Service Training January 2004

Technical Presentation

Caterpillar Electronic Technician

STW Version 2003B

Module Three: Engine Diagnostics with Cat ET

Nigel Wilkinson
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Cat Electronic Technician Course 3-3 Module Three
01/04 Table of Contents

Module Three: Engine Diagnostics with Cat ET

Table of Contents

Module Preparation
Module Description ......................................................................................................... 3 - 5
Prerequisites ......................................................................................................................3 - 7
Objectives .........................................................................................................................3 - 9

Lesson One: Cat ET Engine Diagnostic Functions

Introduction ................................................................................................................ 3 - 1 - 1
Electronic Unit Injector Testing
Accessing Diagnostic Routines ............................................................................ 3 - 1 - 2
Injector Solenoid Test ........................................................................................... 3 - 1 - 3
Cylinder Cutout Tests ........................................................................................... 3 - 1 - 5
ECM Injection Strategies ..................................................................................... 3 - 1 - 9

System Component Calibrations

Speed/Timing Sensor Calibration ....................................................................... 3 - 1 - 10
Pressure Sensor Calibration ................................................................................ 3 - 1 - 12
EUI and HEUI Injector Calibration .................................................................... 3 - 1 - 15
ACERT Injector Trim File Calibration ...............................................................3 - 1 - 17
Downloading Injector Trim Files ........................................................................3 - 1 - 19
Calibrating Injectors with Trim Files ..................................................................3 - 1 - 27
Injector Trim File Exchange ................................................................................3 - 1 - 33

Miscellaneous Diagnostic Routines

Injection Actuation Pressure test ........................................................................ 3 - 1 - 36
Override Parameter Function ............................................................................. 3 - 1 - 37
Wiggle Test ......................................................................................................... 3 - 1 - 38
Lesson One Lab Exercise ................................................................................... 3 - 1 - 41
Cat Electronic Technician Course 3-4 Module Three
01/04 Table of Contents

Lesson Two: Flash Programming and Flash File Search

Introduction ................................................................................................................ 3 - 2 - 1
Flash File Storage ....................................................................................................... 3 - 2 - 3
Flash File Search and Sources ................................................................................... 3 - 2 - 6
Flash Programming Procedure ................................................................................. 3 - 2 - 11
Personality Module Diagnostics ............................................................................... 3 - 2 - 17
Cat ET Communication Problems ............................................................................ 3 - 2 - 15
Lesson Two Lab Exercise ........................................................................................ 3 - 2 - 19
Cat Electronic Technician Course 3-5 Module Three
01/04 Module Description

Module Description

Module Three contains diagnostic and flash programming information needed by a technician to use the
program with a Caterpillar machine, engine or training aid. The modules do not teach specific machine
systems unless otherwise stated in the lesson description.

It is strongly recommended that each student be able to demonstrate competence in PC operations prior
to starting this module. A list of PC training material is located in the STW Course Preparation section.

Additionally, the student should have completed Module One and Two or have demonstrated
competence in the basic tasks described in Module One.

This module can be completed in a self study or classroom environment. In each case, a Training Aid is
useful for performing the labs. If the Training Aid is not available, then a machine or an engine could
be used, however, this may not work for classroom type instruction. It is also possible to obtain an
ECM suitably wired with a power supply and sensors to accomplish some programming tasks.

Cat ET contains ET Trainer which simulates Cat ET being connected to a live ECM. ET Trainer can be
used for some of the training tasks described in this Module. ET Trainer currently in contains four
applications including the 3406E (On Highway) Truck Engine, 950C Wheel Loader, C-9 Industrial
Engine, and the 777C Off-highway Truck.

This module is designed to be printed on both sides of the paper, hence there are blank pages at intervals
throughout the module to accommodate this.
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Cat Electronic Technician Course 3-7 Module Three
01/04 Module Prerequisites

Module Preparation
Prerequisites

The student should have completed courses in the following subjects or

have shown competency in those subjects prior to starting Module Three:

Prerequisite Courses 1. Basic diesel engines

2. Diesel governing systems

3. Diesel fuel systems

4. Air intake and exhaust systems

5. Lubrication systems

6. Cooling systems

7. Basic electrical systems

8. Engine diagnostics

9. Windows™ operations (Prerequisites for Modules One and Two)

10. STW Modules One and Two

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Cat Electronic Technician Course 3-9 Module Three
01/04 Module Objectives

Objectives

Given the Electronic Technician (ET) program and relevant publications,

perform the following functions:

Lesson 1: 1. Test the electronic injectors for mechanical and electronic faults
Cat ET Engine using fault screens, cylinder cutout and solenoid tests.
Diagnostic Applications

2. Calibrate the speed/timing sensors, pressure sensors and injectors.

3. Perform the injection actuation pressure test.

4. Perform the override parameters function.

5. Clear events and change fuel settings using factory passwords.

Lesson 2: 6. Download or copy flash files from all sources.

Flash Programming and
Flash File Search
7. Perform flash programming.

8. Diagnose personality module file problems.

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