Product Link - PL522/523 Electronic Service Tool Does Not Communicate with ECM Caterpillar

System Operation Description:

During the installation of a PL522 or 523 system, the wiring harness is connected to the existing Cat Data Link wiring on the machine. If the installation is not done properly, the continuity of the Cat Data Link wiring may be open intermittently. This condition may not be apparent immediately. Improper installation will cause a problem when you are trying to connect the AVSpare Electronic Technician (Cat ET) service tool to the machine.

• Cat ET may report that no ECM has been found.

• Cat ET may not report every ECM that is on the machine.

• Cat ET may report an ECM but the ECM will not have any data.

If the Cat Data Link wires for the PL522 or 523 are reversed, the ECM will not appear after connecting Cat ET.

Test Step 1. VERIFY THAT THE AVS DATA LINK WIRES ARE NOT REVERSED.

1. Check that the positive AVS Data Link wire (893-GN(Green)) in the wiring harness for the Product Link is connected to the positive AVS Data Link wire (893-GN(Green) or 944-OR(Orange)) of the wire harness for the machine.

2. Check that the negative AVS Data Link wire (892-BR(Brown)) in the wiring harness for the Product Link is connected to the negative AVS Data Link wire (892-BR(Brown) or 945-BR(Brown)) of the wire harness for the machine.

Expected Result:

The AVS Data Link wires are properly connected.

Results:

• OK - The wires for the AVS Data Link are properly connected. Proceed to Test Step 2.

• NOT OK - The wires for the AVS Data Link are reversed.

  Repair: Reinstall the AVS Data Link wires correctly and check the operation of the Product Link module by using Cat ET .

  STOP

Test Step 2. CHECK THE WIRING WITH A MULTIMETER.

1. Turn off the machine and turn the disconnect switch to the OPEN position.

2. Measure the resistance of the negative AVS Data Link wire from the service connector (contact "E") to the location for the spliced AVS Data Link wire. Note the resistance.

3. Measure the resistance of the positive AVS Data Link wire from the service connector (contact "D") to the location for the spliced AVS Data Link wire. Note the resistance.

Expected Result:

The resistance in both wires is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. Proceed to Test Step 3.

• NOT OK - The resistance is greater than 5 ohms.

  Repair: Repair the wiring harness. After repairing, resume the Product Link installation setup procedures.

  STOP

Test Step 3. VERIFY THAT THE WIRING FOR THE AVS DATA LINK IS PROPERLY CONNECTED.

1. Check the spliced connections for the AVS Data Link that were made during the installation. Verify that all connections are clean and tight.

2. Reconnect the harness connectors that were disturbed during the installation. Ensure that all of the pins are correctly seated in the sockets.

3. Reconnect the cable from the service tool connector. Attempt to access the Cat Data Link by using Cat ET .

Expected Result:

Cat ET lists the ECM systems that are available on the machine. The ECM for the PL522 or 523 can be accessed.

Results:

• OK - Cat ET lists the electronic control modules that are available on the machine. The ECM for the PL522 or 523 can be accessed. Resume the setup procedures for the installation of the PL522 or 523.

  STOP

• NOT OK - The Cat ET does not list the electronic control modules that are installed on the machine. The Product Link ECM cannot be accessed. Proceed to Test Step 4.

Test Step 4. CHECK FOR A MONITORING SYSTEM.

Check if the machine is equipped with a monitoring system. Some common monitoring systems include the following systems: Electronic Monitoring System, Computerized Monitoring System, AVSpare Monitoring System, VIDS and VIMS. Also, many machines have monitors that are specific to the type of machine such as excavators and cold planers.

Expected Result:

The machine is equipped with a monitor.

Results:

• YES - The machine is equipped with a monitoring system. Proceed to Test Step 5.

• NO - The machine is not equipped with a monitoring system. Proceed to Test Step 6.

Test Step 5. CHECK FOR A DIAGNOSTIC CODE FOR THE AVS DATA LINK.

Check the monitoring system for a diagnostic code for the Cat Data Link.

Expected Result:

There is a diagnostic code for the Cat Data Link.

Results:

• YES - There is a diagnostic code for the Cat Data Link .

  Repair: Perform the troubleshooting procedure for that diagnostic code that is found in the service manual for that ECM.

  STOP

• NO - There are no diagnostic codes for the Cat Data Link. Proceed to Test Step 6.

Test Step 6. RETURN THE WIRING TO THE ORIGINAL CONDITION.

1. Return the Cat Data Link wires to the original condition. Remove any splices that were made and reconnect the wiring harness.

2. Connect Cat ET to the service connector. Verify that all of the appropriate electronic control modules are present. The ECM for the PL522 or 523 will not be present.

Expected Result:

All of the appropriate electronic control modules are present.

Results:

• YES - All of the appropriate electronic control modules are present. The wiring is correct. Return to the installation procedure for the PL522 or 523 and reinstall the wiring for the Cat Data Link. Continue with the setup of the PL522 or 523.

  STOP

• NO - All of the appropriate electronic control modules are not present.

  Repair: A problem still exists with the Cat Data Link wiring. This problem does not relate to the installation of the PL522 or 523. Troubleshoot the entire Cat Data Link circuit to all available electronic control modules. After the problem is found and corrected, return to the installation procedure for the PL522 or 523. Reinstall the wiring for the Cat Data Link. Continue with the setup of the PL522 or 523.

  STOP