C-10, C-12, C-15 and C-16 Industrial Engines – Electronic Service Tools

Service Tools

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.

Table 1
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)    
7X-1715
134-5195    
Adapter Cable As (40-PIN BREAKOUT)
Harness (40-PIN)
(For ADEM 2 ECM (two 40-pin connectors))    
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 1.5 N·m (13.3 lb in))    
Repair Kits for Connectors    
362-3555     Connector Repair Kit (AMPSEAL)    
175-3700     Connector Repair Kit (Deutsch connector)    
Bypass Harnesses for the ECM    
129-2018     Power Cable
(Stand alone cable for ADEM 2 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”.

Optional Service Tools

Table 2 lists the optional service tools that may be needed during testing or repair.

Table 2
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”.

Caterpillar Electronic Technician (Cat-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.

Table 3
Software, JEBD3003, “CATERPILLAR ELECTRONIC TECHNICIAN”    

Once you have downloaded Cat-ET onto your PC, you will need a license from your Caterpillar dealer in order 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 Cat-ET

Connecting the Communication Adapter

Table 4 lists the standard hardware that is required in order to connect Cat-ET.

Note: The 275-5120 Communication Adapter Gp was canceled and replaced by the 317-7484 Communication Adapter Gp. However, the 275-5120 Communication Adapter Gp can still be used.

Table 4
Standard Hardware for Connecting with Cat ET    
Part Number     Description    
N/A     Personal Computer (PC)    
317-7484     Communication Adapter Gp    
317-7492     Radio Kit (NACD only)    
349-1206     Radio Kit (EAME only)    
Components of the 317-7484 Communication Adapter Gp    
317-7485     Communication Adapter (3)    
370-4617     Cable As (USB)    
327-8981     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 in order to connect Cat-ET and the communication adapter to a PC.

  1. Remove the electrical power from the ECM.



    Illustration 1 g02051513

    (1) PC

    (2) 353-5083 Cable As (USB)

    (3) 317-7485 Communication Adapter (3)

    (4) 327-8981 Cable As (DATA LINK)

  1. 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.

  1. Connect cable (2) to the USB port of the PC.
  1. Connect cable (4) to a service tool connector.
  1. 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.
  1. Establish communication between Cat-ET and the ECM. If Cat-ET indicates that there is more than one ECM, select the engine ECM.
  1. 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 in order 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 in order 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.

Table 5
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 in order to connect the wireless communication adapter for use with Cat-ET.

  1. Remove the electrical power from the ECM.
  1. 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.
  1. Connect cable (9) between communication radio (8) and the service tool connector.
  1. 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 in order 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).

Table 6
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 Assembly C



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 in order to connect the wireless communication adapter for use with Cat-ET.

  1. Remove the electrical power from the ECM.
  1. 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.
  1. Connect cable (9) between communication radio (8) and the service tool connector.
  1. 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.