RENR8091-04

November 2008

Systems Operation
Troubleshooting
Testing and Adjusting
PL1000E Communication ECM

SAFETY.CAT.COM
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
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 .............................................. 72
Service Tools ........................................................ 72
Connector Locations ............................................. 75
Diagnostic Capabilities ......................................... 75

Symptom Procedures
Operational Problems ........................................... 81
Web Browser Problems ........................................ 90

Testing and Adjusting Section

Testing and Adjusting
Electrical Connector - Inspect ............................... 91
Wiring Harness (Open Circuit) - Test .................... 95
Wiring Harness (Short Circuit) - Test .................... 96
Electronic Control Module (ECM) - Flash
Program .............................................................. 96
Electronic Control Module (ECM) - Configure ...... 96
Electronic Control Module (ECM) - Replace ......... 97
System Schematic ................................................ 97

Index Section
Index ..................................................................... 99
4 RENR8091-04
Systems Operation Section
Systems Operation Section
i03326946
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.
The PL1000E can be used in comparable applications
as the older Customer Communications Modules
(CCM).
The PL1000E Communication Module will provide
a user with the ability to configure parameter
translations. That is, Caterpillar proprietary
communications protocol, Cat DataLink can be
translated to a Modbus interface, or from the industry
standard J1939 communications protocol (including
Caterpillar proprietary messaging) to a Modbus
interface. The PL1000E Modbus Interface was
designed based on the Modbus Application Protocol
Specification V1.1a requirements. All refereces in
this document to the standard Modbus protocol will
be assumed to use the Modbus Application Protocol
Specification V1.1a. Modbus can be communicated
with the use of RS-232, RS-422, RS-485 (4 wire
and 2 wire), and Transmission Control Protocol
(TCP)/Ethernet.
Note: Unless otherwise noted, the information
in this document is intended for the PL1000E
configured as a Modbus Slave.
The configuration for the PL1000E is contained in a
Parameter Configuration List (PCL) file. The PCL is
stored in the embedded file system on the ECM. The
PCL file informs the PL1000E about :
which ECMs are in the system
what parameters from each to make available
(translate) to the others,
which protocol to use
which serial port(s) each ECM is using
defines the destination register assignments for
CDL parameters
The destination register assignments for CDL
parameters are assigned through the Parameter
Translation Editor in Caterpillar Tool Kit or Cat ET
version 2007B or higher.
The PCL file informs the PL1000E what information
to translate. The PCL file informs the PL1000E which
protocol to output these translations on.
The PCL files are created and the PCL files are
modified with the use of the Parameter Translation
Editor (PTE). The PTE is found under the Utilities
menu in Caterpillar Communications Tool Kit or Cat
ET version 2007B or higher.
i03327180
Features
SMCS Code: 7610
PL1000E configured as a Modbus
Slave
Cat DataLink (CDL) and/or J1939 to
Modbus Parameter Translation
CDL parameters are given register assignments
for accessibility through the Modbus interface. The
parameters reside in holding register range of 40,001
through 42,000. Register assignments for CDL
parameters are assigned through the Parameter
Translation Editor in Caterpillar Tool Kit or Caterpillar
Electronic Tool (Cat ET).
The PL1000E supports the parameter translations
feature over the following ports:
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.
RENR8091-04
The 285-1138 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 (v4). The 256-7512
Communication Electronic Control Module (v4)
can be configured for RS-485 2 wire or 4 wire.
The 256-7512 (v4) also supports multi-node
communications.
Cat DataLink (CDL) and J1939 to Modbus
Parameter Translation - Dual Data Link
Feature
The CDL and J1939 to Modbus Parameter
Translation feature gathers information from both the
CDL and the J1939 data links simultaneously.
The dual data link feature will translate the CDL and
J1939 data to the industry standard Modbus protocol
interface.
Cat ET version 2007B or later and PL1000E software
release 315-0627 Communication Software Group
or later are required in order to use this feature. Cat
ET version 2007B will allow for both CDL and J1939
objects in the same Parameter Translation Editor
window. Cat ET version 2007B will allow translation
lines to and from a Modbus ECM.
Custom Web Pages
PCL, Extensible Markup Language (XML), Extensible
Stylesheet Language (XSL), and Cascading Style
Sheet (CSS) files all reside on the PL1000E web
server. All of these files work together in order to
provide a customized view of data that is gathered
by the PL1000E. In order for custom web pages to
display information, the PCL file must be configured
with a translation line to a web object. The custom
web pages may include some or all of parameters
on that translation line for monitoring and viewing in
a web browser.
PL1000E configured as a Limited
Modbus Master
Cat DataLink (CDL) to Modbus Parameter
Translation
CDL parameters are written to assigned registers.
The register memory locations are on a Modbus
Slave device which is connected to the PL1000E
with the use of the serial port. The register memory
locations are:
30,001 32,000
40,001 42,000
5
Systems Operation Section
The PCL file informs the PL1000E what information
to translate. The PCL file informs the PL1000E which
protocol to output these translations on.
The PCL files are created and the PCL files are
modified with the use of the Parameter Translation
Editor (PTE). The PTE is found under the Utilities
menu in Caterpillar Communications Tool Kit or Cat
ET version 2007B or higher.
The PL1000E 315-0627 Communication Software
Group is required for Modbus Master.
The PL1000E supports the parameter translations
feature over the following ports:
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 RENR8091-04
Systems Operation Section

Embedded Webserver Note: The previous hardware version of the

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.
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.
PL1000E, that include 258-4548 and 256-7512 v3),
do not support the J1939 data link on Embedded
Communication Adapter (ECA).
Note: The new hardware version of PL1000E,
285-1138 now supports flashing itself and other
ECMs that are on the J1939 datalink when connected
via the ECA. In addition, other ECMs may be serviced
by ET on the J1939 datalink when connected via the
PL1000E's ECA. The PL1000E cannot be serviced
by ET on the J1939 datalink when connected via the
PL1000E's ECA.
i03328182
Electronic Control Module
(ECM)
SMCS Code: 7610

Note: In order to enable CDL boost for the

285-1138 Electronic Control Module v3, pin 7 of
the ECM must be grounded. Cat ET and the web
page will show a status parameter that informs
the user if CDL boost is enabled or disabled.

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
g01705933
compatible with Caterpillar Communication Tool Kit Illustration 1
version 2005A or later. PL1000E Communication ECM

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.
RENR8091-04
g01720098
Illustration 2
Locations of the ECM connector pins. Rear view of connector.
i02794752
Wiring Harness
SMCS Code: 1408
Refer to the wiring schematic that is in the System
Schematic section of this document. The PL1000E
Communications ECM will require a custom wire
harness in order to implement the appropriate
connections that are associated with the PL1000E
features.
A pre-fabricated harness assembly is available. The
harness will provide the connections for ground,
power, key switch, CDL, J1939, and the Service
Tool Port Group. Refer to the wiring that is shown in
BOLD in the schematic that is shown in the System
Schematic section of this document.
Refer to Special Instruction, REHS2362, Installation
Guide for the PL1000E Communications ECM for
additional wiring harness information.
7
Systems Operation Section
i03328480
Quick Start Guide
SMCS Code: 7610
Modbus Parameter Translation and
ECM Configuration Quick Start
Guide
The checklist that is in this section provides
information for implementing and for configuring
Modbus parameter translations with the use of
the PL1000E ECM. Each step or procedure in the
checklist references the appropriate section(s) of
this System Operation Troubleshooting Testing and
Adjusting , RENR8091, PL1000E Communication
ECM that explains the detail of the respective
procedure.
Gathering Information for PL1000E
Commissioning
Preparation for Commissioning PL1000E
1. Identify the type of Programmable Logic
Controller (PLC) that is being used.
2. Verify that the PLC supports the native Modbus,
NOT Modbus+.
3. Verify that the PLC is a Modbus Master that is
capable of requesting registers 40,001 through
42,000.
4. Identify the protocol that is required for the
Modbus. (TCP, RS-232, RS-485 (4 wire), RS-485
(2 wire), and RS-422).
5. Verify the baud rate for the serial port.
6. Identify the Modbus slave address in the PL1000E
that the Master will request the information from.
7. If applicable, locate the unused Modbus slave
address for the internal housekeeping.
8. Verify that the PL1000E is connected to a network.
9. Identify the type of network addressing that is
currently being used.
Note: The address type will be either Dynamic
Host Configuration Protocol (DHCP) or Static
addressing.
a. Locate the Static address information.
b. Verify the Internet Protocol IP Address.
c. Verify the Subnet Address.
8 RENR8091-04
Systems Operation Section

d. If applicable, depending on the network, verify Items During Commissioning

the Gateway Address.
Caterpillar Dealer Questions
1. Verify all of the Cat Data Link ECM addresses.
Note: The ECM address depends on the type
of engine that is being used. To locate the ECM
address, log onto Cat ET. Initially, ECM addresses
may be in hexadecimal format, and will need to be
converted into decimal format for the Parameter
Translation Editor.
2. Locate the data link that the information is on from
each ECM and the starting registers.
System Block Diagram
Refer to Illustration 3 for the system block diagram.
Transferring System Block Diagram to PCL Editor
1. Ensure that each Caterpillar ECM is defined.
Ensure that each ECM has the correct address.
2. Verify all Modbus ECMs, and that each Modbus
ECM has the correct Modbus slave ID.
1. Wire the PL1000E for use with the PLC. Refer
to Caterpillar Dealer Questions for instructions
about the required connections for the PLC.
2. Upload the PCL file into the PL1000E via FTP.
Use the IP address or Internet Host Name.
The IP address or Internet Host Name are
both defined in the Configuration screen in Cat
ET. The default username and the password are
both admin. Check the ECM mapping screen for
correct addresses and for correct Modbus slave
addresses.
3. Verify that the PL1000E is communicating the
correct data.
4. Locate a parameter that is in a Cat ET status
screen. Check for accuracy between the PCL file
and Cat ET.
5. Verify that there are no problems with the
communications. Modify the PCL file in order to
send the data to a RS-232 port. Check to make
sure the data is being sent by the PL1000E.

Note: The PL1000E has two Modbus slave

addresses. The Modbus slave address that is
configured in the PCL file is the address the Modbus
Master uses in order to retrieve engine information.
The Modbus slave address that is configured in Cat
ET, Caterpillar Communication Tool Kit, or through the
web server, is for the PL1000E's internal statistics.

3. Define all of the translation lines from the

Caterpillar ECMs to the Modbus ECMs.

4. Select the NEEDED parameters on each

translation line.

Note: The Modbus registers that are associated with

each parameter are shown in the right hand column.

Note: All of the parameters that are in the General

Parameter Translation Editor (PTE) files may not be
supported.

5. Ensure that each defined ECM has a unique

ECM ID.

Note: Please review the parameter list report for

scaling.

6. Save a .CSV file from each translation line. This

will be given to the PLC integrator.

7. Save the PCL file to a computer.

RENR8091-04
Develop A System Block Diagram
Illustration 3
Sample System Block Diagram
Begin by making a sketch of the system diagram.
The system diagram should identify each ECM that
is in the system. The system diagram should identify
each ECM communication type.
Refer to the sample of a system diagram that is
shown in Illustration 3. Illustration 3 provides an
explanation and a description of each electronic
control that is used. There is certain information that
is needed about each device in order to perform the
integration successfully.
The system diagram that is shown in Illustration
3 is a generic example that could be used for an
application. Each system may vary depending on the
components and on the interfaces that the system
contains.
Caterpillar Electronic Control Numbers 1, 2, and 3
The control numbers can represent an engine control,
a combustion module, or other electronic devices that
exist in the Caterpillar application.
Required Information and Tools:
Package or Engine Serial Number
Parameter Translation Editor PTE file
Data Link Addresses
9
Systems Operation Section
g01395613
Note: The PTE file should be located on same
Compact Disc (CD) with the PL1000E information.
If the PTE file is not included, then contact local
Caterpillar dealer.
Note: For Data Link Addresses information, refer
to the System Operation Troubleshooting, Testing
and Adjusting, RENR8091, Data Link Address of
Caterpillar Electronic Control.
PL1000E Communication ECM
The PL1000E Communication ECM is designed
specifically for communication translations from
Caterpillar electronic controls.
Required Information and Tools:
Modbus Port Configuration
Caterpillar Communication Tool Kit or Caterpillar
ET 2007B or later
List of Requested Parameters
Modbus and PL1000E Modbus Slave Address
10
Systems Operation Section
Modbus Master Device
This device may be any industry available Modbus
communications device so long as it meets the
following criteria:
Capable of Modbus communications over RS-232,
RS-422, RS-485 (4 wire), and RS-485 (2 wire) or
Ethernet
Modbus Protocol communications designed in
accordance with Modbus Application Protocol
Specification V1.1a
Capable of requesting single and multiple Modbus
registers in the range of 40,001 through 42,000
Prepare the PCL File
Use the Caterpillar Communications Tool Kit or
Caterpillar Electronic Technician (Cat ET) in order to
prepare the PCL file as described in this document.
Refer to the System Operation Troubleshooting
Testing and Adjusting, RENR8091, PL1000E
Communication ECM, Parameter Translation
Configuration section.
Refer also to the System Operation Troubleshooting
Testing and Adjusting, RENR8091, PL1000E
Communication ECM, Create Parameter
Translation Design section.
In the PCL design window, each Caterpillar electronic
control from the system block diagram would be
represented by a CDL or a J1939 ECM Object. Each
Caterpillar electronic control from the system block
diagram will require a PTE file association. The
PL1000E Modbus interface would be represented
by a Modbus ECM. The translations are defined
by the Translation Lines. The Translation Lines
are defined by the CDL or J1939 ECM, and by the
Modbus ECM.
Contact Network Administrator
Each network is different. Each network requires
slightly different configurations. The configuration is
dependent upon the hardware and the software that
is used in order to configure, manage, and maintain
the system's servers.
If the embedded web server of the PL1000E
Communication ECM's is to be accessible over a
local network, then the local network administrator
should be contacted in order to obtain the appropriate
configurations. The factory default setting for the
PL1000E is Dynamic Host Configuration Protocol
(DHCP).
RENR8091-04
In order to change from the DHCP setting, refer to
the System Operation Troubleshooting Testing and
Adjusting, RENR8091, PL1000E Communication
ECM, Internet Protocol Configuration section.
Configure the PL1000E
The Modbus communications must be configured in
the PCL file. The Modbus communications must also
be configured separately in the configuration screen
of Cat ET.
Refer to the Modbus Configuration section of this
document in order to determine the appropriate
configurations for the system. The ethernet port
is used to transfer the PCL file to the PL1000E.
The ethernet port can be configured with Cat ET or
Caterpillar Communication Toolkit.
If the embedded web server is to be used, then
the embedded web server must also be initially
configured using Cat ET. Refer to System Operation
Troubleshooting Testing and Adjusting, RENR8091,
PL1000E Communication ECM, Internet Protocol
Configuration for the appropriate configurations for
the system.
Note: Configuration of the PL1000E Communication
ECM and preparation of the PCL file may be
completed prior to the actual installation at the
system site. The PL1000E Communication ECM
does not need to be connected to the Caterpillar
electronic controls in the system in order to allow
proper configurations, PCL file creation, or PCL file
installation.
Install the PCL File onto the PL1000E
Note: The PL1000E must be configured before
installation of the PCL file.
There are several different methods that can be
used in order to install the PCL file, however, all of
the methods must be executed using File Transfer
Protocol FTP over the ECM's ethernet connection.
After the PCL file has been successfully installed
on the ECM, the module is ready for installation.
Also, the module is ready for integration with the
other Caterpillar electronic controls and the Modbus
master.
Refer to the LAN Network Ethernet Connection
section and to the PL1000E Communication ECM
section of this document for information about
connection methods.
Also, refer to System Operation Troubleshooting
Testing and Adjusting, RENR8091, PL1000E
Communication ECM, Direct Crossover Ethernet
Connection section.
RENR8091-04
Install the Necessary Infrastructure to
Integrate the PL1000E Into A System
Refer to Special Instruction, REHS2362 for
installation and wiring requirements of the PL1000E
Communication ECM.
Validate Successful Communications
of the PL1000E to Caterpillar Electronic
Controls
Using either the embedded communication adapter of
the ECM or other external communication adapters,
verify that the service tool can successfully detect all
Caterpillar electronic controls in the system.
Validate Successful Modbus
Communications of the PL1000E to
the Modbus Master
Configure or program the Modbus master to request
any or all of the status and statistics Modbus
registers from the ECM. In order to retrieve the
standard and statistics Modbus register data, the
ECM Modbus slave address that is defined in the
Modbus configuration through the Cat ET, Caterpillar
Communication Toolkit (the ECM configuration), or
embedded web pages must be used.
Alternately, configure or program the Modbus master
in order to request any of the Modbus registers that
are defined in the PCL file for one of the Caterpillar
electronic controls in the system. In order to retrieve
the Modbus registers from the other Caterpillar
electronic controls in the system, the ECM Modbus
slave address that is defined in the PCL file must be
used.
This is the end of Quick Start Guide.
i03328544
Parameter Translation
Configuration
SMCS Code: 7610
The PL1000E Communication Electronic Control
Module (ECM) requires a Parameter Configuration
List (PCL) file in order to execute parameter
translations. The PCL file contains the definition
of parameters on the source data link. The source
data link can be either CDL or J1939, or both CDL
and J1939. The PCL file contains the definition of
how the parameters are to be translated onto the
destination data link. The destination data link can
be either Modbus remote terminal unit (RTU) or
Modbus TCP. There are several processes and
work products that are involved in the creation of a
successful parameter translation configuration.
11
Systems Operation Section
Each process will be discussed in the following
sections.
Parameter Translation Files and
Configuration Tools
Prior to a discussion of the procedure required
to configure the PL1000E Communication ECM
parameter translation, it is necessary to discuss a
few work products used throughout the process.
Parameter Translation Editor (PTE)
The PTE provides a user interface through which a
user may design and architect the communications
paths within his system. It is a software application
available as a utility application within Cat ET and the
Caterpillar Communications Toolkit.
Parameter Translation Editor File (*.pte)
The PTE file contains a list of all parameters for a set
of engine models that are available for translation. A
PTE file is specific to parameters available on either
CDL or J1939. Parameters that are listed within the
PTE file may be selected and may be assigned
a Modbus register through Cat ET or Caterpillar
Communications Toolkit.
Note: The registers are not pre-assigned registers
in the PTE file.
Parameter Configuration List (PCL) File
(*.pcl)
The PCL file is the output of the PTE application.
After a user has designed the desired ECM objects
and associated translations in the PTE and chooses
to save the file, a *.pcl file will be created. This
file then contains all of the information about the
parameter necessary for translation to Modbus.
Create Parameter Translation
Design
1. In the Cat ET application (version 2007B or later)
or the Caterpillar Communications Toolkit (version
2007B or later), select the Parameter Translation
Editor (PTE) from the Utilities menu.
Note: Connection to the PL1000E is not necessary
in order to use the PTE. The PTE software provides
an interface for manual translation design. The PTE
software also provides a PCL wizard for more rapid
translation design for simpler systems. Each of
the translation design methods are covered in the
sections that follow. However, due to the importance
of the interface, the interface will be discussed first.
An explanation will be provided for the terms and
objects that are used in the following sections.
12 RENR8091-04
Systems Operation Section

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.

