Professional Documents
Culture Documents
August 2007
Systems Operation
Troubleshooting
Testing and Adjusting
PL1000T Communication ECM
i01658146
Table of Contents
Systems Operation Section
General Information ................................................ 4
Features .................................................................. 5
Electronic Control Module (ECM) ........................ 47
Wiring Harness ..................................................... 48
Configuration ........................................................ 48
Troubleshooting Section
Introduction
General Information .............................................. 49
Service Tools ........................................................ 49
Connector Locations ............................................. 51
Diagnostic Capabilities ......................................... 51
Symptom Procedures
J1939 Bridge ......................................................... 63
CAN Extension Bridge .......................................... 63
Customer Communication Module ....................... 65
Global Positioning System Interface Module ........ 67
Engine Vision Interface Module ............................ 67
Sea Water Module Interface ................................. 68
Embedded Communication Adapter ..................... 68
Index Section
Index ..................................................................... 84
4 RENR7945-01
Systems Operation Section
General Information
SMCS Code: 7610
J1939 Bridge
CAN Extension Bridge
Cat Datalink (CDL) Tunnel
Cat Datalink (CDL) Boost
Embedded Communications Adapter (ECA)
Note: The product name PL1000T Communications
ECM will be referred to as PL1000T.
Table 1
Applications that may be operated simultaneously and the Physical Connections they affect
CCM RS-232 #1 RS-232 #1 RS-232 #1 RS-232 #1 RS-232 #1
SWMI RS-232 #1 RS-232 #1 RS-232 #1 RS-232 #1
EVIM RS-232 #2 RS-232 #1 RS-232 #2 RS-232 #1
GPSIM RS-232 #2 RS-232 #2 RS-232 #1 RS-232 #2 RS-232 #2
J1939 Bridge CAN Port CAN Port CAN Port
CAN Extension Bridge CAN Port
CDL Tunnel CDL Port CDL Port CDL Port
CDL Boost CDL Port CDL Port CDL Port CDL Port CDL Port CDL Port CDL Port
ECA RS-232 #3 RS-232 #3 RS-232 #3 RS-232 #3 RS-232 #3 RS-232 #3 RS-232 #3
i02813382
Features
SMCS Code: 7610
J1939 Bridge
The PL1000T, when configured to provide the J1939
Bridge functionality, will join two independent J1939
networks into a single J1939 network.
g01114474
Illustration 1
Illustration 1 shows a complete J1939 Bridge All J1939 messages on Network 1 will be relayed
network. The two independent J1939 networks are to Network 2, and all J1939 messages on Network
joined through the PL1000T. When configured to 2 will be relayed to Network 1. Each message
provide the J1939 Bridge functionality, the PL1000T being relayed will be presented on the destination
ECM functions as a repeater between the two J1939 J1939 Network in its entirety and will appear to have
networks. The PL1000T will forward any incoming originated on the destination J1939 network.
J1939 data to the bridged network, regardless of
message format or data content.
6 RENR7945-01
Systems Operation Section
g01114482
Illustration 2
Illustration 2 shows a complete CAN Extension There can also be a logical connection between
Bridge network. Network 1 is logically connected to Network 3 and Network 4 through the same RS-485
Network 2 through the RS-485 network that is used Network and PL1000Ts. When configured to provide
between the two PL1000Ts. the CAN Extension Bridge functionality, each of the
PL1000Ts will multiplexe and de-multiplexe the
J1939 communications over the RS-485 network.
RENR7945-01 7
Systems Operation Section
The two new logical networks share the RS-485 Once integrated into the system, the PL1000T
connection, but the data from CAN networks 1 and alleviates the need for the traditional external
2 is not available on networks 3 or 4. The reverse is communication adapters. The PL1000T provides all
also true. Each message is being relayed on the two of the same electronic control servicing as previously
independent logical networks. provided by the traditional external communication
adapters.
An example application for implementation of the
CAN Extension Bridge feature is on a marine The ECA usage is compatible with Caterpillar
vessel. In some larger marine vessels the engines Electronic Technician version 2004B or later and
are typically located a significant distance from the Caterpillar Communication Tool Kit version 2005A
bridge or engine monitoring station. Typical CAN or later.
data link physical network specifications require the
wiring be limited to a total distance of no greater than Illustration 3 shows alternative use of the ECA or
40 m (131 ft). the 171-4400 Comm Adapter II. The two devices
should not be actively used by separate service
The CAN Extension Bridge feature can accomodate tools at the same time.
four physical networks while maintaining two
independent logical networks. The CAN Extension Note: Illustration 3 depicts only ECA interface to the
Bridge feature will allow wiring on each original CAN Cat Datalink. However, the ECA also allows interface
network to run a total of 40 m (131 ft) each. to J1939 networks.
