Escolar Documentos
Profissional Documentos
Cultura Documentos
November 2008
Systems Operation
Troubleshooting
Testing and Adjusting
PL1000E Communication ECM
SAFETY.CAT.COM
i01658146
RENR8091-04
3
Table of Contents
Table of Contents
Systems Operation Section
General Information ................................................ 4
Features .................................................................. 4
Electronic Control Module (ECM) .......................... 6
Wiring Harness ....................................................... 7
Quick Start Guide ................................................... 7
Parameter Translation Configuration ..................... 11
Hardware Configuration ........................................ 27
Data Link Configuration ........................................ 28
Data Link Address of Caterpillar Electronic
Control ................................................................ 28
Internet Protocol Configuration ............................. 29
Modbus Configuration ........................................... 30
LAN Network Ethernet Connection ....................... 32
Direct Crossover Ethernet Connection ................. 36
ECM Modbus Interface ......................................... 42
Embedded Web Server ........................................ 56
Custom Web Page ................................................ 63
Modbus Master ..................................................... 68
Hexadecimal Conversion ...................................... 70
Troubleshooting Section
Introduction
General Information ..............................................
Service Tools ........................................................
Connector Locations .............................................
Diagnostic Capabilities .........................................
72
72
75
75
Symptom Procedures
Operational Problems ........................................... 81
Web Browser Problems ........................................ 90
91
95
96
96
96
97
97
Index Section
Index ..................................................................... 99
4
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General Information
SMCS Code: 7610
The PL1000E Communication Module is an
Electronic Control Module (ECM). The PL1000E
Communication Module provides the processing
power, memory, and software in order to integrate
Caterpillar engine data in to multiple applications. The
PL1000E Communication Module has the potential
to be upgraded for future applications.
Features
SMCS Code: 7610
RS-232
RS-422
RS-485, 2 wire (285-1138, 256-7512 v4 and later)
RS-485, 4 wire
TCP
The 258-4548 Electronic Control Module is
an ECM with no software installed. After the
PL1000E software is installed on the ECM, the
part number becomes 256-7512 Communication
Electronic Control Module (v3). The 256-7512
Communication Electronic Control Module (v3)
can only be configured for RS-485 4 wire. The
256-7512 (v3) cannot be configured for RS-485 2
wire.
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30,001 32,000
40,001 42,000
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Systems Operation Section
RS-232
RS-422
RS-485, 2 wire (285-1138, 256-7512 v4 and later)
RS-485, 4 wire
J1939 to Modbus Parameter Translation
J1939 to Modbus Parameter Translation provides
translation of parameter data to and from the J1939
protocol supported in Cat ET to the industry standard
Modbus protocol interface. J1939 parameters are
written to or are read from assigned registers. The
memory location for the registers are:
30,001 32,000
40,001 42,000
The registers are on a Modbus Slave. The PCL
file informs the PL1000E which parameters to look
at. Also, the PCL file informs the PL1000E how to
translate the data for another system in order to
understand the information.
The PL1000E supports the parameter translations
feature over the following ports:
RS-232
RS-422
RS-485, 2 wire (285-1138, 256-7512 v4 only)
RS-485, 4 wire
The destination register assignments for the J1939
parameters are assigned through the Parameter
Translation Editor in Caterpillar Tool Kit or Cat ET
version 2007B or higher.
The PL1000E 315-0627 Communication Software
Group is required for Modbus Master.
6
Systems Operation Section
Embedded Webserver
The PL1000E Communication Module provides the
capability to view web pages that are stored on the
ECM. The Status and the Configuration pages are
part of the initial software that is used to configure
the PL1000E Communication Module. The Status
and the Configuration pages are accessible to the
user via most standard web browsers. The Status
and the Configuration pages provide the same
PL1000E information as the Cat ET Status and
Configuration screens.
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CDL Boost
CDL Boost is available with the PL1000E. CDL
Boost enables a customer to extend the lengths
of CDL wire harnesses. The lengths of CDL wire
harnesses can extend to a maximum length of 305 m
(1000 ft). Data integrity will be maintained. Refer to
the Embedded Web Server section of this document
for more information about Boost.
i03328182
Embedded Communications
Adapter (ECA)
The PL1000E Communication ECM provides a
communication adapter for use with standard
Caterpillar service tools such as Cat ET. The
Embedded Communications Adapter (ECA) can be
used in order to configure statistics and to monitor
statistics of the PL1000E. Other devices that are
connected to the CDL data bus may be serviced
and may be flashed. ECA usage is compatible with
Cat ET version 2004B and later. ECA usage is also
compatible with Caterpillar Communication Tool Kit
version 2005A or later.
Perform the following steps in order to utilize the ECA
feature.
1. Connect the serial port of the PL1000E to a
computer that is running standard Caterpillar
service tool software.
2. Configure the service tool preferences in order to
use the ECA.
The ECA feature is always enabled. The ECA feature
is always assigned to serial port 3 of the ECM. Once
the ECA is integrated into the system, the ECM will
provide all of the same electronic control servicing
that was previously provided by external adapters for
Caterpillar electronic modules on CDL and J1939.
Illustration 1
PL1000E Communication ECM
g01705933
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i03328480
g01720098
i02794752
Wiring Harness
SMCS Code: 1408
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g01395613
Illustration 3
Sample System Block Diagram
ET 2007B or later
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Parameter Translation
Configuration
12
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Properties Window
When a device within the design window (large white
area in the middle of the screen) (5) is selected, the
Properties window will list the information that is
related to that type of object. If no objects exist within
the design window (5) or if the user has clicked on the
white part of the design window, then the properties
window will display the information related to the
overall design. Refer to Illustration 4. The following
sections present information about the objects and
the associated properties that can be displayed.