Object - Design Window

Demand Time Out - Total amount of time in
milliseconds that on demand parameters remain
enabled when no additional read requests are
made from the Modbus Master. Since on demand
parameters are not implemented in the current
design of the PL1000E, the Demand Time Out
g01708133
Illustration 4 value has no significant impact on the resulting
(1) Properties Window parameter translation design.
(2) Default PTE Directory
(3)
(4)
Ellipse Toggle Button
Save As Button
Default PTE Directory - The Default PTE
(5) Design Window
Directory is the directory on the computer where
the *.pte files are located. Keep all *.pte files in
one central location. In order to set the *.pte value,
Familiarization with the Parameter click on the button that is located to the right of
Translation Design Interface the Default PTE Directory. An Open dialog will
appear. Use the Open dialog in order to locate the
appropriate folder. Refer to Illustration 4.
File Operations
The New button clears the design interface and Object CDL ECM
prepares the PTE for creation of a new Modbus
Slave or Modbus Master file. A CDL ECM Object in the design window represents
a Caterpillar control attached to Cat DataLink. One
The Open button initiates a standard windows of these types of objects must be added to the
Open dialog that can be used to load a previously design for each Caterpillar control from which data
created *.pcl into the design window. is to be collected. For instance, some Caterpillar
engine models have an engine controller, combustion
The Save button causes the PTE to commit the module, and temperature sensing module. If data
information within the design window to a *.pcl file. is desired from all three of these devices, then a
separate CDL ECM Object must be added to the
The Save As button (4) initiates a standard design window for each device. Refer to Illustration
Windows Save As dialog. The Save As dialog 5 for example of the properties window for a CDL
can be used in order to save the information within object.
the design window to a new *.pcl file. TheSave As
function is useful when using a previously created
*.pcl file as a starting point on a new project. The
previously created file can be opened in PTE and
then can be saved as a new file name. Parameters
can be added or removed in order to create the
*.pcl file for the new project. Refer to the Systems
Operation Troubleshooting Testing and Adjusting,
RENR8091, Parameter Translation Configuration
section of this document for details concerning the
execution of this process.
RENR8091-04
g01336076
Illustration 5
Type ECM Object Type that is selected in the
design window. The valid types are CDL, J1939,
Webserver, and Modbus. The Type field is read
only.
PTE File Path Displays the path and filename of
the *.pte file assigned to the selected ECM object.
This field is read only.
ECM ID - A unique number that is assigned to the
selected ECM Object. Each ECM Object in the
design window must be assigned a unique ECM
ID. When a *.pcl file is generated, this number
will allow the on board software to differentiate
between each ECM Object that is in the *.pcl file.
Description - Free form text field that may be
modified in order to give a visual indication of what
the ECM Object represents within the system that
is being designed. For instance, if the CDL ECM
Object selected will represent the engine controller
in the application, this text field can be modified to
indicate that the object is the 36XX Engine Cntrl.
The maximum length of characters is equal to 20.
Address - The data link address of the ECM
Object. Electronic controls attached to CDL
and J1939 data links must use an address to
communicate on the associated data link. Refer
to the documentation for the specific electronic
control device in order to determine what value
must be entered in the address field. Most engine
controllers default to using the address 36 on CDL
but this may vary depending on the application.
Refer to the Data Link Address of Caterpillar
Electronic Control section of this document.
13
Systems Operation Section
Object J1939 ECM
A J1939 ECM Object that is in the design window
represents a Caterpillar control that is attached to
the J1939 Data Link. One of these type of objects
must be added to the design for each Caterpillar
control from which data is desired to be collected.
For instance, some Caterpillar engine models
have an engine controller, combustion module, and
temperature sensing module. If data is desired from
all three of these devices, then a separate J1939
Object must be added to the design window for each
device. Refer to Illustration 6 for an example of the
properties window for a J1939 object.
Illustration 6
g01336078
Type - ECM Object Type of the object selected
in the design window. The valid types are CDL,
J1939, Webserver, and Modbus. This field is read
only.
PTE File Path Displays the path and filename of
the *.pte file assigned to the selected ECM Object.
This field is read only.
ECM ID - A unique number assigned to the
selected ECM Object. Each ECM Object in the
design window must be assigned a unique ECM
ID. When a *.pcl file is generated, this number
will allow the on board software to differentiate
between each ECM Object in the *.pcl file.
Description - Free form text field that may be
modified in order to give a visual indication of what
the ECM Object represents within the system that
is being designed. For instance, if the CDL ECM
Object selected will represent the engine controller
in the application, this text field can be modified to
indicate that the object is the 36XX Engine Cntrl.
14
Systems Operation Section
Address The data link address of the ECM
Object. Electronic controls attached to CDL
and J1939 Data Links must use an address to
communicate on the associated data link. See the
documentation for the specific electronic control
device in order to determine what value must be
entered in the address field.
Object Modbus ECM
A Modbus ECM in the design window represents a
Modbus interface to the PL1000E Communication
ECM. The characteristics and attributes that are
assigned to this object represent the definition of the
Modbus Slave Device. The Modbus Slave Device
will communicate with the Modbus Master Device.
Multiple Modbus ECM Objects may be included in
the design window, but each must be assigned to a
different physical port of the ECM. Multiple Modbus
ECM Objects may not be added to the design window
and assigned the same Port attribute, or the *.pcl
file will be unusable by the on board ECM software.
Refer to Illustration 7 for an example of the properties
window for the Modbus ECM object.
g01336084
Illustration 7
Type - ECM Object Type of the object selected in
the design window. The valid objects types are
CDL, J1939, webserver, and Modbus. This field
is read only.
ECM ID - A unique number assigned to the
selected ECM Object. Each ECM Object in the
design window must be assigned a unique ECM
ID. When a *.pcl file is generated, this number
will allow the on board software to differentiate
between each ECM Object in the *.pcl file.
Description - Free form text field that may be
modified in order to give a visual indication of what
the ECM Object represents within the system that
is being designed. For instance, if the Modbus
ECM Object that is selected will represent the
ECM Modbus TCP Slave in the application, this
text field can be modified to indicate that the object
is the PL1000E TCP.
RENR8091-04
Modbus Slave Address - The Modbus Slave
Address to which all Modbus commands should
be addressed to retrieve data as defined in the
parameter translation arrows. This Modbus slave
address is not the same address configured
through Cat ET or Websever.
Port - The physical port of the ECM on which
the selected Modbus Slave Device should be
accessible. If multiple ports are needed for each
port, a modbus must be defined. Valid ports are
RS-232-1, RS-232-2, RS-422, RS-485 (4 wire),
RS-485 (2 wire), or TCP standard.
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.
Note: Defining a parameter for register write
capability does not mean the CDL or J1939 ECM
devices will support a write for these parameters.
Closed loop control of write-able parameters is strictly
the responsibility of the Modbus Master Device. The
PL1000E Communication ECM is designed with the
intention to provide remote system control. Caution
should be exercised when attempting parameter
writes J1939 to Modbus.
g01336128
Illustration 8
RENR8091-04 15
Systems Operation Section

Parameter The drop down menu contains a list of
the parameters that are available for assignment to
the selected Translation Object. When a parameter
is selected from the drop down menu, the selected
parameter is added to the parameter listing. Also,
a new click here to add row will be added to the
properties window.
Request Rate Time in milliseconds the PL1000E
will wait before attempting to obtain updated data
from the ECM Object from which this data is being
translated. If this time elapses and the PL1000E
is unable to obtain updated information from the
source ECM Object, this data will be considered to
be stale. The minimum valid value for this data is
500 milliseconds.
ECM ID A unique number assigned to the selected
ECM Object. Each ECM Object in the design
window must be assigned a unique ECM ID. When
a *.pcl file is generated, this number will allow the on
board software to differentiate between each ECM
Object in the *.pcl file.
Description Free form text field that may be
modified to give a visual indication of what the ECM
Object represents within the system being designed.
Refer to Illustration 9 for an example of the properties
window for the WebServer ECM object.

Modbus Register These registers are assigned

in sequential order starting with 40,001 as the
parameters are added. When the program assigns
the Modbus Registers it calculates the appropriate
amount of registers for each parameter. These
registers may be reassigned automatically with a
new starting address or manually changed.

Note: When manually changing registers, take

caution that the registers do not interfere with
other existing parameters which have already
g01336142
been assigned. Illustration 9

The Modbus Master may request a read of a Manual Parameter Configuration

parameter at a faster rate than that defined for the
Request Rate, but the data associated with this
Modbus Register will only be updated within the
PL1000E at the assigned request rate.
Note: The request rate configuration should be
considered carefully for each parameter. Smaller
request rates will increase the amount of additional
messaging on the source data link. Dynamic
parameters such as Engine Speed or Load Factor
can be obtained at a faster update rate, while less
dynamic parameters such as Temperatures and
Pressures can be obtained at a slower rate. Defining
translations for a large number of parameters at the
minimum request rate could cause excessive loading
of the source data link and affect performance of the
electronic controls attached to that data link.
Object Web Server
List Creation
Refer to Illustration 10 for creating a simple system
parameter configuration list. Illustration 10 is an
example of a system consisting of one engine
controller, one PL1000E Communication ECM, and
the Modbus Master Device. The Modbus Master
Device is shown here only for reference. The
configuration and operation of the Modbus Master
Device is outside of the scope of this document.
For the example shown in Illustration 10, we have
assembled a simple translation from Cat Data Link
to Modbus RTU (using the RS-232 Port 1 of the
PL1000E) for a Caterpillar 36XX model engine.
The *.pte file used is a sample file and the Modbus
Register assignments discussed are arbitrarily
chosen for use in this example.

A Web Server ECM in the design window represents

a Web interface to the PL1000E Communication
ECM.

Type ECM Object Type of the object selected in

the design window. The valid types are CDL, J1939,
Modbus, and WebServer. This field is read only.
16 RENR8091-04
Systems Operation Section

g01398013
Illustration 10

The following information refers back to Illustration

10 as needed to give system perspective to some of
the new terms and concepts used with the PL1000E
Communication ECMs Configuration and the use of
the PTE design interface. g01720134
Illustration 11

Set the Default PTE Directory 4. Select the default PTE directory. Press OK.
Before starting the design process, ensure the
Default PTE Directory represents the location of the
desired *.pte files. For this example, all of the *.pte
files have been located in the C:\PL1000E Example\
directory.

To set the default directory, perform the following

steps.

1. Identify the current default directory. Refer to

Illustration 4.

2. Copy PTE files from CD to chosen location on PC.

(In this example, C:\PL1000E Example\directory
is used). Illustration 12
g01336160

3. Click on the ellipse button. Refer to Illustration 4.

RENR8091-04
Add a CDL ECM Object
g01336162
Illustration 13
Click on the Add ECM Object. Refer to Illustration
13. Select CDL from the resulting drop down menu.
Note: PTE files are located on CD with PL1000E.
Assign the *.pte file to the CDL ECM
Object
Selecting a CDL ECM Object to be added to the
translation design will cause PTE to display an Open
PTE File dialog box as shown in Illustration 11. In
this dialog select the *.pte file and click on the Open
button.
This step is repeated for each CDL ECM object that
is added to the design in order to define different
ECM applications.
17
Systems Operation Section
g01708273
Illustration 14
The design window will then be updated to reflect the
addition of the new CDL ECM.
Modify the Properties for the New CDL
ECM Object
It is good practice to modify the properties of an ECM
object immediately after adding it to the design. This
will aid in distinguishing ECM objects as more objects
are added to the design.
Perform the following in order to modify the properties
for the new CDL ECM object:
1. Select the new CDL ECM Object.
2. View the information in the properties window.
Note: The type should be CDL. The PTE File
Path will display the appropriate path and file name
selected for this ECM Object. For our example it is
C:\PL1000E Example\Sample 36XX.pte.
3. Modify the ECM ID by entering a number that will
be unique among all ECM Objects in the design.
Note: In this example there will only be the CDL ECM
Object and the Modbus ECM Object. Therefore, an
ECM ID of 1 will be assigned to the CDL ECM Object.
4. Modify the Description for operator distinction.
Note: For this example, identify the ECM Object as
36XX Engine Cntrl.
5. Modify the Address.
18 RENR8091-04
Systems Operation Section

Note: Enter the Cat DataLink address of this

ECM Object. For this example, a product support
representative was contacted. The product support
representative obtained the appropriate address
of 36. The address value must be a decimal. The
Cat DataLink address can vary depending on the
device and application. Be sure to contact the
product support representative in order to acquire
the appropriate address. The PTE should look
similar to Illustration 14. Refer to the Data Address
of Caterpillar Electronic Control section of this
document.

g01708298
Illustration 16

Modify the Properties for the Modbus

ECM Object
For this example, identify this ECM Object as
PL1000E Interface using the following steps.

1. Select the new Modbus ECM object.

2. View information in the properties window.

g01708294
Illustration 15
Add Modbus ECM Object
To make data available from the CDL ECM Object
(36XX Engine Cntrl) through a Modbus Slave Device,
add a Modbus ECM Object.
Perform the following in order to add a Modbus ECM
object:
1. Click on the Add ECM Object button.
2. Select Modbus from the drop down menu.
Note: A new Modbus ECM will be added to the
design window. For Modbus ECM Objects, it is
not necessary to select a *.pte file. The data that
the PL1000E makes available on the registers of
the Modbus Slave object are limited to the set of
translation parameters from the *.pte files for each
CDL or each J1939 object. In the PCL file, an
output of the PL1000E is represented by this Modbus
(slave) ECM.
3. Modify the ECM ID by entering a number that is
unique among all objects in the design.
Note: In this example, there only is the CDL ECM
Object and the Modbus ECM Object. Assign an
ECM ID of 2 to the Modbus ECM Object.
4. Modify the description for operator distinction.
Note: For this example, the description is PL1000E
Interface.
5. Modify the Modbus slave address. The Modbus
slave address that is defined in the PCL editor is
not the same as address that is defined through
Cat ET or Webserver.
6. Enter the desired Modbus Slave Address for this
PL1000E Interface ECM Object.
Note: All data assigned to translation objects that
point to this ECM Object will be available from the
Modbus Slave Address assigned here. For this
example, the Modbus Slave Address of 3 has been
assigned.

7. Modify the port settings to match the PL1000E

Port over which this Modbus interface will be
implemented.
RENR8091-04
Note: The following port settings are
available:RS-231 Port 1, RS-232 Port 2,
RS-422, RS-485, and TCP-Standard.
Note: In this example system, the Modbus interface
is designed to operate over RS-232 Port 1. The PTE
Design window should now look similar to Illustration
16.
Add Translation Object
Perform the following in order to add the translation
object:
1. Click on the Add Translation Object button.
g01336295
Illustration 17
2. Select the desired translation for this design.
Note: In this example, design the translation of the
Cat DataLink parameter data to Modbus. The 36XX
Engine Cntrl to PL1000E Interface Translation
Object has been selected. A Translation Object is
added to the design window.
Assign Parameters to the Translation
Object
Perform the following in order to assign parameters
to the Translation Object:
1. Select the Translation Object in the design
window.
Note: The properties dialog will display a Parameter
Request Rate and Modbus Register selection list.
2. Click on the Click to Add text in the first row of
the Parameter Selection list.
19
Systems Operation Section
3. Select the first parameter that is to be added to
the translation from the drop down menu.
4. Continue to click and add parameters until all
desired parameters have been added to the
translation.
Note: An Alternate way to add parameters is to
select the icon to add all parameters and then delete
the unwanted parameters. Refer to Illustration 18 for
the icon location.
Note: Caterpillar does not recommend more than
120 parameters total for all translations.
Modify Request Rate for All Selected
Parameters
More dynamic parameters should be assigned a
smaller update rate, and less dynamic parameters
should be assigned a larger update rate.
The parameters need not be grouped by their
associated Request Rate, and each can be assigned
its own unique rate.
The PTE design window should now look similar to
Illustration 18.
g01708333
Illustration 18
(8) Select All Parameters Icon
(9) Reassign Modbus Registers Icon
(10) View/Save Parameter List Report Icon
Modify Modbus Registers
By default, when adding a parameter, a modbus
register is assigned.
A modbus register can be change by use of the
Reassign the Modbus Registers function. Refer to
Illustration 18.
20
Systems Operation Section
g01398234
Illustration 19
Note: This method is recommended because all
parameters are assigned the appropriate amount of
modbus registers.
In order to change the parameter:
1. Click on the Modbus register parameter that is to
be changed.
2. Enter the register value. Manually entering the
register value is an alternative to allowing PTE to
reassign the Modbus registers.
Note: The operator is able to overwrite other
registers.
3. Click on the view/save parameter list button
to save the modbus register map. This method
is generally used by an integrator for parameter
mapping. Refer to Illustration 18, (3) and resolution
of parameters. Refer to Illustration 20.
g01708433
Illustration 20
Parameter The parameter name
Request Rate The rate the PL1000E will request
the data if not updated through a general broadcast
Modbus Register The first register for the
parameter number where the parameter resides.
Modbus registers are two bytes in length.
RENR8091-04
Data Type The data type in the Modbus register
Data Length The number of bytes in the
parameter (2 bytes equals 1 Modbus Register)
Resolution The factor that the data in Modbus
Registers should be multiplied by in order to transfer
the data range from the data type of the register to
engineering units.
DSI (Data Status Indicator) indicates if parameter
supports DSI
Signed Specifies if data is signed or unsigned
Data Offset Used in conjunction with Resolution
in order to provide a transfer function from the binary
data type of the register to real world engineering
units. The data is scaled according to the Resolution
factor. The data is adjusted according to the Data
Offset after being retrieved by the PLC or other
modbus master.
Save *.pcl File To Disk
Perform the following in order to save a *.pcl file to
disk.
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.
Delete an ECM Object
Deleting an ECM Object will automatically delete any
attached translation arrows.
Perform the following in order to delete an ECM
object:
1. Select the ECM Object that is to be removed in
the PTE Design window.
2. Click on Remove ECM Object or press Delete
on the computer keyboard.
Note: The PTE will ask the user to confirm the
removal of the selected ECM Object.
3. Click Yes on the confirmation dialog.
RENR8091-04 21
Systems Operation Section

Note: The selected ECM Object will be removed. Select the Source ECM Object

Delete Translation Object The source ECM refers the ECM Object in the design
that the translation arrow is pointing away from. The
Perform the following in order to delete a Translation following illustrations will show that the wizard uses
Object: these terms to assign bi-directional translations. One
will be available for Source to Target ECM and one
1. Select the Translation Object to be removed in for Target to Source ECM.
the PTE Design window.
If a Modbus ECM is selected, the user may also
2. Click on Remove Translation Object or press the define the ECM ID on this screen. refer to Illustration
Delete key on the computer. 22.

Note: The PTE will ask the user to confirm the

removal of the Translation Object.

3. Click Yes in the confirmation dialog.

Note: The selected Translation Object will be

removed.

Create *.pcl File Using the PCL

Wizard
Perform the following in order to create *.pcl file using
the PCL Wizard: g01708456
Illustration 22

1. Start the PTE as described in the Create

Parameter Translation Design section of this If a CDL or J1939 ECM Object is selected, assign the
ECM ID and select the PTE file. Refer to Illustration
manual.
23.
2. Select PCL Wizard in the lower left hand of the
screen.

Note: The PCL Wizard will begin asking for

information in order to generate the PTE Design.
Refer to Illustration 21.

3. Review the information on the Wizard Start Up

screen.

4. Click Next.

g01708495
Illustration 23

Click Next.

Choose Target ECM

The Target ECM refers to the ECM Object that is
in the design window that the translation arrow is
pointing toward.

Perform the following in order to choose a target

Illustration 21
g01708453 ECM:
22 RENR8091-04
Systems Operation Section

1. If a Modbus ECM or a Webserver ECM is selected,

define the ECM ID on this screen. If a CDL or
J1939 ECM Object is selected, assign the ECM ID
and select the PTE file.

2. Click Next.

Select Source to Target Translations

Each parameter that is available for inclusion in this
translation is listed. Each parameter can be selected
by clicking the check box that is to the left of each
parameter. Illustration 24 shows that Engine Speed
and Desired Engine Speed have been selected.
g01708622
Illustration 26

g01708514
Illustration 24

Select Target to Source Translations

Each parameter available for inclusion in this
translation is listed and can be selected by clicking
the check box to the left of each parameter.
Illustration 25 shows that Remote E-Stop Switch g01708623
Illustration 27
has been selected.
Perform the following in order to finish and display
the translations:

1. Review the information displayed as a result of

the PCL Wizard. Refer to Illustration 27.

2. Refer to the Parameter Translation Configuration

and the Manual Parameter Configuration List
Creation sections of this document for information
concerning the process of how to manually adjust
the values for the ECM Objects.

Note: The descriptions, addresses, and ports are not

set by the PCL Wizard.
g01708616
Illustration 25
3. Assign registers for the Modbus.
Finish and Display the Translations 4. Save the file.
The PCL Wizard notifies the user that all necessary
Note: Refer to the Parameter Translation
data for creation of the PTE Design has been
Configuration and the Save *.pcl File to Disk
entered. Refer to Illustration 26.
sections of this manual.

Note: The *.pcl file has now been created.

RENR8091-04 23
Systems Operation Section

5. Install the *.pcl file into the PL1000E file system.

Note: Refer to the Quick Start Guide section of this

document.

