Lesson 7: Flash Programming with Cat ET

Lesson 7: Flash Programming with Cat ET

Introduction:
This lesson covers flash Programming using Cat ET on Caterpillar
engines. Also included are flash file sources.
The subjects covered are:
• Flash File Sources
• Flash Programming
• Troubleshooting Personality Module Software
• Communications between Cat ET and machine
Objectives:
After completion of this lesson the student will be able to:
1. Download or copy flash files from all sources.
2. Perform flash programming.
3. Diagnose personality module file problems.
Tooling:
Laptop Computer (PC) with STW Version 2006A
All tooling required to properly connect Cat ET to a machine or
engine is listed in the complete tooling list on page 1 and 2 of Unit 3.
Unit 3 3-7-2 Caterpillar Communications
Lesson 7

Fig. 3.7.1 Flash File Directory

Flash Programming is the process whereby electronic files are copied

from the PC to the Personality Module in the ECM. An engine flash
file contains information peculiar to the engine application such as:
fuel settings, low and high idle, and torque rise.
The ECM is generic in nature and will normally cover many
applications and arrangements. For example, a 3500 engine comes in
many cylinder arrangements such as 8,12, 16, and 24 cylinders but
has the same ECM. There are many applications from off-highway
trucks to industrial engines.

The Personality Module which contains the Flash File determines

how the ECM works and how many injectors will be driven. Also
determined by the Personality Module are the warning trip points
such as oil pressure coolant temperature and overspeeds. This
information is contained in spreadsheets of pressures and engine
speeds for the lubrication system. Also derates are specified in the
spreadsheets along with much more detail.

During the flash process, the original files are completely erased and
the new file is loaded. If the process is interrupted during the file
transfer and the file is incomplete, two things will happen. Firstly,
the engine will not start and secondly, the Cat ET service tool will not
be able to communicate with the ECM.
Unit 3 3-7-3 Caterpillar Communications
Lesson 7

In the case of no communication, the technique is to switch to the

Winflash program. If no ECM is detected, this deficiency will be
indicated by the caption "Not Programmed." If this situation
happens, the ECM must be re-flashed.

A subdirectory called "Flash" must be created in the [C] drive using

the Windows Explorer program. This (Flash) directory is used for
downloading flash files. The directory also becomes the source for
Flash Programming file transfers.

Figure 3.7.1 shows the Flash folder in the left hand column and the
flash files "1365703.FLS"on the right.
These files can then be flashed (copied) from the Flash folder to the
ECM Personality Module.
The flash folder can be put anywhere on the hard drive, for example,
within the Cat ET program folder. Be sure to reset the flash file path
if the flash directory is moved.
NOTE: Most new or recent engines have permanent (hard
wired) Personality Modules in the ECMs. It will not be possible
to physically replace the Personality Modules on these engines.
Flash Programming is the only option with ADAM III and later
ECMs.

This procedure is not recommended except in the case of an

emergency. Failure could occur if dirt or moisture enters the
Personality Module when removed.
Unit 3 3-7-4 Caterpillar Communications
Lesson 7

Fig. 3.7.2 Preferences Menu (Directories Tab)

The Flash File directory location can also be set with Cat ET using
the Directories tab. This procedure will direct Cat ET to find the
flash files before performing the flash process.
Make the following selections to set the Flash File directory location:
- Select Directories and Modify from the Preferences screen
(the "Browse for Folder" Window should appear)
- Select the C drive on the Browse for Folder screen
- Double click on the "C" drive on the Browse for Folder screen
- Double click Flash directory on the list (Browse for Folder
screen)
- Click OK
The Flash directory will now appear in the Set File Locations box as
follows:
FLASH Files c:\flash\

Click OK to close the Preferences screen and complete the process.

Unit 3 3-7-5 Caterpillar Communications
Lesson 7

Fig. 3.7.3 Flash File Search

Flash File Search and Sources

Two methods used within STW to identify the flash file Part
Number/File Name are:
- Flash File Search in STW
- Flash File Search in SIS Web

Flash File Search within STW is the easiest to use and is therefore the
process of choice.

