Caterpillar Inc.

, 2015

Engine Reprogramming Tool

Version 2.1
Installation and User Guide
Kevin O'Neil
Engine Reprogramming Tool Version 2.1

{Intentionally left blank}

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Contents
Engine Reprogramming Tool (ERt) ........................................................................................................... 3
1.1 General Description.......................................................................................................... 3
1.2 Acronyms and Definitions ............................................................................................... 3
1.3 Requirements and Hardware ............................................................................................ 4
1.4 Application Download and Installation............................................................................ 4
1.4.1 Application Download .............................................................................................. 4
1.4.2 Application Installation ............................................................................................. 6
1.4.3 Repair or Remove the ERt Application .................................................................... 9
1.5 Application User Guide.................................................................................................. 10
1.5.1 One-time Setup of the ERt Application .................................................................. 10
1.5.2 Obtain a DPK flash file ........................................................................................... 13
1.5.3 Flashing Engine ECU or Aftertreatment ACU ....................................................... 17
1.5.4 Troubleshooting Guide ........................................................................................... 21
1.5.5 Change History ....................................................................................................... 26

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Engine Reprogramming Tool (ERt)

1.1 General Description

The Engine Reprogramming Tool (ERt) is a Windows PC-based application to assist with
flashing specific Engine ECUs or Aftertreatment ACUs that do not follow the conventional
Caterpillar ™ Flash File process. The ERt application can flash these specific ECUs and ACUs
when the service tool (Electronic Technician) is not currently capable of flashing these specific
devices.

The ERt application expects a specific type of flash file known as a DPK file. The *.DPK file
extension differs from the traditional *.FLS, *.FL2 or *.FL3 file extensions used with the
Electronic Technicians service tool. The ERt application is only meant to flash specific Engine
Classes such as C1.8, C2.4, C3.3B and C3.8, plus an Aftertreatment ACU associated with the
Tier4 Final Engine (C3.8). These Engine Classes are typically installed on SSL, CTL, MTL,
certain Paving Products, CWL or other small construction machine equipment.

1.2 Acronyms and Definitions

The following table provides a list of acronyms or definitions used within this document and the
associated descriptions for each.

Acronym Description

Engine Reprogramming tool – is a Windows PC-based application used

ERt to assist with flashing various Engine ECUs that do not follow the
conventional Caterpillar ™ Flash File process

Electronic Control Unit / Electronic Control Module - A generic term

ECU, ECM for an Embedded Control System that controls one or more electrical
or mechanical systems within a machine or vehicle.

Aftertreatment Control Unit – A specific term for an Embedded

ACU Control System that controls aftertreatment systems within a machine
or vehicle.

Electronic Technician – The Service Tool application used to

ET retrieve the ECU information from Caterpillar Machines, and perform
calibrations and configurations for these ECU devices.

CA3 or Communication Adapter 3 – This is the module used to enable

CA3
communication between a set devices on a Machine and a Windows PC.

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Technical Information Bulletin – This is a newsletter type of
providing a quick and easy way to alert Dealers to new and better
TIB
procedures, parts, ideas, etc. TIB’s are for information only and do
not authorize warranty claims.

FLS or Flash Files – are the traditional Caterpillar type flash

*.fls, files. FLS is the original flash file; FL2 contains release notes
*.fl2, and flash file data for a specific ECU. FL3 contains release notes
*.fl3 and flash file data for several ECUs. Electronic Technician service
tool is used to flash update Caterpillar ECU devices.

MSI – Microsoft Installer file extension. This is the executable

file that will install the ERt application.
*.msi
The * is simply the name of the file, such as ERT_install.msi (* is
ERT_install)

DPK or Data Pack file – Similar to a Caterpillar Flash (FLS, FL2,

FL3) File, this Data Pack contains all the information to define how
*.dpk
the Engine ECU or Aftertreatment ECU uses to control their specific
electronic system.

Table 1: Engine Reprogramming Tool - Acronyms

1.3 Requirements and Hardware

• A PC with a Windows Operating System (XP, Windows 7, Windows 8). Adequate RAM
and hard drive memory available for installation.
• Communication Adapter 3 (317-7485) and related cables.
• Electronic Technician 2015B (or more recent) is installed.

1.4 Application Download and Installation

1.4.1 Application Download

The ERt application can be found via the Product Support web portal (dealer.cat.com), selecting
the “Service Operations” on the lower left-hand side of the web page, then select “Additional
Downloads” line item listed within the “Service Software (Cat ET, SIS, STW)” menu.