Create a Modbus Master PCL File

1. Use Cat ET or Cat Communications Toolkit
version 2007B in order to access the Utilities
menu. Open the Parameter Translation Editor.
Select New (11) then select Modbus Master
(12). Refer to Illustration 28.

g01709153
Illustration 30

Refer to the call outs that are shown in Illustration

30. The type of configuration that is discussed in this
section will allow the following:
g01709113
Illustration 28

2. A screen similar to Illustration 29 will appear. The

title PCL File Configuration Modbus Master
(13) will be shown at the top of the design window.

g01709135
Illustration 29

3. The remaining portion of the configuration of

the PCL file is identical to the Modbus Slave
Configuration. The translation lines have a slightly
different meaning for the PL1000E as a Modbus
Master. Refer to Table 1 for detailed information
on what each type of translation line means.

Illustration 30 is an idea of what could be done with

the PL1000E as a Master. However, each system
will vary and may not look exactly like Illustration 30.
24 RENR8091-04
Systems Operation Section

Table 1
Call
Entity Description
Out
Translation from Modbus Slave Represents a translation taking place. In this case the PL1000E is requesting
17
1 to J1939 Engine information from Modbus Slave 1 and writing that information on J1939.
Represents a Caterpillar ECM that the PL1000E, as a Modbus Master, is
18 J1939 ECM
communicating with.
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
19 Scale Parameters Utility
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.
The rate at which the PL1000E is requesting information from Modbus or
J1939. For example, (4) is requesting information from the J1939 Engine. So
20 Request Rate
the Request Rate in this instance would be how fast the PL1000E is requesting
the specific parameter from the J1939 Engine.
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
21 Production Rate 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.
The register that the PL1000E is either requesting, or writing to, depending on
22 Modbus Register
the translation line that is selected.
Represents a Modbus Slave ECM that the PL1000E, as a Master, is
23 First Modbus Slave ECM
communicating with.
Represents a translation taking place. In this case the PL1000E is requesting
Translation from J1939 Engine
24 information from the J1939 Engine, and writing that information to the Modbus
to Modbus Slave 1
Slave ECM.
Represents a second Modbus Slave ECM that the PL1000E, as a Master, is
25 Second Modbus Slave ECM
communicating with.

Open an Existing *.pcl file for

Modification
Sometimes it may become necessary to modify a
file to either remove or add translation parameters
as the needs of the Modbus Master change with
modifications to system monitoring and control
strategies. What follows is an explanation of how to
open, modify, and update an existing *.pcl file to add
two new parameters and delete one of the existing
parameters defined in the translation.

Set the Default PTE Directory

Before starting the design process, ensure the
Default PTE Directory represents the location of the
desired *.pte files.

Note: For this example, all of the *.pte files have

been located in the C:\PL1000E Example\ directory.
g01723334
Illustration 31
(30) Scale Parameter Utility Screen
RENR8091-04
When a *.pcl file is opened, the PTE must be able to
locate the *.pte file that was originally used in order
to create the *.pcl file.
Open the Parameter Control List
Perform the following in order to open the Parameter
Control list:
1. Click on Open in the PTE.
Note: An Open dialog will be displayed. Refer to
Illustration 32.
g01336395
Illustration 32
2. Use the dialog to navigate to the disk location
where the *.pcl file to be modified is located.
3. Select the file.
4. Click Open.
Note: The PTE will read in the *.pcl file. The PTE
will recreate the Design window objects. The screen
should look similar to Illustration 33.
Delete Parameters from the 36XX Engine
Cntrl to PL1000E Interface Translation
Perform the following steps in order to delete
parameters from the 36XX Engine Cntrl to the
PL1000E interface translation.
1. Select the Translation Object in the Design
window.
2. View the parameters in the Properties window.
3. Click on the name of the parameter that is to
removed.
25
Systems Operation Section
Note: As an example, the Atmospheric Pressure
parameter has been chosen to be removed.
4. Press the delete key that is on the keyboard of
the computer.
Note: The parameter will be removed from the
Translation Parameter List.
Add Parameters to the 36XX Engine Cntrl
to PL1000E Interface Translation
Perform the following in order to add parameters
from the 36XX Engine Cntrl to the PL1000E interface
translation:
1. Select the Translation Object in the Design
window.
2. View the parameters in the Properties Window.
3. Click on Click to Add in the Parameter List.
4. Select the desired parameters that are to be
added to the translation.
Note: For this example, add the Diagnostic Clock.
Modify the Request Rate for the New
Parameter(s)
The request rates should be carefully considered.
More dynamic parameters should be defined with
smaller request rates and less dynamic parameters
should be defined with larger request rates. Since
the diagnostic clock will not change with extreme
frequency, Request Rate of 100000 milliseconds has
been selected.
The PTE Design window should now look similar to
Illustration 33.
26
Systems Operation Section
Illustration 33
g01709154
Save the Modified *.pcl File To Disk
Perform the following in order to replace the existing
*.pcl file to a disk:
1. Click the Save button.
Note: The PTE will write the new data directly into
the previously saved file.
Perform the following steps in order to retain the
previously configured file as a history.
1. Select the Save As button just below the Save
button.
Note: This will open a Save As dialog box.
2. Define a new file name and location for the
modified file.
Note: The *.pcl file has been successfully modified. It
is always a good practice to keep a copy of the file
that was previously working correctly, until the new
file can be tested and verified in the system.
3. Install the *.pcl file into the PL1000E file system.
Note: See Installation of PCL File to PL1000E
Section of this document.
RENR8091-04
Installation of PCL File to PL1000E
Installation of a *.pcl file is necessary for the PL1000E
Communication ECM to begin making translated
data available on the target data link. The example
in this manual has focused on the creation of a *.pcl
file for translation of CDL parameters to Modbus.
Discussions will continue to reference this same
example.
PCL files are installed on the PL1000E using a
standard FTP connection. An FTP connection may
be established through either the facility network or
through a direct crossover connection. Each method
requires a different procedure for both the PC and
ECM.
Each method requires different settings for both the
PC and ECM.
Refer to the LAN Network Ethernet Connection and
Direct Crossover Ethernet Connection sections in
this manual.
The PL1000E includes an Ethernet 10Base-T
interface. The on board application software uses this
port for access to an embedded web server, the ECM
file system, and as an interface for Modbus TCP.
There are two primary methods used to connect the
ECM Ethernet port to a system, Local Area Network
(LAN) connection and direct crossover connection
to a single PC.
The LAN connection allows the gateway to be
accessed on a multiuser network and share
information with all other nodes on that network. The
direct crossover connection is a single point-to-point
connection to one PC without the overhead of a
network.
Note: There are many ways to set up networks. This
discussion is only a brief description of methods that
should work in a majority of cases. The user should
consult the facility network administrator in order to
insure an implementation method that will work for
the unique network.
Initiate Configuration of PL1000E
with New PCL File
NOTICE
The steps in this section will cause the PL1000E Com-
munication Module to perform a warm boot sequence.
During this boot sequence all data retrieval and com-
munications will be disabled for a few seconds. En-
sure the system is prepared for a temporary loss of
data before executing the following instructions.
RENR8091-04
Note: The PL1000E needs to be configured before
the PCL file is transferred. If needed due to site setup,
then refer to the ECM Configuration, LAN Network
Ethernet Connection, or the Direct Crossover
Ethernet Connection section of this manual.
Perform the following in order to initiate configuration
of PL1000E with new PCL file:
1. Enter xxx.yyy.zzz.aaa in the address field of
the browser. The xxx.yyy.zzz.aaa is the IPv4
address of the PL1000E which is defined in the
Cat ET configuration screen.
Note: The browser will display the PL1000E Home
Page.
2. Navigate to the Configuration/Reset web page
3. Select the Reset action.
4. Click Submit.
Note: The user will be prompted for a User Name
and Password for access to reset the PL1000E.
5. Enter the appropriate User Name and Password.
Note: The browser will indicate the following:
The PL1000E device will RESET. This page will
automatically go back to the Home Page. The
browser will display the PL1000E Home Page.
6. Enter ftp://xxx.yyy.zzz.aaa in the address field of
the browser.
Note: An FTP Folder Error dialog will appear. This is
a normal security message. The security message
indicates that the user has not yet logged into the
FTP session.
7. Click OK in this dialog box.
8. In the browser menu, select File / Login As.
Note: A login dialog will be displayed. The login
dialog will prompt for a User Name and Password.
The default User Name is admin, and the default
password is admin.
9. Enter the appropriate User Name and Password
and click Login.
Note: The browser will display the PL1000E files and
folders on the modules root directory.
10. Navigate to the Current directory.
11. Initiate a browser Refresh.
12. Make note of the file that is shown in the Current
directory.
27
Systems Operation Section
Note: If the file was processed successfully, a time
and date stamp appended to the end of the file name.
An example of the file name is:
The original file name:
36XX_Sample_PCL_File.pcl
The modified file name:
36XX_Sample_PCL_File_YYYYMM
DDHHNNSS.pcl
Where:
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.
28 RENR8091-04
Systems Operation Section

i03345200 i03331925

Data Link Configuration Data Link Address of

SMCS Code: 7610
Caterpillar Electronic Control
SMCS Code: 7610

The data link address for each Caterpillar engine

can be found in the engine documentation that is
provided with each engine. The data link address
can also be found by connecting to the engine with
Cat ET. Press Ctrl+I.

Note: Pressing Ctrl+I is only functional for devices

on the CDL network.

After the Cat ET screen appears, scroll to the bottom

of the screen. Select Real ID Device. The first two
values of this field is the address that needs to be
entered. The number will need to be converted into
a decimal number for entry into the PCL Editor. The
following is an example of how to convert a number
to a decimal number for entry into the PCL Editor:

1. Start Cat ET.

g01720155
Illustration 34
Refer to Illustration 34. The Cat Data Link Module
Identifier Configuration (1) selection is for CDL
communications only. The PL1000E is able to select
from three different MID numbers. The Cat Data Link
Module Identifier Configuration (1) is NOT available
on the CAN/J1939 network as a dynamic protocol.
Cat Data Link Module Identifier
Configuration
Possible values follow:
2. Connect to the engine.
3. Select the ECM.
4. At the Summary screen, select Ctrl+I.
5. Scroll to the bottom of the window.
6. The first two values that are shown in the field
for the Real Device ID values, is the ECM
address. In Illustration 35, the Real Device ID is
24000000e001 so 24 is the address of the ECM.

PL1000 #1
PL1000 #2 (Default)
PL1000 #3

Cat Data Link Boost Function

Enable Status
Possible values follow:

Enabled Illustration 35
g01709835

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.
RENR8091-04 29
Systems Operation Section

i03331987 Internet Protocol (IPv4) Network

Internet Protocol Configuration Mask
SMCS Code: 7610 The Internet Protocol (IPv4) Network Mask (3) is
sometimes called the Subnet Mask. This value
specifies what range of IP addresses are considered
to be on the same local subnet. The Internet gateway
value for this configuration is 255.255.255.0. The
default value for this configuration indicates that
all devices with the same first three octets as this
device, will be considered to be on the same local
subnet. Consult the network administrator in order to
determine the appropriate value for the configuration.

Network Default Gateway Internet

Protocol (IPv4) Address
The Network Default Gateway Internet Protocol
g01710119 (IPv4) Address (5) is the address of the networks'
Illustration 36
(1) Ethernet Media Access Control (MAC) Address Internet gateway. The initial value for this
(2) Internet Protocol Host Name parameter is 0.0.0.0. The value of the parameter
(3) Internet Protocol (IPv4) Address must be set if the PL1000E is to be used in a
(4) Internet Protocol (IPv4) Network Mask networked environment. Contact the network
(5)
(6)
administrator in order to determine the appropriate
Network Default Gateway IP address.

Ethernet Media Access Control

Dynamic Host Configuration
(MAC) Address
Protocol (DHCP) Enable Status
The Ethernet (MAC) Address (1) is a read only
value. The Ethernet (MAC) Address is programmed The DHCP (6) has two possible values:
into the device at manufacture time. The Ethernet
(MAC) is used in order to uniquely identify the node Disabled (Default)
on the network to which the PL1000E is connected.
The address value will be required by the network Enabled
administrator when configuring the device for
operation on the network. The defaults are:

IP address:192.168.1.1
Internet Protocol Host Name
Network Mask: 255.255.255.0
The Internet Protocol Host Name (2) is a free form
text field where the host name may be entered. By Default Gateway: 1.0.0.0
default, the IP address is 192.168.1.1.. The address
must be changed if the PL1000E is to be used in a
networked environment. The IP value is limited to
25 characters. The Internet Protocol Host Name is
assigned by the network administrator.

Internet Protocol (IPv4) Address

The Internet Protocol (IPv4) Address (3) is configured
according to the kind of network environment in
which it is installed. The IP address value must be
configured with the value defined by the network
administrator.
30 RENR8091-04
Systems Operation Section

i03332563 ModBus #1 Echo/No Echo

Modbus Configuration The ModBus #1 Echo/No Echo selections are:
SMCS Code: 7610 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
g01743935
Illustration 37
8 (default)
ModBus Configuration Details ModBus #1 Parity
ModBus #1 Port Selection The ModBus #1 Parity selections are:

The ModBus #1 Port selections are: Even

Disabled Mark
Serial Port #1 (default) No Parity (default)
Serial Port #2 Odd
Serial Port #4 Space
ModBus #1 Baud Rate ModBus #1 Data Link Address
The ModBus Baud Rates selections are: The ModBus #1 Data Link Address selections are
any value between zero (0) and 254. It is recommend
1200 that the value remain at default.

2400 The default value is 254.

4800 ModBus #2 Port Selection

9600 (default) The ModBus #2 Port selections are:
19200 Disabled
38400 Serial Port #1
57600 Serial Port #2 (default)
Serial Port #4
RENR8091-04 31
Systems Operation Section

ModBus #2 Baud Rate ModBus #2 Data Link Address

The ModBus #2 Baud Rate selections are: The ModBus #2 Data Link Address selections are
any value between zero (0) and 254. It is recommend
1200 that the value remain at default.

2400 The default value is 254.

4800 ModBus #3 Port Selection

9600 (default) The ModBus #3 Port Selection selections are:

19200 Disabled
38400 Serial Port #1
57600 Serial Port #2
ModBus #2 Echo/No Echo Serial Port #4 (default)
The ModBus #2 Echo/No Echo selections are: ModBus #3 Baud Rate
Echo The ModBus #3 Baud Rate selections are:

No Echo (default) 1200

ModBus #2 Flow Control 2400
The ModBus #2 Flow Control selections are: 4800
Hardware (CTS/RTS) 9600 (default)
None (default) 19200
Reserved 38400
Software (Xon/Xoff) 57600
ModBus #2 Data Size ModBus #3 Echo/No Echo
The ModBus #2 Data Size selections are: The ModBus #3 Echo/No Echo selections are:

7 Echo
8 (default) No Echo (default)

ModBus #2 Parity ModBus #3 Flow Control

The ModBus #2 Parity selections are: The ModBus #3 Flow Control selections are:

Even Hardware (CTS/RTS)

Mark None (default)
No Parity (default) Reserved
Odd Software (Xon/Xoff)
Space ModBus #3 Data Size
The ModBus #3 Data Size selections are:
32 RENR8091-04
Systems Operation Section

7 i03332863

8 (default) LAN Network Ethernet

Connection
ModBus #3 Parity
SMCS Code: 7610
The ModBus #3 Parity selections are:
LAN Network Ethernet Connection
Even
Overview
Mark
LAN Networks share common cables, routers,
No Parity (default) switches, etc. Each node on the LAN may have a
static Internet Protocol (IP) address or the network
Odd may be set up to use Dynamic Host Configuration
Protocol (DHCP). The PL1000E Communication
Space ECM may be configured to support either method.

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.

ModBus TCP Data Link Address

The ModBus TCP 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:

2 wire (half duplex)

4 wire (full duplex) (default)
If a PL1000E is being commissioned in a system that
has RS-485 communications, then the appropriate
wiring standards must be used for the RS-485 mode.
RENR8091-04 33
Systems Operation Section

g01414942
Illustration 38

Note: DHCP is used to allow a network server to Loading the PCL File Using FTP
manage the network node connections dynamically.
Each node needs an IP address, but there are a finite
With a Web Browser
number of addresses. The server can maximize the Perform the following with a standard web browser:
number of addresses available by assigning them
as devices are connected to the network. DHCP
1. In the address field of the browser, type in the IP
requires specialized server software and is not always (IPv4) Address that was noted in Step 7.
available on small networks. In a non-DHCP network
for nodes to communicate through IP dedicated IP
Note: The browser will display the PL1000E
addresses must be assigned to each node. Communication ECM Home Page. This confirms the
connection of the ECM and the PC to the network. If
Perform the following in order to complete a LAN
the user is unable to browse to the ECM Home Page,
network ethernet connection: refer to Troubleshooting, RENR8091.
1. Connect the ECM serial port 3 (ECA) harness
2. In the address field of the browser, enter the
connector to the PC. following: ftp://xxx.yyy.zzz.aaa
2. Apply power to the system and start the service
Note: Where ftp://xxx.yyy.zzz.aaa is the address
tool on the PC. noted in the previous steps, an FTP Folder Error
dialog will appear. The FTP Folder Error is a normal
3. Once connected to the PL1000E, navigate to the
security message that indicates the user has not yet
Configuration screen for IP. logged into the FTP server.
4. Determine whether the network requires support
3. Click OK in this dialog box.
for DHCP or static IP addresses.
4. In the browser menu, select File/Login As.
5. If DHCP support is required, configure the DHCP
Enable Status to Enabled. Note: A login dialog will be displayed prompting for a
User Name and Password. The Default User Name
6. If static IP addressing is required, configure DHCP
is admin, and the Default Password is admin.
Enable Status to Disabled and configure the IP
(IPv4) Address, IP (IPv4) Network Mask, and
5. Enter the appropriate User Name and Password
Network Default Gateway Internet Protocol (IPv4)
and click Login.
Address to the values specified by the network
administrator.
Note: The browser will display the ECM files
and folders on the module's root directory. As a
7. Make note of the IP (IPv4) Address. default, the folders and files displayed are shown in
Illustration 39.
8. Connect the PC and login to the same network as
the PL1000E and start a web browser.
34 RENR8091-04
Systems Operation Section

6. Double click on the New folder in order to

navigate into the New folder.

Note: The browser will display the contents of the

New folder. By default, this directory is empty.
Therefore, a blank screen will be shown.

7. Use Windows Explorer in order to locate the *.pcl

file that is on the disk that was created with the
use of Parameter Translation Editor (PTE).

8. Copy the *.pcl file.

9. In the blank browser window, right-click and select

Paste, or select Edit / Paste from the browser
menu.

Note: The file will be placed into the New directory

on the PL1000E file system. The browser should
be refreshed after file system changes are made.
Microsoft Internet Explorer usually will cache the
contents of the file system. Microsoft Internet
Explorer usually displays cached information instead
of updated information from the server.

10. Verify the file is located in the new directory.

g01176569
Illustration 40

g01176577
Illustration 41

1. Start a DOS session.

g01397626
Illustration 39 Note: This can be done on most versions of Microsoft
Windows by clicking on Start, then selecting Run.
Loading the PCL File Using FTP
with the Command Prompt
Perform the following with a DOS FTP session:
RENR8091-04
g01397624
Illustration 42
2. In the Run dialog, type CMD and click OK.
Note: If Microsoft Windows 95 or Microsoft Windows
98 are being used, then the word command must
be used instead of CMD.
3. At the DOS command prompt, type ftp
xxx.yyy.zzz.aaa.
Note: xxx.yyy.zzz.aaa is the IPv4 address of the
device. The address of the device is defined in the
Configuration screen in Cat ET.
g01402161
Illustration 43
4. Press Enter.
Note: The screen will be similar to the screen in
Illustration 43.
35
Systems Operation Section
g01402164
Illustration 44
5. At the prompt, type in the user name.
6. Press Enter.
7. At the password prompt, type in the password.
Note: After entering the user name and password,
the screen will be similar to the screen in Illustration
44.
8. Set the local directory and remote directory for
proper transfer of the file.
Note: In order to specify the local working directory,
use the command lcd PL1000E. See Illustration 45.
g01402167
Illustration 45
9. Set the remote directory.
Note: By default, when the user logs into FTP, the
remote directory is /ram. Confirm that the remote
directory is /ram by issuing a Print Working Directory
(PWD) command. If the current working directory is
not returned as /ram/, then use a Change Directory
(CD) command such as ftp> cd / in order to return
to the root directory. See Illustration 46.
36
Systems Operation Section
g01402168
Illustration 46
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.
g01402169
Illustration 47
11. In order to confirm the remote directory is set
up correctly, use the PWD command again. The
current remote directory should be returned as
/ram/New/. Refer to Illustration 48.
12. Type Binary and press Enter. (This process
forces DOS ftp to transfer file in binary format
instead of the default ASCII.)
g01402179
Illustration 48
RENR8091-04
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 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 50
g01402183
15. Initiate configuration of the PL1000E
Communication ECM with the new PCL file by
either removing and reapplying power to the ECM
or by executing the steps outlined in System
Operations, RENR8091, Parameter Translation
Configuration.
i03332946
Direct Crossover Ethernet
Connection
SMCS Code: 7610
The following instructions cover both the setup
requirements for the PL1000E Communication ECM
and the single Personal Computer (PC) that will
connect to it. The PC instructions are different for the
specific operating system used.
RENR8091-04 37
Systems Operation Section

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 g01710894

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.
Illustration 52
4. Once the configuration screen loads, go into
the Internet Protocol section and change the
Dynamic Host Configuration Protocol (DHCP)
Enable Status to disabled by highlighting it and
clicking Change.

