors.
on CAN not possible Service literature does not always mention the requirement for terminating
without the resistors resistors on engine CAN data link circuits.

• Terminating resistor Termination resistors can be compared with a 3408E HEUI engine
analogy hydraulic system as an analogy. When an injector shuts off, a pressure
wave is created which moves back through the system and interferes with
the timing of the injectors on the opposite bank. Check valves are
installed in the system to prevent this interference with the other injectors.

In the same way the CAN signals move down the circuit and are reflected
back from the end of the circuit causing false signals to bounce around the
system causing corruption of data. This process can also be compared to
water hammer in a domestic water circuit where a sudden interruption in
flow causes reverse flow shock waves to travel back through the system.
This explanation is very much simplified but describes the concept for the
layman. Termination resistors prevent this interference.
Cat Electronic Technician Course 2 - 2 - 14 Module Two
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2-14

• Information sources Information and Help

Visit the following Websites

Service Training
https://psmktg.cat.com/srvtrng/index.htm

Service Technician Workbench

https://psmktg.cat.com/srvtrng/elearn/stw/index.htm

SIS Web
https://psmktg.cat.com/srvtrng/elearn/stw/find.htm

Check the Service Training Tech Tips Newsletter on the website for more
information.
Cat Electronic Technician Course 2 - 2 - 15 Module Two
01/04 Lesson Two

Caterpillar Websites
DBSi Website

To access the DBSi website:

1. Connect to the DBSi website: https://dbsi.cat.com

2. Enter your CWS Logon ID and Password in the text boxes
3. Press: Login
4. Select: DCS Knowledge Database
5. Select: Select STW/SIS/ET
6. In the "Enter a description of your problem here" textbox, enter
the error code number or a brief description of the problem
7. Select: Submit
8. Select a solution to view

Caterpillar ET Websites

NACD Infocast: https://nacd.cat.com

https://nacd.cat.com/infocast/frames/psfulfill/sfulfill/et/

APDNet: https://apd.cat.com

https://apd.cat.com/infocast/frames/pss/service/et/

CatAmericasNet: https://lacd.cat.com

https://lacd.cat.com/infocast/frames/PSE/ops/servtech/et/

FlashNet: https://cosa.cat.com

https://cosa.cat.com/infocast/frames/prod_supp/serv_tech/et/

Cat Power Net: https://engines.cat.com

https://engines.cat.com/infocast/frames/truck/service/catet/
Cat Electronic Technician Course 2 - 2 - 16 Module Two
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2-15

• Help available Assistance is available at the Help Line

Contact: Dealer Channel Systems Service Center

Hours: 6:00 am – 6:00 pm (Monday – Friday)

North American Central Time
Cat Electronic Technician Course 2 - 2 - 17 Module Two
01/04 Lesson Two

2-16

• Questions Discuss and review the handout “Communication Diagnostics with Cat
ET" (on the following pages) with the class and ask relevant questions.
Cat Electronic Technician Course 2 - 2 - 18 Module Two
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2-17

Lab Assignment and Student Handout

• Discuss student Discuss the Student Handout on the following pages in detail.
handout
Complete the lab assignment for Lessons One and Two as follows:
• Lab assignment
Getting Connected with Cat ET
Communication Diagnostics with Cat ET

Instructor Note: It is suggested that the following pages (Student

Handout and Lab Exercise) be duplicated for a student handout and for
the test.
Cat Electronic Technician Course 2 - 2 - 19 Module Two
01/04 Lesson Two

Communication Diagnostics
with
Cat Electronic Technician

Student Handout
and
Lab Exercise
2 - 2 - 20
Cat Electronic Technician Course 2 - 2 - 21 Course Handout
01/04

Data Link Troubleshooting for Communication Adapter II

Cat ET will not Communicate with the ECM
Tool Issues
1. Communication 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 Communication Adapter (no power light), check keyswitch, master switch, fuse
4. Communication Adapter II - hardware and software:
A. Physical or internal damage to Communication Adapter, defect (test by substituting a new
Communication Adapter)
B. Communication Adapter II Firmware (Flash File) missing,corrupted or wrong version
(re-flash the Firmware). All lights ON, indicates no Firmware Flash File installed
C. Communication Adapter II (early) software version/operating system conflict (see following
page for more details)
NOTE: Software updates and compatibility issues are listed on the 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 (Communication 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
(default rate 57,600)
E. Conflict with competitor's software
6. Computer comm port not enabled or comm port conflicting with another device
Cat Electronic Technician Course 2 - 2 - 22 Course Handout
01/04

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 Communication Adapter at Service Tool Connector failed (check cable
harness continuity)
11. Termination resistors not installed in the CAN data link circuit, causing flash process
communication failure.