Illustration 4
(1)
(2)
(3)
(4)
(5)
g01708133
Properties Window
Default PTE Directory
Ellipse Toggle Button
Save As Button
Design Window
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Illustration 5
g01336076
Illustration 6
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Object Translation
A Translation Object appears on the design window
as an arrow indicating the direction of data flow.
The direction of data flow indirectly also shows
the read/write accessibility of data. In other words,
if there is a translation arrow pointing from the
CDL ECM Object to the Modbus ECM Object,
this indicates the Modbus Slave Device will only
support register read commands for the parameters
assigned to this translation object. Modbus register
write commands will only be supported in J1939
to Modbus translations. An arrow pointing from
the Modbus ECM Object to the CDL ECM Object
indicates the Modbus Slave Device will only support
register write commands for the parameters assigned
to this translation object.
If it is desired to read and write a parameter, then
that parameter must be assigned to translations in
both directions.
Illustration 7
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Illustration 8
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Illustration 9
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Illustration 10
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Illustration 11
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Illustration 12
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Illustration 14
Illustration 13
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Illustration 16
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g01708294
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Illustration 17
g01336295
Illustration 18
g01708333
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g01398234
1. Click on Save.
Note: PTE will display a standard Save PCL File
dialog, which opens the default PTE directory.
2. Select the appropriate path and filename for the
*.pcl file.
Note: File names are limited to a total length of 33
characters. If a file name is longer than 33 characters,
the on board software will truncate the name to 33
characters while processing the configuration. The
file name may NOT include any spaces.
3. Select Save.
g01708433
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Illustration 22
g01708456
Illustration 23
g01708495
Click Next.
Illustration 21
g01708453
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Illustration 24
Illustration 26
g01708622
Illustration 27
g01708623
g01708514
g01708616
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Illustration 30
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Illustration 29
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Table 1
Call
Out
Entity
17
18
J1939 ECM
Description
Represents a translation taking place. In this case the PL1000E is requesting
information from Modbus Slave 1 and writing that information on J1939.
Represents a Caterpillar ECM that the PL1000E, as a Modbus Master, is
communicating with.
19
This utility is only available on a translation line from a Modbus Slave ECM to a
J1939 ECM. The basics of this utility are to allow the user to scale their data to
match a public J1939 PGN. For example, a sensor is on Modbus as a slave,
and the user wants to translate the sensor data to J1939 and have it match the
J1939 protocol. The user would simply enter the offset and resolution of the
data, upload the PCL file to the PL1000E, and the PL1000E would scale the
data from Modbus to match the scaling factors of the parameters to J1939.
NOTE: This utility should only be used for a linear sensor.
An expert should only use this utility. Please contact the dealer technical
communicator for more detailed information.
20
Request Rate
21
Production Rate
The rate as which the PL1000E is sending the information it requests to the
particular ECM. Take (4) again. The PL1000E is requesting information from
the J1939 ECM, and then sending it out on Modbus. So the Production Rate
in this case would be the speed that the PL1000E is sending the information
on Modbus.
22
Modbus Register
The register that the PL1000E is either requesting, or writing to, depending on
the translation line that is selected.
23
24
25
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Illustration 32
g01336395
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Illustration 33
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YYYY = year
MM = month
DD = day
HH = hour
NN = minute
SS = second
13. Verify that the appended time and date stamp
reflect the actual time and date of the PL1000E
warm boot sequence.
i02796160
Hardware Configuration
SMCS Code: 7610
ECM Configuration
The PL1000E Communication Electronic Control
Module (ECM) requires configuration before the
PCL file can be loaded. The PL1000E requires
configuration before the modbus ports will function.
This section contains information about all of the
configuration parameters for the PL1000E.
The PL1000E is configured either by Caterpillar
Communciation Tool Kit or by Cat ET for the first
time. After the first setup, the embedded web pages
may be used in order to change the configuration. In
order to access the PL1000E configuration the first
time, the Embedded Communication adapter or a
Caterpillar Communication Adapter II must be used.
For more information about configuration parameters
for the PL1000E ECM, please refer to System
Operation Troubleshooting, Testing and Adjusting,
RENR8091, Internet Protocol Configuration, Modbus
Configuration, and Data Link Configuration.
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i03345200
i03331925
g01720155
PL1000 #1
PL1000 #2 (Default)
PL1000 #3
Enabled
Disabled (Default)
NOTICE
CDL Boost should be enabled only if the wiring lengths
for the harnesses are 30.5 m (100 ft) or greater. If
the wiring lengths for the harnesses are under 30.5 m
(100 ft), then CDL Boost may cause failure.