The following web link provides the direct web location to download the Engine
Reprogramming Tool application.

https://dealer.cat.com/en/ps/service/software/downloads.html

Click on the “Engine Reprogramming Tool Download” hyperlink to download the ERt
application (Figure 1).

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Figure 1: Engine Reprogramming Tool – Web Link Location

An informational window may appear at the bottom of the web browser (Figure 2). Select either
“Save”, “Save As”, or “Save and Run” to download the MSI installer file to a specific folder
location and / or run the MSI installer once it has been downloaded.

NOTE: Filename may be different from what is in Figure 2 depending on the revision of ERt being downloaded.

Figure 2: Engine Reprogramming Tool – Download

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Click “Run” to download the file to the selected file location. This may take a moment
depending on network connection and speed.

1.4.2 Application Installation

Navigate to the folder where the *.msi installer file was downloaded and double-click on the icon
to start the installation process. The first pop-up window should resemble Figure 3.

Select either “Cancel”, “Next” or “Back” for each of the subsequent pop-up windows. Select
“Cancel” to terminate the installation at this time. To proceed with the installation, hit the
“Next” button.

Figure 3: Engine Reprogramming Tool – Setup Wizard

Select to either “Agree” or “Not Agree” with the ERt License Agreement presented (Figure 4).
Please read the license agreement carefully and select the appropriate action. Select “Cancel” to
terminate the installation, or “Back” to change the previous selection (if applicable). To proceed
with the installation, select the “I Agree” option and then click “Next”.

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Figure 4: Engine Reprogramming Tool – License Agreement

Select where on the Windows PC to install the ERt application (Figure 5).

Figure 5: Engine Reprogramming Tool –Select Installation Folder

A default path is provided (recommended) but can be personalized to be a custom path install.
There is also an option to install the ERt application for the current user (“Just me”) or all users
(“Everyone”) on the PC.

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Select “Cancel” to terminate the installation “Back” to change a previous selection (if
applicable). To proceed with the installation select an installation folder and the user(s)
associated with the installation and hit the “Next” button.

Confirm the installation choices or select “Cancel” to terminate the installation or “Back” to
change a previous selection (if applicable) (Figure 6).

Figure 6: Engine Reprogramming Tool – Confirm Installation

Once installation is complete, close the Setup Wizard application (Figure 7). The application is
now installed and a new ERt Icon is placed on the desktop.

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Figure 7: Engine Reprogramming Tool – Installation Complete

1.4.3 Repair or Remove the ERt Application

With an ERt application already installed, the user may need to repair (cases where installation
files were accidentally deleted or corrupted) or remove the application entirely. To perform
either of these tasks, re-open the *.msi file downloaded and select either Repair or Remove
(Figure 8) and then “Finish”. Select “Cancel” to terminate the repair or removal request.

Figure 8: Engine Reprogramming Tool – Repair or Remove

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Alternatively, remove or uninstall the ERt Application via the Windows “Control Panel”
process (Figure 9), select “Uninstall a Program”, select the “Engine Reprogramming tool
program” from the drop down list, and then choose “Yes” or “No” to complete the action.

Figure 9: Engine Reprogramming Tool –Remove ERt using Control Panel

1.5 Application User Guide

With the Engine Reprogramming tool application installed, complete the one-time setup to
ensure maximum flash performance of the tool.

1.5.1 One-time Setup of the ERt Application

Before flashing the Engine ECU or Aftertreatment ACUs the following steps must be checked
and completed before proceeding.

1. Ensure Cat ET 2015B or more recent version is installed. ET release 2015B (or more
recent) contains specific Communication Adapter 3 drivers to aid in the ERt flash
process. Future releases may contain further updates to these drivers and continue to
update the CA3 when updates are available.

2. Cat Communication Adapter 3 (CA3) is required.

NOTE: Do not use Cat Communication Adapter 2 as it is no longer supported when using Version 2.0 or
higher of the ERt application.

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3. Check the Cat Communication Adapter 3 software release using the “Caterpillar Comm
Adapter 3 Toolkit”. The Toolkit can be launched using the ERt application – open the
ERt application, and on the ERt main screen select “Launch Toolkit” (Figure 10).