Embedded Communications
Adapter (ECA)
The PL1000T provides an embedded communication
adapter for standard Caterpillar service tools such
as Electronic Technician. The PL1000T has been
designed to be a direct embedded communication
adapter replacement of all previous communication
adapters. In order to utilize the ECA feature, simply
connect the serial port 3 of the PL1000T to a laptop
computer that is running a standard Caterpillar
service tool. Configure the service tool preferences
to use the Embedded Communication Adapter. The
ECA feature is always enabled and assigned to serial
port 3 within the PL1000T.
8 RENR7945-01
Systems Operation Section
g01114578
Illustration 3
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Illustration 4
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Illustration 5
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Illustration 6
RENR7945-01 11
Systems Operation Section
Illustration 6 shows an example integration of the Refer to the M5X programming section or the M50
PL1000T into a system that is designed as a SWMI. programming section of this manual for information
about the communications requirements and the
This manual is intended to address the SWMI methods of using the instruction identifiers for
interface capability of the PL1000T. Refer to M5X or M50 protocol. The programming section of
the documentation of the Caterpillar display for this manual does not address the engine specific
specific information for installation, operation, and parameters that are necessary for monitoring
troubleshooting its ability to display the Sea Water engines. The parameters that are specific to the
Module information. engine and the supported M5X or M50 protocol
should be referenced in the System Operation Test
CDL Boost and Adjust manual for the specific engine.
g01265160
Illustration 8
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Illustration 9
RENR7945-01 15
Systems Operation Section
The checksum is an important part of the M5X The heartbeat message is a method used in order
protocol message and of the M50 protocol message. to continuously monitor and in order to verify the
The checksum is calculated the same way for PL1000T data stream. The heartbeat message
both protocols. This document includes necessary should be used in order to verify the PL1000T
considerations related to checksum calculation. connection before the login process. The heartbeat
message should be used periodically during normal
The checksum provides a mechanism by which operations. The heartbeat PID is $F0 $12 that uses a
the integrity of each message and associated data Single Parameter Read IID $24.
is maintained. When a message is received, the
checksum is calculated and the message integrity Periodic read requests and received responses will
is validated in order to confirm that the received serve to validate the RS-232 connection. Periodic
data is the intended information. Each message read requests and received responses will provide
sent contains a checksum located in the next to an ability to monitor the security level of the PL1000T
last byte before the ASCII carriage return character for unexpected changes. Unexpected changes in
string $0D. Checksum values are calculated by the security level received in the heartbeat response
determining the twos complement value of the message may prevent some data from being
hexadecimal summation of all data bytes in the transmitted.
message. The message is valid if the summation of
all data bytes is zero. Refer to Table 5 for an example. Security Levels
Checksum Calculation Example Every individual PID that is supported by the engine
electronic controller has an associated security
For example, consider the following message string: level 0, 1, 2, or 3. Likewise, there is a security level
associated with every PID that is supported by the
50002404005801082AE<cr> PL1000T. The security levels are numerically related
in an equal or lower relationship. For instance,
Table 5
when the security level response indicates a security
Byte ASCII Value Hexadecimal level of 2, any PID with a security level of 3 would not
Value be accessable. For troubleshooting information and
$50 $35 $30 $50 procedures related to security level issues, please
refer to the Systems Operation Test and Adjust
$00 $30 $30 $00 manual.
$24 $32 $34 $24
Table 6 lists the PIDs that are supported by the
$04 $30 $34 $04 PL1000T and also lists the associated security level
requirements.
$00 $30 $30 $00
$58 $35 $38 $58
$00 $30 $30 $00
$82 $38 $32 $82
PL1000T Login
The first step toward establishing protocol
communications with the PL1000T is to perform the
login procedure. Login must be accomplished before
any PIDs can be assessed. The login procedure
consists of sending the appropriate password to
the PL1000T via IID $34 writing to PID $AA $8A.
All PL1000T communication modules are shipped
from the factory with blank passwords. To login to a
PL1000T with a blank password, send the following
message.
500034040061AA8AE3
g01265173
Illustration 10
EERP1000 Caterpillar Communications Toolkit 2. Write PID $AA $12 using IID $34 to MID $61 with
the Password Enable Bit set to 1. For specifics
Electronic Technician on the appropriate format of the message, please
refer to the example message section. Since there
Custom device using M5X or M50 protocol. are several options in PID $AA $12 that will need
to be considered for each application.