Illustration 35
g01709835
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i03331987
g01710119
Disabled (Default)
Enabled
The defaults are:
IP address:192.168.1.1
Network Mask: 255.255.255.0
Default Gateway: 1.0.0.0
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i03332563
Modbus Configuration
Echo
No Echo (default)
ModBus #1 Flow Control
The ModBus #1 Flow Control selections are:
Hardware (CTS/RTS)
None (default)
Reserved
Software (Xon/Xoff)
ModBus #1 Data Size
The ModBus #1 Data Size selections are:
7
Illustration 37
g01743935
8 (default)
ModBus #1 Parity
Even
Disabled
Mark
No Parity (default)
Serial Port #2
Odd
Serial Port #4
Space
1200
2400
4800
9600 (default)
19200
Disabled
38400
Serial Port #1
57600
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1200
2400
4800
9600 (default)
19200
Disabled
38400
Serial Port #1
57600
Serial Port #2
Echo
No Echo (default)
1200
2400
4800
Hardware (CTS/RTS)
9600 (default)
None (default)
19200
Reserved
38400
Software (Xon/Xoff)
57600
Echo
8 (default)
No Echo (default)
ModBus #2 Parity
Even
Hardware (CTS/RTS)
Mark
None (default)
No Parity (default)
Reserved
Odd
Software (Xon/Xoff)
Space
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7
8 (default)
ModBus #3 Parity
The ModBus #3 Parity selections are:
Even
Mark
No Parity (default)
Odd
Space
ModBus #3 Data Link Address
The ModBus #3 Data Link Address selections are
any value between zero (0) and 254. It is recommend
that the value remain at default.
The default value is 254.
RS-485 Mode
The RS485 Mode configuration item only appears
on the 285-1138 Electronic Control Modules or
newer. The RS485 Mode selections are as follows:
i03332863
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g01414942
Illustration 38
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Illustration 41
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Illustration 42
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g01397624
Illustration 44
g01402164
6. Press Enter.
Illustration 43
g01402161
4. Press Enter.
Note: The screen will be similar to the screen in
Illustration 43.
Illustration 45
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13. Move the PCL file to the ECM. Using the Put
command, execute the FTP process as shown
in Illustration 49 and Illustration 50, replacing
G3612_Engine.pcl with the name of the PCL file.
Illustration 46
g01402168
10. Since all new PCL files must be loaded into the
New directory, change from the remote directory
to the New directory using the Change Directory
New (CD New) command.
Illustration 49
g01402180
14. After the file has been sent successfully, exit the
FTP session using the Bye command. The FTP
session will close, and the screen will return to a
DOS command prompt.
Illustration 47
g01402169
Illustration 50
g01402183
Illustration 48
g01402179
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g01415005
Illustration 51
PL1000E configuration
Configuring a PL1000E Communication
Module to Work on a Non-DHCP network
Perform the following steps in order to configure
a PL1000E Communication Module to work on
a network that does not have Dynamic Host
Configuration Protocol(DHCP).
Note: If a PC is to be connected directly to the
PL1000E via a crossover ethernet cable, then leave
the IP configuration set to the default settings. Go
to the Configuring a Stand - Alone Windows PC
to Access the PL1000E Communication Module
section.
For more information on the default settings, see the
section on Internet Protocol Configuration.
1. Connect a computer with Caterpillar Electronic
Technician (Cat ET) or Caterpillar Communications
Tool Kit to a PL1000E Communication ECM either
by using a Comm Adapter II or the ECA Service
Port (serial port 3) on the PL1000E.
2. Start Cat ET and wait for it to connect to the
PL1000E.
3. Once Cat ET is started and the selected device is
the PL1000E, click on the Configuration Screen
or press the F5 key.
Illustration 52
g01710894
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Illustration 53
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Illustration 54
Illustration 55
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Illustration 56
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Illustration 57
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g01710914
Illustration 59
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Illustration 60
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Illustration 62
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Illustration 61
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Illustration 63
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Illustration 64
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Illustration 66
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Illustration 65
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Table 2
Function
Code
Description
Modbus Address
Range
Read Holding
Registers
Preset Single
Register
16
Preset Multiple
Registers
Illustration 67
g01404041
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Contents
Count of active events
Comments
Most Significant Byte (MSB): Count of active events
Least Significant Byte (LSB): Maximum table size
MSB: Bit mapped status indicator
Bits 8 through 3: Reserved
Bit 2: 1= table is being updated, 0= table is not being updated
Bit 1: 1= data is stale, 0= data is not stale
Bit 0: 1= overflow, 0= no overflow(1)
LSB: Reserved
MSB: update rate (HI byte)
LSB: update rate (LO byte). The rate in milliseconds that the
source ECM sends updates of the Event Code table to the
PL1000E.
MSB: Event Identifier 1
LSB: Reserved
MSB:
Bits 8 through 4: Reserved
Bits 3 through 1: Warning Category Indicator (WCI)
WCI values: 0 or 1 = Warning, 2 = Service, 3 = Shut Down
LSB: Reserved
(1)
Overflow status means that there are more DTCs present than the table can contain.
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Table 4
Contents
Count of active diagnostics
Comments
Most Significant Byte (MSB): Count of active diagnostics
Least Significant Byte (LSB): Maximum table size
MSB: Bit mapped status indicator
Bits 8 through 3: Reserved
Bit 2: 1= table is being updated, 0= table is not being updated
Bit 1: 1= data is stale, 0= data is not stale
Bit 0: 1= overflow, 0= no overflow(1)
LSB: Reserved
The minimum update rate at which the source ECM can provide
diagnostic code updates to the PL1000E in milliseconds. (MSB
first)
MSB: Component Identifier 1
LSB: Reserved
MSB
Bits 8 through 6: Warning Category Indicator (WCI)
WCI values: 0 or 1 = Warning, 2 = Service, 3 = Shut Down
Bits 5 through 1: Failure Mode Identifier (FMI)
LSB: Reserved
(1)
Overflow status means that there are more DTCs present than the table can contain.