3. Once Cat ET is started and the selected device is

the PL1000E, click on the Configuration Screen
or press the F5 key.
38 RENR8091-04
Systems Operation Section

g01710895 g01710899
Illustration 53 Illustration 55

5. Select Disabled from the drop down box. 8. Enter the address of the default gateway, if
applicable, in the form of 1.0.0.0 and click OK.
6. Click OK and click Yes to program the ECM.
9. Click Yes to program the PL1000E.

g01710898
Illustration 54
g01710913
Illustration 56
7. Highlight the Network Default Gateway Internet
Protocol (IPv4) Address entry and click Change. 10. Highlight the Internet Protocol (IPv4) Network
Mask entry and click Change.
RENR8091-04 39
Systems Operation Section

g01710914 g01710916
Illustration 57 Illustration 59

11. Enter the Subnet mask value of 255.255.255.0
and click OK.
12. Click Yes in order to program the PL1000E.
14. Enter the four parts of the IP address in the four
fields according to the information that is provided
by the network administrator. Click OK.
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.

15. Click Yes in order to program the PL1000E.

16. In order to make the PL1000E changes effective,

turn the key switch to the OFF position, then
turn the key switch back to the ON position. The
PL1000E is ready for direct connect use.

Configuring a Stand - Alone Windows PC

to Access the PL1000E Communication
Module
Note: The PC must be equipped with a wired Ethernet
adapter. If the PC is normally on a wired network, this
procedure requires temporarily disconnecting the PC
from the network in order to connect to the PL1000E.

g01710915 Perform the following steps in order to configure

Illustration 58 a Windows based PC that is not on a network to
access the PL1000E.
13. Highlight the Internet Protocol (IPv4) Address"
entry and click Change. Note: A crossover ethernet cable is required in order
to directly connect the network adapter port (RJ-45)
of the PC to the network adapter port of the PL1000E
without the use of a hub or switch.

1. Click Start Menu.

2. Click Control Panel.

3. Click the Internet Options (9) program.

40 RENR8091-04
Systems Operation Section

g01710918 g01404032
Illustration 60 Illustration 62

4. Select the Connections tab (10). 6. Make a note of the current settings. Uncheck all
checked boxes.

7. Click OK.

8. Click OK again in order to close the Internet

Properties window.

9. In the Control Panel click the Network

Connections (12).

g01404026
Illustration 61

5. Click LAN Settings (11). Illustration 63

g01710920

10. Click Local Area Connection (13).

RENR8091-04 41
Systems Operation Section

Note: There is a possibility that an ethernet adapter

card has not installed on a Windows based PC that
is not networked. If an ethernet adapter card has not
installed, then the item, Internet Protocol (TCP/IP),
will not appear in the list. In order to proceed with this
type of connection, an ethernet adapter card must be
installed or a different PC that is equipped with an
ethernet adapter must be used.

g01710921
Illustration 64

11. In the Local Area Connection Status window click

Properties (14).

g01404064
Illustration 66

13. Highlight Internet Protocol (TCP/IP) (16).

14. Click Properties (17).

15. Make a note of the current settings.

16. Select Use the Following IP Address.

g01404040
Illustration 65

12. In the box that is titled This connection uses the

following items:, scroll down the screen and then
select Internet Protocol (TCP/IP) (15). Refer to
Illustration 66.
42
Systems Operation Section
Illustration 67
g01404041
17. Enter the IP address in the form 192.168.1.10.
Enter the Subnet mask as 255.255.255.0. The data is housed according to the source data link
18. Click OK.
19. Click OK on the Local Area Connection
Properties window in order to close the window.
i03334148
ECM Modbus Interface
SMCS Code: 7610
PL1000E Communication ECM
Modbus Interface Overview
The PL1000E supports a subset of the common
Modbus Function Codes that are used for data
transfer. Table 2 documents the Function Codes and
the addressing ranges which are supported by the
PL1000E. The specific Modbus Registers in each
application will vary depending on the configuration
in the Parameter Translation Editor (PTE).
RENR8091-04
Table 2
Function Description Modbus Address
Code Range
3 Read Holding 40001 through 42000
Registers inclusive
6 Preset Single 40001 through 42000
Register inclusive
16 Preset Multiple 40001 through 42000
Registers inclusive
Modbus Parameter Translation Data
Location and Formats
The PL1000E Communication ECM provides
parameter translations of Cat Data Link and J1939
data to Modbus.
The data that is provided on the Modbus
Communication Link has the same scaling as the
source data link. The Modbus application can use
the scaling information in order to transform the data
to a value that can be displayed.
Each parameter that is defined in the PCL file has
a starting Modbus Register. Each parameter that is
defined in the PCL file has an associated number of
registers that are required to house the data.
definition and according to the data length definition.
The process to house the data applies to all of
the parameters with the exception of Events and
Diagnostics.
The next section covers the format, length, and
definition of the Event and Diagnostic data as the
data is presented to the Modbus interface.
Events and Diagnostics
Event and Diagnostic information is internally
retrieved and tabulated by the PL1000E if the Event
and Diagnostic parameter translations were included
in the PCL file. Event or Diagnostic parameter
translations can also be defined independently.
Therefore, the user can only configure translations
for diagnostics that are desired.
Event and Parameter Translations - Cat Data Link
Event and Diagnostic Codes
Different versions of ECMs that are on Cat Data Link
and J1939 are capable of transmitting the event
and diagnostic information in multiple versions of
communication protocols.
RENR8091-04 43
Systems Operation Section

The different communication protocols are managed

internally by the PL1000E. The Modbus application
does not need to be aware of these communication
differences. The PL1000E determines the appropriate
communication method from the source data link.
The PL1000E presents a list of event and diagnostic
data that is consistent regardless of the source data
link communication method.

The tables for each type of code are very similar.

However, there is some additional information that is
available or required for certain codes. The additional
information dictated minor differences in the table
format and content. The events and diagnostics
are available in the following form beginning at the
starting Modbus Register as defined in the PCL file.

If the CDL Event Translations were configured in

the PCL file to begin at Modbus Register 40,207,
then referring to Table 6, offset zero (0) would be
available at Modbus Register 40,207. Offset 1 would
be available at 40,208.

Table 3
Cat Data Link Events
Modbus
Contents Comments
Register Offset
Most Significant Byte (MSB): Count of active events
0 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
1 Event retrieval status 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)

2 Negotiated update rate 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
3 First Event Identifier (EID)
LSB: Reserved
MSB:
Bits 8 through 4: Reserved
Additional Event Identifier Bits 3 through 1: Warning Category Indicator (WCI)
4
information 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.

Register offsets 3 and 4 are repeated for each

event reported by the source device. The Cat
Data Link Events Table that is shown above, will
hold a maximum of 20 event entries. Refer to the
explanation that is in the footnote (2) of Table 3 for
overflow in status bytes when more than 20 events
are active on a device.
44 RENR8091-04
Systems Operation Section

Table 4
Cat Data Link Diagnostics
Modbus
Contents Comments
Register Offset
Most Significant Byte (MSB): Count of active diagnostics
0 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
1 Diagnostics retrieval status 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
2 Negotiated update rate diagnostic code updates to the PL1000E in milliseconds. (MSB
first)
MSB: Component Identifier 1
3 First Component Identifier (CID)
LSB: Reserved
MSB
Bits 8 through 6: Warning Category Indicator (WCI)
Additional Component Identifier WCI values: 0 or 1 = Warning, 2 = Service, 3 = Shut Down
4
Information 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.

Register offsets 3 and 4 are repeated for each

diagnostic reported by the source device. The Cat
Data Link Diagnostics Table that is shown above,
will hold a maximum of 20 diagnostic entries. Refer
to the explanation that is in the footnote (2) of Table
4 for overflow in status bytes when more than 20
events are active on a device.

Event and Parameter Translations - J1939

Diagnostic Trouble Codes (DTC)

When the Conversion Method (CM) of all DTC's

reported by a device is set to 1, the pairs of DTC
Modbus Registers will be sorted in ascending order
by SPN. There will be two instances of Table 5 for
each device for which diagnostic retrieval has been
configured in the PCL file. The two tables will be
contiguously located in the Modbus Register ranges
beginning with the starting register as defined in the
PCL file. The first table will contain all DTCs that are
reported by the device. The second table will contain
all emission related DTCs that are reported by the
device. Non-emission related DTCs will not appear
in the table.
RENR8091-04
Table 5
J1939 Diagnostic Trouble Codes (DTCs) and Emissions Related DTCs
Modbus Register
Contents
Offset
0 Count of active DTC
1 DTCs retrieval status
2 Lamp status
First two bytes of the
3 first Suspect Parameter
Number (SPN)
Lower order bits of the
first SPN
4 Failure Mode Identifier (FMI)
Conversion Method (CM)
Occurrence Count (OC)
(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.
Register offsets 3 and 4 are repeated for each SPN
reported by the source device. The J1939 DTC's
and Emissions Related DTC's Table will hold a
maximum of 20 DTC entries. See explanation in table
of overflow in status byte when more than 20 are
active on a device. Refer to the explanation that is in
the note of Table 5 for overflow in status bytes when
more than 20 DTC events are active on a device.
Note: Some devices may have implemented both
CMs, so some of the DTCs may be in the appropriate
format while some remain indeterminate.
45
Systems Operation Section
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
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)
LSB (When CM has a value of 1): SPN bits (10 through 3)
MSB (When CM has a value of 0): Indeterminate
LSB (When CM has a value of 0): Indeterminate
MSB (When CM has a value of 1):
Bits 8 through 6: SPN bits (2 through 0)
Bits 5-1: Failure Mode Identifier
LSB (When CM has a value of 1):
Bit 8: Conversion Method
Bits 7-1: Occurrence Count
MSB (When CM has a value of 0):(3) Indeterminate
LSB (When CM has a value of 0): Indeterminate
PL1000E Communication ECM Default
Status Modbus Registers
The PL1000E Communication ECM has been
designed to support a set of default status Modbus
Registers that can be used to verify initial connectivity
and status of the ECM communications. The registers
and associated data are listed in the table shown in
Table 6.
46 RENR8091-04
Systems Operation Section

Table 6
Default Status Modbus Registers
Starting Register Modbus Register Contents Format and Length
ECM Part Number String
40,001
5 registers (10 ASCII bytes)
ECM Serial Number String
40,006
5 registers (10 ASCII bytes)
Personality Module (Software) Part String
40,011
Number 5 registers (10 ASCII bytes)
Module Release Date (Application Date String
Code) string 3 registers (5 ASCII bytes) (MM MY Yx) Where
40,016
MM M is the month (JAN, FEB, etc.) and Y Y is
the last two digits of the year (2005 would be 05)
40,019 Reserved 2 registers (4 bytes)
Module Description String
40,021
13 registers (26 ASCII bytes)
PCL file status (0 = Initializing, 1 = OK, 2 = 1 register (1 byte LSB)
40,034 error or not present) PCL file status (0 = Initializing, 1 = OK, 2 = error
or not present)
ECM Lifetime Clock 2 registers (4 bytes)
40,035
Hours (MSB)
40,037 Reserved 4 registers (8 bytes)
40,041 CDL Received Messages (MSB) 2 registers
40,043 CDL Received Errors (MSB) 2 registers
40,045 CDL transmitted messages (MSB) 2 registers
40,047 CDL transmitted errors (MSB) 2 registers
40,049 Reserved 2 registers (4 bytes)
40,051 J1939 received messages (MSB) 2 registers
40,053 J1939 received errors (MSB) 2 registers
40,055 J1939 transmitted messages (MSB) 2 registers
40,057 J1939 transmitted errors (MSB) 2 registers
40,059 Reserved 2 registers (4 bytes)
RS-232 Port 1 received Modbus - RTU (MSB) 2 registers
40,061
messages
RS-232 Port 1 received Modbus - RTU (MSB) 2 registers
40,063
errors
RS-232 Port 1 transmitted Modbus - RTU (MSB) 2 register
40,065
messages
RS-232 Port 1 transmitted Modbus - RTU (MSB) 2 registers
40,067
errors
40,069 Reserved 2 registers (4 bytes)
RS-232 Port 2 received Modbus - RTU (MSB) 2 registers
40,071
messages
RS-232 Port 2 received Modbus - RTU (MSB) 2 registers
40,073
errors
RS232 Port 2 transmitted Modbus - RTU (MSB) 2 registers
40,075
messages
(continued)
RENR8091-04 47
Systems Operation Section

(Table 6, contd)
RS232 Port 2 transmitted Modbus - RTU (MSB) 2 registers
40,077
errors
40,079 Reserved 2 registers (4 bytes)
RS422/485 Port 4 received Modbus - RTU (MSB) 2 registers
40,081
messages
RS422/485 Port 4 received Modbus - RTU (MSB) 2 registers
40,083
errors
RS422/485 Port 4 transmitted Modbus - (MSB) 2 registers
40,085
RTU messages
RS422/485 Port 4 transmitted Modbus - (MSB) 2 registers
40,087
RTU errors
40,089 Reserved 2 registers (4 bytes)
40,091 Ethernet received Modbus - TCP messages (MSB) 2 registers
40,093 Ethernet received Modbus - TCP errors (MSB) 2 registers
Ethernet transmitted Modbus - TCP (MSB) 2 registers
40,095
messages
40,097 Ethernet transmitted Modbus - TCP errors (MSB) 2 registers
40,099 number of Modbus - TCP connections (MSB) 1 register
40,100 Reserved 100 registers (200 bytes)
ECM Mapping - Number of Entries (30 (MSB) 1 register
40,201
entries or 15 pairs)
40,202 ECM Address (from) (MSB) 2 registers
ECM Type and Port 1 register
40,204
high byte = Type low byte = Port
40,205 ECM Address (to) (MSB) 2 registers
ECM Type and Port 1 register
40,207 MSB = Type
LSB = Port

Description of Default Status Data Response from PL1000E Slave 15 03 0A 32 35

38 34 38 2D 30 31
All sample messaging in the following table assumes
that the Modbus slave address, that is also referred Data = 2584548-01
to as the Device ID, of the PL1000E is set to $15.
The default address is 254 ($FE). In order to retrieve ECM Serial Number
the status data from the PL1000E, use the Modbus
slave address or Device ID that was defined in The serial number of the PL1000E communication
the Cat ET configuration screen for the respective module in the standard Caterpillar serial numbering
Modbus object. format.

The following sample messages do not include the Sample Message:

checksum. The checksum would be the last two
bytes in a request or a response. Request from Modbus Master 15 03 00 05 00 05
ECM Part Number Response from PL1000E Slave 15 03 0A 30 35
30 35 42 30 30 31 48 55
The Caterpillar part number of the PL1000E
communication module Data = 0505B001HU
Sample Message:

Request from Modbus Master 15 03 00 00 00 05

48
Systems Operation Section
Personality Module Part Number
The application software flash file part number
currently programmed into the PL1000E
communication module.
Sample Message:
Request from Modbus Master 15 03 00 0A 00 05
Response from PL1000E Slave 15 03 0A 32 35
38 36 38 30 36 2D 30 30
Data = 2586806
Application Date Code
The month and year (last two digits) of the application
software flash file release.
Sample Message:
Request from Modbus Master 15 03 00 0F 00 03
Response from PL1000E Slave 15 03 06 41 55
47 30 38 00
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:
Request from Modbus Master 15 03 00 14 00 0D
Response from PL1000E Slave 15 03 1A 50 4C 31
30 30 30 45 20 43 6F 6D 6D 75 6E 69 63 61 74
69 6F 6E 20 45 43 55 00
Data = PL1000E Communication ECU
PCL File Status
Each time the PL1000E is powered on, it searches
for a new PCL file. If the PCL is present in the NEW
directory, then the PL1000E will process the PCL file
and the PL1000E will assume the configuration that
is contained within the PCL file.
Sample Message:
Request from Modbus Master 15 03 00 21 00 01
Response from PL1000E Slave 15 03 02 00 01
Data = 01 (Refer to the following note.)
Note: Data = 01 means PCL File OK.
RENR8091-04
Refer to Table 6 for the definitions of the possible
data values.
ECM Lifetime Clock
An internal timer that indicates the amount of time that
the PL1000E has been in operation over its lifetime.
The ECM lifetime clock is NOT the service meter
hours. The ECM lifetime clock is an independent
accumulation of operation hours of the PL1000E
device itself.
Sample Message:
Request from Modbus Master 15 03 00 22 00 02
Response from PL1000E Slave 15 03 04 00 00
00 B2
Data = 178 hours
Scale = 1 hour/bit
CDL Received Messages
An accumulator that indicates the number of
messages that have been successfully received on
CDL. Use this information as an indicator of whether
or not the PL1000E is receiving data on 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:
Request from Modbus Master 15 03 00 28 00 02
Response from PL1000E Slave 15 03 04 00 00
50 1D 24
Data = 5,250,340 messages
CDL Received Errors
An accumulator that indicates the number of errors
that have been received on CDL. Received errors
can indicate incorrect system wiring or incorrectly
configured parameter translation. The accumulator
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:
Request from Modbus Master 15 03 00 2A 00 02
RENR8091-04
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
Request from Modbus Master 15 03 00 2C 00 02
Response from PL1000E Slave 15 03 04 00 50
1D 24
Data = 4436 messages
Scale = 1 message/bit
CDL Transmitted Errors
An accumulator that indicates the number of
errors that have occurred while the PL1000E was
attempting to transmit a CDL message. Transmitted
errors can indicate incorrect or faulty system wiring.
The accumulator 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:
Request from Modbus Master 15 03 00 2E 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
Data = 0 errors
49
Systems Operation Section
J1939 Received Messages
An accumulator that indicates the number of
messages that have been successfully received
on J1939. Use this information as an indicator
of whether or not the PL1000E is receiving data
on J1939. 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:
Request from Modbus Master 15 03 00 32 00 02
Response from PL1000E Slave 15 03 04 00 50
1D 24
Data = 5,250,340 messages
Scale = 1 message/bit
J1939 Received Errors
An accumulator that indicates the number of errors
that have been received on J1939. Received errors
can indicate incorrect or faulty system wiring or
incorrectly configured parameter translation. The
accumulator 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:
Request from Modbus Master 15 03 00 34 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
Data = 0 errors
Scale = 1 error message/bit
J1939 Transmitted Messages
An accumulator that indicates the number of
messages that have been successfully transmitted
by the PL1000E over J1939. 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:
50
Systems Operation Section
Request from Modbus Master 15 03 00 36 00 02
Response from PL1000E Slave 15 03 04 00 00
11 54
Data = 4436 messages
J1939 Transmitted Errors
An accumulator that indicates the number of
errors that have occurred while the PL1000E was
attempting to transmit a J1939 message. Transmitted
errors can indicate incorrect or faulty system wiring.
The accumulator 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:
Request from Modbus Master 15 03 00 38 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
Request from Modbus Master 15 03 00 3C 00 02
Response from PL1000E Slave 15 03 04 00 50
1D 24
Data = 5,250,340 messages
Scale = 1 message/bit
RENR8091-04
RS-232 Port 1 Received Modbus-RTU Errors
An accumulator that indicates the number of modbus
errors that have been received on RS-232 Port
1. Received errors can indicate incorrect or faulty
system wiring or incorrectly formatted modbus
messages that are being sent by another modbus
device. The accumulator 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:
Request from Modbus Master 15 03 00 3E 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
Request from Modbus Master 15 03 00 40 00 02
Response from PL1000E Slave 15 03 04 00 00
11 54
Data = 4436 messages
Scale = 1 message/bit
RENR8091-04
RS-232 Port 1 Transmitted Modbus-RTU Errors
An accumulator that indicates the number of
errors that have occurred while the PL1000E was
attempting to transmit a modbus message over
RS-232 Port 1. Transmitted errors can indicate
incorrect or faulty system wiring or incorrect baud
rate settings. The accumulator 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:
Request from Modbus Master 15 03 00 42 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
Data = 0 errors
Scale = 1 transmit error/bit
RS-232 Port 2 Received Modbus-RTU Messages
An accumulator that indicates the number of modbus
messages that have been successfully received on
RS-232 Port 2. Use this information as an indicator
of whether or not the PL1000E is receiving modbus
requests on RS-232 Port 2. 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:
Request from Modbus Master 15 03 00 46 00 02
Response from PL1000E Slave 15 03 04 00 50
1D 24
Data = 5,250,340 messages
Scale = 1 message/bit
51
Systems Operation Section
RS-232 Port 2 Received Modbus-RTU Errors
An accumulator that indicates the number of modbus
errors that have been received on RS-232 Port
2. Received errors can indicate incorrect or faulty
system wiring or incorrectly formatted modbus
messages that are being sent by another modbus
device. The accumulator 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:
Request from Modbus Master 15 03 00 48 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
Data = 0 errors
Scale = 1 error message/bit
RS-232 Port 2 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 2. 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:
Request from Modbus Master 15 03 00 4A 00 02
Response from PL1000E Slave 15 03 04 00 00
11 54
Data = 4436 messages
Scale = 1 message/bit
52
Systems Operation Section
RS-232 Port 2 Transmitted Modbus-RTU Errors
An accumulator that indicates the number of errors
that have occurred while the PL1000E was attempting
to transmit a modbus message over RS-232 Port 2.
Transmitted errors can indicate incorrect or faulty
system wiring or incorrect baud rate settings. The
accumulator 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:
Request from Modbus Master 15 03 00 4C 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
Request from Modbus Master 15 03 00 50 00 02
Response from PL1000E Slave 15 03 04 00 50
1D 24
Data = 5,250,340 messages
Scale = 1 message/bit
RENR8091-04
RS-422 and RS-485 Port 4 Received Modbus-RTU
Errors
An accumulator that indicates the number of modbus
errors that have been received on RS-422 and
RS-485 Port 4. Received errors can indicate incorrect
or faulty system wiring or incorrectly formatted
modbus messages that are being sent by another
modbus device. The accumulator 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:
Request from Modbus Master 15 03 00 52 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
Request from Modbus Master 15 03 00 54 00 02
Response from PL1000E Slave 15 03 04 00 00
11 54
Data = 4436 messages
Scale = 1 message/bit
RENR8091-04
RS-422 and RS-485 Port 4 Transmitted
Modbus-RTU Errors
An accumulator that indicates the number of
errors that have occurred while the PL1000E was
attempting to transmit a modbus message over
RS-422 and RS-485 Port 4. Transmitted errors can
indicate incorrect or faulty system wiring or incorrect
baud rate settings. The accumulator 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:
Request from Modbus Master 15 03 00 56 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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.
Sample Message:
Request from Modbus Master 15 03 00 5A 00 02
Response from PL1000E Slave 15 03 04 00 50
1D 24
Data = 5,250,340 messages
Scale = 1 message/bit
53
Systems Operation Section
Ethernet Received Modbus-TCP Errors
An accumulator that indicates the number of modbus
errors that have been received on the Ethernet
port. Received errors can indicate incorrect or faulty
system wiring or incorrectly formatted modbus
messages that are being sent by another modbus
device. 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:
Request from Modbus Master 15 03 00 5C 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
Request from Modbus Master 15 03 00 5E 00 02
Response from PL1000E Slave 15 03 04 00 00
11 54
Data = 4436 messages
Scale = 1 message/bit
54 RENR8091-04
Systems Operation Section

