DaimlerChrysler Co-Pilot 3 2 1 13 12 11 10 4 5 6 8 7 Reorder Number Co-Pilot Data Recorder, Deluxe Kit... OT5031A Co-Pilot Data Recorder, Basic Kit... OT5030B Component Reorder Numbers 1. Co-Pilot Data Recorder... OT1200 2. J1962 Right Angle Adapters... OT2050 3. OBD II MMC EATX Data Transfer Cable (Trans., Blue) OT2092 4. OBD II MMC Data Transfer Cable (Engine)... OT2091 5. Remote Controller Trigger... OT2000 6. SCI Data Transfer Cable (Engine, LH vehicle)... OT2030 7. SCI Data Transfer Cable (Engine)... OT2010 8. Adjustable Straps... OT2015 9. MDS2 Data Transfer Cable... OT2020A 10. OBD II SCI Data Transfer Cable (Engine, Black)... OT2090 11. EATX Data Transfer Cable (Trans., Blue)... OT2040 12. J1962 Data Transfer Cable (Engine, Yellow)... OT2095 13. J1962 Transmission Data Transfer Cable (Trans., Green).. OT2045 14. Carrying Case (not shown)... OT1202 Denotes OT5030B Basic Kit Items 9 1
Introduction The Co-Pilot is a portable recorder that captures engine and transmission data for intermittent problems that cannot be reproduced in the service bay. The Co-Pilot works with the following Mopar Diagnostic Systems (MDS) and vehicles: MDS1 for most 1987 1 2 to 1995 Chrysler vehicles equipped with On Board Diagnostic (OBD) systems. MDS2 for 1996 to current year Chrysler vehicles equipped with On Board Diagnostic OBD systems. The Co-Pilot is simple to use. First: A service technician programs the Co-Pilot Data Recorder and installs it, along with the Remote Controller Trigger, in the customer s vehicle. Second: The customer drives the vehicle. When the intermittent problem occurs, the customer simply presses a Record button on the the Remote Controller Trigger to capture the data. The Co-Pilot records approximately 45 seconds of engine data. From one (1) to three (3) separate recordings can be made. The Co-Pilot always saves the three (3) most recent recordings. Third: A service technician removes the Co-Pilot components from the vehicle, uploads the recorded data to the MDS1 or MDS2, and begins vehicle data analysis. 2
Programming the Co-Pilot 1. Turn the MDS2 unit ON. Co-Pilot Data Recorder MDS2 Power Supply MDS2 Data Transfer Cable MDS2 Serial Port 2. Connect the Co-Pilot Data Recorder to the MDS2 as follows: a. Connect the Data Transfer Cable (Item 9; see page 1) to the Co-Pilot Data Recorder. b. Connect the Data Transfer Cable s serial port connector to the MDS serial port. NOTE: If the Cart was not purchased, locate the 9-pin male serial connector located on the back of the computer. This connector is marked with the symbol: c. Connect the Data Transfer Cable s 8-pin plug to the MDS2 power supply. This turns the Co-Pilot Data Recorder ON. The red and green Light Emitting Diodes (LEDs) flash alternately. (Refer to the LED charts on the next page.) NOTE: When the MDS2 communicates to the Co-Pilot Data Recorder, it verifies that the software version is current. If the software is not current, it prompts you to update the software. 3
Green LED (2) Red LED (1) LED Program Load Status Red Green Status LED (1) LED (2) On On Test Memory Off Flashing MDS2 Recognized Off Flashing Loading Program Flashing Off Needs MDS2 template On Off Memory Failure LED Record Status Red Green Status LED (1) LED (2) Flashing On Attempting to communicate with vehicle Off Flashing Triggered Off On Recording Trouble Shooting If the LEDs indicate Memory Failure, LEDs do not light or the Program stays in Memory Test: 1. Make sure the Co-Pilot and the MDS2 are powered up. 2. Check for broken or bent pins in the connections. 3. Check all cables for secure connections. 4. Check for correct cable-to-connector setup. 5. Make sure you have completed the correct program load instructions for the MDS2 and the Co-Pilot. If all trouble shooting attempts fail, return the Co-Pilot to the manufacturer. 4
3. Log on to the MDS2 using the customer s vehicle VIN. 4. Click the Tools tab. 5. Click the Template tab. This displays the Templates window. 6. In the Available Templates list, click the name of the template to download to the Co-Pilot Data Recorder. 7. Click the Download to Co-Pilot button. The red LED on the Co-Pilot stops flashing; the green LED continues flashing. Refer to the LED charts on page 4. 8. From the Choose Part Number screen that appears, click the part number for the vehicle controller and then click the OK button. (Use DRBIII to get the part number from the vehicle.) 9. The message Template download was successful appears. Click the OK button. 10. Disconnect the Co-Pilot Data Recorder from the MDS2. 11 Install the Co-Pilot Data Recorder and Remote Controller Trigger on the vehicle. Refer to Installing the Co-Pilot on page 6. 5
