Lesson 4: Flash Programming with ET

Lesson 4: Flash Programming with ET

Caterpillar Electronic Technician

• Getting Started with ET
• Using ET Screens
• Engine Diagnostics with ET
• Flash Programming with ET

Fig. 1.4.1

Objective
At the completion of this lesson, the student will be able to:
Introduction
This lesson covers Flash Programming using 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 ET and machine
Unit 1 1-4-2
Lesson 4

Fig. 1.4.1
Flash File Sources
There are various sources of flash files, the most commonly used are:
- SIS Set Up and Tool Guide CD
- SIS Web
- Corporate Mailbox System

NOTE: An engine flash file contains information peculiar to the

engine application such as: fuel settings, low and high idle and
torque rise.
Unit 1 1-4-3
Lesson 4

Fig. 1.4.2
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.
Double click on the Winflash icon, or start the ET program and click
on the Flash Programming icon.
The screen shown above will appear. Note that the correct ECM is
selected for flashing. If the ECM cannot be flashed (for example, an
ADEM I ECM), a message will appear saying "ECM is not
flashable."
On the screen above, check the "Selected ECM." The information to
the right shows the ECM information including the Personality
Module "Software Part #."
The upper box shows the ECM application information. This is
important if the engine is on the dynamometer and the application is
not obvious. The lower box shows the flash file application
information.
Click on the Select File button.

NOTE: The same dual purpose cable from the Communication

Adapter to the machine, used for normal programming can be
used for Flash Programming.
Unit 1 1-4-4
Lesson 4

Fig. 1.4.3

The Select File button (previous page) (Fig. 1.4.2) has been selected
and the Flash File Selection dialog box is displayed (Fig. 1.4.3).
This dialog box allows the user to select the drive, the directory
where the file is located and finally, the file.
Information on the selected is displayed in the File Info box of this
screen, this should agree with the engine and application.
The Flash File can be selected with a mouse click (as seen above).
Click the OPEN button.

The program is now ready to start the flash process.

The program returns to the previous screen, (shown above under the
Flash File Selection Screen).

NOTE: This screen has been changed with version 3.0.

Unit 1 1-4-5
Lesson 4

Fig. 1.4.4

Select the Begin Flash button (Fig. 1.4.4) (lower right )

The files are transferred to the ECM. The status bar indicates the
percent of the flash file that has been copied.
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.
If for any reason the process is interrupted due to computer crash or
the process is cancelled, the engine will not start and ET will not
communicate with the ECM. The process must be repeated using the
Begin Flash button.
This scenario can cause a difficult troubleshooting problem due to a
lack of communication between ET and the engine. This
troubleshooting problem is covered later under Personality Module
Diagnostics.
Unit 1 1-4-6
Lesson 4

Fig. 1.4.5

When the files transfer is complete, the "Flash Completed

Successfully dialog box appears (Fig. 1.4.5). It only remains to
verify the system with a functional test of the engine and 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 ET, use the following menu sequence:
File / Return to ET
Unit 1 1-4-7
Lesson 4

Fig. 1.4.6
The Configuration Screen (Fig. 1.4.6) 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 part number,
using the following screens:
- Flash Program

- Summary Screen

- Configuration Screen
Unit 1 1-4-8
Lesson 4

Fig. 1.4.7
Personality Module Diagnostics
A functional test along with a check of the Active Fault screen
confirms that all is well with the system.
One further function of Flash Programming is diagnostics. It is
possible to use the program during a no start or a no communication
problem to eliminate the possibility of a missing or corrupted
Personality Module file.
Select the Flash Program to identify that a valid Personality File is in
place. Without this file, there will be no diagnostic communication
with ET, neither will the engine start.
Using the Flash Program as a diagnostic exercise allows the user to
check this part of the ECM.
Most machines use the CAT Data Link for diagnostics, whereas the
Flash Program uses the ATA data link and its own wiring (there are
exceptions).
The (139-4166) Unicable has both CAT Data Link and ATA lines, so
the user does not need to change cables for either function. (This
cable replaced individual ATA and CAT Data Link cables.)
A no communication with ET problem could be due to a variety of
other causes, some of which are listed on the following page.
Unit 1 1-4-9
Lesson 4

No communication between ET and the machine or engine can be

caused by any of the following:
Damaged ET cables, check for opens or shorts

Communication Adapter problem such as:

Blown fuse
Missing SPM

Computer com port not set

ET preferences not set correctly, wrong com port selected

No power to ECM
Key switch off
Wiring fault, connector loose

CAT Data link problem

Connector or wiring fault

No Personality Module installed in ECM

Unit 1 -1-
Student Copy Lab 1.4.1.

Student Copy: Lab 1.4.1

LAB 1.4.1: FLASH PROGRAMMING WITH ET

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

1. Name sources to access or download flash files:

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

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

4. 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.

5. Troubleshoot a communication problem between ET and machine.