There are also various sources of flash files for downloading. The
most commonly used are:
- SIS Flash File DVD
- SIS Web
Due to the volume of Flash Files and injector trim files, the CDs have
been replaced by one DVD.
NOTE: There are other sources of flash files outside STW.
Unit 3 3-7-6 Caterpillar Communications
Lesson 7

Fig. 3.7.4 SIS Main Screen

With SIS, the procedure requires the user to have access to SIS Web.
To obtain flash files from SIS Web, open SIS Web and type in the
serial number prefix under Product Identification in the upper left
corner. Then click on the Service Software Files (arrow) in the lower
right hand corner, as shown above.

NOTE: Accessing SIS Web within STW became effective with

STW version 2003B.
Unit 3 3-7-7 Caterpillar Communications
Lesson 7

Fig. 3.7.5 Flash File Downloading

The flash file home page, shown above, searches using the full serial
number (not just the prefix) or the flash file name. The search feature
will list all flash files pertaining to that machine.
On the Flash File main menu, type in a complete serial number into
the serial number box and click the Search button. The valid flash
files for that serial number are displayed on the right. Select the
orange file name (1) and click “Save” (2) to save the file.
Additional methods can also used to find a flash file by selecting one
of the three options (3) on the Flash File main menu.
Unit 3 3-7-8 Caterpillar Communications
Lesson 7

Fig. 3.7.6 Flash File Download Complete

A window will appear which displays "Download Complete." At this

point, either Open, Open Folder (if you have the software to
interpret the flash file), or Close can be chosen.

The other way to retrieve flash files is through the SIS Flash Files
disk #1. The following procedure requires that the PC be equipped
with a DVD drive. Insert the Flash File disk into the DVD drive.
(Do not start SIS).
Access the Flash Files using Windows Explorer.
Drag the files using the mouse from the DVD to the flash
folder. It is also possible to flash directly from the DVD if
desired.

SIS also contains a Flash File cross reference the same as the find
system. The file name is "readxref.txt" and is located in the flash
directory of the SIS CD.
Unit 3 3-7-9 Caterpillar Communications
Lesson 7

Fig. 3.7.7 Accessing Winflash

Flash Programming Procedure

Once the flash file has been received, it must then be copied
(programmed) to the Personality Module in the ECM. The
Personality Module can be likened to a floppy disk in that it performs
similar functions.

Within Cat ET, either press the Winflash Icon or use the following
drop-down menu which is shown above:
Utilities / Winflash

The Summary Screen also shows the Personality Module part number
which is the Flash File name. The Configuration Screen also shows
the same ECM information.

Although not strictly pertinent to the flash programming operation,

the Cat ET Version number shown on the top right hand side of the
screen is important. This screen shows that Cat ET version 2004A is
installed.

It is important to verify the percentage of battery charge in the

computer (or connect a power supply) prior to starting the flash
process. Also the connections should be secure.
Unit 3 3-7-10 Caterpillar Communications
Lesson 7

If for any reason the process is interrupted due to a computer crash or

the process is cancelled, the engine will not start and Cat ET will not
communicate with the ECM. The process must be repeated.
Unit 3 3-7-11 Caterpillar Communications
Lesson 7

Fig. 3.7.8 Flash File Information Screen

After flash programming is selected, the screen shown above will

appear. Ensure that the correct ECM is selected for flashing if more
than one ECM is available. If the ECM cannot be flashed, a message
will appear saying "ECM is not flashable."

Also displayed is the ECM information including the Personality

Module "Software Part Number." If the wrong ECM or no ECM is
selected, press the down arrow and choose the ECM from the list
provided.

Click on the Browse button to select the flash file.

Unit 3 3-7-12 Caterpillar Communications
Lesson 7

Fig. 3.7.9 Selecting the Flash File

The Flash File Selection dialog box is displayed above (left). This
dialog box allows the user to select the drive, the directory where the
file is located, and the file to be flashed. However, if the file is
located on the hard drive and the preferences are correctly set, the
browse button will automatically select the Flash File folder.