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Table 5
Contents
Comments
Most Significant Byte (MSB): Count of active DTCs
Least Significant Byte (LSB): Maximum table size
MSB: Bit mapped status indicator
Bits 8 through 4: Reserved
Bit 3: 1 = Non-standard format, 0 = Standard format(1)
Bit 2: 1= table is being updated, 0= table is not being updated
Bit 1: 1= data is stale, 0= data is not stale
Bit 0: 1= overflow, 0= no overflow(2)
LSB: Reserved
Lamp status
MSB:
Bits 8-7: Malfunction indicator lamp status
Bits 6-5: Red stop lamp status
Bits 4-3: Amber warning lamp status
Bits 2-1: Protect lamp status
LSB:
Bits 8-1: Reserved for SAE assignment lamp status
For each pair of bits, the following values represent the associated
status: 00 = Lamp is OFF, 01 = Lamp is ON
MSB (When CM has a value of 1): SPN bits (18 through 11)
(1)
Non-standard format - ECM's that implement the J1939 DTC transmission method prior to 1996 may format data in any of three
unidentifiable formats. These formats can not be dependably translated for display.
(2) Overflow status means that there are more DTCs present than the table can contain.
(3) For details on implementations of the DTC communication methods where CM is 0, please refer to SAE J1939-73.
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Table 6
String
5 registers (10 ASCII bytes)
String
5 registers (10 ASCII bytes)
String
5 registers (10 ASCII bytes)
String
3 registers (5 ASCII bytes) (MM MY Yx) Where
MM M is the month (JAN, FEB, etc.) and Y Y is
the last two digits of the year (2005 would be 05)
Reserved
2 registers (4 bytes)
Module Description
String
13 registers (26 ASCII bytes)
2 registers (4 bytes)
Hours (MSB)
40,037
Reserved
4 registers (8 bytes)
40,041
(MSB) 2 registers
40,043
(MSB) 2 registers
40,045
(MSB) 2 registers
40,047
(MSB) 2 registers
40,049
Reserved
2 registers (4 bytes)
40,051
(MSB) 2 registers
40,053
(MSB) 2 registers
40,055
(MSB) 2 registers
40,057
(MSB) 2 registers
40,059
Reserved
2 registers (4 bytes)
40,061
(MSB) 2 registers
40,063
(MSB) 2 registers
40,065
(MSB) 2 register
40,067
(MSB) 2 registers
40,069
Reserved
2 registers (4 bytes)
40,071
(MSB) 2 registers
40,073
(MSB) 2 registers
40,075
(MSB) 2 registers
Starting Register
40,001
40,006
40,011
40,016
40,019
40,021
40,034
40,035
(continued)
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(Table 6, contd)
40,077
(MSB) 2 registers
40,079
Reserved
2 registers (4 bytes)
40,081
(MSB) 2 registers
40,083
(MSB) 2 registers
40,085
(MSB) 2 registers
40,087
(MSB) 2 registers
40,089
Reserved
2 registers (4 bytes)
40,091
(MSB) 2 registers
40,093
(MSB) 2 registers
40,095
(MSB) 2 registers
40,097
(MSB) 2 registers
40,099
(MSB) 1 register
40,100
Reserved
40,201
(MSB) 1 register
40,202
(MSB) 2 registers
1 register
high byte = Type low byte = Port
(MSB) 2 registers
1 register
MSB = Type
LSB = Port
40,204
40,205
40,207
Data = 2584548-01
ECM Serial Number
The serial number of the PL1000E communication
module in the standard Caterpillar serial numbering
format.
Sample Message:
Data = 0505B001HU
Sample Message:
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Data = 2586806
Application Date Code
The month and year (last two digits) of the application
software flash file release.
Sample Message:
Data = AUG08
Personality Module Description
Text description of the PL1000E communication
module as it is identified in the Service Tool. This is
the same description seen on the ECM Summary
screen in Service Tool.
Sample Message:
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Sample Message:
Sample Message:
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Data = 0 errors
Scale = 1 error message/bit
CDL Transmitted Messages
An accumulator that indicates the number of
messages that have been successfully transmitted
by the PL1000E over CDL. The value is reset each
time that the PL1000E has the power removed and
then has the power turned back on. The accumulator
value is not a lifetime total. If power to the PL1000E
is left on for an extended amount of time, then the
accumulator value can roll over and will begin to
increment from zero once again.
Sample Message:
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Scale = 1 message/bit
1D 24
Data = 0 errors
00 00
Data = 0 errors
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11 54
Data = 0 errors
Scale = 1 transmit error/bit
RS-232 Port 1 Received Modbus-RTU Messages
An accumulator that indicates the number of modbus
messages that have been successfully received on
RS-232 Port 1. Use this information as an indicator
of whether or not the PL1000E is receiving modbus
requests on RS-232 Port 1. The value is reset each
time that the PL1000E has the power removed and
then has the power turned back on. The accumulator
value is not a lifetime total. If power to the PL1000E
is left on for an extended amount of time, then the
accumulator value can roll over and will begin to
increment from zero once again.
Sample Message:
Data = 0 errors
Scale = 1 error message/bit
RS-232 Port 1 Transmitted Modbus-RTU
Messages
An accumulator that indicates the number of modbus
messages that have been successfully transmitted
by the PL1000E over RS-232 Port 1. The value is
reset each time that the PL1000E has the power
removed and then has the power turned back on.
The accumulator value is not a lifetime total. If power
to the PL1000E is left on for an extended amount of
time, then the accumulator value can roll over and
will begin to increment from zero once again.