Password Enable Sequence
Note: When a password enable or disable sequence
Password enabling requires a specific sequence. is successfully completed, the default passwords
Any deviation from the following steps will result in an are set to blank. If password protection is
unsuccessful password enabling procedure. implemented after either of these actions, the
passwords for each security level must be
1. Write PID $AA $12 using IID $34 to MID $61 programmed.
with the password enable bit cleared to zero.
For specifics on the appropriate format of this
message, please refer to the example message
section since there are several options in PID
$AA $12 that need to be considered for each
application.
Activate a Standard Broadcast List IID $11 Deactivate Standard Broadcast List IID $12
The IID $11 Standard Broadcast List is used to The IID $12 command is used to deactivate a
activate a previously configured Standard Broadcast Standard Broadcast List that was previously
List. After a Standard Broadcast List has been configured and that was previously activated . Once
successfully configured in the PL1000T, the list is activated, a Standard Broadcast List remains
defaulted to a deactivated state. The host device activated until the PL1000T receives the deactivation
must then execute an activation command in order command. Since the active state of the Standard
to request the PL1000T to begin sending the data Broadcast List is retained even through the power
that is requested in the broadcast list. Response to is cycled for the system, therefore, the list must be
the activation command is the status reply IID $15. deactivated by the IID $12 command before the
The status reply IID $15 is discussed in Standard PL1000T will cease transmissions of the list data.
Broadcast List Status Reply IID $15 section of this
document. The response to a deactivation command is status
reply IID $15. Refer to the Detail Breakdown of an
Detail Breakdown of an example of IID $11 Example IID $15 Message section for more IID $15
message status reply information.
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Illustration 12
Table 8
Field Description
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Always $50 $00 for host to Illustration 13
Standard Premable
PL1000T Messages
Table 9
Specific command sent to
IID Field Description
the PL1000T
Number of bytes in the Always $50 $00 for host to
Standard Preamble
message starting after the PL1000T Messages
Byte Count
byte count byte location Specific command sent to
excluding checksum IID
the PL1000T
The Standard Broadcast Number of bytes in the
List Number List Number for which message starting after the
data is being activated. Byte Count
byte count byte location
Refer to the Checksum excluding checksum
Checksum Calculation Example The Standard Broadcast
section List Number List Number for which data
is being activated.
Refer to the Checksum
Checksum Calculation Example
section
RENR7945-01 21
Systems Operation Section
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Illustration 14
22 RENR7945-01
Systems Operation Section
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Illustration 16
RENR7945-01 25
Systems Operation Section
Table 15
Field Description
Standard Preamble Always $50 $00 for host to
PL1000T Messages
IID Specific command sent
to the PL1000T
Byte Count Number of bytes in the
message starting after the
byte count byte location
excluding checksum
List Number The Standard Broadcast
g01265570
Illustration 18 List Number for which
data is being returned.
Table 14
MID One byte value indicating
Field Description unique identifier of module
for which data is being
Standard Preamble Always $50 $00 for host to
returned. Please refer to
PL1000T Messages
the MID discussion earlier
IID Specific command sent to in this section.
the PL1000T
Update Rate The rate at which the data
Byte Count Number of bytes in the for this standard broadcast
message starting after the list will be transmitted on
byte count byte location the M5X or the M50 data
excluding checksum link. Resolution is 0.5
seconds per bit. A value
List Number The Standard Broadcast of $00 causes a .5 second
List Number for which rate default minimum.
data is being activated.
Flags Bit level flags to indicate
Checksum Refer to the Checksum desired characteristics of
Calculation Example PL1000T response.
section
PID 1 Data for the first PID in the
Advanced Broadcast List
PID 2 Data for the second
PID in the Advanced
Broadcast List
PID 3 Data for the third PID in the
Advanced Broadcast List
Checksum Refer to the Checksum
Calculation Example
section
g01266264
Illustration 19
28 RENR7945-01
Systems Operation Section
g01266268
Illustration 20
30 RENR7945-01
Systems Operation Section
Table 17
Field Description
Standard Preamble Always $50 $00 for host to
PL1000T Messages
IID Specific command sent
to the PL1000T
Byte Count Number of bytes in the
message starting after the
byte count byte location
excluding checksum
Flags Bit level flags to indicate
desired characteristics of
PL1000T response.
MID One byte value indicating
unique identifier of module
returning PID data. Refer to
earlier discussion on MID
PID Two or three bytes
depending on range of
first PID $D0-$D4. First
byte is three bytes all
others are 2 bytes. Pad
with leading zeros.
