PIKOSYS PIKOLOAD Instruction Manual

PikoSys Vertriebs GmbH
Wildbichler Straße 2e
A – 6341 Ebbs
Tel. [phone]
ax: [phone]
[email protected]
www.pikosys.com
Guideline Installation
PikoLoad
Version 2

Revision History
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Version 2
Revision History
Version Date Changes Name
1 11.04.2011 irst version KeAr
2 27.06.2012 Added: Tachograph settings KeAr

ENGLISH
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Version 2
ENGLISH

Table of Contents
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Version 2
Table of Contents
Revision History 2
ENGLISH 3
Table of Contents 4
List of Figures 5
1 Introduction 6
1.1 Global........................................................................................................... 6
2 Check of the vehicle connection 7
2.1 Vehicle ordered with function remote download ?............................................... 7
2.2 Vehicle ordered with function MS-Standard ? ................................................... 7
2.3 Look for the „green connector“ ........................................................................ 7
3 Installation of PikoLoad 9
3.1.1 Make up of the MS wiring (no MS connector in the vehicle) .................. 9
3.1.2 Installation in the Vehicle .................................................................... 9
3.1.3 Connection to the Tachograph (change of Tacho only) ...........................10
4 Start-up PikoLoad 11
4.1 Lock data at the tachograph to the company ....................................................11
4.2 Do a MS test (only for vehicles with MS interface)..........................................11
4.2.1 LED Display unction „PikoTest“ ..........................................................12
4.3 Remote Download Test ..................................................................................13
4.3.1 Insertion of the Company Card ...........................................................13
4.3.2 Start of the Remote Download Tests with a USB-Stick ...........................15
4.3.3 LED Display unction PikoTest Remote Download (RDL-Test) ..................16
4.3.4 Remote Download (RDL-Test) test report .............................................17
4.4 Tachograph Settings......................................................................................21
4.4.1 Settings at Continental Tachographs (with CTC II) ................................22
4.4.2 Settings at Stoneridge Tachograph ......................................................24
4.5 Inbetriebnahme System.................................................................................27
4.5.1 LED display (with Company Card) .......................................................28
5 Appendix 29
5.1 Technical Data..............................................................................................29
5.2 Pin Assignment .............................................................................................29
5.2.1 PikoLoad CAN 1 Pin Assignment ..........................................................29
5.2.2 PikoLoad CAN 2 Pin Assignment ..........................................................30
5.2.3 PikoLoad RS 232 Pin Assignment.........................................................31
5.3 Checklist Installation / Start-up ......................................................................32

List of Figures
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List of Figures
igure 1: „Green connector“ in overhead compartment ............................................................ 8
igure 2: Make up of MS wiring ........................................................................................... 9
igure 3: PikoLoad wiring ..................................................................................................... 9
igure 4: Connection to Tachograph .................................................................................... 10
igure 5: C-CAN Tachograph Pin Assignment ........................................................................ 10
igure 6: MS-Test card ..................................................................................................... 11
igure 7: Example data MS test ......................................................................................... 11
igure 8: LED Display ........................................................................................................ 12
igure 9: Press to the hinge................................................................................................ 13
igure 10: Open ront Lid................................................................................................... 13
igure 11: Insert Company Card (Chip up) ........................................................................... 14
igure 12: Inserted Company Card ...................................................................................... 14
igure 13: Content of the file for Remote Download Test ........................................................ 15
igure 14: LED Display unction PikoTest Remote Download................................................... 16
igure 15: Directory Content remote download test report ..................................................... 17
igure 16: ile content remote download test report successful ............................................... 18
igure 17: ile content remote download test report with error ............................................... 19
igure 18: Excerpt from "User Guide for Remote Download" ................................................... 20
igure 19: result RDL test due to missing configuration for C-CAN at Continental ...................... 22
igure 20: CTC II .............................................................................................................. 23
igure 21: result RDL test due to missing configuration for C-CAN at Stoneridge ....................... 24
igure 22: Display Stoneridge „SETTINGS“ ........................................................................... 25
igure 23: Display Stoneridge „Parameter“ ........................................................................... 25
igure 24: Display Stoneridge „Download CAN selection“........................................................ 25
igure 25: Display Stoneridge „Download CAN selection C“..................................................... 26
igure 26: Display Stoneridge „Changes saved“ .................................................................... 26
igure 27: LED display ....................................................................................................... 28
igure 28: PikoLoad CAN 1 Pin Assignment........................................................................... 29
igure 29: PikoLoad CAN 2 Pin Assignment........................................................................... 30
igure 30: PikoLoad CAN 2 connection ................................................................................. 30
igure 31: PikoLoad RS232 Pin Assignment .......................................................................... 31
igure 32: PikoLoad RS connection ...................................................................................... 31

Introduction
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1Introduction
1 1 Global
The intention of this guideline is to help to install / start-up the PikoLoad unit.
Due to the different vehicle brands and models it is not possible to have a global
installation guideline. The connectors, if already factory fitted, can be found at different
locations in the vehicle.
Some tools and guidelines in this document should assist you to install the PikoLoad in the
right way.