Sample Message:
Sample Message:
Scale = 1 message/bit
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Sample Message:
Sample Message:
Data = 0 errors
Data = 0 errors
00 00
00 00
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Data = 0 errors
Scale = 1 transmit error/bit
RS-422 and RS-485 Port 4 Received Modbus-RTU
Messages
An accumulator that indicates the number of modbus
messages that have been successfully received on
RS-422 and RS-485 Port 4. Use this information
as an indicator of whether or not the PL1000E is
receiving modbus requests on RS-422 and RS-485
Port 4. The value is reset each time that the PL1000E
has the power removed and then has the power
turned back on. The accumulator value is not a
lifetime total. If power to the PL1000E is left on for
an extended amount of time, then the accumulator
value can roll over and will begin to increment from
zero once again.
Sample Message:
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Data = 0 errors
Scale = 1 error message/bit
RS-422 and RS-485 Port 4 Transmitted
Modbus-RTU Messages
An accumulator that indicates the number of modbus
messages that have been successfully transmitted by
the PL1000E over RS-422 and RS-485 Port 4. The
value is reset to zero each time that the PL1000E has
the power removed and then has the power turned
back on. The accumulator value is not a lifetime total.
If power to the PL1000E is left on for an extended
amount of time, then the accumulator value can roll
over and will begin to increment from zero once
again.
Sample Message:
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Data = 0 errors
Scale = 1 transmit error/bit
Ethernet Received Modbus-TCP Messages
An accumulator that indicates the number of modbus
messages that have been successfully received on
the Ethernet port. Use this information as an indicator
of whether or not the PL1000E is receiving modbus
requests on the Ethernet port. The value is reset
to zero each time that the PL1000E has the power
removed and then has the power turned back on.
The accumulator value is not a lifetime total. If power
to the PL1000E is left on for an extended amount of
time, then the accumulator value can roll over and
will begin to increment from zero once again.
53
Systems Operation Section
Data = 0 errors
Scale = 1 error message/bit
Ethernet Transmitted Modbus-TCP Messages
An accumulator that indicates the number of modbus
messages that have been successfully transmitted
by the PL1000E over the Ethernet port. The value is
reset to zero each time that the PL1000E has the
power removed and then has the power turned back
on. The accumulator value is not a lifetime total. If
power to the PL1000E is left on for an extended
amount of time, then the accumulator value can roll
over and will begin to increment from zero once
again.
Sample Message:
Sample Message:
11 54
54
Systems Operation Section
Data = 0 errors
Scale = 1 transmit error/bit
Number of Modbus-TCP Connections
The number of modbus TCP connections that are
currently recognized by the PL1000E.
Sample Message:
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55
Systems Operation Section
Table 7
Translation Pair # 1
byte#
data
00 24 01 10 (From ECM)
1-2
00 24
01
10
byte#
data
00 10 02 20 (To ECM)
5-6
00 10
02
20
Translation Pair # 2
byte#
data
00 6D 01 10 (From ECM)
9-10
00 6D
11
01
12
10
byte#
data
00 10 02 20 (To ECM)
13-14
00 10
15
02
16
20
Translation Pair # 3
byte#
data
00 6E 01 10 (From ECM)
17-18
00 6E
19
01
20
10
byte#
data
00 10 02 20 (To ECM)
21-22
00 10
23
02
24
20
byte#
data
00 00 00 00 00 00 00 00 . . .
25-90
00
Remaining Bytes
ECM Address
ECM Type
ECM Port
56
Systems Operation Section
RENR8091-04
Table 8
PL1000E Port
J1939 ECM
Modbus ECM
Table 9
ECM Port
identifier
01
CAN Port 1
10
20
21
23
30
Modbus-TCP Ethernet
i03340883
Illustration 68
g01720178
Events / Diagnostics
The following web pages display active events
and diagnostic information. The active events and
diagnostic information are from ECMs that are
currently sending data to CDL or to the J1939 data
link.
Note: A translation line to a web object must exist
in the PCL file for the event and the diagnostic
information to be displayed on this page. This
translation line must include the desired active events
and / or the active diagnostics parameters.
Illustration 69
Diagnostics
Events
g01717075
RENR8091-04
57
Systems Operation Section
Illustration 70
g01717145
Configuration
The Configuration pages are an alternate means of
setting the ECM Configuration Parameters that are
available in the service tool.
Clicking on the small symbol to the left of
Configuration (refer to the navigation menu shown
in Illustration 71) will cause additional page links to
be displayed under Configuration. These additional
page links are as follows:
Illustration 72
Internet Protocol
g01720734
Modbus
Password
Reset
g01720181
58
Systems Operation Section
RENR8091-04
Modbus Configuration
Illustration 73
g01717148
There are four locations (1), (2), (3), and (4) on the
PL1000E that can be configured to provide a physical
port for Modbus communications. There are three
locations (2), (3), and (4) that are for a serial port and
one TCP port (1).
Modbus registers are made available on these ports
as specified by the ECM objects that are defined in
the PCL file. Any location can serve any port. The
numbers are for identification only. The locations
provide the expected resource for the ECM objects
that are specified in the PCL file.
RENR8091-04
Boost
The ECM has the capability to extend the physical
harness length limitations of the Cat Data Link
network from the standard of 30.5 m (100 ft.) to a
maximum of 305 m (1000 ft.). Enabling the Boost
function of the PL1000E will allow Cat Data Link
harnessing to which this device is connected to be
run a maximum of 305 m (1000 ft.). See Special
Instructions, REHS2362 for more information related
to harnessing and wiring requirements.