Checksum Refer to the Checksum
Calculation Example
section
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Illustration 21
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Illustration 22
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Illustration 23
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Illustration 24
RENR7945-01 35
Systems Operation Section
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Illustration 25
$FA0D PID Format
Table 23
Table 24 Table 25
Turn Off All Diagnostic Messages per IID $81 Response to IID $81
Byte Position Byte Contents Description Byte Position Byte Contents Description
1-2 $5000 Preamble 1-2 $5001 Preamble
3 $81 IID 3 $85 IID
4 $09 Number of 4 $0B Number of
Bytes Bytes
5 $24 Unit Number 5 $00 All Devices
(Turn Off Only)
6 %00000001 Programming
Flags 6 %00000001 Programming
Flags
7 $00 Reserved
7 $00 IID Errors 0 =
8-10 $AAFA0D PID for Data OK
Diagnostic
Broadcast 8 $00 Reserved
11 %00000010 Activation Flags 9-11 %AAFA0D PID For
Diagnostic
12 $02 Update Rate Broadcast
4 sec/bit max
1020 seconds 12 %00000000 Programming
Flags
13 $00 Reserved
13 %00000010 Activation Flags
14 $3E Checksum
14 $02 Update Rate
4 sec/bit max
1020 seconds
15 $00 Reserved
16 $5B Checksum
38 RENR7945-01
Systems Operation Section
Table 26 Table 27
Start Event Broadcast Start Event Broadcast
Byte Position Byte Contents Description Byte Position Byte Contents Description
1-2 $5000 Preamble 1-2 $5001 Preamble
3 $81 IID 3 $85 IID
4 $09 Number of 4 $0B Number of
Bytes (Except Bytes (Except
Checksum) Checksum)
5 $24 Unit Number 5 $24 Unit Number
(MID) (MID)
6 %00000000 Programming 6 %00000000 Programming
Flags Flags
7 $00 Reserved Set 7 $00 Errors 0 = Data
to Zero OK
8-10 $AAFA0E PID For Event 8 $00 Reserved
Broadcast
9-11 $AAFA0E PID For Event
11 %00000010 NA Broadcast
12 $02 Update Rate 12 %00000000 Programming
4 Sec/Bit Max Flags
1020 Seconds
13 %00000001 Activation Flags
13 $00 Reserved
14 $02 Update Rate
14 $4D Checksum 4 sec/bit max
1020 seconds
15 $00 Reserved
16 $37 Checksum
RENR7945-01 39
Systems Operation Section
Table 29
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Illustration 26
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Illustration 27
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Illustration 28
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Illustration 29
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Illustration 30 Illustration 31
After the selections have been made click OK A file named PL1000TComm.ht is created that
once more. The screen will close to leave only the contains all of the settings just were just configured.
HyperTerminal window workspace. Next the property Next time the file is needed HyperTerminal may be
setting will need to be changed in order to make sure started with the use of a shortcut to this file from
the data received from the PL1000T will be in the the desktop. The file that was created will eliminate
proper format for viewing. From the Hyperterminal the need for future configuration when establishing
menu bar select File/Properties. Click the ASCII a connection to a PL1000T that was similarly
setup button as shown in Illustration 31. When the configured.
ASCII setup screen appears click on each section
box so that all items have a checkmark next to them. The communications status of the HyperTerminal can
Click OK. be readily determined from the status bar located at
the lower left hand corner of the application window.
If HyperTerminal is connected to the PL1000T the
status message reads Connected. Otherwise the
status message reads Disconnected.
g01265148
Illustration 32
g01265152
Illustration 33
g01265126
Illustration 34
Table 30
Typical Answering Modem Setup Commands
Item Explanation Command Example
A Set the modem to the factory defaults. This is important AT&F
if the setup of the modem is unknown.
B Set to communicate in error control and asynchronous AT&Q5
mode. If the modem does not support this command enter
the AT command for error control. Set to communicate in
asynchronous mode with a separate command (Item C).
C Set to communicate in asynchronous mode. If the AT&Q0
&Q5 command is supported the modem will never
answer an incoming call. The value of this register
can be seen with the ATSQ? command
D Set Auto answer to ON. This tells the modem to ATS0=1
answer the phone line after the first ring. If left at 0 the
modem will never answer an incoming call.
E Set Flow Control to XON/OFF. This turns off RTS/CTS AT&K4
hardware handshaking between the modem and CCM
since the CCM does not have RTS or CTS lines. It
turns on the XON/OFF software shaking.
F Set DCD to track status of carrier detect signal. This causes AT&C1
the DCD line from the modem to follow the state of the
phone line carrier. When the call to the CCMs modem
has been made and the modem to modem handshaking
is done the DCD line will change and allow the CCM to
receive data. This is very important. If the DCD line is not
at the right state the CCM cannot receive data.