The flash file can be selected with a mouse click.

Information on the selected file is displayed in the File Description

and ECM/File Information boxes and should agree with the engine
and application information. The file application information should
agree with the current information shown on the Winflash screen
shown on the right.

Click the OPEN button.

Unit 3 3-7-13 Caterpillar Communications
Lesson 7

Fig. 3.7.10 Flash File Screen (File Transfer in Progress)

After selecting the Open button, Flash File Selection dialog box
disappears and the program is now ready to start the flash process.

Select the Begin Flash button located at the lower right hand corner
of the screen.

The top right hand side of the screen shows the ECM application
information. This is important if the engine is on the dynamometer
and the application is not obvious. The lower half of the screen
shows the flash file application information.
Unit 3 3-7-14 Caterpillar Communications
Lesson 7

Fig. 3.7.11

After the Begin Flash button is selected, the process begins

The files are transferred to the ECM. The status bar indicates the
percent of the flash file that has been copied.

INSTRUCTOR NOTE: Following is a list of typical reasons to

flash a new file to an ECM:
- New ECM replacement (no software installed)
- Personality Module update (to correct a software problem)
- Personality Module enhancement (example, torque rise
increase)
- Corrupted Personality Module file (possible lightening
strike or electrical surge due to welding)
Unit 3 3-7-15 Caterpillar Communications
Lesson 7

Fig. 3.7.12 Flash Process Interrupted

If for any reason the process is interrupted due to a low battery, a

computer crash, or the process is cancelled, the engine will not start
and Cat ET will not communicate with the ECM. The above screen
will appear after the interruption occurs

The process must be repeated using the Begin Flash button (lower
right).

This scenario can cause a difficult troubleshooting problem due to a

lack of communication between Cat ET and the engine. This
troubleshooting problem is covered later under Personality Module
Diagnostics.

Once again, it is important to verify the percentage of battery charge

in the computer (or connect a power supply) prior to starting the flash
process. Also the cable connections should all be secure.
Unit 3 3-7-16 Caterpillar Communications
Lesson 7

The following is a summary of possible causes of a failure in the

flash process:

- Low PC battery charge

- Loose cable connectors
- PC lock up
- Low application (engine/machine) battery charge
- Application power interruption
Unit 3 3-7-17 Caterpillar Communications
Lesson 7

Fig. 3.7.13 Flash Process Diagnostics

If the flash process appears to be very slow on an engine with

ACERT technology, check the information shown under "Detected
ECMs." This type of engine uses a relatively large flash file.

If for some reason the ECM is using the ATA data link, the process
will be about four times slower and will be shown on the screen
above.

The flash process will be much faster using the J1939 CAN data link.
To change the data link in use, it may be necessary to disconnect
power to the ECM and restart the flash process. (Certain engines
may inadvertently initiate the flash process using the ATA data link.)

NOTE: If the flash process is interrupted, the engine will not

start and there will be no communication with Cat ET. It will be
possible to communicate through Winflash however.
Unit 3 - 18 - Caterpillar Communications
Lesson 7

Fig. 3.7.14 File Transfer Complete

When the file transfer is complete, the dialog box appears showing
"Flash Completed Successfully." It only remains to verify the system
with a functional test of the engine and to check for active and logged
faults.
If an attempt is made to install the wrong Personality Module flash
software (mismatch) for another application, a message will appear
prompting the user to double check the intended action.
To return to Cat ET, press the Cat ET button in the window shown
above.
Unit 3 - 19 - Caterpillar Communications
Lesson 7

Fig. 3.7.15 Verifying Flash File Installation

This illustration shows the modified Configuration Screen introduced

with Cat ET Version 2004A.

The Configuration Screen can be used to identify the Personality

Module part number which has been installed.

This is a good time to verify that the correct Personality Module file
has been installed. Using the Configuration Screen, the part number
can be double checked.