Note: CDL boost that is available for the PL1000E,
256-7512 Communications ECM (v3) , that uses the
258-4548 ECM, is enabled through a configuration
parameter in Cat ET or through the embedded web
page.
59
Systems Operation Section
Reset
Reset Action
Occasionally, it will be necessary to cause the ECM
to perform either a warm or cold boot sequence,
such as when updating the PL1000E Configuration
Parameters or installing new PCL files. This web
page provides the ability to request the PL1000E to
perform a warm boot function.
Note: The warm boot function feature is protected
by the password. The password is discussed in this
Symptom Procedures section of this document.
Password Configuration
Change Password
The PL1000E Write Access Password may be
modified from this interface. The current password is
required to authorize updating to the new password.
Perform the following in order to change the
password:
1. In the Change Password screen enter the new
password in the New Password and Confirm
Password boxes.
2. Click on Submit.
Illustration 74
g01720755
60
Systems Operation Section
Illustration 75
RENR8091-04
g01720774
Illustration 76
g01720933
FROM
TO
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61
Systems Operation Section
Statistics
Physical
Illustration 78
g01720953
Illustration 77
g01402195
62
Systems Operation Section
RENR8091-04
Illustration 79
g01720993
RENR8091-04
63
Systems Operation Section
i03341123
Overview
PCL, Extensible Markup Language (XML), Extensible
Stylesheet Language (XSL), and Cascading Style
Sheet (CSS) files all reside on the PL1000E web
server. These files work together to provide a
customized view of data gathered by the PL1000E.
Illustration 81 displays the relationship between the
file types.
Illustration 80
g01721055
64
Systems Operation Section
RENR8091-04
g01214643
Illustration 81
RENR8091-04
Illustration 82
65
Systems Operation Section
g01721356
66
Systems Operation Section
Illustration 83
RENR8091-04
g01717224
RENR8091-04
67
Systems Operation Section
Table 10
Number
Tag Name
Description
<Title>
Contains the Custom Page title (see Illustration 83). Unique titles for custom pages
allow better organization when analyzing larger or more complex systems.
<Item>
<UID>
A unique identifier for a parameter used in a web server translation. The UID
contained in the XML file will be converted to the decimal equivalent value of the UID
included in the PTE file as a hexadecimal value. Refer to Converting a Hexadecimal
Number to a Decimal Number for more information on converting the hexadecimal
number to a decimal value.
<ECMUID>
The same unique number that is assigned for the ECM ID in the Parameter
Translation Editor for the PCL file. Refer to Modify the properties for the New CDL
ECM object in the Manual Parameter Configuration List Creation section to identify
the ECM ID.
ECM Description
Contains a label created by the user to describe the ECM from which the parameter
was obtained. This description is free form text and can be customized to clearly
describe the ECM from which data is being collected. It may be helpful to identify this
ECM with the same description as was used in the PCL file creation, but it is not
necessary. These two descriptions may be different.
UID Description
Value
Decimals
Unit
10
Type
The value of the parameter being monitored. The OSEFUNC tag is formatted as:
/ssi/getparm/X,Y where X is the ECM ID, and Y is the UID. Refer to the
description for item 4 for more information on the ECM ID
The number of decimal places to apply to the value of the parameter to be monitored.
Illustration 84
g01721400
68
Systems Operation Section
RENR8091-04
Modbus Master
SMCS Code: 7610
Illustration 85
g01721413
Illustration 86
g01721414
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69
Systems Operation Section
g01412383
Illustration 87
LengthReqBit = Total Length of the Request Message in Bits.
BaudRate = The Baud rate you system configured.
TotalPropagationTime = Time that it takes the message to reach the destination.
SlaveResponseTime = Time it takes the Modbus slave to respond to the request from PL1000E.
LengthRespBits = Total Length of the Response Message in Bits.
Illustration 88
g01412389
70
Systems Operation Section
RENR8091-04
Translation
CDL to Modbus
Modbus to CDL
J1939 to Modbus
Modbus to J1939
CDL to Webserver
Not Supported
Not Supported
J1939 to Webserver
Not Supported
i03346182
Hexadecimal Conversion
SMCS Code: 7610
Hexadecimal UID numbers must be converted to
their decimal equivalents in order to be placed in the
XML code for the custom pages. The hexadecimal
numbers that are associated with a specific UID can
be found by opening the PTE file associated with
the ECM that is being monitored in the Parameter
Translation Editor. Perform the following in order to
convert a hexadecimal number to a decimal number:
1. Click Start.
2. Click Programs.
3. Click Accessories.
4. Click Calculator.
5. From the View menu, select Scientific. Refer to
Illustration 89.
RENR8091-04
Illustration 89
71
Systems Operation Section
g01747434
Illustration 90
g01721453
Illustration 91
g01721454
72
Troubleshooting Section
RENR8091-04
Troubleshooting Section
Table 12
Introduction
Description
Laptop Computer
i03346184
General Information
SMCS Code: 7610
Refer to the appropriate system or the schematics of
the engine harness if a troubleshooting procedure
instructs the user to Analyze and Repair the
Harnessing.
Continuity checks and resistance checks should
be performed at the connector locations in order
to locate a failure in the harness. At a component
connector, always check the ground circuit. Less
than five ohms of resistance is required from the
ground contacts to frame ground. A problem can be
incorrectly diagnosed if resistance is greater than 5
ohms in the ground circuit.
During a troubleshooting procedure, inspect all
component and harness connections before a
component is replaced. If these connections are
not clean and tight, the connection can cause an
electrical problem.