Ethernet Transmitted Modbus-TCP Errors
An accumulator that indicates the number of
errors that have occurred while the PL1000E was
attempting to transmit a modbus message over
the Ethernet port. Transmitted errors can indicate
incorrect or faulty system wiring or incorrect Ethernet
configuration. The accumulator 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:
Request from Modbus Master 15 03 00 60 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00
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:
The following example shows a configuration for a
parameter translation from three ECM's, that are
on Cat Data Link, to a Modbus Master that is
communicating with the PL1000E on RS-232 port 1.
The PL1000E is configured with a Modbus Slave at
address of 0x10 on RS232 Port 1.
Engine Controller (CDL address 0x24)
ICSM#1 (CDL address 0x6D)
ICSM#2 (CDL Address 0x6E)
To: Modbus Master on RS-232 Port 1
Note: The default Status Registers and the
Parameter Translation Registers are located at
different modbus slave addresses on the same
physical port. Refer to the Object - Modbus
ECM section that is located within the Parameter
Translation Configuration. The Object - Modbus
ECMsection contains information on assigning the
appropriate modbus slave address for Parameter
Translation Registers.
Sample Message:
Request from Modbus Master 15 03 00 C8 00 10
Response from PL1000E Slave 15 03 20 00 24 01
10 00 10 02 20 00 6D 01 10 00 10 02 20 00 6E 01
10 00 10 02 20 00 00 00 00 00 00 00 00

Request from Modbus Master 15 03 00 62 00 01 Data = Refer to Table 7

Response from PL1000E Slave 15 03 02 00 01
Data = 1 Modbus TCP Connection
Scale = 1 Modbus TCP Connection / bit
ECM Mapping

The ECM mapping registers contain a summary of

the parameter translation (PCL) file that is currently
loaded into the PL1000E. Each mapping contains:

A pair of ECM's, that is, a FROM ECM and a TO

ECM

The ECM type

The PL1000E port that is used to communicate to
the ECM

The ECM mapping modbus registers are capable of

containing a configuration summary for up to 15 pairs
of ECM's for a maximum total of 90 registers.
RENR8091-04 55
Systems Operation Section

Table 7
Translation Pair # 1
byte# data 00 24 01 10 (From ECM)
1-2 00 24 ECM Address (Engine Controller MID 0x24)
3 01 ECM Type (Cat Data Link ECM)
4 10 ECM Port (Cat Data Link Port)
byte# data 00 10 02 20 (To ECM)
5-6 00 10 ECM Address (Modbus Slave address 0x10)

7 02
ECM Type (Modbus ECM)
8 20 ECM Port (Modbus-RTU RS232 Port 1)
Translation Pair # 2
byte# data 00 6D 01 10 (From ECM)
9-10 00 6D ECM Address (ICSM#1 MID 0x6D)
11 01 ECM Type (Cat Data Link ECM)
12 10 ECM Port (Cat Data Link Port)
byte# data 00 10 02 20 (To ECM)
13-14 00 10 ECM Address (Modbus Slave address 0x10)
15 02 ECM Type (Modbus ECM)
16 20 ECM Port (Modbus-RTU RS232 Port 1)
Translation Pair # 3
byte# data 00 6E 01 10 (From ECM)
17-18 00 6E ECM Address (ICSM#2 MID 0x6E)
19 01 ECM Type (Cat Data Link ECM)
20 10 ECM Port (Cat Data Link Port)
byte# data 00 10 02 20 (To ECM)
21-22 00 10 ECM Address (Modbus Slave address 0x10)
23 02 ECM Type (Modbus ECM)
24 20 ECM Port (Modbus-RTU RS232 Port 1)
Remaining Bytes
byte# data 00 00 00 00 00 00 00 00 . . .
25-90 00 end of list of mapped ECMs

Note: All of the remaining registers that are requested
by the modbus master, that exceed the total number
of ECM mapping pairs, are set to zero.
ECM Mapping Fields - Valid Values
ECM Address
ECM Address - Any value in the range of 1 through
254. This value will represent either an ECM on
a datalink, or a Modbus Slave address that is
assigned to the PL1000E by the system integrator.
ECM Type - Refer to Table 8 for definitions of valid
values.

ECM Type ECM Port (of the PL1000E Communication

Module) - Refer to Table 9 for definitions of valid
ECM Port values.
56 RENR8091-04
Systems Operation Section

Table 8
ECM Type identifier PL1000E Port
0 J1939 ECM
1 Cat Data Link ECM
2 Modbus ECM

Table 9

ECM Port PL1000E Communications Port

identifier
01 CAN Port 1
10 Cat Data Link Port
20 Modbus-RTU RS-232 Port 1
21 Modbus-RTU RS-232 Port 2
23 Modbus-RTU RS-422 / RS-485
Port 4
30 Modbus-TCP Ethernet
g01720178
Illustration 68

i03340883 Events / Diagnostics

Embedded Web Server
SMCS Code: 7610
Using a standard web browser, navigate to the
PL1000E Communication ECM Home Page by
entering either the Internet Protocol (IP) address or
Host Name. The PL1000E Communication ECM
Home Page will be displayed.
Note: See this System Operation Troubleshooting
Testing and Adjusting, RENR8091, PL1000E
Communication ECM for information about the
configuration of the ECM and the PC for either direct
cross over connection or network connection.
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.

Available embedded web pages can be accessed

with the left navigation menu shown in Illustration 68.
The following sections explain each available web
page and the contents of the web pages.

g01717075
Illustration 69
Diagnostics
Events
RENR8091-04 57
Systems Operation Section

Internet Protocol Configuration

Refer to Illustration 72 for an example of an IP
Configuration screen that shows parameters that may
be customized for the application. The illustration
will also display the status of those parameters that
may need to be monitored for use in verification or
troubleshooting.

g01717145
Illustration 70

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:

Cat Data Link Illustration 72

g01720734

Internet Protocol MAC Address Assigned at manufacture time, this

value is read only and will be required by a network
Modbus administrator to properly set up the ECM on the
network.
Password
Host Name If Dynamic Host Configuration
Reset Protocol (DHCP) is enabled, the host name must be
programmed with a descriptive name of the PL1000E
device or its function in the system. Consult the
network administrator to determine the appropriate
Host Name for the device.

IP Address This field is only applicable if

DHCP is not enabled. If DHCP is disabled, then
a static IP address must be defined here. This is
also used when connecting a PC directly to the
ECM using a cross-over cable. See this System
Operation Troubleshooting Testing and Adjusting,
RENR8091-01, Explorer Gateway Service Manual
for details on connecting to this device directly using
a cross-over cable.

SubNet Mask If connecting to a network, contact

the network administrator for the appropriate
configuration of the SubNet Mask. If DHCP is not
enabled, this will be required for static IP addressing.

g01720181
Illustration 71
58
Systems Operation Section
Default Gateway IP Address If connecting to a
network, contact the network administrator for the
appropriate configuration of the Default Gateway IP
Address. If DHCP is not enabled, this will be required
for static IP addressing.
DHCP Dynamic Host Configuration Protocol is
a process by which a device on a network may
automatically obtain its IP address from a network
server when the device is powered on or when the
device is reconnected to the network. This process
enables the use of either the Host Name or assigned
IP address in a standard web browser to view the
device's embedded web pages. Consult with the
network administrator for proper configuration of the
DHCP enable function.
DHCP Results If DHCP is enabled and executed
successfully, the DHCP results will display the
assigned IP address, the assigned SubNet Mask,
the assigned Gateway, the assigned Hostname, and
the assigned Domain. If DHCP is enabled, then the
information that is typed into the fields above the
DHCP area is not in effect.
Modbus Configuration
g01717148
Illustration 73
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
All four Modbus locations may be configured at the
same time on a single PL1000E module, but no two
locations can be set for the same port at the same
time.
The default data link address is 254. The default data
link address is also referred to as the Device ID (5)
and (6) for all Modbus locations, including Modbus
TCP.
The Device ID (5) and (6) does not need to
be changed unless the system integrator has a
specific reason for changing the Device ID. All four
Modbus locations may use the same Device ID
because each must be on different physical ports.
The address, (5) and (6), is only used to access
the Default Status Registers of the PL1000E. The
Default Status Registers contain performance
statistics of the PL1000E.
The address, (5) and (6), is distinct from the address
that is used for the Device ID's that are used by the
ECM objects that are defined in the PCL file. The
address, (5) and (6), is distinct from the parameters
that are being translated. A Modbus Master device
or ECM uses the Modbus Slave addresses that
are defined in the PCL file in order to access the
parameters for the ECM objects that are defined in
the PCL file.
TCP
The PL1000E supports Modbus TCP over its
Ethernet port. Since this communication can only
be executed over the Ethernet port, there is no port
selection associated with this Modbus Configuration.
The PL1000E Modbus Slave Address configured
here is the Modbus Slave Address that should be
used by the Modbus Master to access the Default
Status Registers of the PL1000E.
Config 1 / Config 2 / Config 3
Address - The Device ID (5) and (6) on which the
Default Status Registers are provided.
Port - The PL1000E physical port (7) on which
this location will provide Modbus communications.
For example: if the PCL file specifies an ECM with
Modbus translations over RS-232 port 2, then one
of the Modbus locations must have RS-232 port 2
selected (7) for use by the ECM in the PCL file.
Baud - The baud rate at which the Modbus
communications should be processed for this
Modbus location and port (8). This setting must
match that of the Modbus Master and all other
Modbus devices on this network.
2 wire or 4 wire - The mode configuration must be
set for the RS-485.
RENR8091-04 59
Systems Operation Section

Cat Data Link Configuration
PL1000E Module ID (MID)
The PL1000E Communication Module can be
manually configured to occupy any one of three
distinct source addresses on the Cat Data Link.
This parameter indicates which of the three source
addresses the PL1000E should utilize. When multiple
PL1000E Communication Modules are connected to
the same Cat Data Link network, each must each be
configured with a unique source address.
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.
Note: A prompted will appear. The prompt will
request the current password.
3. Enter the current password.
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.
PL1000E Status Web Pages
These web pages display the same status information
that is available in the status screens of the service
tool and can be used for communication verification
and troubleshooting.

Note: CDL boost that is available for the PL1000E,

256-7512 Communications ECM (v4) that uses the
285-1138 ECM is enabled by grounding pin 7. Cat
ET and the web page will show a status parameter
that informs the user if CDL boost is enabled, or
disabled.

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.

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:
g01720755
Illustration 74
Access the status web pages using the left navigation
menu shown in Illustration 74. The following sections
explain the ECM Summary and ECM Mapping
screens and their contents.

1. In the Change Password screen enter the new

password in the New Password and Confirm
Password boxes.

2. Click on Submit.
60
Systems Operation Section
g01720774
Illustration 75
PL1000E Summary Screen
ECM Serial Number Hardware serial number of
the PL1000E Communication ECM. The ECM Serial
Number can be used in order to verify which ECM
web pages are being viewed when multiple PL1000E
devices are integrated into the same network.
Personality Module Description The text
description of the PL1000E Communication ECM as
it is identified in the service tool data base. This is the
same description seen on the ECM Summary screen
in the service tool.
Personality Module Part Number The Caterpillar
part number of the application flash file currently
programmed into the PL1000E Communication ECM.
Personality Module Release Date The month and
the year (last two digits) of the application software
flash file release.
ECM Part Number The Caterpillar part number of
the PL1000E Communication ECM.
ECM Lifetime Clock In earlier versions of software
this text was Service Meter Hours, but was later
changed to ECM Lifetime Clock. The ECM Lifetime TO
Clock is a more accurate name, as this hour counter
represents the total amount of time that the ECM has
had power applied. It is not the number of hours the
engine or system to which it is connected has been
operated.
RENR8091-04
g01720933
Illustration 76
ECM Mapping Screen
The ECM Mapping screen displays a tabular overview
of the ECMs that are programmed into the device for
parameter translations as defined in the PCL file. The
table is separated into two sections of three columns.
The ECM#, Type, and Port in each section combine
to describe an ECM in the translation. The group of
three columns on the left represent the From ECM,
and the group of three columns on the right represent
the To ECM. This From and To relationship describe
the ECMs and direction of data translation relative to
the communication ports and protocols.
FROM
ECM # - This is the ECM address defined in the
PCL file for this ECM object that the PL1000E
Communication ECM will use to request data from
the ECM.
Type The ECM Type as defined in the parameter
configuration list (PCL file).
Port The physical port of the PL1000E to which
this ECM is connected.
ECM # - This is the ECM address to which data
translations from the source ECM will be made
available.
Type The ECM type to which the data translations
for the source ECM will be made available.
Port The physical port of the PL1000E
Communication ECM to which data translations
from the source ECM will be made available.
RENR8091-04
Statistics
The PL1000E Communication ECM is capable of
tracking and displaying communication statistics that
indicate the level and presence of communications
for the various protocols and physical communication
ports the ECM supports.
g01402195
Illustration 77
To access the communication statistics pages, simply
expand the statistics menu by clicking on the symbol
to the left of Statistics. See Illustration 77. There are
three pages available under the Statistics sub menu.
The pages are: Physical, Modbus, and Protocol.
61
Systems Operation Section
Physical
g01720953
Illustration 78
The Physical Port Statistics page displays the total
number of bytes received, total number of bytes
transmitted, total number of receive errors, and
total number of transmit errors. This information
represents the communication statistics of the
physical port, and may include counts of bytes
received or transmitted from various protocols on the
same physical port.
The physical communication statistics is a good tool
to use to verify the PL1000E is capable of receiving
data at the most basic level. The communication
statistics on this page are automatically updated by
the PL1000E every one second. These totals are
the accumulated totals since the warm or cold boot
sequence of the PL1000E.
They are NOT lifetime totals and will be reset with
each boot sequence of the PL1000E. The Clear
Counters button simply forces these values to all
zeros without the need for a warm or cold boot. The
Clear Counters button is password protected.
Total Number of Bytes Received (Rx Bytes) The
total number of bytes successfully received on the
physical port. These byte counts may represent bytes
received across various protocols on the same port.
Total Number of Bytes Transmitted (Tx Bytes)
The total number of bytes successfully transmitted on
the physical port. These byte counts may represent
bytes transmitted across various protocols on the
same physical port.
62
Systems Operation Section
Total Number of Receive Errors (Rx Errors) The
total number of errors that have been identified by
the PL1000E while attempting to receive data on
the physical port. These errors can be caused by
incorrect baud rate or other port configurations. The
lack of receive errors does not necessarily indicate
that protocol communications are successful. It
simply indicates that all individual bytes are being
received successfully. Successful communications
still depends on the communication protocols and the
transmitting devices adherence to the same.
Total Number of Transmit Errors (Tx Errors)
The total number of errors that have been identified
by the PL1000E while attempting to transmit data
on the physical port. These errors can be caused by
incorrect baud rate and other port configurations,
faulty wiring, or incorrect ECM configuration. The
lack of transmit errors does not necessarily indicate
that protocol communications are successful.
It simply indicates that the PL1000E is able to
successfully transmit the individual bytes. Successful
communications still depends on the communication
protocols and the receiving device's adherence to
the same.
Modbus
The Modbus communication statistics page displays
the Total Number of Messages Received, Total
Number of Messages Transmitted, Total Number
of Receive Errors, Total Number of Exceptions
Transmitted, Total Number of Transmit No Response
Occurrences, and Total Number of Connections (only
applicable to Modbus-TCP). These totals represent
the total accumulations since the last warm or cold
boot sequence of the ECM. These are NOT lifetime
totals.
g01720993
Illustration 79
RENR8091-04
Total Number of Messages Received (Rx
Messages) The total number of valid properly
formatted Modbus messages successfully received
on the communications port.
Total Number of Messages Transmitted (Tx
Messages) The total number of messages
successfully transmitted by the PL1000E on the
communications port.
Total Number of Receive Errors (Rx Errors) The
total number of errors identified by the PL1000E
while attempting to receive Modbus messages on the
communications port. These errors can be caused
by incorrectly formatted messages being transmitted
by the Modbus Master or another Modbus Slave
connected to the communications port.
Total Number of Exceptions Transmitted (Tx
Exceptions) The total number of exception
messages successfully transmitted by the PL1000E
on the communications port. The PL1000E generates
exceptions in response to requests for invalid Modbus
registers or unsupported Modbus Function Codes.
Total Number of Transmit No Response
Occurrences (Tx No Rsp) Every time the
PL1000E receives a valid properly formatted Modbus
message, the ECM increments this counter. Each
time the PL1000E transmits a Modbus Message,
the ECM decrements this counter. The increment
and decrement actions occur within milliseconds
and are typically not viewable on the web page.
However, if this value is other than zero it indicates
the PL1000E is receiving Modbus messages and not
responding. The PL1000E configuration should be
verified and the PCL file should be reviewed to insure
the desired parameters and Modbus communications
are configured appropriately.
Total Number of Connections (Connections)
The total number of active Modbus TCP connections
identified and being serviced by the PL1000E on the
Ethernet port. The PL1000E is capable of supporting
up to ten Modbus TCP connections at the same time.
Protocol
This statistics page displays the communication
information for all other protocols supported by the
PL1000E. This page displays the Total Number of
Messages Received,, Total Number of Messages
Transmitted, Total Number of Receive Errors, Total
Number of Transmit Errors, Total Number of No
Response Occurrences, and Total Number of Web
Connections (only applicable to the Web Protocol).
These totals represent the total accumulations since
the last warm or cold boot sequence of the PL1000E.
These are NOT lifetime totals.
RENR8091-04 63
Systems Operation Section

i03341123

Custom Web Page

SMCS Code: 7610

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.

g01721055
Illustration 80

Total Number of Messages Received (Rx

Messages) The total number of valid properly
formatted messages received by the PL1000E for the
given protocol. This total does not indicate that the
message contained valid data, but rather indicates
the number of messages received that satisfied the
requirements of the communications protocol. The
data requested or transmitted may or may not be
supported by the receiving ECM.