Figure 10: Engine Reprogramming Tool – Launch Tool Kit via ERt

The CA3 Toolkit may also be found via the “Start” menu: select “All Programs” and
selecting the “Caterpillar Comm Adapter 3” folder. The toolkit is found within that
folder (Figure 11)

Figure 11: Communication Adapter 3 – Launch Tool Kit via Start Menu

4. With a Communication Adapter 3 connected to the PC and with the Toolkit open (Figure
12), the present version of the Communication Adapter 3 software version can be seen by
selecting “Information” >> “Summary” from the drop-down list. The expected version
should be (at minimum) software release version 1.19.50

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Figure 12: Communication Adapter 3 – Software Release Version

The Communication Adapter 3 software version can also be seen by selecting the
following Icon shortcut from the toolkit (Figure 13).

Figure 13 Communication Adapter 3 – Toolkit Summary Icon

5. If the software version number is lower than the recommended software release version
1.19.50, update the CA3. Select “Utilities” >> “Reprogram CA3” from the drop down
list to view the list of CA3 firmware files (Figure 14).

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Figure 14: Communication Adapter 3 – CA3 Software File Update

This action can also be performed by using the following Icon shortcut from the toolkit
(Figure 15).

Figure 15: Communication Adapter 3 – CA3 Software Program Icon

7. Select the appropriate CA3 driver file and begin the CA3 driver reprogramming upload.

1.5.2 Obtain a DPK flash file

If the Engine or Aftertreatment flash update is driven by a TIB or Service Letter, follow those
instructions for obtaining the specific *.DPK file. If this is for an Engine ECU or Aftertreatment
ACU replacement, or to obtain the latest *.DPK files, then use the following instructions.

NOTE: The following represent the steps to obtain the *.DPK file specifically for the 3.3B and C3.8 Engine ECUs.
Obtaining DPK files for C1.8, C2.4 and Aftertreatment ACUs may require similar steps, but the processes to obtain
their DPK files have not been completed at this time. Assume these files will be available via SISWeb at a future
date.

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1. Go to SISWeb and select the “View More” hyperlink located under the “Additional
Service Information” section (Figure 16).

Figure 16: SISWeb – Home Page

2. Click on “C3.3B and C3.8 Downloads” hyperlink (Figure 17) or select to add this
hyperlink option into the SISWeb main menu for future access.

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Figure 17: SISWeb – Additional Service information

3. Select “C3.3B & C3.8 Downloads” hyperlink (Figure 18).

Figure 18: SISWeb – C3.3B and C3.8 Downloads

4. Select “Type 1 SPK (PGM)” or “Type 2 DPF (PGM+Trim)” (Figure 19).

Figure 19: SISWeb – ECU Data Pack Download

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NOTE: In a future update to the Engine DPK downloads website, the ERt related DPK files will be provided
via their own download button. As of the date when this document was written only ET related DPK files are
available on the website.

ERt files must be obtained from your Engine service support person until the website is
updated. Future filenames for DPK files may resemble the following:

ET_1H00069951_A38.DPK, ERT_21H00069951_C33.DPK

5. Enter the Engine Serial Number (Figure 20).

Figure 20: SISWeb – Enter Engine S/N

6. Click on the button to select the Engine. If more than one Engine is shown and it is not
known which Engine to select, contact the Dealer Solution Network (DSN).

7. Enter the Engine ECU ECM SN that is located on the ECM or obtained via the Electronic
Service Tool Summary screen.

8. Click on the “Download” button to begin the download.

NOTE: The Type 2 DPK download will load the injector trim codes recorded from the manufacturer. If any
injectors have been manually replaced, the DPK website may not be aware of this, and an incorrect injector trim
codes will therefore be installed. Performance problems may occur and the Engine may not meet emission
targets. When in doubt, visually inspect and compare the injector trim codes to what is stored in the Engine
ECU (or Aftertreatment ACU) using the Electronic Technician (ET) service tool.

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1.5.3 Flashing Engine ECU or Aftertreatment ACU

With the one-time setup completed and DPK files now in hand, proceed with flash updating the
device. If there are any issues please refer to the Troubleshooting section of this.

1. Connect the Communication Adapter 3 to the PC and the Machine’s service port.

2. Turn the Machine’s key switch to the power on position. Do not run the Engine while
performing a DPK flash update.

3. Run the ERt application by double-clicking the ERt application icon on the desktop
(Figure 21) or by entering the Start Menu and selecting “ALL Programs >> Engine
Reprogramming Tool”.