There are various ways to check the Personality Module flash file
part number within the ECM, using the following screens:

- Flash Program
- ECM Summary Screen
- Configuration Screen shown above (highlighted)

INSTRUCTOR NOTE: This is a good opportunity to

demonstrate the various methods to check the flash file
installation, using the methods listed above.
Unit 3 - 20 - Caterpillar Communications
Lesson 7

Fig. 3.7.16 Diagnostics with Flash Program

Personality Module Diagnostics

Select the flash program to identify that a valid Personality Module
file is in place. Without this file, there will be no diagnostic
communication with Cat ET, and the engine will not start.

Using the Winflash program as a diagnostic exercise allows the user

to check this part of the ECM.

A functional test of the engine along with a check of the Active Fault
screen will confirm that the system is functioning properly.

Here is a very brief explanation of the data links with typical uses:

CDL Cat Data Link - Communication with Cat ET

ATA American Trucking Association - For flash
programming
CAN Controller Area Network, J1939 - For flash
programming
Unit 3 3-7-21 Caterpillar Communications
Lesson 7

The flash program allows some techniques for diagnosing unrelated

communication problems between the PC and Cat ET.

It is possible to use the Winflash program during a no start and/or a

no communication problem, to determine the possibility of a missing
or corrupted Personality Module file.

As the flash program data link normally uses a different wiring

circuit (usually ATA or CAN), it therefore may bypass a
communication problem with the Cat Data Link.
Unit 3 -1- Caterpillar Communications
Instructor Copy Lab 3.7.1

Instructor Copy Lab 3.7.1

Shop Lab Exercises

Lab Objectives: The following exercises will reinforce the material introduced in this lesson and will
allow questions to be asked:

1. Create a directory for the flash files, locate the directory using Cat ET preferences.

2. Use STW, Flash File Search to locate the correct flash file for the engine or training aid.
Download the flash files to the PC.

3. Flash the files from a PC to the ECM and perform a functional test on the engine.

4. Use the Flash Program to verify that a valid or correct flash file exists in the ECM.

5. Perform a functional test of the engine including the following:

Check for active and logged faults.
Check the configuration screen for the correct flash file for the application.

6. Troubleshoot a communication problem between Cat ET and the machine.

INSTRUCTOR NOTE: Install a "bug" to create a Cat ET communication problem such
as: no flash file in ECM, defective communication adapter or cable, correct
communications port not selected.
Unit 3 -1- Caterpillar Communications
Student Copy Lab 3.7.1

Student Copy Lab 3.7.1

Shop Lab Exercises

Lab Objectives: The following exercises will reinforce the material introduced in this lesson and will
allow questions to be asked:

1. Create a directory for the flash files, locate the directory using Cat ET preferences.

2. Use STW, Flash File Search to locate the correct flash file for the engine or training aid.
Download the flash files to the PC.

3. Flash the files from a PC to the ECM and perform a functional test on the engine.

4. Use the Flash Program to verify that a valid or correct flash file exists in the ECM.

5. Perform a functional test of the engine including the following:

Check for active and logged faults.
Check the configuration screen for the correct flash file for the application.

6. Troubleshoot a communication problem between Cat ET and the machine.

Unit 3 -1- Caterpillar Communications
Instructor Copy Unit 3 Quiz

CAT ET

Instructor Copy Unit 3 Quiz

UNIT 3 QUIZ

1. What screen automatically appears when Cat ET is connected to a machine if multiple ECMs are
connected to the data link?