A problem can be persistent or intermittent. Ensure
that the wires are pushed into the connectors
completely. Make sure that the connections are
tight before other tests are performed. A failure of a
connection of one electrical component can cause
the failure of another electrical component. Always
attempt to find a failure of a connection. Correct the
failed connection before replacing a component.
JERD2124
JERD2129
171-4400
237-7547
9U-7330
Digital Multimeter
7X-1710
Multimeter Probe
1U-5804
175-3700
(1)
i03341900
Service Tools
Troubleshooting Software
RENR8091-04
73
Troubleshooting Section
Table 13
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Perform Calibrations
Yes
No
Illustration 93
g01721458
Illustration 92
g01721457
74
Troubleshooting Section
RENR8091-04
Illustration 94
g01721459
Illustration 95
Communication Gps
Note: Items (3), (4), and (5) are part of the 171-4400
Communication Adapter Gp.
Use the following procedure to connect Cat ET and
the 171-4400 Communication Adapter Gp.
Note: The PL1000E Communication ECM's
embedded communications adapter may also be
used for communications with Cat ET. The use of
a Communication Adapter Gp is not necessary.
In order to use the embedded communications
adapter, a custom built service cable (2) must be
connected between the RS-232 serial port of the
PC and the RS-232 Serial Port 3 of the PL1000E
Communication ECM.
1. Turn the engine key switch to the OFF/RESET
position. If the key switch is not placed in the
OFF/RESET position, then the engine may start.
RENR8091-04
75
Troubleshooting Section
i03346200
Diagnostic Capabilities
SMCS Code: 7610
Connector Locations
i02809396
are displayed.
76
Troubleshooting Section
RENR8091-04
Illustration 96
g01397803
RENR8091-04
77
Troubleshooting Section
Illustration 97
g01397805
Illustration 98
g01721473
78
Troubleshooting Section
RENR8091-04
RENR8091-04
79
Troubleshooting Section
Illustration 99
g01721475
Illustration 100
g01721476
80
Troubleshooting Section
RENR8091-04
Illustration 101
g01180273
RENR8091-04
81
Troubleshooting Section
Symptom Procedures
i03341884
Operational Problems
Probable Cause
Symptom Procedures
Problem - Unable to Browse to the
PL1000E Home Page - Network
Connection
Probable Cause
1. Using Cat ET, confirm the Internet Protocol
configuration. Confirm these settings with the
network administrator.
2. Confirm the PL1000E Communication ECM is
properly connected to power, ground, and key
switch inputs in the system.
3. If the ECM Internet Protocol configurations are
configured properly, try using a DOS shell window
to ping the ECM.
At the command prompt, type the following
command and press the enter key. Where
xxx.yyy.zzz.aaa is the IP address or domain
name of the module.
Ping xxx.yyy.zzz.aaa.
If the ping command indicates successful
communications to the ECM and are still unable
to connect to the device using the browser, then
check the browser settings. Confirm the ability to
connect to other sites on the network. Contact
the network administrator for help concerning the
appropriate settings in order to connect a personal
computer to the ECM that is on the network.
4. Confirm the network cable is not a Cross-Over
cable. The cable used to connect the ECM to a
network should be a standard pass-through or
patch cable.
Ping xxx.yyy.zzz.aaa
If the ping command indicates successful
communications to the ECM and are still unable
to connect to the device using the browser,
review the PC settings and contact the network
administrator. Certain settings are sometimes
controlled by automatic logon scripts for certain
networks. These will need to be temporarily
disabled for direct cross over connections.
82
Troubleshooting Section
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83
Troubleshooting Section
Error
Probable Cause
Remedy
84
Troubleshooting Section
RENR8091-04
Table 15
Error
Probable Cause
Application Started
Remedy
Use the Parameter Transltion Editor
to re-create the PCL file and review
the configuration parameters for any
invalid data
No Remedy, since this is just an
informational message.
RENR8091-04
85
Troubleshooting Section
Table 16
Error
Probable Cause
Remedy
86
Troubleshooting Section
RENR8091-04
Table 17
Error
Probable Cause
Remedy
RENR8091-04
87
Troubleshooting Section
Table 18
Error
Probable Cause
Remedy
88
Troubleshooting Section
RENR8091-04
Table 19
Error
Probable Cause
Remedy
RENR8091-04
89
Troubleshooting Section
Table 20
Error
Probable Cause
Remedy
Probable Cause
Remedy
Probable Cause
Remedy
Error
Error reading string blob
Error validating Base Config
Error validating Data Link Types
Error validating ECM table
Error validating Tag table
Error validating DSWrite table
Error validating DSRead table
Table 22
Error
Error validating Enum table
Error validating
Error validating
lfp
Error fread !=readSize
Invalid source path/file name
Invalid destination path/file name
Error writing to destination file
90
Troubleshooting Section
RENR8091-04
Troubleshooting
2. Press Enter.
If the browser displays good values or error
messages other than Parameter Unavailable,
the parameter exists in the PCL file. The error is
potentially in the XML coding in the XML file.
If the browser displays the error message Parameter
Unavailable, the parameter does not exist in the PCL
file. In order to view this parameter in a custom page,
edit the PCL file using the Parameter Translation
Editor. Republish the PCL file to the web server.
Note: After a PCL file has been published, the
power to the PL1000E ECM must be turned off and
then turned back on in order to activate the new
configurations.
Q: Why are all of the parameters showing up as
Parameter Unavailable?