Figure 21: Engine Reprogramming Tool – ERt icon

4. Select the ECM Type (Engine or Aftertreatment) to be flashed (Figure 22).

Figure 22: Engine Reprogramming Tool – Select ECM Type and Start

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Care should be taken to select the correct type of Engine (C1.8, C2.4, C3.3B or C3.8) as
they employ different ECU modules or they may not be compatible with the specific
DPK file.

Once the ECM Type has been selected, click the “Start” button.

A new window will appear (Figure 23) that allows the user to “Browse” for a specific
DPK file, “Validate” that the DPK file is compatible with the ECU type selected, and
“Write” after the DPK file has successfully been validated.

5. Select “Browse” to select a compatible *.DPK Flash File for the ECM Type selected.

Figure 23: Engine Reprogramming Tool – Select ECM Type and Start

6. Click “Validate” to confirm the DPK file is compatible with the ECM type selected. If
the DPK is meant for this ECM Type device, two of the four fields in the “Present ECU
Information” section will highlight GREEN (Figure 24).

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Figure 24: Engine Reprogramming Tool – Validate and Write

The ERt application window may not appear exactly as shown in Figure 23, but if
“Validate” was successful, the “Write” option can now be selected. Consult the
troubleshooting section within this document if one or more of the items are highlighted
RED.

7. If available, select “Write” to reprogram the Boot Loader, Main Program and Data
upload. This process will take several minutes to complete and additional instructions
may appear.

8. The following window (Figure 25) will appear midway through the flashing process,
with the further instructions that must be followed to ensure a successful flash process:
• Turn Key Switch to Off
• Wait 10 seconds
• Turn Key Switch to On (Engine not running)
• Press OK

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Figure 25: Engine Reprogramming Tool – Additional Flash Instruction

9. Once the previous instructions are complete and reprogramming was successful, select
“Close” to close the “Engine Reprogramming Tool” application.
NOTE: As stated earlier, reprogramming the injector trim data for the Engine ACU or Aftertreatment ACU
depends on whether the DPK file included the data for the installed injector(s).

The device has now been successfully flashed. You may close the window.

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1.5.4 Troubleshooting Guide

Symptom or Issue Reason and Possible Resolution

Communication between devices is broken.

Step 1: For ERt, connect a CA3 and not CA2.

Step 2: Ensure only 1 application (either ET

or ERt) are actively using the CA3.

Step 3: Ensure the CA3 is properly connected

to a working USB port, and firmly connected
to the Machine’s service port.

Step 4: Ensure the Machine power disconnect

is on, key switch is in the on position, and
power is provided to the CA3 (see LED on
device).

Step 5: Check CA3 connector cables for

damage. The USB cable can break internally
near the connection at the CA3. The
Cannot Detect ECU using ET or ERt connector(s) may need replacing.

Step 6: If using the ET application (to get

Engine Serial Number information etc), ensure
the correct CA3 Communication Device is
selected in the preferences menu. The
selection can be found in ETs “Utilities” >>
“Preferences” >> “Modify”. Refer to ET Help
for more information.

Error warning when selecting the Select an ECM Type from the list of 3 options
“Launch Toolkit” within the ERt first before selecting the “Launch Toolkit”
Tool button.

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Engine Reprogramming Tool Version 2.1
Step 1: For ERt, connect a CA3 and not CA2.

Step 2: Ensure only 1 application (either ET

or ERt) are actively using the CA3.

Step 3: Ensure the CA3 is properly connected

to a working USB port, and firmly connected
to the Machine’s service port.
“Launch Toolkit” does not detect
an CA3 Step 4: Ensure the Machine power disconnect
is on, key switch is in the on position, and
power is provided to the CA3 (see LED on
device).

Step 5: Check CA3 connector cables for

damage. The USB cable can break internally
near the connection at the CA3. The
connector(s) may need replacing.

Select an ECM Type from the list of 3 options

first before selecting “Start”.
The following pop-up screen when
hitting “Start” button

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Engine Reprogramming Tool Version 2.1
The following pop-up screens when
trying to “Validate” a DPK file

Step #1: The DPK file is not compatible with

the ECM Type selected in the ERt main screen.
Ensure the correct ECM Type and DPK file are
selected before Validating.

Step #2: Ensure the DPK selected matches the

Engine Class. The DPK file selected may be
for a different Engine class (C3.3B vs C3.8)
installed on the machine.

One of the following pop-up

screens appear while attempting
to “Validate” a DPK file

The DPK files have a date stamp associated

with them, typically 1 month. A DPK file will
not flash onto any device if it is outdated.