Check of the vehicle connection
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2Check of the vehicle connection
Please check the existing connections of the vehicle.
Try to get the configuration of the vehicle.
2 1 Vehicle ordered with function remote download ?
If yes, the wiring harness to the C-CAN of the tachograph (green connector) should be
available in the vehicle and the tachograph is configured to support remote download.
If no, the risk is that the tachograph is not configured to support remote download. The
wiring harness to the C-CAN of the tachograph might be missing as well.
Remark:
The configuration of the tachograph to support remote download can only be
done by an authorized workshop (with a workshop card) using a workshop toll
For Continental (Siemens VDO) a CTC II is necessary
2 2 Vehicle ordered with function FMS-Standard ?
If yes, the wiring harness should be available in the vehicle and the MS gateway is
correctly configured.
If no, there might be no MS data available at PikoLoad.
Remark:
The function must be configured at the workshop of the manufacturer of the vehicle.
The configuration can only be done with the brand specific workshop tool. In most cases it
is not necessary to install additional hardware.
Depending on the brand there might be new parameters needed. In some cases it is
necessary to install a new wiring harness.
2 3 Look for the „green connector“
If you did not get any information where the connector for MS/remote download can be
found in the vehicle, try to search it near the tachograph in one of the compartments. In
most cases the connector can be found in the overhead compartment of the driver. The
connector is green and with a wiring harness of about 1m length. If you are not sure that

Check of the vehicle connection
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you found the correct connector, please check if the power supply (Pin 12 = clamp 30),
ground (Pin 1 = clamp 31) and the ignition (Pin 10 = clamp 15) are available.
Figure 1: „Green connector“ in overhead compartment

Installation of PikoLoad
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3Installation of PikoLoad
3.1.1 Make up of the MS wiring (no MS connector in the vehicle)
Make up the MS wiring in the vehicle (if no standard MS connector is available).
This step is not necessary if the vehicle has already a standard MS connector
(green colour).
1.Make up the wiring for the PikoLoad (exact description in the appendix).
Pin 1
Pin 6
Pin 9
Pin 10
Pin 12
FMS-Plug
(female)
Figure 2: Make up of FMS wiring
2.Connect the wiring to the vehicle:
Pin 1 Clamp 31 (ground)
Pin 6 CAN high (C-CAN Tacho Pin 5 + MS CAN high)
Pin 9 CAN low (C-CAN Tacho Pin 7 + MS CAN low)
Pin 10 Clamp 15 (24 V DC UBat - Ignition)
Pin 12 Clamp 30 (24 V DC)
3.1.2 Installation in the Vehicle
3.1.2.1 Standard MS connector existing or made
FMS-Plug
(female)
Pin 1
Pin 6
Pin 9
Pin 10
Pin 12
PikoLoad
Figure 3: PikoLoad wiring
Connect the wiring harness to PikoLoad

Installation of PikoLoad
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3.1.3 Connection to the Tachograph (change of Tacho only)
Please do this step only if your tachograph has been not factory fitted as
remote download (with green connector)
Connecting Tacho (Example is Continental)
Figure : Connection to Tachograph
1
5
4
8
Figure 5: C-CAN Tachograph Pin Assignment
Pin 1 Not used
Pin 2 GND
Pin 3 Not used
Pin 4 Not used
Pin 5 CAN high
Pin 6 Not used
Pin 7 CAN low
Pin 8 Not used
Connect the C-CAN connector (red) to the C-CAN of the tachograph.
Attention: The connectors are coded (fits only to C-CAN)!
Please do not use any other connection to the tachograph! You might disturb the
correct function of the tachograph. Please keep in mind that any work at
tachographs is only allowed by authorized workshops!

Start-up PikoLoad
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4Start-up PikoLoad
4 1 Lock data at the tachograph to the company
If the data are not yet locked to the company you have to do it now with a valid
company card.
Insert the company card in the slot of the tachograph and lock the data (see
description of your tachograph).
Remark:
The data must be locked to the company otherwise you will not get access to your
data.
4 2 Do a FMS test (only for vehicles with FMS interface)
This test is only possible by using a MS-Test card. This card is part of the delivery
of the evaluation kit.
Figure 6: FMS-Test card
Insert the MS-Test card in the PikoLoad and plug in a USB-Stick.
The test starts automatically and runs for 1 minute.
The result are stored on the USB-Stick in the directory “pikotest”.
The data format is ASC.
The description of the format can be found on www.fms-test.com.
Each file is stored with a consecutive number:
Figure 7: Example data FMS test
The logged data can be avaluated under www.fms-test.com (no fee). The evaluation
shows as well which data are available at the fms interface.