G Set DTR to monitor DTR signal and hang up and reset AT&D3
modem on an on-to-off DTR transition. This causes the
modem to hang up and reset the CCM drops the DTR line.
H Result codes do not have to be returned. Or if the ATQ2
result codes are returned the codes must be in originate
mode but not in answer mode.
I Set DTR transition response delay to maximum value ATS25=250
less than 10 seconds. This example would cause the
modem to hang up the line 2.5 seconds after the DTR
line from the CCM changes. Refer to the particular
manual. Some modems specify the in 1/100th of a
second and some in 1/10th of a second.
J Set delay before forced hang-up to maximum ATS38=2
value less than 3 seconds
K Write the setup parameters into memory 0. When AT&W0
the setup parameters are written any that were not
changed are stored into the memory.
L Set to recall memory 0 on reset. AT&Y0
M View the modem active profile. This is an optional command AT&V
that allows the user to view the above parameters
stored in the modem. The profile should be written
down and saved for future reference.
1. Connect the RS-232 port of the Answering 2. Use the terminal emulator on the PC in order
Modem directly to the RS-232 port of the PC. to set the parameters. Set the parameters for
This connection is temporary. This connection is communication for the RS-232 port. Use the same
required to start up the Answering Modem. values that were chosen in Step 2.
46 RENR7945-01
Systems Operation Section
i02813381
g01115230
Illustration 35
The PL1000T Communications ECM
g01116887
Illustration 36
ECM connector pin locations viewed from the back of the connector
48 RENR7945-01
Systems Operation Section
i02811933
Wiring Harness
SMCS Code: 1408
i02813379
Configuration
SMCS Code: 7610
Table 32
Service Tool Capability
Service Tool Feature Caterpillar Electronic Technician Caterpillar Communication Tool Kit
PL1000T ECM Summary Yes Yes
PL1000T ECM Configuration Yes Yes
PL1000T ECM Status Yes Yes
PL1000T ECM Totals Yes Yes
Connecting Cat ET and the Note: A 237-7547 Adapter Cable As. is required to
Communications Adapter adapt the cable (3) to the USB port on computers
that are not equipped with a RS-232 serial port.
i02813376
Connector Locations
SMCS Code: 7553-546-WW
Print reports.
The following list contains some of the diagnostic
functions and programming functions that are
performed by the service tools.
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Illustration 38
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Illustration 39
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Illustration 40
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Illustration 41
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Illustration 42
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Illustration 43
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Illustration 44
g01266402
Illustration 45
The GPSIM Statistics status screen is used to The configuration of both modules should be
observe the rate of messages being received by the checked. The modules must match exactly for proper
PL1000T. communications to be enabled.
The Number of NMEA-183 messages Received is The Number of NMEA-183 VTG messages
the total count of the NMEA-183 messages that Received is the total count of the NMEA-183 VTG
were received on the configured serial port since messages that were received on the configured serial
the last time that power to the module was turned port. The VTG messages contain the Ground Speed
off then turned back on. When the message count information. Use this message counter to confirm that
reaches the maximum, the count will roll to zero and the PL1000T is receiving the VTG messages.
then will continue to increment. The count will reflect
the total of all other message counts displayed on
this status screen. If the counter is not incrementing,
this can indicate communication problems between
the PL1000T and the GPS sensing device.
RENR7945-01 61
Troubleshooting Section
g01266407
Illustration 46
This status screen is used to observe the following: When CAN Extension Bridge Function is Enabled
- The total number of messages received on CAN
Number of Messages Received on CAN Port 1 Port 1 and CAN Port 2 should equal to the total
number of messages that were transmitted on the
Number of Messages Transmitted on CAN Port 1 RS-485 port. Likewise, the total number of messages
that are received on the RS-485 port should be
Number of Messages Received on CAN Port 2 equal to the total number of messages that were
transmitted on CAN Port 1 and CAN Port 2.
Number of Messages Transmitted on CAN Port 2
When J1939 Bridge Function is Enabled - The
Number of Messages Received on RS-485 Port total number of messages received on CAN Port 1
should increment at a similar rate to the total number
Number of Messages Transmitted on RS-485 Port of messages received on CAN Port 2.
RENR7945-01 63
Troubleshooting Section
i02840939
Customer Communication
Module
SMCS Code: 1926-035
g01266605
Illustration 47
66 RENR7945-01
Troubleshooting Section
g01266608
Illustration 48
RENR7945-01 67
Troubleshooting Section
Reference: Special Instruction, SEHS9615, The original source of the problem must then be
Servicing DT Connectors. identified in order to ensure that the problem does
not reoccur.