Total Number of Messages Transmitted (Tx

Messages) The total number of messages
successfully transmitted by the PL1000E for the
given protocol. This total does not indicate that the
message contained valid data, but rather indicates
the number of messages transmitted that satisfied
the requirements of the communications protocol.
The data requested or transmitted may or may not be
supported by the receiving ECM.

Total Number of Receive Errors (Rx Errors)

The total number of errors detected by the PL1000E
while attempting to receive a message for the given
protocol. These errors can be caused by incorrectly
formatted messages or baud rate and other port
configurations for the port over which the protocol
is being communicated.

Total Number of Transmit Errors (Tx Errors) The

total number of errors detected by the PL1000E while
attempting to transmit a message for the relative
protocol. These errors can be caused by excessive
data link loading and faulty/incorrect harnessing.
64 RENR8091-04
Systems Operation Section

g01214643
Illustration 81

The PCL file contains configurations that translate Creating Custom XML Pages
parameters in a web-based solution. The XML
custom page file consists of a select group of Custom Pages allow user-selected parameters to be
parameters to monitor and view together gathered monitored through a web browser. A Custom Page
from the larger list in the PCL file. The XML, XSL, is configured using an XML file that is published to
and CSS files are read by the browser to provide the the PL1000E Web Server.
user with the view of their data.
To create a custom page:
Understanding the XSL File 1. Copy the CSPL1000E_Custom_Page.xml
template. The template is located on the CD that
The XSL file is a stylesheet for the XML file. The .XSL
was included with the ECM to a PC with a text
file calls the CSS file to use for the web page, places
elements on the page, and associates error strings editor.
with certain values gathered from the ECM.
Throughout this section of the document, there
The style sheet must be indicated in the XML file. The are references to a Parameter Translation Editor
(PTE) .
style sheet controls the format of the data as it will be
displayed on the page. The programmer associates
an XML file with a specific XSL file in the .xsl?> tag
with the filename for the XSL file.

Note: Refer to Illustration 82. The preceeding

paragraph is referring to line 2, href=
ParameterGroup.xls?>, that is, the style
sheet file name.

The XSL file does NOT provide formatting such as

italics, bold, or other visual formatting. The XSL file
calls out a CSS file to provide that formatting for the
XML page.

The .XSL file contains a series of If-Then type

statements written in XSL language. Each of
theseIf-Then statements associates a given value
returned from an ECM with an error string. The .XSL
file also contains code that configures the structure
and formatting for numbers and text.
RENR8091-04 65
Systems Operation Section

g01721356
Illustration 82
66 RENR8091-04
Systems Operation Section

g01717224
Illustration 83

2. Modify the information contained in the appropriate

XML tags to include the data to monitor.

Only the parameters defined in a web translation

object in the PCL file are available for display on
the Custom Pages.

Table 10 contains a detailed description of the

XML tags that are shown in Illustration 82 and
that are used in the web page. Each XML tag
described in Table 10 is the source of a different
part of the web page. Refer to Illustration 83. The
call outs in Illustration 83 show each area of the
web page that is rendered from each XML.
RENR8091-04 67
Systems Operation Section

Table 10
Number Tag Name Description
Contains the Custom Page title (see Illustration 83). Unique titles for custom pages
1 <Title>
allow better organization when analyzing larger or more complex systems.
Each parameter is represented by an item element containing the attributes of that
2 <Item>
parameter.
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
3 <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.
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
4 <ECMUID>
ECM object in the Manual Parameter Configuration List Creation section to identify
the ECM ID.
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
5 ECM Description 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.
Contains a label chosen by the user to describe the parameter that is to be
monitored. This description is free form text and can be customized to clearly
6 UID Description
describe the parameter being displayed. It may be helpful to identify this Parameter
with the same description as viewed in the PCL file creation, but it is not necessary.
The value of the parameter being monitored. The OSEFUNC tag is formatted as:
7 Value /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
8 Decimals The number of decimal places to apply to the value of the parameter to be monitored.
9 Unit The units of measure used for the parameter to be monitored.
10 Type Always set to Zero.

3. Save the file in a text-only format with the filename

CS<name>.xml where <name> is the name of
the file.

Note: The filename must always begin with CS.

For example, a correctly formatted filename could be
CSPL1000ECustomPage.xml.

4. Publish the custom page XML file to the PL1000E

web server in the /status/user/ folder using
FTP. See System Operation, RENR8091, LAN
Network Ethernet Connection.

g01721400
Illustration 84

5. Verify file exists on the server and is correct by

browsing to the page using any standard web
browser.
68
Systems Operation Section
Note: If the page does not appear to reflect the
changes, force the browser to execute a refresh. If
the page still does not appear to reflect the changes,
then close the browser and start the browser again.
Viewing Custom XML Pages Using
a Browser
A list of Custom Pages on a PL1000E server
will appear under the Custom Pages tab on the
navigation menu for the specific server.
Perform the following in order to view the list of
Custom Pages:
1. Click the Custom Pages tab on the navigation
menu.
2. Click the link in the navigation menu or the link on
the Custom Pages web page to view the desired
Custom Page.
g01721413
Illustration 85
g01721414
Illustration 86
3. The web browser displays the Custom Page as
shown in Illustration 86. Each of the parameters
used in the XML file will be listed with the
appropriate characteristics.
RENR8091-04
Note: If parameters used in the XML file do not
appear on the page, make sure that the parameters
were added to the web translation object in the PTE
when the PCL file associated with the page was
created.
i02836787
Modbus Master
SMCS Code: 7610
Limited Modbus Master
The PL1000E can act as a Modbus Master in a
limited fashion. As a Modbus Master, the features
of the PL1000E are limited to translating data from
CDL or J1939 to Modbus. The PL1000E cannot act
as a full Modbus Master.
Considerations for Designing a Robust
System
Modbus is a Point-to-Point protocol. Therefore, the
PL1000E will send a request message on Modbus
and then will wait for a response. In a Point-to-Point
protocol system that operates properly, the process
to send a request and wait for a response is not an
issue. If the PL1000E does not receive a response,
the PL1000E will wait for 250ms, and then move on
to the next request. If some slaves do not respond to
the requests of the PL1000E, then system operation
will slow due to the wasted time. If this happens
with too many messages, then the data may not be
received in a timely fashion.
There is another issue that must be considered with
the Point-to-Point protocol. If too many parameters
are being requested within a given time period, there
is possibility that the transmit buffer on the PL1000E
may become full. If the transmit buffer becomes
full, then transmit messages may be dropped. The
equation below is a guideline in order to determine
the load on the Modbus Link. The equation calculates
the total time the system takes to send one request
and receive one response.
RENR8091-04 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.

Modbus Load Equation Example

The following values are used in order to provide an

example of how to use the equation.

The PL1000E has been configured to request 10

registers at rate of 500ms.

The PL1000E has been configured for a baud rate

of 9,600 bps.

The PL1000E can only request one register at

a time, so the total length of a Modbus request
message is 7 bytes, which is equal to 56 bits.

Since the PL1000E can only request one register

at a time as a Master. The response is a total of 6
bytes, which is equal to 48 bits.

The PL1000E is close to the Modbus slave that the

PL1000E is requesting information from, therefore,
for this example, the propagation time is 0

The response from the Modbus slave takes 100ms.

The equation would look like this:

g01412389
Illustration 88

The total time that is required in order to send one In summary, make sure that the system design
request and receive one response from the system is makes sense. Make sure that high request rates of
110.8ms. In theory you should be able to request 9 the data do not say rates of speed because they
messages per second. In the example, 20 requests a are the inverse of each other.
second are being sent to the transmit buffer, but only
9 messages per second can be sent out. The buffer
for the PL1000E will eventually become full because
the amount of messages that are being queued per
second is more than what is being sent out.
70 RENR8091-04
Systems Operation Section

Configuring the PL1000E as a Modbus

Master
The Table 11 shows what the translation lines mean
for the PL1000E as a Slave, and compares those to
the PL1000E as a Master.

Table 11
Translation PL1000E as Modbus Slave PL1000 as Modbus Master
The PL1000E requests data on CDL and holds PL1000E requests data on CDL, then writes
CDL to Modbus the data in a Modbus register waiting for a the data to a Modbus Slave.
register request from a Modbus Master
The PL1000E waits for data to be written to it
Modbus to CDL from a Modbus Master, then the PL1000E Not Supported
writes the informationon CDL.
The PL1000E requests data on J1939 and The PL1000E requests data on J1939 and
J1939 to Modbus holds the data in a Modbus register waiting for writes the data in a Modbus Slave.
a register request from a Modbus Master.
The PL1000E waits for data to be written PL1000E requests information from a Modbus
Modbus to J1939 to it from a Modbus master, then writes the slave, then the PL1000E writes the information
information on J1939. on J1939.
The PL1000E requests data on CDL, then
CDL to Webserver Not Supported
pases the data to the webserver.
The PL1000E requests data on J1939, then
J1939 to Webserver Not Supported
pases the data to the webserver.

The steps to configure the PL1000E as a Modbus i03346182

Master are very similar to those to a Modbus Slave.
The steps are as follows:
1. Develop a system block diagram. Refer to the
Quick Start Guide section of this document.
2. Obtain information on all the ECMs that are on the
data link, Modbus, CDL, and J1939. Refer to the
Quick Start Guide section of this document.
3. Configure the PL1000E so it can be accessed with
the Ethernet port. refer to the ECM Configuration,
LAN Network Ethernet Connection, or the Direct
Crossover Ethernet Connection section of this
manual.
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.

4. Configure the serial ports that are on the PL1000E. 2. Click Programs.

5. Develop a PCL file. Refer to the Features 3. Click Accessories.

section and the Quick Start Guide section of this
document for Modbus Master and Modbus Slave 4. Click Calculator.
information. In the Quick Start Guide section,
refer to the Prepare the PCL File section. The 5. From the View menu, select Scientific. Refer to
Modbus Slave section may also provide useful Illustration 89.
information.

6. Upload the PCL file.

7. Test the system in order to ensure proper

communications.
RENR8091-04 71
Systems Operation Section

g01747434 g01721454
Illustration 89 Illustration 91

6. Select Hex and Qword under the data entry

window.

7. Enter the hexidecimal number that is to be

converted. Refer to Illustration .

8. Select Dec and Degrees under the data entry

window.

g01721453
Illustration 90
72
Troubleshooting Section
Troubleshooting Section
Introduction
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.
i03341900
Service Tools
SMCS Code: 0785
The recommended Caterpillar service tools listed in
Table 12 are required in order to enable a service
technician to perform the procedures.
RENR8091-04
Table 12
Required Service Tools
Part Description
Number
Laptop Computer
JERD2124 Caterpillar Electronic Technician (CAT
ET) Version 2004B or later (optional)(1)
JERD2129 Date Subscription for all engines
171-4400 Communication Adapter Gp (CAT ET to
ECM interface) (optional)(2)
237-7547 Adapter Cable As.(3)
9U-7330 Digital Multimeter
7X-1710 Multimeter Probe
1U-5804 Crimp Tool (12-AWG TO 18-AWG)
175-3700 Connector Repair Kit (DT)
Two short jumper wires(4)
Long extension wire(5)
4 mm (hex) key
(1) Caterpillar Communications Tool Kit version 2005A or later
may also be used.
(2) The 7X-1700 Communication Adapter Gp or the PL1000E
Communication ECM's embedded communication adapter
may also be used.
(3) The 237-7547 Adapter Cable As. is required to adapt the
Communication Adapter's RS-232 serial cable (196-0055)
to the USB port on computers that are not equipped with a
RS-232 serial port.
(4) Two short jumper wires are needed to check the continuity of
some wiring harness circuits by shorting two adjacent terminals
together in a connector.
(5) A long extension wire may also be needed to check the
continuity of some wiring harness circuits.
Note: Due to all the new features of the PL1000E,
the PL1000E requires the use of Caterpillar
Communication Toolkit or Caterpillar Electronic
Technician that is version 2007B or newer.
Troubleshooting Software
The Cat ET Service Tool or Caterpillar
Communications Tool Kit is used to connect,
configure, and monitor the PL1000E Communication
Module. Information related to operation
of the Cat ET can be found online at
https://productsupportglobalcontent.cat.com.
The PL1000E Communication Module requires
version 2007B or later of the Cat ET and version
2007B or later of the Caterpillar Communications
Tool Kit.
The Caterpillar Communications Tool Kit provides
customer level access to information on the data link.
Table 13 lists and compares the information access
capabilities of these two service tools.
RENR8091-04 73
Troubleshooting Section

Table 13
Service Tool Capability
Service Tool Feature Caterpillar Electronic Technician Caterpillar Communication Tool Kit
PL1000E ECM Summary Yes Yes
PL1000E ECM Configuration Yes Yes
PL1000E ECM Status Yes Yes
PL1000E ECM Totals Yes Yes

All other ECM Summary Yes Yes

All other ECM Configuration Yes No
All other ECM Status Yes No
All other ECM Totals Yes No

All ECM Events Yes No

All ECM Diagnostics Yes No

Flash New ECM Software Yes No

Perform Calibrations Yes No

When service tool is started, service tool will attempt

to identify modules on the target data link. All
identified devices are displayed in a selection dialog
box by the service tool.

If the Embedded Communication Adapter of the

PL1000E is used for the service tool connection,
ensure the preference settings in the service tool are
correctly set . Refer to Illustrations 92, 93, and 94 for
the correct settings.

g01721458
Illustration 93

Note: In Cat ET versions prior to 2005A, this product

is identified as Gateway Translator. For the purpose
of the screen illustrations in this manual, the terms
Gateway Translator and PL1000E refer to the same
device.

g01721457
Illustration 92

After Caterpillar Embedded Communication

Adapter is selected, click on the Advanced button in
order to access the Baud Rate setting options.
74 RENR8091-04
Troubleshooting Section

Connecting Cat ET and the

Communications Adapter

g01721459
Illustration 94

Select PL1000E as shown in Illustration 94 and

click the OK button. Cat ET will then display the
ECM Summary screen. The ECM Summary screen
displays the following PL1000E Communication
Module information:

ECM Serial Number

Personality Module part number
Personality Module description
Personality Module release date
g01132698
ECM part number Illustration 95
Communication Gps
Refer to the System Operation/Test and Adjust, (1) Personal computer (PC)
RENR8091, Electronic Control Module (ECM) - (2) Custom built PL1000E Communication ECM service cable
Configure for more information. (optional)
(3) 196-0055 Serial Cable
(4) 171-4401 Communication Adapter As
(5) 207-6845 Adapter Cable As (Data Link)
(6) Connects to RS-232 Serial Port 3 of PL1000E Communication
ECM