Start-up PikoLoad
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4.2.1 LED Display unction „PikoTest“
Figure 8: LED Display
The LED’s indicate the following status information (USB interface to the left)
The PikoTest mode is indicated by flashing LED’s
off off
Ignition off
No power supply -> check the wiring harness
off red
Ignition on
Initialization and self test is running
off green
Wait for ignition on
-> Recording starts by ignition on
off orange
Wait for USB-stick
-> Recording starts by plugging the USB-stick
orange green
Recording started, USB-stick is in writing mode
-> Do not unplug the USB-Stick, you might loose data
red red
Error, e.g.
-> no CAN data -> check wiring
-> USB error -> check the USB-stick
( ormatting, maybe the USB-stick is full)
-> no CAN data received since more than 5 seconds
-> internal error -> replace the unit
green green
Recording finished – Data stored on the USB-Stick
or further record: unplug USB-Stick and plug USB-stick
or PikoLoad mode: remove MS-Test card and insert a company card
orange orange
„Service-Mode“ (not flashing in any mode)

Start-up PikoLoad
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4 3 Remote Download Test
Please do always a remote download test during installation. This test shows you
whether the tachograph is correctly configured and the company data are correctly
locked to the company. The successful test report can be archived with the
installation information. This gives you the possibility to have always the information
about the installed tachograph / vehicle present.
4.3.1 Insertion of the Company Card
Open the front lid of PikoLoad
Figure 9: Press to the hinge
Figure 10: Open Front Lid
Press the hinge from the button with both thumbs – then the front lid can be
opened easily.
Attention: Do not use force to open the front lid !

Start-up PikoLoad
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Figure 11: Insert Company Card (Chip up)
Pay attention to the correct position of the chip (chip up – see picture) !
Push up the company card against the end
Figure 12: Inserted Company Card
Please shut the front lid afterwards.

Start-up PikoLoad
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4.3.2 Start of the Remote Download Tests with a USB-Stick
Be sure that a company card is inserted in the slot of the PikoLoad.
Be sure that the PikoLoad is connected to the tachograph and power supply and
the ignition is on. Please make sure that ignition is not switched off during the
test run as it might result in an error message.
Insert the USB-stick with the following file in the PikoLoad:
ile name: RemDwlTest.PSS
Content ile: ACTION:RemDwlTest<CR><L >
Figure 13: Content of the file for Remote Download Test
Please note that:
•The file must be stored in the root directory of the USB-Stick
•After the remote download test run the file will be deleted automatically
at the
USB - Stick
The test starts automatically (see LED display) after the plug-in of the USB-Stick
containing this file.
After the test run the test result is stored on the USB-stick. The end of the test
run is shown by the LED display. Now remove the USB-Stick.
Note:
The test works with all valid company cards It is not necessary that the
data are locked to this company

Start-up PikoLoad
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4.3.3 LED Display unction PikoTest Remote Download (RDL-Test)
Figure 1 : LED Display Function PikoTest Remote Download
The LED’s indicate the following status information (USB interface to the left)
off off
Ignition off
No Power supply -> check the wiring harness
off red
Ignition on
Initialization and self test is running
Inserted card is checked
red red
Ignition on, no card inserted
Start PikoLoad Mode with company card
Start PikoTest ( MS-Test) with MS-Test card
Start RDL Test Mode with workshop card or
By inserting a USB-Stick (with special ile)
off green
-> Check of the inserted card successful
orange off
Remove workshop card (if RDL Test has been started with
workshop card)
Insert company card
Plug in a USB-Stick for running the RDL Test
Blink
orange orange
Remote Download Test in progress
Duration ca. 2 minutes (max. 4 minutes)
!! Do not remove the USB-Stick, do not switch off ignition !!
Blink
orange green
Remote Download Test successful finished
Remove USB-Stick, report is saved on the USB-Stick
Is shown for ca. 3 seconds after having removed the USB-Stick
Blink
orange red
Remote Download Test with errors finished
•Remove the USB-Stick and check report
•Error Codes can be checked in the document:
„User guide for remote Download“
Remove the USB-Stick, report is on the USB-Stick
Is shown for ca. 3 seconds after having removed the USB-Stick
red red
Stop the Test mode after the RDL test by
Removing the card
Removing the USB-Stick
Ignition off

Start-up PikoLoad
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4.3.4 Remote Download (RDL-Test) test report
The test report can be found in the directory “pikotest”
Figure 15: Directory Content remote download test report
ile name:
registration no. (if exists)_Date_Time_sequential number.DDD
The „.DDD file“ consists of:
•Overview
•Technical Data
This file can be read by a DDD software.
ile name:
registration no. (if exists)_Date_Time_sequential number _language.txt
This file consists of the test report in the indicated language and can be opened
with any editor.
g : for German language
e : for English language

Start-up PikoLoad
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Example: report successful test - English
ile „__________20091209_110121_0000004_e.txt“:
igure 16: ile content remote download test report successful

Start-up PikoLoad
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Example: Test report with errors - English
ile: „0000005_g.txt“
If the remote authentication fails the file name consists of a sequential number only
(registration no, date, time are not known)
Figure 17: File content remote download test report with error
There are up to 4 received error messages listed in point 4.
The test was made with an expired company card in this example. The tachograph tries up
to 5 times to read the company card. After these tries the following error message
(positive response in the documentation) is sent:„ 71 01 01 80 0E“

Start-up PikoLoad
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In the document „User Guide for Remote Download“ the message is indicated as:
•Company Card expired
•Bad card type (not a company card)
•Company Card corrupted
•Card reader use different T=0/T=1 than the VU is requesting
Figure 18: Excerpt from "User Guide for Remote Download"