Reference: Special Instruction, REHS0148, Listing
Of Deutsch Connector Components Perform the following in order to thoroughly inspect
the connectors and determine if the connectors are
Reference: Special Instruction, SEHS9065, Use Of the cause of the problem.
CE Connector Tools.
g00820688
Illustration 49
(1) Correctly Routed Harness (3) Incorrectly Routed Harness
(2) Correctly Inserted Plug (4) Incorrectly Inserted Plug
g00690571 g00828600
Illustration 50 Illustration 51
Proper Installation of Plug DT Type sealing plug
The 8T-8729 Connector Pin (2) and the 8T-8730 Connector
Socket (1) is designed to accept only one 16/18 AWG wire. Do not
insert multiple wires of a smaller wire size. An incorrect method
would be using two 24 AWG wires. The 9W-0852 Connector Pin
and the 9W-0844 Connector Socket is designed to accept only one
14 AWG wire. Do not insert multiple wires of a smaller wire size. An
example of an incorrect method is the use of two 20 AWG wires.
a. Ensure that the connector is properly locked. a. Each connector contact should withstand 45 N
Also, ensure that the two halves of the (10 lb) of pull. Each wire should remain in the
connector can not be pulled apart. connector body. This test checks whether the
wire was properly crimped in the contact and
b. Verify that the latch tab of the connector is whether the contact was properly inserted into
properly latched. Verify that the latch tab of the the connector.
connector is fully latched.
b. The DT connectors use an orange wedge to
Expected Result: The connector will securely lock the terminals in place.
lock. The connector and the locking mechanism
are without cracks or breaks. c. Check in order to ensure that the orange wedge
is not missing and that the orange wedge is
Results: installed properly on the DT connectors.
OK The connector will securely lock. The Note: A crimp tool should ALWAYS be used in order
connector and the locking mechanism are to crimp wires on connector contacts. Do not solder
without cracks or breaks. Proceed to test step the terminals. Use the proper crimp tool.
2.
Expected Result: Each connector contact
NOT OK A problem exists with the connector. should withstand 45 N (10 lb) of pull. Each wire
remains in the connector body.
Repair: Repair the connector or replace the
connector, as required. Results:
Repair: Repair the wires or replace the wires, OK All of the connectors are completely
as required. coupled and all of the seals are completely
inserted. The harness and the wiring are free of
STOP. corrosion, moisture, abrasions or pinch points.
Proceed to test step 6.
5. CHECK THE CONNECTORS FOR MOISTURE
OR CORROSION. NOT OK A problem exists with the connector,
the wiring or the wiring harness. Moisture is
a. Ensure that the connector seals and the white present.
sealing plugs are in place. If any of the seals or
plugs are missing, replace the seal or plug. If Repair: Repair the connectors or wiring and/or
necessary, replace the connector. replace the connectors or wiring. Ensure that
all of the seals are properly in place and ensure
b. Check all of the wiring harnesses in order to that the connectors are completely coupled.
verify that the harness does not make a sharp Verify that the repair eliminates the problem by
bend out of a connector. This will deform the operating the machine for several minutes and
connector seal and this will create a path for the by checking again for moisture.
entrance of moisture. Refer to Illustration 49.
STOP.
Note: It is normal to see some minor seal abrasion
on the ECM connector seals. Minor seal abrasion will 6. INSPECT THE CONNECTOR CONTACTS.
not allow the entry of moisture.
a. Verify that the contacts are not damaged.
c. Thoroughly inspect ECM connectors for Verify that the contacts are properly aligned in
evidence of moisture entry. If moisture or the connector and verify that the contacts are
corrosion is evident in the connector, the properly located in the connector.
source of the moisture entry must be found
and the source of the moisture entry must be Expected Result: The contacts are properly
repaired. If the source of the moisture entry is aligned and the contacts appear undamaged.
not repaired, the problem will reoccur. Simply
drying the connector will not fix the problem. Results:
Likely paths for the entrance of moisture are
from missing seals, improperly installed seals, OK The contacts are properly aligned and
nicks in exposed insulation, and improperly the contacts appear undamaged. Proceed to
mated connectors. test step 7.
Note: Moisture can also travel from one connector NOT OK A problem exists with the connector
through the inside of a wire to the ECM Connector. If contacts.
moisture is found in the ECM connector, thoroughly
check all connectors and wires on the harness that Repair: Repair the contacts and wiring and/or
connect to the ECM. The ECM is not the source of replace the contacts and wiring.
the moisture. Do not replace an ECM if moisture is
found in either ECM connector. STOP.