Step 1: Obtain a recent DPK file associated

with the Engine Serial Number / Engine ECU
Serial Number.

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Engine Reprogramming Tool Version 2.1
One of the following pop-up
screens appear while attempting
to “Validate” a DPK file that
contain various “Communication
Error has occurred [########]”
error codes.
There was no response from device being
validated. Ensure Key is On and the Engine
ECU or ACU is providing data to the display
(Engine Coolant Temp, DEF Fluid level for
example). There may be an issue with CAN Bus
connection between device and service port or
the ACU is without a program.

The DPK file chosen may be valid for this

Engine ECU serial number, but the file is
designed for a different flash tool,
typically “Diagmaster” or “Electronic
Technician”.

Please ensure the file obtained is meant for

the ERt reprogramming application tool and
not Diagmaster or ET

A DPK file that is outdated will be deleted

from the directory during “Validation”
After having an issue validating
TIP: Right-click on a DPK file, select
a DPK file, the DPK file is no
“Properties” and check the “Read Only”
longer in the directory, it seems
option. This will prevent these files from
to have been deleted. being deleted (though they do not serve a
purpose as they cannot be loaded into any
device).

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The following pop-up appears.
The DPK file property is “Read-Only”, and the
ERt application attempted to delete it. The
deletion fails because of the “Read Only”
setting.

This DPK file is not valid. Ignore this

warning if electing to keep the DPK file as
“Read Only”. Do not select this DPK file in
the future.

Step #1: The DPK file is not compatible with

the ECM Type selected in the ERt main screen.
Ensure the correct ECM Type and DPK file are
selected before Validating.

Step #2: Ensure the DPK selected matches the

When validating a DPK file one or
Engine Class. The DPK file selected may be
more ECU Information Entries is
for a different Engine class (C3.3B vs C3.8)
RED
installed on the machine.

Step #3: Ensure the Engine ECU or

Aftertreatment ACU serial number that
generated this DPK file match the unit on
machine. There may be a mismatch.

Step #1: Ensure the CA3 Software Release

Version is 1.19.50 at minimum. Refer to the
“One-Time Setup” section for more
The Flash process keeps failing
information.
midway through either the
Programming Boot Loader, Main
Step 2: Check CA3 connector cables for
Program, ECU Data flash process damage. The USB cable can break internally
near the connection at the CA3. The
connector(s) may need replacing.

The injector trim data programmed with the

DPK file may not reflect the injector(s)
installed on machine – the injector(s) may
The Engine or Aftertreatment have been serviced / replaced.
device is not performing
optimally after flashing the DPK Step #1: Confirm the DPK file has the same
file. injector trim data associated with the
injector(s) on the machine. If different,
obtain the injector QA or QR codes and re-
program using the ET service tool.

Table 2: Engine Reprogramming Tool - Troubleshooting

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The previous table (Table 2) above provides possible resolutions to the most common issues
encountered while using this ERt flash application. This is not a comprehensive list as some
issues are based on individual PCs and may not have been experienced during testing.

If problems persist, close the ERt and / or ET applications. Remove power to the CA3 by
disconnecting the CA3 from the PCs USB Port, and from the Machines’ 9-pin service port.
Reconnect the CA3 using a different USB port on the PC and reconnecting to the 9-pin service
port. Reopen either the ERt or ET and continue. Check the CA3 connector for broken wires,
typically seen on cable 370-4617 nearest the CA3 connection. Reconfirm DPK file chosen is
meant for the device under flash. If problems persist, disconnect everything, reboot PC and start
again.

If further assistance is needed, contact your Product Support Person at this web location:

https://dealer.cat.com/en/ps/service/software/downloads/product-support-information-engine.html

1.5.5 Change History

1.5.5.1 ERt Version 1.0
• Original

1.5.5.2 ERt Version 2.0

• ERt version 2.0 supports multiple Engine ECUs and Aftertreatment ECUs. These include
Engine classes C1.8, C2.4 (Bosch Engine ECU), and the C3.3B and C3.8 (Denso Engine
ECU). This also supports the Aftertreatment ACU used with the C3.8 Tier4F engines.
• The ERt version 2.0 corrected several minor issues found within version 1.0.
• This document provides additional instructional information related to installation,
configuration and includes a troubleshooting section.

1.5.5.3 ERt Version 2.1

• Update the hyperlink and picture for the ERt download website.
• Update the figure to show the 4 types of DPK files from the download site (Figure 19).

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