Installing the Co-Pilot 1. Remove the MDS2 Data Transfer Cable (Item 9; see page 1) from the Co-Pilot Data Recorder and connect the appropriate Data Transfer Cable (Transmission: Items 3, 11 or 13; Engine: Items 4, 6, 7, 10 or 12; see page 1). 2. Connect the Data Transfer Cable to the vehicle Diagnostic Link Connector (DLC) located under the vehicle hood or in the passenger area. You may need to use a Right Angle adapter (Items 2; see page 1) to access the DLC. Refer to the appropriate Driveability or Diagnostic Test Procedure Manual for the location of the vehicle s DLC. 3. Depending on the DLC location, position the Co-Pilot in the vehicle as follows: Diagnostic connector located under the dash (most 1996 and later models): Clean the outside surfaces of the Co-Pilot Data Recorder and the Data Transfer Cable. Then secure the Co-Pilot Data Recorder inside the driver side door pocket or in a safe, out-of-the-way location. Warning: Secure the cables away from the brake and accelerator pedal area. A loose cable can entangle a foot and possibly lead to an accident. Slide Into Door Pocket 6
Diagnostic connector located under the hood (most 1995 and previous models): Locate the brackets on the back of the Co-Pilot Data Recorder. Secure it to a stable area near the DLC and out of the way of moving engine components. Use the Adjustable Straps provided with the Co-Pilot kit (Item 8; see page 1). Co-Pilot Data Recorder Adjustable Straps DLC Receptacle 4. Connect the Remote Controller Trigger (Item 5; see page 1) to the Co-Pilot Data Recorder. Place the Remote Controller Trigger inside the passenger area and attach it to the visor. Position it so that the driver can easily press the Record button while driving. Remote Controller Trigger Warning: Secure the cables away from the windshield viewing area. Make sure the driver can easily locate the Remote Controller Trigger without having to look away from the road. 5. Turn the ignition ON, the green LED on the Remote Controller Trigger must light. This indicates the Co-Pilot is ready. Perform a test to make sure the Co-Pilot is functioning properly. NOTE: Many newer model vehicles do not have switched battery power to the DLC. When using the Co-Pilot with these vehicles, the LEDs stay ON for 30 to 40 seconds after turning the key OFF. Also, opening a door on these vehicles causes the Co-Pilot to re-activate and to stay active for 30 to 40 seconds after closing the door. 7
Chrysler Co-Pilot Instructions The Chrysler Co-Pilot is a portable recorder designed to capture engine data for intermittent problems that cannot be reproduced in the service bay. The Co-Pilot is simple to use. First: The recorder is installed in your vehicle by a Chrysler service technician. Second: Take the vehicle out on the road and drive in a normal manner until the intermittent problem reappears: Then, press the button on the remote controller positioned in the vehicle. The Co-Pilot will record approximately 45 seconds of engine data. Any amount of recordings can be made. The Co-Pilot saves the three (3) most recent recordings. Third: When you are satisfied that the problem is captured, bring the data recorder back to your Chrysler dealer. The service technician will remove the recorder and begin the analysis of the vehicle data. Additional information you should know: The light on the Remote Controller will illuminate when the key is turned ON; it will flash while the event is being recorded. For LH models, the light will also illuminate when the door is opened. It will turn off 30-40 seconds after the key is turned off and the door is closed. Up to three separate recordings can be made. + Green LED ON means No recording stored. Instructing the Customer Take a few minutes to show the customer where the Co-Pilot components are located in their vehicle and how to use the Remote