A. Status screen
B. Configuration screen
C. ECM selector screen
D. Diagnostic codes screen

2. If Cat ET is running within STW, an active code can be further diagnosed by clicking the
Troubleshoot Code button to open which of the following programs:

A. Component Based Troubleshooting

B. SIS
C. DataView
D. Engine Performance Estimator

3. Which of the following items may require a password to clear the items from the ECM?

A. Active diagnostic codes

B. Logged diagnostic codes
C. Logged events
D. All of the above

4. Which screen is used to graphically show overspeeds?

A. Status screen
B. Event Histogram screen
C. Configuration screen
D. Diagnostic codes screen

5. Which screen is used to change fuel settings or equipment ID information?

A. Status screen
B. Event Histogram screen
C. Configuration screen
D. Diagnostic codes screen

6. When a test is performed with Cat ET and there are a number of items that need to be checked
simultaneously, what Cat ET function should be performed?

A. Customize a status screen

B. Customize a Configuration screen
C. Review diagnostic codes
D. View parameter history
Unit 3 -2- Caterpillar Communications
Instructor Copy Unit 3 Quiz

7. An intermittent injector fault can be recognized by the ________________ portion of the logged
diagnostic codes screen.

A. Code
B. Description
C. Value
D. Occurrences "Occ"

8. All electronically controlled injectors require calibration.

A. True
B. False

9. What must the rpm be set at before performing the Speed/Timing sensor calibration?

A. High idle
B. Low idle
C. 800 rpm
D. Not necessary because it is performed automatically by Cat ET

10. The injection actuation pressure test performs a functional check on which of the following
components:

A. Injection actuation pump

B. Injection actuation pressure control valve
C. Hydraulic pressure sensor
D. All of the above

11. If the wrong Engine ECM flash file is installed what will happen?

A. Engine will run only at low idle

B. Engine will run only at high idle
C. Engine will not start
D. An injector trouble code will be set

12. Using the File/Open drop down menu will allow access to which of the following files:

A. ECM Replacement File

B. Fleet configuration File
C. Data Log File
D. All of the above
Unit 3 -1- Caterpillar Communications
Student Copy Unit 3 Quiz

CAT ET

Student Copy Unit 3 Quiz

UNIT 3 QUIZ

1. What screen automatically appears when Cat ET is connected to a machine if multiple ECMs are
connected to the data link?

A. Status screen
B. Configuration screen
C. ECM selector screen
D. Diagnostic codes screen

2. If Cat ET is running within STW, an active code can be further diagnosed by clicking the
Troubleshoot Code button to open which of the following programs:

A. Component Based Troubleshooting

B. SIS
C. DataView
D. Engine Performance Estimator

3. Which of the following items may require a password to clear the items from the ECM?

A. Active diagnostic codes

B. Logged diagnostic codes
C. Logged events
D. All of the above

4. Which screen is used to graphically show overspeeds?

A. Status screen
B. Event Histogram screen
C. Configuration screen
D. Diagnostic codes screen

5. Which screen is used to change fuel settings or equipment ID information?

A. Status screen
B. Event Histogram screen
C. Configuration screen
D. Diagnostic codes screen

6. When a test is performed with Cat ET and there are a number of items that need to be checked
simultaneously, what Cat ET function should be performed?

A. Customize a status screen

B. Customize a Configuration screen
C. Review diagnostic codes
D. View parameter history
Unit 3 -2- Caterpillar Communications
Student Copy Unit 3 Quiz

7. An intermittent injector fault can be recognized by the ________________ portion of the logged
diagnostic codes screen.

A. Code
B. Description
C. Value
D. Occurrences "Occ"

8. All electronically controlled injectors require calibration.

A. True
B. False

9. What must the rpm be set at before performing the Speed/Timing sensor calibration?

A. High idle
B. Low idle
C. 800 rpm
D. Not necessary because it is performed automatically by Cat ET

10. The injection actuation pressure test performs a functional check on which of the following
components:

A. Injection actuation pump

B. Injection actuation pressure control valve
C. Hydraulic pressure sensor
D. All of the above

11. If the wrong Engine ECM flash file is installed what will happen?

A. Engine will run only at low idle

B. Engine will run only at high idle
C. Engine will not start
D. An injector trouble code will be set

12. Using the File/Open drop down menu will allow access to which of the following files:

A. ECM Replacement File

B. Fleet configuration File
C. Data Log File
D. All of the above