Note: If corrosion is evident on the contacts or the 7. CHECK THE FIT OF THE CONTACTS.
connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush
to remove the corrosion. Do not use cleaners that
contain trichloroethylene because trichloroethylene
may damage the connector.
74 RENR7945-01
Testing and Adjusting Section
Results:
STOP.
i02811974
i02811981 i02813373
Electrical problems are often caused by failed The PL1000T is flashed in order to upgrade the
electrical wires that have either an open circuit or a software. Flash programming of the PL1000T must
short circuit. If one part of the circuit contacts another also be done if the ECM has been replaced. Cat ET
part of the same circuit, the flow is diverted from the contains the program WinFlash. WinFlash is used
desired path. This would be short circuit. in order to load software into an ECM. Perform the
following procedure in order to flash program the
Perform the following in order to test for a short PL1000T:
circuit:
Note: Three communications adapters are available
Test for a short circuit. to flash electronic control modules:
1. Turn the battery disconnect switch key and the 7X-1700 Communication Adapter Group
key start switch to the OFF position.
171-4400 Communication Adapter II Group
2. Disconnect both ends of the wiring harness.
Embedded Communications Adapter - Available
3. Turn the multimeter dial to the 200 ohm range and on serial port 3 of the PL1000T. The Embedded
measure the electrical resistance. Communications Adapter feature supports only
ECM flashing functionality when NO application
4. Turn the multimeter probe in order to make software is installed on the PL1000T. The
contact with the connector of the suspected faulty configuration and status information is not
electrical wire. accessible.
5. Use the other probe from the multimeter to check Note: When the ECM is a Blank Box, the embedded
for continuity across all electrical wires in the same communication adapter is defaulted to serial port 1
wiring harness and check all wires for continuity instead of serial port 3. After the application software
across the frame to ground. is installed, the embedded comm adapter is returned
to serial port 3.
6. If there is continuity between any of the electrical
wires, the multimeter will have a reading of less 1. Connect the appropriate data link cable between
than 5 ohms. Continuity between any other wires the communication adapter and the personal
in the wiring harness indicates that there is a short computer (PC) that contains Cat ET software.
between those wires. The wiring harness must be When using the embedded communications
repaired or replaced. adapter, the data link cable is a serial connection
directly between the PC and the PL1000T serial
7. Use the multimeter in order to test for continuity port 3.
across the frame or ground. If there is continuity
between any of the electrical wires, the multimeter 2. When using other than the embedded
will have a reading of less than 5 ohms. If there communications adapter, connect the data link
is continuity between any of the wires and the cable between the communication adapter and
frame, there is a short circuit between the wire the diagnostic connector of the engine. If using
and the frame. Identify the wire that has a short to the embedded communications adapter, it is
the frame. already connected to the system via its standard
Cat Datalink or J1939 connection.
Reference: To determine if the wire is a part of
the ground circuit refer to the Electrical System 3. Use WinFlash in order to load the software.
Schematic.
4. Early versions of the 256-7511 PL1000T
If the wire is a part of the ground circuit and the wiring Communications ECM default the ECA to
harness is damaged, the wiring harness must be RS-232 serial port 1 when the ECM is blank. If
repaired or replaced. connecting to a blank ECM and Cat ET cannot
detect the ECA, connect the PC to serial port 1 of
the PL1000T and attempt the connection again.
Once flashed, the PL1000T will return the ECA
connection to RS-232 serial port 3.
76 RENR7945-01
Testing and Adjusting Section
i02509122
g01411693
Illustration 53
Embedded Communications
Adapter
The embedded communications adapter functionality
is always enabled and always available for physical
connection on serial port number 3. Cat ET or
Caterpillar Tool Kit preferences must be modified to
identify the embedded communication adapter as the
interface hardware.
g01411702
Illustration 55
g01132152
Illustration 56
Link Configuration
Once the preference settings in the service tool
are set correctly, the user can navigate to the
configuration screen through the menu within the
service tool. For each configuration discussed below,
refer to Illustration 57 to help locate them on the
configuration screen.
78 RENR7945-01
Testing and Adjusting Section
g01411704
Illustration 57
PL1000T 1 - Configures the PL1000T to occupy Note: Enabling the boost function when Cat Datalink
the first of the three available MIDs on the Cat is less than 31 m (100 ft) can cause communication
Datalink. failures. Only enable the boost function when harness
lengths greater than 31 m (100 ft) are required. When
PL1000T 2 - Configures the PL1000T to occupy multiple PL1000Ts are connected to the same Cat
the second of the three available MIDs on the Cat Datalink, CDL Boost should be enabled on only one
Datalink. of the devices. Enabling CDL Boost on multiple
PL1000Ts connected to the same Cat Datalink
PL1000T 3 - Configures the PL1000T to occupy network will prevent normal communications.
the third of the three available MIDs on the Cat
Datalink.