Controller Trigger. Review the following items with the customer: The LED on the Remote Controller Trigger lights when the key is turned ON; it flashes while an event is recording. If the LED does not light, check all connections to be sure they are tightly connected. If the LED still fails to light, return to the Dealer. Take the vehicle out on the road and drive in a normal manner until the intermittent problem appears. Then, press the Record button on the Remote Controller Trigger. After recording the intermittent problem, bring the vehicle back. NOTE: With a copy machine, duplicate the DaimlerChrylsr Customer Co-Pilot Instructions located on the back cover of this instruction manual. Place the instructions on half of the paper, leave the other half open for customer notes and comments. As you explain the Co-Pilot, give the copy to the customer and explain that it is for reference and for writing notes. Customer Instructions Leave blank for customer comments and notes 8
Uploading Co-Pilot Data to MDS2 When the customer has recorded the event(s), use the following steps to upload the data to the MDS2 for analysis. 1. Remove the Co-Pilot components from the vehicle. 2. Remove the Data Transfer Cable from the Co-Pilot Data Recorder (Transmission: Items 3, 11 or 13; Engine: Items 4, 6, 7, 10 or 12; see page 1). 3. Connect the MDS2 Data Transfer Cable (Item 9, see page 1) to the Co-pilot Data Recorder and to the MDS2. For specific steps, refer to page 3. 4. Log on to the MDS2 using the customer s vehicle VIN. 5. Click the Tools tab. 6. In the Select a Tool Display box, click the down arrow and then click Controller Recording Viewer. This displays the Select Recording window. 7. In the Select Recording Location box, shown above, click the down arrow and then click Co-Pilot. This displays a list of the recordings, shown on the next page. 9
8. Highlight all the recordings in the list and click the Move button. This displays the Move Recording window. 9. In the Recording Destination box, click the down arrow and then click MDS2. 10. Use the bottom part of the window to name each recording. In each of the boxes, enter an appropriate name for the listed event. 10
11. After entering the names for the recordings, click the Move button. A message appears to indicate the uploading of data. It may take approximately 1 minute for each recording to transfer to the MDS2. When the upload is finished, the Select Recording window displays again; the Select Recording Location is MDS2 and the recordings are listed in the Recording area. 12. Click the name of the recording you want to view and click the View ON MDS button. This displays the data on the Controller Recording Viewer window of the Tools tab, shown below. 11
Replacement Parts 1. Co-Pilot Data Recorder... OT1200 2. J1962 Right Angle Adapters... OT2050 3. OBD II MMC EATXData Transfer Cable (Trans., Blue)... OT2092 4. OBD II MMC Data Transfer Cable (Engine)... OT2091 5. Remote Controller Trigger... OT2000 6. SCI Data Transfer Cable (Engine, LH vehicle)... OT2030 7. SCI Data Transfer Cable (Engine)... OT2010 8. Adjustable Straps... OT2015 9. MDS2 Data Transfer Cable... OT2020A 10. OBD II SCI Data Transfer Cable (Engine, Black)... OT2090 11. EATX Data Transfer Cable (Trans., Blue)... OT2040 12. J1962 Data Transfer Cable (Engine, Yellow)... OT2095 13. J1962 Transmission Data Transfer Cable (Trans., Green)... OT2045 14. Carrying Case (not shown)... OT1202 Additional Co-Pilot kits (Basic - OT5030B or Deluxe - OT5031A) can be ordered through the DaimlerChrysler Corporation Pentastar Service Equipment Program. ORDER INFORMATION Replaceable and optional parts can be ordered directly from DaimlerChrysler Pentastar Service Equipment. Your order should include the following information: Quantity, Part Number and Item description. Send your order to: Pentastar Service Equipment DaimlerChrysler Motors Corporation Phone: (800)-223-5623 Fax: (800) 734-4334 CUSTOMER SERVICE When sending your SPX electronic product in for repair, please include the following information: company name, contact name, telephone number, description of the problem, proof-of-purchase for warranty repairs and preferred method of payment for non-warranty repairs. If sent to the United States, payment