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
2. Connect cable (3) between the Computer end of
communication adapter (4) and the RS-232 serial
port of PC (1).
Note: A 237-7547 Adapter Cable As. is required to
adapt the cable (3) to the USB port on computers
that are not equipped with a RS-232 serial port.
3. Connect cable (5) between the Data Link end of
the communication adapter (4) and the service
tool connector.
4. Turn the engine key switch to the ON position,
then start the Cat ET. The Cat ET will initiate
communications with the electronic control
modules on the engine. The Cat ET will list
the available electronic control modules on the
engine after communication has been established.
If Cat ET and the communication adapter
do not communicate with the ECM, refer to
Troubleshooting, RENR8091, Problem - CAT ET
unable to detect any electronic control modules.
Embedded Communications Adapter
The Embedded Communications Adapter (ECA)
functionality is always enabled and always available
for physical connection on serial port number 3. Cat
ET preferences must be modified to identify the ECA
as the interface hardware. In order to modify the
Cat ET preferences select Tools/Preferences from
the menu. After the Preferences screen appears,
click on the Advanced the button. Select Embedded
Communications Adapter from the available list
of communication adapters. Refer to Systems
Operation, RENR8091, Service Tool.
i02809396
Connector Locations
SMCS Code: 7553-546-WW
The location of the service tool connector will vary
between applications. Cat ET can be connected to
the system as follows:
By using the 7X-1700 Comm Adapter
By using the 171-4400 Comm Adapter II
Through the embedded com adapter within the
PL1000E Communication ECM (pins 62, 63, and
64). In order to use the embedded communications
adapter, a custom built service cable must be
connected between the RS-232 port of the PC and
the RS-232 Serial Port 3 of the PL1000E.
Refer to the Electrical System Schematic section
of this document in order to locate the service tool
connector for a specific application.
75
Troubleshooting Section
i03346200
Diagnostic Capabilities
SMCS Code: 7610
The Caterpillar Electronic
Technician (ET)
The Caterpillar Electronic Technician (ET) is a
software program that can be used on an IBM
compatible personal computer. Cat ET is used to
communicate to, and access data from the ECM
over the data link by connecting to the service tool
connector. Refer to the Electrical System Schematic
section of this document in order to locate the service
tool connector for a specific application.
The service technician can use Cat ET in order to
perform maintenance work on the engine. Some of
the options that are available with Cat ET are listed
below:
View the status of parameters
Perform calibration of engine systems
Program the ECM (Flash)
Print reports
Note: In order to Flash program the ECM, use the
WINflash program. Refer to the Electronic Control
Module (ECM) - Flash Program section of this
document for information about the process to flash
program the ECM.
The following list contains some of the diagnostic
functions and programming functions that are
performed by the service tools.
The failures of the ECM system are displayed.
The status of most of the inputs and the outputs
are displayed.
The settings for the ECM are displayed.
Display the status of the input and output
parameters in real time.
Display the clock hour of the internal diagnostic
clock.
Load new FLASH software.
76
Troubleshooting Section
Status Groups For The Electronic
Technician
Cat ET is used as the primary reference in the
discussion and Illustrations that follow. The reference
to the Cat ET also implies a reference to the
Caterpillar Communication Tool Kit when features are
common between the two.
Status Group 1 - Serial Port Statistics
g01397803
Illustration 96
Serial Port Statistics screens 1 and 2
The PL1000E tracks the communications on
its physical ports. The PL1000E displays the
communications statistics on the Cat ET Serial Port
Statistics screens. The first of the screens displays
the communication statistics for serial ports 1, 2, and
3, that is, RS-232 Port 1, RS-232 Port 2, and RS-232
Port 3 respectively.
RENR8091-04
The second of these screens displays the
communication statistics for serial port 4 which is
the RS-422 and 485 port. For each serial port, the
physical layer bytes that are received, physical
layer bytes that are transmitted, the physical layer
receive errors, and the physical layer transmit errors
are displayed. This information represents the
communication statistics of the physical port and may
include counts of bytes received or transmitted from
various protocols on the same physical port. The
physical communication statistics is a good tool to
use to verify the ECM is successfully receiving data
at the most basic level. The communication statistics
on this page are automatically updated by the ECM
every 1 second. These totals are the accumulated
totals since the last warm boot sequence or cold
boot sequence of the ECM (Keyswitch or power
cycle). These totals are not Lifetime totals and will
be reset with each boot sequence of the ECM. The
Clear Counters button (password protected) simply
forces these values to all zeros without the need for a
warm boot or cold boot.
Physical Layer Bytes Received (Rx Bytes) The
total number of bytes successfully received on the
physical port. These byte counts may represent bytes
received across various protocols on the same port.
Physical Layer Bytes Transmitted (Tx Bytes)
The total number of bytes successfully transmitted on
the physical port. These byte counts may represent
bytes transmitted across various protocols on the
same physical port.
Physical Layer Receive Errors (Rx Errors) The
total number of errors that have been identified
by the ECM while attempting to receive data on
the physical port. These errors can be caused by
incorrect baud rate or other port configurations. The
lack of receive errors does not necessarily indicate
that protocol communications are successful. It
simply indicates that all individual bytes are being
received successfully. Successful communications
still depends on the communication protocols and the
transmitting device's adherence to the same.
Physical Layer Transmit Errors (Tx Errors)
The total number of errors that have been identified
by the ECM while attempting to transmit data on
the physical port. These errors can be caused by
incorrect baud rate and other port configurations,
faulty wiring, or incorrect ECM configuration. The lack
of transmit errors does not necessarily indicate that
protocol communications are successful. It simply
indicates that the ECM is able to successfully transmit
the individual bytes. Successful communications still
depend on the communication protocols and the
receiving device's adherence to the same.
RENR8091-04
Status Group 2- Modbus Statistics
g01397805
Illustration 97
Modbus Statistics screens 1 and 2
The PL1000E tracks all Modbus communications on
all configured ports and displays the communication
statistics on the Cat ET Modbus Statistics screens.
The first of these screens displays the communication
statistics for Serial Port 1 (RS-232 Port 1) and
Serial Port 2 (RS-232 Port 2).
The second of these screens displays the
communication statistics for Serial Port 4
(RS-422/485). The third displays communication
statistics for Modbus TCP over the Ethernet port.
All of the totals that are displayed on these screens
represent the total accumulations since the last
warm boot sequence or cold boot sequence of
the ECM. The totals are not lifetime totals and will be
reset with each warm boot sequence of the ECM.
Modbus RTU Messages Received The
total number of valid, properly formatted
Modbus messages successfully received on the
communications port.
77
Troubleshooting Section
Modbus RTU Receive Errors The total number
of errors identified by the ECM while attempting to
receive Modbus messages on the communications
port. These errors can be caused by incorrectly
formatted messages being transmitted by the
Modbus Master or another Modbus Slave
connected to the communications port. Additionally,
these errors may be caused by requests for registers
or Modbus Function Code not supported by the
ECM.
Modbus RTU Messages Transmitted The total
number of messages successfully transmitted by the
ECM on the communications port.
Modbus RTU Transmit Errors The total number
of errors identified by the ECM while attempting to
transmit Modbus messages on the communications
port.
Modbus RTU no response Every time the
ECM receives a valid properly formatted Modbus
message, the ECM increments this counter. Each
time the ECM transmits a Modbus Message, the
ECM decrements this counter. The increment and
decrement actions occur within milliseconds and
are typically not viewable on the status screen.
However, if this value is other than zero, this would
indicate the ECM is receiving Modbus messages and
not responding. The ECM configuration should be
verified and the PCL file should be reviewed to insure
the desired parameters and Modbus communications
are configured appropriately.
g01721473
Illustration 98
Modbus Statistics screen 3
Modbus TCP packets received The total number
of valid properly formatted Modbus TCP packets
successfully received by the PL1000E over the
Ethernet port.
78
Troubleshooting Section
Modbus TCP Receive Errors The total number
of errors identified by the ECM while attempting to
receive Modbus TCP packets on the Ethernet port.
These errors can be caused by incorrectly formatted
messages being transmitted by the Modbus Master
or another Modbus Slave connected to the Ethernet
port. Additionally, these errors may be caused by
requests for registers or Modbus Function code not
supported by the ECM.
Modbus TCP packets transmitted The total
number of Modbus TCP packets successfully
transmitted by the ECM on the Ethernet port.
Modbus TCP transmit errors The total number
of errors identified by the ECM while attempting to
transmit Modbus messages on the communications
port.
Modbus TCP no responses Every time the
ECM receives a valid, properly formatted Modbus
message, the ECM increments this counter. Each
time the ECM transmits a Modbus message, the
ECM decrements this counter. The increment and
decrement actions occur within milliseconds and
are typically not viewable on the status screen.
However, if this value is other than zero this would
indicate the ECM is receiving Modbus messages
and not responding. The ECM configuration should
be verified and the PCL file should be reviewed in
order to insure the desired parameters and Modbus
communications are configured appropriately.
Modbus TCP connections The total number of
Active Modbus TCP connections identified and
being serviced by the ECM on the Ethernet port. The
ECM is capable of supporting up to 10 Modbus TCP
connections at the same time.
Modbus RTU packets received The total number
of RTU messages received successfully by the ECM.
These totals represent all Modbus RTU messages
received on all configured Modbus ports. The ports
are RS-232 Port 1, RS-232 Port 2, and the
RS-422/485 Port. The ECM does not include any
message counts from Modbus TCP messages
received that are on the Ethernet port.
Modbus RTU receive errors The total number
of Modbus RTU messages received by the
ECM determined to contain incorrect checksum
information. These totals represent all Modbus RTU
receive errors received on all configured Modbus
ports. The ports are RS-232 Port 1, RS-232 Port
2, and the RS-422/485 Port. The ECM does not
include any message counts from Modbus TCP
receive errors received on the Ethernet port.
RENR8091-04
Modbus RTU packets transmitted The total
number of Modbus RTU messages transmitted
successfully by the ECM. These totals represent
all Modbus RTU messages transmitted on all
configured Modbus ports. The ports are RS-232
Port 1, RS-232 Port 2, and the RS-422/485 Port.
The ECM does not include any message counts
from Modbus TCP messages transmitted on the
Ethernet port.
Modbus RTU transmit errors The total number
of Modbus RTU exception messages transmitted
by the ECM. These totals represent all Modbus
RTU exception messages that are transmitted on
all configured Modbus ports. The ports are RS-232
Port 1, RS-232 Port 2, and the RS-422/485 Port.
The ECM does not include any message counts
from Modbus TCP exception messages transmitted
on the Ethernet port. An exception message will be
transmitted under the following conditions:
The ECM receives a Modbus function code it
does not support. The ECM supports the following
function codes: 3 = Read Holding Register, 6 =
Write Single Register, 8 = Diagnostics, 16 =
Write Multiple Registers.
The ECM receives a Modbus request for a register
outside of the supported register ranges. The ECM
supports registers in the range of 40,001 to 42000.
Modbus RTU no responses The total number
of Modbus RTU messages received successfully
by the ECM for which the ECM has not transmitted
a response. These totals represent all Modbus no
responses on all configured Modbus ports. The
ports are RS-232 Port 1, RS-232 Port 2, and the
RS-422/485 Port.
RENR8091-04
Status Group 3- Cat Data Link (CDL) Statistics
g01721475
Illustration 99
CDL Statistics screen.
CDL packets received The total number of
valid properly formatted messages successfully
received on Cat Data Link (CDL) by the PL1000E
Communication ECM.
CDL receive errors The total number of errors
identified by the ECM while attempting to receive
a CDL message. An increment of this number can
indicate improper CDL harnessing. CDL harness
pin-outs and total bus length should be analyzed.
CDL packets transmitted The total number of
messages successfully transmitted on CDL by the
ECM.
CDL transmit errors The total number of errors
identified by the ECM while attempting to transmit
a CDL message. An increment of this number can
indicate improper CDL harnessing. The harness
should be analyzed and repaired.
79
Troubleshooting Section
Status Group 3- J1939 Statistics
g01721476
Illustration 100
J1939 Statistics screen.
J1939 packets received The total number of valid
properly formatted messages successfully received
on J1939 by the PL1000E Communication ECM.
J1939 receive errors The total number of errors
identified by the ECM while attempting to receive a
J1939 message. An increment of this number can
indicate improper J1939 harnessing. J1939 harness
pin-outs and total bus length should be analyzed.
J1939 packets transmitted The total number of
messages successfully transmitted on J1939 by the
ECM.
J1939 transmit errors The total number of errors
identified by the ECM while attempting to transmit a
J1939 message. An increment of this number can
indicate improper J1939 harnessing. The harness
should be analyzed and repaired.
80 RENR8091-04
Troubleshooting Section

Messaging Statistics Quick Reference

Troubleshooting Guide

g01180273
Illustration 101
RENR8091-04
Symptom Procedures
i03341884
Operational Problems
SMCS Code: 7610-035
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.
81
Troubleshooting Section
Problem - Unable to Browse to the
PL1000E Home Page Direct - Cross Over
Connection
Probable Cause
1. Use Cat ET in order to confirm the Internet Protocol
configuration. Confirm that the IP settings are set
appropriately for direct cross over connections.
Refer to the System Operation Troubleshooting
Testing and Adjusting, RENR8091, Internet
Protocol Configuration section in order to help
determine the appropriate settings.
2. Confirm that the cable being used is a cross over
cable.
3. Confirm the PC settings. Refer to the Configuring
a Non-networked Windows-based PC to Access
the PL1000E Communication Module section.
Any deviation from the required settings may
prevent browser access to the PL1000E
Communication ECM embedded web pages.
4. 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,
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.
Problem - Unable to Establish
FTP Connection with the PL1000E
Communication ECM
Probable Cause
1. Confirm the ability to browse the embedded web
pages using a browser. If unable to browse the
embedded web pages, refer to the LAN Network
Ethernet Connection or the Loading the PCL file
Using FTP or DOS sections of this manual.
2. Confirm proper log on to the FTP server. Refer
to the Loading the PCL file Using FTP or DOS
section of this manual to review the procedure to
log in to FTP server.
82 RENR8091-04
Troubleshooting Section

3. Attempt to establish an FTP connection to the

ECM using the DOS shell FTP feature that is
covered in the , DOS FTP Session with the
PL1000E Communication ECM using a command
Prompt section of this manual. Some browsers
and graphical FTP programs manage FTP
connections differently. Some browsers and
graphical FTP programs may not be compatible
with the PL1000E. FTP using DOS will always be
compatible with the PL1000E.

Problem - PCL file not moved from "New"

folder to "Current" folder
Probable Cause

1. Using a standard web browser, connect to the

PL1000E Communication ECM and browse to the
ECM mapping page. On the ECM Mapping web
page will be displayed any known errors or issues
with the PCL file. There are several things that
can prevent proper processing of the PCL file.
The table below shows the potential errors that
can be displayed there as well as the remedy to
repair the problem.
RENR8091-04
Log_Status.txt errors and the associated
remedies
Table 14
Error
Status: Reset Configuration Parameters
to Default
Status: Rolling Reset counter reset
ERROR: Port conflict MODBUS CFG 1
with Modbus CFG 2 on RS-232-1
ERROR: Port conflict MODBUS CFG 1
with Modbus CFG 3 on RS-232-1
ERROR: Port conflict MODBUS CFG 2
with Modbus CFG 3 on RS-232-1
ERROR: Port conflict MODBUS CFG 1
with Modbus CFG 2 on RS-232-2
ERROR: Port conflict MODBUS CFG 1
with Modbus CFG 3 on RS-232-2
ERROR: Port conflict MODBUS CFG 2
with Modbus CFG 3 on RS-232-2
ERROR: Port conflict MODBUS CFG 1
with Modbus CFG 2 on RS-422/RS-485
ERROR: Port conflict MODBUS CFG 2
with Modbus CFG 3 on RS-422/RS-485
ERROR: Port conflict MODBUS CFG 1
with Modbus CFG 3 on RS-422/RS-485
Probable Cause
Module is in reset due to invalid
configuration parameter. ex: invalid
network mask caused a rolling reset
The PCL file is of an incompatible format
or there is an invalid configuration
parameter causing the reset condition.
Modbus Configuration 1 is configured for
the same port as Modbus Configuration
2.
Modbus Configuration 1 is configured for
the same port as Modbus Configuration
3.
Modbus Configuration 2 is configured for
the same port as Modbus Configuration
3.
Modbus Configuration 1 is configured for
the same port as Modbus Configuration
2.
Modbus Configuration 1 is configured for
the same port as Modbus Configuration
3.
Modbus Configuration 2 is configured for
the same port as Modbus Configuration
3.
Modbus Configuration 1 is configured for
the same port as Modbus Configuration
2.
Modbus Configuration 1 is configured for
the same port as Modbus Configuration
3.
Modbus Configuration 2 is configured for
the same port as Modbus Configuration
3.
83
Troubleshooting Section
Remedy
Review log_config.txt file in Error
directory. An invalid configuration
parameter value has been entered and
should be corrected.
Use the Parameter Transltion Editor
to re-create the PCL file and review
the configuration parameters for any
invalid data.
Select a different port for one of the
conflicting modbus configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
Select a different port for one of the
conflicting modbus Configurations
84
Troubleshooting Section
Table 15
Error
Error: Rolling Reset
315-0627 Communication Software
Group and earlier software
Application Started
Error: Creating File : log_config.txt
Error initializing TCP socket
Error initializing PX language
Error validating file
Error reading file
Probable Cause
The PCL file is of an incompatible format
or there is an invalid configuration
parameter causing the reset condition.
Indicates that the application software
initialized properly.
Unable to create the log_config.txt file
indicating the module is out of available
RAM space for file storage.
Unable to create socket at port 502 or
PCL file is of an invalid format.
Potential Operating System error
PCL file formatted incorrectly
Unable to open and process *.pcl file
RENR8091-04
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.
Delete older files from Archive folder.
Use the Parameter Transltion Editor
to re-create the PCL file and review the
configuration parameters for any invalid
data. If problem persists, contact the
product support representative and be
prepared to provide a copy of the PCL
file and any log status messages to
the product support representative for
analysis.
Contact the product support
representative. Be prepared to
provide a copy of the PCL file and any
messages from the log status files to
the product support representative.
Obtain latest copy of service tool and
re-create the *.pcl file from scratch.
There may be a version issue between
the service tool and PL1000E software.
Indicates no *.pcl file found in the New
or Current directory. Load the *.pcl file
into the New directory.
RENR8091-04
Table 16
Error
Error initializing Modbus stack
Error initializing software
Status: Valid - .pcl file loaded
successfully
Unable to create Current directory
Unable to create New directory
Unable to create Archive directory
Unable to create Error directory
Probable Cause
The PCL file was created containing
Bodbus communications defined for
both RS-422 and RS-485. The PL1000E
cannot support these communications
simultaneously, as they occupy the
same physical serial port.
Indicates some low level initialization
failed during application software startup
sequence.
PCL file was validated and processed
successfully
During initializing, the software was
unable to successfully create the Current
directory.
During initializing, the software was
unable to successfully create the New
directory.
During initializing, the software was
unable to successfully create the Archive
directory.
During initializing, the software was
unable to successfully create the Error
directory.
85
Troubleshooting Section
Remedy
Open and modify the PCL file to change
the RS-422 or RS-485 connection
definitions so that there is only one or
the other defined.
Power down the unit for approximately
10 seconds and attempt to start it up
again. If the problem persists, flash
the module with undated application
software.
No remedy, since this is just an
informational message.
Power down the unit for approximately
10 seconds and attempt to start it up
again. If the problem persists, flash
the module with undated application
software.
Power down the unit for approximately
10 seconds and attempt to start it up
again. If the problem persists, flash
the module with undated application
software.
Power down the unit for approximately
10 seconds and attempt to start it up
again. If the problem persists, flash
the module with undated application
software.
Power down the unit for approximately
10 seconds and attempt to start it up
again. If the problem persists, flash
the module with undated application
software.
86
Troubleshooting Section
Table 17
Error
Error: Multiple .pcl files found in the
Current directory.
Multiple .pcl files found in the New
directory.
Error: Unable to move the .pcl from the
Current directory to the Error directory.
Status: Moved the .pcl from the Current
directory to the Error directory.
Error: pcl file not found in the Current
directory.
Error: Unable to set the RW permission
on the Current directory.
Error: Unable to move the .pcl from
the Current directory to the Archive
directory.
Error: .pcl file name truncated to 33
characters.
Probable Cause
Indicates that multiple *.pcl files were
found in the New or Current directory
during initialization and the software did
not know which one to process.
Unable to move the PCL file indication
the module is out of available RAM
space for file storage.
PCL file was successfilly moved from
the Current to the Error directory.
No PCL file exists in the Current
directory.
Potential operating system error
This error indicates the module is out of
available file space for storage.
The maximum length for PCL file names
is 33 characters.
RENR8091-04
Remedy
Delete the directory before resetting
the PL1000E. Browsers sometimes
cache the names of the files in the New
and Current directories. Go to Menu,
View, and click Refresh in order to
force the browser to display the most
recent list.
Delete the older files from the archive
folder
When a file is moved to the error
directory, it indicates an error in the file
content or format. The latest service
tool should be used in order to create
a new file.
The module first determines if a PCL
file is loaded into the New directory,
and if not, then searches for a PCL file
in the Current directory. Lod a new PCL
file into the New directory and power
cycle the unit.
Contact the Technical Communicator
(TC) and be prepared to provide a copy
of the PCL file and any messages from
the log status files.
Delete older files from the Archive
folder.
No action is necessary unless a
different file name is desired. If a
different file name is desired, then
load the newly named file in the New
directory observing the maximum
character limitation of 33 characters.
RENR8091-04 87
Troubleshooting Section

Table 18
Error Probable Cause Remedy
Unable to move the .pcl file from the Unable to move the .pcl file indicates Delete the older files from the Archive
New directory to the Current directory. the module is out of available file space folder.
for storage.
Unable to set the RW permission on the Potential operating system error Contact the Technical Communicator
Current directory. (TC) and be prepared to provide a copy
of the PCL file and any messages from
the log status files.
Invalid .pcl file in the New directory. Invalid PCL file format. Obtain the latest copy of the service
tool. Recreate the *.pcl file from
scratch. There may be a version issue
between the service tool and the
PL1000E software.
Status: Invalid .pcl file in the Current Invalid PCL file format Obtain the latest copy of the service
directory. tool. Recreate the *.pcl file from
scratch. There may be a version issue
between the service tool and the
PL1000E software.
Status: Unable to read the .pcl file into This is a general status message that Obtain the latest copy of the service
the memory. indicates there was and error parsing tool. Recreate the *.pcl file from
the .PCL file into the PL1000E memory. scratch. There may be a version issue
The specific error should also be logged. between the service tool and the
PL1000E software.
On-board file header
On-board file header ID !=0xB100
On-board file header Version !0x0002
On-board file header File Contents Type
!=0xC480
Config Data Record block
On-board file header Recblock
!=0xC480
Config Data Record ID !=1
Software Config Data
Software Config Data BlockID !=0xC490 Obtain the latest copy of the service
tool. Recreate the *.pcl file from
.pcl file Base Config Invalid PCL file format scratch. There may be a version
.pcl file Revision issue between the service tool and
the PL1000E software.
Invalid size
Checksum position
Checksum not found
File seeking pk_OnboardFileHeader_t
????? File seeking
pk_CfgDataRecBlock_t
File seeking
File seeking pk_PX_Baseconfig_t
File seeking builderBaseBlobSize
Allocating memory for the tables
88 RENR8091-04
Troubleshooting Section

Table 19
Error Probable Cause Remedy
This is a general error message that indicates
Error reading the
there was and error parsing the .PCL file into the
configuration tables
PL1000E memory. The specific error should also
into memeory Obtain the latest copy of the service tool.
be logged.
Recreate the *.pcl file from scratch. There
Error reading data Specific error message for reading the may be a version issue between the service
link table configuration tables into memeory. tool and the PL1000E software.
Error reading ECM Specific error message for reading the
table configuration tables into memeory.
The PCL file specifies that a serial port for Modbus Use the service tool in order to configure the
Modbus port not communications that has not been properly appropriate Modbus communications serial
configured configured on the PL1000E configuration screen port to match that is defined in the PCL file.
in ET
The PL1000E will not accept a Modbus slave Modifiy the Modbus slave address to a value
Illegal Modbus address
address of zero. between 1 and 254.
The slave address that is defined in the PCL file
for RS-232 port 1 is the same as the Modbus
slave address that is defined in the service tool
configuration. These two slave addresses must be
Use the service tool in order to change the
Modbus slave address different. The Modbus slave address that is defined
slave address for the configuration that is
conflict RS-232 port 1 in the PCL file is used to access data that is defined
associated to the RS-232 port 1.
in the PCL file. The Modbus slave address that is
defined in the service tool configuration screen is
used to access communication statistics and ECM
information from the PL1000E.