A: The PCL file that is associated with the XML file
must have at least one parameter configured to be a
web translation in the Parameter Translation Editor. If
all of the parameters on the page show Parameter
Unavailable, perform the following:
1. Open the PCL file in the Parameter Translation
Editor.
2. Click Status.
RENR8091-04
91
Testing and Adjusting Section
92
Testing and Adjusting Section
RENR8091-04
g00820688
Illustration 102
(1) Correctly Routed Harness
(2) Correctly Inserted Plug
Illustration 103
Proper Installation of Plug
g00690571
Illustration 104
g00828600
RENR8091-04
93
Testing and Adjusting Section
Exposed insulation
Points of rubbing wire
b. Check all of the hold down clamps for the
harness in order to verify that the harness is
properly clamped. Also check all of the hold
down clamps for the harness in order to verify
that the harness is not compressed by the
clamp. Pull back the harness sleeves in order
to check for a flattened portion of wire. The
flattened portion of wire is caused by the clamp
that holds the harness.
Expected Result: The wires are free of
abrasion, nicks, or cuts and the harness is
properly clamped.
Results:
94
Testing and Adjusting Section
RENR8091-04
Results:
OK All of the connectors are completely
coupled and all of the seals are completely
inserted. The harness and the wiring are free of
corrosion, moisture, abrasions or pinch points.
Proceed to test step 6.
NOT OK A problem exists with the connector,
the wiring or the wiring harness. Moisture is
present.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that
all of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem by
operating the engine for several minutes and
by checking again for moisture.
STOP.
6. INSPECT THE CONNECTOR CONTACTS.
a. Verify that the contacts are not damaged.
Verify that the contacts are properly aligned in
the connector and verify that the contacts are
properly located in the connector.
Expected Result: The contacts are properly
aligned and the contacts appear undamaged.
Results:
OK The contacts are properly aligned and
the contacts appear undamaged. Proceed to
test step 7.
NOT OK A problem exists with the connector
contacts.
Repair: Repair the contacts and wiring and/or
replace the contacts and wiring.
STOP.
7. CHECK THE FIT OF THE CONTACTS.
RENR8091-04
95
Testing and Adjusting Section
g00838765
96
Testing and Adjusting Section
RENR8091-04
i02815888
i03342206
RENR8091-04
97
Testing and Adjusting Section
System Schematic
SMCS Code: 7566
Illustration 106
g01721477
98
Testing and Adjusting Section
Illustration 107
RENR8091-04
g01717876
RENR8091-04
99
Index Section
Index
I
C
Connector Locations..............................................
Custom Web Page ................................................
Creating Custom XML Pages ............................
Overview ............................................................
Understanding the XSL File ...............................
Viewing Custom XML Pages Using a Browser ..
75
63
64
63
64
68
D
Data Link Address of Caterpillar Electronic
Control .................................................................
Data Link Configuration .........................................
Cat Data Link Boost Function Enable Status.....
Cat Data Link Module Identifier Configuration ...
Diagnostic Capabilities ..........................................
The Caterpillar Electronic Technician (ET) ........
Direct Crossover Ethernet Connection ..................
PL1000E configuration.......................................
28
28
28
28
75
75
36
37
E
ECM Modbus Interface.......................................... 42
PL1000E Communication ECM Modbus Interface
Overview .......................................................... 42
Electrical Connector - Inspect................................ 91
Electronic Control Module (ECM) ............................ 6
Electronic Control Module (ECM) - Configure ....... 96
Electronic Control Module (ECM) - Flash
Program ............................................................... 96
Electronic Control Module (ECM) - Replace.......... 97
Embedded Web Server ......................................... 56
Configuration...................................................... 57
Events / Diagnostics .......................................... 56
F
Features ..................................................................
CDL Boost............................................................
Embedded Communications Adapter (ECA) .......
Embedded Webserver .........................................
PL1000E configured as a Limited Modbus
Master ................................................................
PL1000E configured as a Modbus Slave.............
4
6
6
6
5
4
G
General Information........................................... 4, 72
H
Hardware Configuration......................................... 27
ECM Configuration............................................. 27
Hexadecimal Conversion....................................... 70
30
30
68
68
O
Operational Problems............................................ 81
Symptom Procedures ........................................ 81
P
Parameter Translation Configuration...................... 11
Create *.pcl File Using the PCL Wizard ............. 21
Create a Modbus Master PCL File..................... 23
Create Parameter Translation Design ................ 11
Familiarization with the Parameter Translation
Design Interface ............................................... 12
Initiate Configuration of PL1000E with New PCL
File ................................................................... 26
Installation of PCL File to PL1000E ................... 26
Manual Parameter Configuration List Creation.. 15
Open an Existing *.pcl file for Modification......... 24
Parameter Translation Files and Configuration
Tools.................................................................. 11
Q
Quick Start Guide .................................................... 7
Modbus Parameter Translation and ECM
Configuration Quick Start Guide ........................ 7
S
Service Tools ......................................................... 72
Troubleshooting Software .................................. 72
Symptom Procedures ............................................ 81
System Schematic................................................. 97
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 91
Testing and Adjusting Section ............................... 91
Troubleshooting Section........................................ 72
W
Web Browser Problems......................................... 90
Troubleshooting ................................................. 90
Wiring Harness ........................................................ 7
Wiring Harness (Open Circuit) - Test..................... 95
Wiring Harness (Short Circuit) - Test ..................... 96
2008 Caterpillar
All Rights Reserved
Cat, Caterpillar, their respective logos, Caterpillar Yellow and the Power edge
trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.
Printed in U.S.A.