RENR7945-01 79
Testing and Adjusting Section
M50
Primary
Service
Enabled
Disabled
Enabled
Disabled
Direct
Modem
RENR7945-01 81
Testing and Adjusting Section
Table 33
CCM Example Message Table
Description and Command String sent to CCM Response from CCM
Set access security to Level 1 using password ABCDEF123 5001350B61AA874142434445313233F8
5000340C0061AA874142434445313233F9
Set access security Level 2 using password XYZ12345 5001350B61AA8858595A3132333435D2
5000340C0061AA88585955A3132333435D3
Set access security to Level 3 using password 5001350B61AA8941424358595A3132A7
5000340C0061AA8941424358595A3132A8
Standard Broadcast List 01 Setup for Parameters ($40, $44, 50015010099
$54, $F118, $F50E, $F509, $F119, $F58E)
5000A13150124030020004000440054F118F50eF509F119F58ED1
Activate Standard Broadcast List 01 500115010099
50001101019D
Deactivate Standard Broadcast List 01 50011501099
50001201019C
Advanced Broadcast List 01 Setup for Parameters ($40, $44, 50011F0D1E012401000000000845150000DD
$54, $F118, $F50E, $F509, $F119, $F58E)
50001E1F012401000000000000400000044000054
00F11800F50900F58EDE
Activate Advanced Broadcast List 01 5001F0D1C012401000000000845150000DF
50001C010192
Deactivate Advanced Broadcast List 01 5001F0DFD012401000000000845150000DE
50001D010191
Activate Event Broadcasts 5001850B24000000AAFA0E0001010047
50008109240000AAFA0E0101004E
Deactivate Event Broadcasts 5001850B00000000AAFA0E000201006A
50008109000000AAFA0E02010071
Activate Diagnostics Broadcasts 5001850B00000000AAFA0D000201006B
50008109000000AAFA0D02010072
Activate Event Composite 01 (M50 Only) 50611508200B6
50008209580000AAFA0E01020018
Deactivate Diagnostic Composite 01 (M50 Only) 506115028200B6
50008209580000AAFA0E01020018
Activate Events Composite 01 (M50 Only) 5001850B58000000AAFA0E0001020012
Deactivate Events Composite 01 (M50 Only) 5001850B00010000AAFA0E0002020068
50008109000100AAFA0E0202006F
Engine Vision Interface Module Engine Vision Interface Serial Port Baud
(EVIM) Configuration Rate
Possible Values
EVIM Function Port Selection
Possible Values 19200 (Default)
Disabled (Default)
Serial Port 1
Serial Port 2
i02813372
Procedure
g01416325
Illustration 58
84 RENR7945-01
Index Section
Index
C F
General Information........................................... 4, 49
E PL1000T Communications Module...................... 4
Global Positioning System Interface Module......... 67
Electrical Connector - Inspect................................ 70 Problem-GPS Information Available on CatData
Electronic Control Module (ECM) .......................... 47 Link but not J1939............................................ 67
Electronic Control Module (ECM) - Configure ....... 76 Problem-Intermittent GPS Information Availability
Customer Communications Module (CCM) on J1939 or Cat Datalink.................................. 67
Configuration.................................................... 79 Problem-No GPS Information Available on Cat
Embedded Communications Adapter ................ 76 Datalink or J1939 ............................................. 67
Engine Vision Interface Module (EVIM)
Configuration.................................................... 81
Global Position System Interface Module (GPSIM) I
Configuration.................................................... 81
Link Configuration .............................................. 77 Important Safety Information ................................... 2
Sea Water Module Interface (SWMI) Introduction............................................................ 49
Configuration.................................................... 82
Electronic Control Module (ECM) - Flash
Program ............................................................... 75 J
Electronic Control Module (ECM) - Replace.......... 82
Embedded Communication Adapter...................... 68 J1939 Bridge ......................................................... 63
Problem-Cat ET unable to detect any electronic Problem-Remote CAN Network receives no data
control modules ............................................... 68 from Local CAN Network.................................. 63
Problem-Cat ET unable to detect any electronic Problem-Remote CAN Network receives partial
control modules other than the PL1000T ......... 69 data from Local CAN Network.......................... 63
Engine Vision Interface Module............................. 67
Problem-Engine Vision Display does not properly
display data from the engine control ................ 67 S
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 70
Testing and Adjusting Section ............................... 70
Troubleshooting Section........................................ 49