can be made with Visa, Master Card, COD, or with approved credit terms. To receive a credit application, please fax your request to the Credit Department at 800-962-8734. United States SPX Corporation, Owatonna Facility 2300 Park Drive, Owatonna, MN 55060 Attn: Repair Phone: (800)-344-4013 Canada Air/Electric Services Ltd. 6739 76th Avenue Edmonton, Alberta T6B 09A Phone: (403) 465-0906 U.A.P. Centre DeDistribution Electronic Service Department 2045 Haig Avenue Montreal, Quebec H1N 2B3 Phone: (514) 253-1820 Farmtronics Ltd. 605 Henderson Drive Regina, Saskatchewan S4N 6A8 Phone: (306) 721-6455 Motron Limited 245-G Exeter Road London, Ontario N6L 1A4 Phone: (519) 652-9080 12
Data Transfer Cable Color Char t Cable# /Color System Years Vehicle Usage OT-2040 Blue OT-2045 Green TCM TCM 98-00 JA/JX/NS 01 - Up RS/JR 00-01 AN/DN 99 - Up WJ 98-01 LH 98 - Up PR 01 - Up PT 02 - Up PL 02 - Up KJ 02 - Up LH 02 - Up AN/DN/DR 03 - Up JR 03 - Up LH (02-Up if flashed with 03 software) 03 - Up AN/DN/DR (02-Up if flashed with 03 software) OT-2090 Black PCM All All SBEC (Except 02-Up LH, 03 Up JR) JTEC (Except 02-Up AN/DN/DR) OT-2095 Yellow PCM 02 - Up LH 03 - Up JR 02 - Up AN/DN/DR 13
NOTES 14
Limited Warranty THIS WARRANTY IS EXPRESSLY LIMITED TO ORIGINAL RETAIL BUYERS OF SPX ELECTRONIC DIAGNOSTIC TOOLS ( UNITS ). SPX Units are warranted against defects in materials and workmanship for two years (24 months) from date of delivery. This warranty does not cover any Unit that has been abused, altered, used for a purpose other than that for which it was intended, or used in a manner inconsistent with instructions regarding use. The sole and exclusive remedy for any Unit found to be defective is repair or replacement, at the option of SPX. In no event shall SPX be liable for any direct, indirect, special, incidental or consequential damages (including lost profit) whether based on warranty, contract, tort or any other legal theory. The existence of a defect shall be determined by SPX in accordance with procedures established by SPX. No one is authorized to make any statement or representation altering the terms of this warranty. DISCLAIMER THE ABOVE WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SOFTWARE Unit software is proprietary, confidential information protected under copyright law. Users have no right in or title to Unit software other than a limited right of use revocable by SPX. Unit software may not be transferred or disclosed without the written consent of SPX. Unit software may not be copied except in ordinary backup procedures. TECHNICAL SERVICE If you have any questions on the operation of the product, please call: (800) 533-0492 15
Co-Pilot Customer Instructions The DaimlerChrysler Co-Pilot is a portable recorder that captures engine and transmission data when an intermittent problem appears. The Co-Pilot is simple to use. First: The Co-Pilot Data Recorder and Remote Controller Trigger (shown below) are installed in your vehicle by a DaimlerChrysler service technician. Second: Take the vehicle out on the road and drive in a normal manner until the intermittent problem appears. Then, press the Record button on the Remote Controller Trigger, which is positioned in the vehicle. The Co-Pilot records approximately 45 seconds of vehicle data. Make as many recordings as needed. The Co-Pilot always saves the three (3) most recent recordings. Third: When you are satisfied that the problem has been recorded, return the vehicle to your DaimlerChrysler dealer. The service technician will remove the Co-Pilot and analyze the vehicle data. Additional information you should know: The light on the Remote Controller Trigger illuminates when the key is turned ON and it flashes while recording. If the light does not illuminate, check all connections to be sure they are tightly connected. If the light still fails to illuminate, return to the Dealer. The vehicle battery must be fully charged before using the Co-Pilot. Under normal conditions, the automobile alternator charges the battery to full strength within 5 to 10 minutes after starting your vehicle. If the battery is at a low charge, have it charged by your DaimlerChrysler Dealer. Please use the blank side of this sheet for writing notes or comments. 504760 9/4/01