Communication Adapter I (Gp. No. 7X1700)

Many of these checks can also apply to the Communication Adapter I (7X-1701). In place of the
Communication 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 Communication Adapter I
3. Check baud rate if using the USB Adapter (9,600 KB)

NOTE: Communication Adapter I will not service the CAN (J1939) Data Link,
Communication Adapter II must be used for CAN Data Link communications.
Cat Electronic Technician Course 2 - 2 - 23 Course Handout
01/04

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. Device Manager Screen

a. Select Ports (Com & LPT)

b. Select Communications Port (Com 1)

6. 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, or physically check to
identify the port in use.
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.
Cat Electronic Technician Course 2 - 2 - 24 Course Handout
01/04

Communications Adapter II Software Information

(Group No. 171-4400)
Current STW and Cat ET Software: STW 2003B and Cat ET 2003B
PC Operating Systems PC Software Driver CA II Firmware Flash Files Version

95B*, 98, 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, 1.0 1.0 or 1.1

95, 95A, 95B, 98, NT, 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, 2000, XP 1.93 (2001B) 2.2

95B, 98, NT, 2000, XP 2.22 (2003A) 2.2 (current)

Miscellaneous Information
* Windows 95 is no longer tested or supported for Cat ET which may not function with Windows 95. Windows 98 or later
should be used with STW/ET Version 2004A and later.

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. Adapter requires a preferences baud
rate change to 9,600 with CA I.

Refer to the Communication 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]

Phone: 1-800 765-0999 or (309) 675-4000

Cat Electronic Technician Course 2 - 2 - 25 Course Handout
01/04

Troubleshooting Communication Adapter II Error Codes

Error Code Description Suggested Remedies

142 Unable to communicate with Verify the following cable connections, power,
Caterpillar Comm Adapter II (CA II) preferences, comm port enabled.

230 The selected comm port is in use Reboot the computer, make sure no other
by another program or device programs are using the comm port.

231 Requested port not valid for Check cable connections. Verify that port is
configuration enabled and agrees w/prefer. Change serial
cable to 196-0055 (special use cable). Change
baud rate.

441 PC tries to connect w/CA II, Close and restart CA II Toolkit, and/or re-boot
cannot open data link communication. the PC
Cannot use 2 data links such as CDL
and ATA at the same time.

443 Flash file missing Re-flash the CA II.

453 No response from CA II See 441 remedy above.

 01/04

Caterpillar Electronic Technician (Cat ET)

PC To Machine/Engine Connections
Communication Adapter II
Engine Electronic 207-6845 Universal 196-0055 Serial Cable (25 ft) *
Control Module (ECM) Data Link Cable (2 ft) or 225-5985 Parallel Cable (25 ft) **
Cat Electronic Technician Course

160-0133 (discontinued) 160-0141 Serial Cable (25 ft) *** STW/E

160-0142 Serial Cable, short (10 ft) T

To PC Serial USB or
Service Tool
Parallel Port
Connector Communication
(Comm Port)
Adapter II
171-4400 (Group) 237-7547
Supports ATA CDL & CAN data links USB/Serial Port Adapter
* Included with Comm Adapter Group
2 - 2 - 26

** For use only on newer PC's without serial ports

*** For all PC's except IBM Think Pads and Compaq Computers

Engine Electronic
Communication Adapter I
Control Module (ECM)
139-4166 7X1425
Data Link Cable (18 ft) Serial Cable (4 ft) STW/E
T

PC Serial or USB Port

Service Tool (Comm Port)
Connector
Communication
Adapter I
7X1700 (Group)
Supports ATA & CDL data links
(discontinued but still in use)
Course Handout
Cat Electronic Technician Course 2 - 2 - 27 Lab Exercise
01/04

Lab Exercise
Connections and Communication Diagnostics with
Cat Electronic Technician

Name: ______________________________________________________

Objective
On completion of this lab, proficiency in Lessons One and Two will be demonstrated by successfully
completing the lab tasks summarized here:

Make all the connections between the computer and the ECM

Troubleshoot communication problems

The instructor will provide the necessary tools, PC, and Communication Adapter.