The slave address that is defined in the PCL file

for RS-232 port 2 is the same as the Modbus
slave address that is defined in the service tool
configuration. These two slave addresses must be
Use the service tool in order to change the
Modbus slave address different. The Modbus slave address that is defined
slave address for the configuration that is
conflict RS-232 port 2 in the PCL file is used to access data that is defined
associated to the RS-232 port 2.
in the PCL file. The Modbus slave address that is
defined in the service tool configuration screen is
used to access communication statistics and ECM
information from the PL1000E.

The slave address that is defined in the PCL

file for RS-422/485 is the same as the Modbus
slave address that is defined in the service tool
configuration. These two slave addresses must be
Use the service tool in order to change the
Modbus slave address different. The Modbus slave address that is defined
slave address for the configuration that is
conflict RS-422/485 in the PCL file is used to access data that is defined
associated to the RS-422/485.
in the PCL file. The Modbus slave address that is
defined in the service tool configuration screen is
used to access communication statistics and ECM
information from the PL1000E.
The slave address that is defined in the PCL file for
the Modbus TCP port is the same as the Modbus
slave address that is defined in the service tool
configuration. These two slave addresses must be
Use the service tool in order to change the
Modbus slave address different. The Modbus slave address that is defined
slave address for the configuration that
conflict TCP in the PCL file is used to access data that is defined
is associated to the TCP port.
in the PCL file. The Modbus slave address that is
defined in the service tool configuration screen is
used to access communication statistics and ECM
information from the PL1000E.
RENR8091-04 89
Troubleshooting Section

Table 20
Error Probable Cause Remedy
Error reading the tag table
Error reading the DSWrite table
Error reading the DSRead table Obtain the latest copy of the service
tool. Recreate the *.pcl file from
Specific error message for Error reading
Error reading the Enum lookup table scratch. There may be a version issue
the configuration tables into memeory.
between the service tool and the
Error reading the Unit Conversion table PL1000E software.
Error reading the language table
Error reading the string index table

Table 21
Error Probable Cause Remedy
Error reading string blob
Error validating Base Config
Error validating Data Link Types Obtain the latest copy of the service
tool. Recreate the *.pcl file from
Specific error message for Error reading
Error validating ECM table scratch. There may be a version issue
the configuration tables into memeory.
between the service tool and the
Error validating Tag table PL1000E software.
Error validating DSWrite table
Error validating DSRead table

Table 22
Error Probable Cause Remedy
Error validating Enum table
Error validating
Error validating
Obtain the latest copy of the service
lfp tool. Recreate the *.pcl file from
Specific error message for Error reading
scratch. There may be a version issue
Error fread !=readSize the configuration tables into memeory.
between the service tool and the
PL1000E software.
Invalid source path/file name
Invalid destination path/file name
Error writing to destination file
90
Troubleshooting Section
Problem - No response to data requests
from Modbus Master
Probable Cause
1. The PL1000E Communication ECM provides
communication statistics for received and
transmitted Modbus protocol messages as well
as the physical layer statistics for received and
transmitted bytes. If the Physical Layer Bytes
Received is not incrementing, analyze and
repair the harness. If the Physical Layer Bytes
Received is incrementing but the Protocol
Layer Modbus Messages Received are not
incrementing, analyze and correct the Modbus
message format. The ECM will not respond to
an improperly formatted Modbus message. Refer
to the Troubleshooting, RENR8091, Diagnostic
Capabilities for the Messaging Statistics Quick
Reference Troubleshooting Guide.
i02810225
Web Browser Problems
SMCS Code: 7610-035
Troubleshooting
Q: Why does the browser not show the changes
made on the pages that were just uploaded to the
web server?
A: The issue may be that the browser still has old
data cached within the memory set aside for this
purpose. Select the web page within the web browser
by clicking within the page but not on a link. Click the
Refresh button on the tool bar of the browser or use
the Refresh function for the browser. If this process
does not work, browse off of the page and clear the
cache of the browser according to the instructions of
the browser. Then try to browse the page again.
Q: Why does the message Parameter Unavailable
appear for a parameter that is on the custom page?
A: If the custom page displays the message
Parameter Unavailable in the value part of the table,
then the parameter either does not exist in the PCL
file on the PL1000E web server or there is an error in
the coding of the XML file.
To directly test whether the parameter exists within
the PCL file:
1. Enter the URL http://xxx.yyy.zzz.aaa/ssi/get
parm/<ECM ID>, <UID> in the address field of
the browser.
Note: xxx.yyy.zzz.aaa is the address of the ECM.
ECM ID is the numerical ID given to the ECM being
monitored. UID is the UID number in decimal format.
RENR8091-04
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.
3. Click ECM Mapping.
Note: Two tables will be displayed. Look at the bottom
table which contains a summary of translations in the
PCL file. At least one of the translations must be a
CDL to Web translation. If not, create a CDL to web
translation for each desired parameter.
4. Save the PCL file.
5. Republish the PCL file.
6. Cycle the power to the ECM.
7. Browse to the custom page in order to confirm that
the changes are updated.
RENR8091-04 91
Testing and Adjusting Section

Testing and Adjusting Simply disconnecting the connectors and then

reconnecting the connectors can temporarily solve
Section a problem at times. If this occurs, likely causes are
loose terminals, bent terminals, improperly crimped
terminals, corrosion, or harness routing that is
improper.
Testing and Adjusting
The original source of the problem must then be
identified in order to ensure that the problem does
i02815851 not reoccur.
Electrical Connector - Inspect Perform the following in order to thoroughly inspect
SMCS Code: 7553-040-WW the connectors and determine if the connectors are
the cause of the problem.
Reference: Special Instruction, SEHS9615,
Servicing DT Connectors.

Reference: Special Instruction, REHS0148, Listing

Of Deutsch Connector Components

Reference: Special Instruction, SEHS9065, Use Of

CE Connector Tools.

Reference: Service Magazine, SEPD0342, 27

January 97, Field Repair Of Single Wire Breaks In
Harnesses (Sealed Splice).

Reference: Service Magazine, SEPD0371, 28 July

97, Protection Of Unsealed Electrical Terminations
For Machines In Corrosive Applications.

Reference: Service Magazine, SEPD0473, 24 May

99, New DT Connector Plugs With Improved Seal
Retention.

Reference: Service Magazine, SEPD0545, 09

October 00, Dielectric Grease Should Not Be Used
In Electrical Connectors.

Reference: Pocket Guide, SEBD0402, Guidelines

For Routing And Installing Wire Harness Assemblies.

Use this procedure under the following situation:

Use the following steps to help determine if the

connector is the cause of the problem. If a problem is
found in the electrical connector, repair the connector
and verify that the problem has been corrected.

The following background information is related

to this procedure:

Many of the operational procedures and the

diagnostic code procedures in this troubleshooting
guide will instruct to check a specific electrical
connector.

Intermittent electrical problems are often caused

by poor connections. Always check for an active
diagnostic code before breaking any connections.
Also, always check for an active diagnostic code after
the connector is reconnected in order to verify that
the problem disappears.
92 RENR8091-04
Testing and Adjusting Section

g00820688
Illustration 102
(1) Correctly Routed Harness (3) Incorrectly Routed Harness
(2) Correctly Inserted Plug (4) Incorrectly Inserted Plug

g00690571 g00828600
Illustration 103 Illustration 104
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.

1. CHECK THE CONNECTORS.

RENR8091-04
a. Ensure that the connector is properly locked.
Also, ensure that the two halves of the
connector can not be pulled apart.
b. Verify that the latch tab of the connector is
properly latched. Verify that the latch tab of the
connector is fully latched.
Expected Result: The connector will securely
lock. The connector and the locking mechanism
are without cracks or breaks.
Results:
OK The connector will securely lock. The
connector and the locking mechanism are
without cracks or breaks. Proceed to test step
2.
NOT OK A problem exists with the connector.
Repair: Repair the connector or replace the
connector, as required.
STOP.
2. CHECK THE ALLEN HEAD SCREW ON THE
HARNESS CONNECTOR OF THE ECM.
a. Ensure that the connector bolt is properly
tightened. Be careful not to tighten the bolt too
much. The bolt may break.
b. Do not exceed 6.0 Nm (53.0 lb in) of torque
on the connector bolt of the harness when the
connector is being installed on the ECM.
Expected Result: The harness connector is
secure and the connector bolt of the ECM is
properly torqued.
Results:
OK The harness connector is secure and
the connector is properly torqued. Proceed to
test step 3.
NOT OK A problem exists with the connector.
Repair: Secure the harness connector of the
ECM. Ensure that the connector bolt is properly
torqued.
STOP.
3. PERFORM A PULL TEST ON EACH
CONNECTOR CONTACT.
93
Testing and Adjusting Section
a. Each connector contact should withstand 45 N
(10 lb) of pull. Each wire should remain in the
connector body. This test checks whether the
wire was properly crimped in the contact and
whether the contact was properly inserted into
the connector.
b. The DT connectors use an orange wedge to
lock the terminals in place.
c. Check in order to ensure that the orange wedge
is not missing and that the orange wedge is
installed properly on the DT connectors.
Note: A Crimp Tool should ALWAYS be used in order
to crimp wires on connector contacts. Do not solder
the terminals. Use the proper Crimp Tool.
Expected Result: Each connector contact
should withstand 45 N (10 lb) of pull. Each wire
remains in the connector body.
Results:
OK Each connector contact withstands
45 N (10 lb) of pull. Each wire remains in the
connector body. Proceed to test step 4.
NOT OK A problem exists with the connector.
Repair: Repair the wiring or replace the
connector contact.
STOP.
4. CHECK THE WIRES FOR NICKS OR
ABRASIONS IN THE INSULATION.
a. Carefully inspect each wire for signs of
abrasion, nicks, or cuts.
The following areas are locations that should
be checked:
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 RENR8091-04
Testing and Adjusting Section

OK The wires are free of abrasion, nicks, Results:

or cuts and the harness is properly clamped.
Proceed to test step 5.
NOT OK A problem exists with the wiring.
Repair: Repair the wires or replace the wires,
as required.
STOP.
5. CHECK THE CONNECTORS FOR MOISTURE
OR CORROSION.
a. Ensure that the connector seals and the white
sealing plugs are in place. If any of the seals or
plugs are missing, replace the seal or plug. If
necessary, replace the connector.
b. Check all of the wiring harnesses in order to
verify that the harness does not make a sharp
bend out of a connector. This will deform the
connector seal and this will create a path for
the entrance of moisture. See Illustration 102.
Note: It is normal to see some minor seal abrasion
on the ECM connector seals. Minor seal abrasion will
not allow the entry of moisture.
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.

c. Thoroughly inspect ECM connectors for
evidence of moisture entry. If moisture or
corrosion is evident in the connector, the
source of the moisture entry must be found
and the source of the moisture entry must be
repaired. If the source of the moisture entry is
not repaired, the problem will reoccur. Simply
drying the connector will not fix the problem.
Likely paths for the entrance of moisture are
from missing seals, improperly installed seals,
nicks in exposed insulation, and improperly
mated connectors.
Note: Moisture can also travel from one connector
through the inside of a wire to the ECM Connector. If
moisture is found in the ECM connector, thoroughly
check all connectors and wires on the harness that
connect to the ECM. The ECM is not the source of
the moisture. Do not replace an ECM if moisture is
found in either ECM 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.

Note: If corrosion is evident on the contacts or the

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.

Expected Result: All of the connectors should

be completely coupled and all of the seals
should be completely inserted. The harness
and the wiring should be free of corrosion,
moisture, abrasion or pinch points.
RENR8091-04
g00838765
Illustration 105
Retention of the Connector
(1) Pin Contact
(2) Socket Contact
Note: This is especially important for intermittent
problems.
a. Use a new pin contact. Insert the pin contact
into each socket contact one at a time in order
to check for a good grip on the pin contact by
the socket contact.
b. Use a new socket contact. Insert the pin
contact into each socket contact one at a time
in order to check for a good grip on the pin
contact by the socket contact. The pin contact
are located on the mating side of the connector.
c. The connector contact should stay connected
when the connector is held in the position
shown in Illustration 105. The connector
contact is the pin contact or the socket contact.
Expected Result: The pin contacts and the
socket contacts appear to be OK.
Results:
95
Testing and Adjusting Section
OK The pin contacts and the socket contacts
appear to be OK. STOP.
NOT OK A problem exists with the connector
terminal.
Repair: Replace the connector contact.
STOP.
i02815873
Wiring Harness (Open Circuit)
- Test
SMCS Code: 1408-081
Electrical problems are often caused by failed
electrical wires that have either an open circuit or a
short circuit.
If an electrical wire or a connection is broken, the flow
of electrical current through the circuit is interrupted.
This would be an open circuit. The following
procedure explains the test for an open circuit.
Test for an open circuit.
1. Turn the battery disconnect switch and the key
start switch to the OFF position.
2. Disconnect both ends of the wiring harness.
3. Install a jumper (connecting wire) between two
of the electrical wires at one end of the wiring
harness.
4. Use a multimeter in order to check for continuity
across the same two electrical wires at the other
end of the wiring harness.
5. Turn the multimeter dial to the 200 ohm range and
measure the electrical resistance.
6. If there is continuity between the electrical wires,
the multimeter will have a reading of less than 5
ohms. If there is not continuity, the electrical wire
is faulty. The wiring harness must be repaired or
replaced.
96
Testing and Adjusting Section
i02815888
Wiring Harness (Short Circuit)
- Test
SMCS Code: 1408-081
Electrical problems are often caused by failed
electrical wires that have either an open circuit or a
short circuit. If one part of the circuit contacts another
part of the same circuit, the flow is diverted from the
desired path. This would be a short circuit.
Perform the following in order to test for a short
circuit:
Test for a short circuit.
1. Turn the battery disconnect switch key and the
key start switch to the OFF position.
2. Disconnect both ends of the wiring harness.
3. Turn the multimeter dial to the 200 ohm range and
measure the electrical resistance.
4. Turn the multimeter probe in order to make
contact with the connector of the suspected faulty
electrical wire.
5. Use the other probe from the multimeter to check
for continuity across all electrical wires in the same
wiring harness and check all wires for continuity
across the frame to ground.
6. If there is continuity between any of the electrical
wires, the multimeter will have a reading of less
than 5 ohms. Continuity between any other wires
in the wiring harness indicates that there is a short
between those wires. The wiring harness must be
repaired or replaced.
7. Use the multimeter in order to test for continuity
across the frame or ground. If there is continuity
between any of the electrical wires, the multimeter
will have a reading of less than 5 ohms. If there
is continuity between any of the wires and the
frame, there is a short circuit between the wire
and the frame. Identify the wire that has a short to
the frame.
Reference: In order to determine if the wire is a part
of the ground circuit, refer to the Electrical System
Schematic section of this document.
If the wire is a part of the ground circuit and the wiring
harness is damaged, the wiring harness must be
repaired or replaced.
RENR8091-04
i03342206
Electronic Control Module
(ECM) - Flash Program
SMCS Code: 7610-591
The PL1000E is flashed in order to upgrade the
software. Flash programming of the ECM must
also be done if the ECM has been replaced. The
Caterpillar Electronic Technician (ET) contains the
program WinFlash. WinFlash is used in order to load
software into an ECM.
Three communications adapters are available in
order to flash electronic control modules:
7X-1700 Communication Adapter Gp
171-4400 Communication Adapter Gp
Embedded Communications Adapter (ECA) is
available on serial port 3 of the ECM. The ECA
feature supports ECM flashing functionality when
application software is installed on the ECM. If a
Blank Box condition occurs due to connection
related probems or due to power lost during the
flashing procedure for the PL1000E, then use of
the 171-4400 Communication Adapter Group will
be necessary in order to flash the PL1000E.
Perform the following procedure in order to flash
program the PL1000E:
1. Connect the appropriate data link cable between
the communication adapter and the personal
computer (PC) that contains Cat ET software.
When using the ECA, the data link cable is a serial
connection directly between the PC and serial port
3 of the ECM .
2. When the ECA is not used, connect the data link
cable between the communication adapter and
the diagnostic connector of the engine. If the ECA
is used, the ECA is already connected to the
system by the use of the standard Cat DataLink or
J1939 connection.
3. Use WinFlash in order to load the software.
i03346220
Electronic Control Module
(ECM) - Configure
SMCS Code: 7610-025
Cat ET or Caterpillar Tool Kit is required in order to
configure the PL1000E Communications ECM.
RENR8091-04 97
Testing and Adjusting Section

Once Cat ET is connected and the PL1000E 6. Verify that the ECM operates correctly.
Communication ECM has been selected, the user
can navigate to the configuration screen through the
i03342500
use of the service tool menus.
System Schematic
SMCS Code: 7566

g01721477
Illustration 106

Select PL1000E 2, then click OK. CAT ET will then

display the ECM Summary Screen, which displays
the ECM's basic identification information, including:
ECM Serial Number, Personality Module Description,
Personality Module Part Number, Personality Module
Release Date, and ECM Part Number.

i02811340

Electronic Control Module

(ECM) - Replace
SMCS Code: 7610-510

Prior to the replacement of the ECM, ensure that

replacement is absolutely necessary. The ECM is
seldom the cause of a failure. Always check that
power is available to all of the contacts of the ECM
that are marked with + Battery and Keyswitch.
Continue Only if all other attempts to isolate the
problem have failed. Always consult the dealership's
Technical Communicator for possible consultation
with Caterpillar. This consultation may greatly reduce
the time required for a repair.

Perform the following in order to replace the ECM:

1. Disable the supply voltage to the system and

confirm no voltage is present at the PL1000E
Communication ECM connector.

2. Disconnect the system harness from the ECM.

3. Remove the ECM.

4. Make sure that the replacement ECM is the

correct part number.

5. Install the replacement ECM according to the

procedures in Special Instruction, REHS2362.
98 RENR8091-04
Testing and Adjusting Section

g01717876
Illustration 107
RENR8091-04
Index
C I
Connector Locations..............................................
Custom Web Page ................................................
Creating Custom XML Pages ............................
Overview ............................................................
Understanding the XSL File ...............................
Viewing Custom XML Pages Using a Browser ..
D Internet Protocol Host Name.............................. 29
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.......................................
E Prompt.............................................................. 34
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.............
G Installation of PCL File to PL1000E ................... 26
General Information........................................... 4, 72
H
Hardware Configuration......................................... 27
ECM Configuration............................................. 27
Hexadecimal Conversion....................................... 70
99
Index Section
75 Important Safety Information ................................... 2
63 Internet Protocol Configuration.............................. 29
64 Dynamic Host Configuration Protocol (DHCP)
63 Enable Status................................................... 29
64 Ethernet Media Access Control (MAC)
68 Address ............................................................ 29
Internet Protocol (IPv4) Address........................ 29
Internet Protocol (IPv4) Network Mask .............. 29
Network Default Gateway Internet Protocol (IPv4)
Address ............................................................ 29
28 Introduction............................................................ 72
28
28
28 L
75
75 LAN Network Ethernet Connection........................ 32
36 LAN Network Ethernet Connection Overview .... 32
37 Loading the PCL File Using FTP With a Web
Browser ............................................................ 33
Loading the PCL File Using FTP with the Command
M
Modbus Configuration ........................................... 30
ModBus Configuration Details ........................... 30
Modbus Master...................................................... 68
Limited Modbus Master...................................... 68
O
Operational Problems............................................ 81
Symptom Procedures ........................................ 81
P
4
6 Parameter Translation Configuration...................... 11
6 Create *.pcl File Using the PCL Wizard ............. 21
6 Create a Modbus Master PCL File..................... 23
Create Parameter Translation Design ................ 11
5 Familiarization with the Parameter Translation
4 Design Interface ............................................... 12
Initiate Configuration of PL1000E with New PCL
File ................................................................... 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

Service Tools ......................................................... 72

Troubleshooting Software .................................. 72
Symptom Procedures ............................................ 81
System Schematic................................................. 97
Systems Operation Section ..................................... 4

Table of Contents..................................................... 3
Testing and Adjusting ............................................ 91
Testing and Adjusting Section ............................... 91
Troubleshooting Section........................................ 72

Web Browser Problems......................................... 90

Troubleshooting ................................................. 90
Wiring Harness ........................................................ 7
Wiring Harness (Open Circuit) - Test..................... 95
Wiring Harness (Short Circuit) - Test ..................... 96

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