The attached Student Handout should be used for reference.

NOTE: Although this Lab exercise focuses on the Communication II, the lab could be adapted
for the earlier Communication Adapter I.

Version 1.5
Cat Electronic Technician Course 2 - 2 - 28 Lab Exercise
01/04

Lab Assignments
Part 1 Data Link Connections
1. Select the correct equipment for communication between Cat ET and the application.

2. Connect the laptop computer and Communication Adapter to the simulator or engine.

3. Start the computer and select Cat ET. What light/lights are observed on the Communication
Adapter? Note the light sequence on power up as follows.
Power Y / N CAN (J1939) Y / N ATA (J1708) Y / N CDL Y / N

4. The Service Tool Connector provides power to the Communication Adapter, also positive and
negative data link connections (terminals A and B).
a. Disconnect the (CA II) data link cable at the Service Tool Connector.
b. Verify the power at the Service Tool Connector: using a multimeter check the voltage

______________ Volts

5. The Communication Adapter may have power with the key off, but Cat ET will NOT
communicate until the key switch is ON, why?

_________________________________________________________________________
Cat Electronic Technician Course 2 - 2 - 29 Lab Exercise
01/04

Part 2 Communication Adapter II

In the "Communication Adapter II Tool kit" screen, identify the version numbers for the following
components (the Data Link should be open) NOTE: Do not select Winflash.

1. Communication Adapter II Hardware Version Number _________________

2. Communication Adapter II (PC) Driver Version Number ________________

3. Application Firmware (flash file) Version Number ______________

4. Application Firmware (flash file) file name ____________________

Part 3 Cat ET Preferences Screen

Using Cat ET, set the following preferences (with the Data Link open)
Note: Press F8 to open or close the data link

1. Set the correct Communication Interface Device selection to "Communication Adapter II".

2. Set the Comm Port selection to the appropriate number. (Comm Port 2, LPT1 etc)

3. Change to Metric measurements.

Cat Electronic Technician Course 2 - 2 - 30 Lab Exercise
01/04

Part 4 Communication Adapter II (CA II)

1. Using the Cat ET Ctrl I command, identify the PC Operating system, ie: Windows 98, 2000, XP.

Windows _________________________ Operating System

2. Using the handout for reference, identify the correct Flash File for Windows 95A operating system
(use the most recent file).
Flash File name ____________________ Version _______________

3. Flash the Communication Adapter with the file in question 2 above

(re-boot computer if no communication with CA II).
Attempt to communicate with Cat ET, what is the error message?
_____________________________

4. Using the handout for reference, identify the correct Flash File for the current PC operating system
(from question one above).
Flash File name ____________________ Version _______________

5. Flash the Communication Adapter with the file in question 4 above

6. Check for proper communication between Cat ET and the ECM (ie check Status Screen
functionality)
Cat Electronic Technician Course 2 - 2 - 31 Lab Exercise
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Part 5 PC Comm (Communication) Port

Using the instructions on the handout:

1. Disconnect the data link

2. Check the status of the Comm Port using the instructions in the "PC Port Enabling Procedure"
handout.

3. Disable the PC comm port.

4. Check the PC and comm port operation by operating Cat ET. Select a Status Screen and check for
normal Cat ET functions and communication.

5. What code and error message is displayed?

_______________________________________________________________________________

6. Enable the PC comm port.

7. What is the instruction for this fault code? Refer to "Troubleshooting Communication Adapter II
Fault Codes."

Part 6 PC Requirements
Using the "Getting Started with Caterpillar Electronic Technician" manual, identify the Recommended
(not minimum) Configurations (functional specifications) for a computer using Cat ET (a wrongly
configured computer can easily be the cause of a communication problem).

_______________________________________________________________________________

_______________________________________________________________________________
Cat Electronic Technician Course 2 - 2 - 32 Lab Exercise
01/04

Part 7 Finish Lab

1. Switch from Metric to English measurements

2. Review lab with Instructor before continuing

3. Shut down Service Technician Workbench and/or Cat ET

4. Shut off computer and monitor.

Cat Electronic Technician Course 2 - 1 - 33 Course Notes
01/04

NOTES
 Printed in U.S.A.
01/04