Installation Procedure for the Product Link® PL641 on Certain Caterpillar Telehandlers {1408, 7338, 7490, 7602, 7606} Caterpillar

Telehandler

TL642D (S/N: ML81-UP)

TL943D (S/N: MLJ1-UP)

Introduction

This Special Instruction will provide the parts and procedures to install the Product Link^® PL641 on the machines listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS. FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS. PROPER CARE IS YOUR RESPONSIBILITY.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

Prepare the Machine

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, place the travel select lever in the (N) Neutral position, and shut the engine off.

2. Use wheel chocks to prevent the machine from moving.

3. If equipped remove the key from the MAIN switch located inside the engine compartment.

4. Properly disconnect the battery.

5. Place a Do Not Operate Tag on both the ignition key-switch and the steering wheel, stating that the machine should not be operated.

   Note: Use all applicable safety precautions while working on, around or under any machinery.

   Note: Read the entire publication before beginning.

   Note: Certain parts have been hidden in several Illustrations for clarity.

   Note: Apply thread locking compound to all threaded fasteners that do not have an integral locking feature.

   Note: Apply dielectric grease to all male electrical connectors, except module connectors or cable connections unless noted.

   Note: Do not tighten the tie straps until installation is complete.

The following parts must be ordered according to the machine configuration.

• Group 1 - TL642D & TL943D with A/C

• Group 2 - TL642D & TL943D without A/C

Installation Procedure for Group 1 with A/C

Required Parts

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Illustration 1	g06148891
(1) 518-1351 Bracket As (2) 480-9645 Communication Installation Gp (3) 6V-7357 Bolt (4) 8T-4205 Hard Washer (A) Blanking plug

1. Mount the PL641 480-9645 Communication Installation Gp (2) to the product link 518-1351 Bracket As (1), using four 6V-7357 Bolt (3) and four 8T-4205 Hard Washer (4). Refer to Illustration 1.

2. Locate the blanking plug (A) zip tied in a bag to the product link 501-0350 Control Harness As (5). Connect it to the product link controller.

3. Set completed assembly to the side.
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   Illustration 2	g06148194
   (B) Upper roof cap cover

4. Remove and retain the hardware and the long upper roof cap cover (B) from the cab. Refer to Illustration 2.
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   Illustration 3	g06148224
   (5) 501-0350 Control Harness As

5. Refer to Illustration 3 for the general location of the component layout. Detail (C) for the mounting location of the PL641 communication installation group, antenna, and the product link 501-0350 Control Harness As (5). Detail (D) for the installation location of the connection of the other end of the product link 501-0350 Control Harness As (5).
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   Illustration 4	g06148240
   Detailed view of area C (4) 8T-4205 Hard Washer (6) 8T-4138 Bolt

6. Mount the previously assembled PL641 communication installation group and the product link 518-1351 Bracket As (1) to the cab using three 8T-4138 Bolt (6) and three 8T-4205 Hard Washer (4). Refer to Illustration 4.
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   Illustration 5	g06148256
   Detailed view of area D (5) 501-0350 Control Harness As (7) 455-3027 Cable Tie (8) 159-9496 Lock washer (9) 159-9495 Nut (10) 501-1119 Dust Cap (E) Connect X2011 (F) Connect X1611 (G) Connector X2110 (ET connector)

7. Insert five 455-3027 Cable Tie (7) into the cab. Position the product link 501-0350 Control Harness As (5). Connect X2011 (ET connector) to the product link bracket with one terminal 159-9496 Lock washer (8) and one terminal 159-9495 Nut (9). Fasten the 501-1119 Dust Cap (10). Refer to Illustration 5.

8. Continue making the appropriate connections as shown in Illustration 5.
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   Illustration 6	g06148289
   (5) 501-0350 Control Harness As (H) MS2113 (J) MS729-1 (K) MS2113-3

9. Route the product link 501-0350 Control Harness As (5) down the rear of the cab and into the engine side area, following the route as the front frame harness. Refer to Illustration 3, Illustration 5, and Illustration 6.

10. Locate the CAN TEE. Remove the engine harness connector MS729-1 (J) from it and plug into MS2113 (H) of the product link 501-0350 Control Harness As (5).

11. Plug the MS2133-3 (K) of the product link 501-0350 Control Harness As (5) into the empty CAN TEE location.

12. Secure the harness and loose the legs with the tie straps.
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    Illustration 7	g06148318
    (L) Antenna

13. Refer to the instructions provided in the product link PL641 communication installation group. Mount the antenna (L) in the location as shown in Illustration 7. Make the connection to the product link controller.
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    Illustration 8	g06148351
    (M) 308 mm (12.1 inch) (N) Decals (P) 10 mm (0.4 inch) (R) 253 mm (10.0 inch)

14. Install the decals (N) using the dimensions shown in Illustration 8 that were supplied with the PL641 communication installation group.

15. Connect the battery properly.

16. Connect ET to connector X2110 (E) and complete the installation.

17. Install the long upper roof cap cover (B) from the cab that were saved in Step 4.

18. Remove the Do Not Operate Tag on both the ignition key-switch and the steering wheel.

19. Remove the wheel chocks.

20. Place the machine back in service.

Installation Procedure for Group 2 without A/C

Required Parts

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Illustration 9	g06148396
(1) 480-9645 Communication Installation Gp (2) 501-0361 Bracket As (3) 8T-4138 Bolt (4) 8T-4205 Hard Washer (6) 5C-2890 Nut

1. Mount the PL641 480-9645 Communication Installation Gp (1) to the product link 501-0361 Bracket As (2), using four 8T-4138 Bolt (3), four 8T-4205 Hard Washer (4), and four 5C-2890 Nut (6). Refer to Illustration 9.

2. Set completed assembly to the side.

3. Remove and retain the hardware and the long upper roof cap cover (B) from the cab. Refer to Illustration 2.

4. Refer to Illustration 3 for the general location of the component layout. Detail (C) for the mounting location of the PL641 controller, antenna, and the product link 501-0350 Control Harness As (5). Detail (D) for the installation location of the connection of the other end of the product link 501-0350 Control Harness As (5).
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   Illustration 10	g06148406
   (2) 501-0361 Bracket As (5) 501-0350 Control Harness As (7) 159-9496 Lock washer (8) 159-9495 Nut (9) 501-1119 Dust Cap (10) 455-3027 Cable Tie (11) 8T-4200 Bolt (12) 8T-4224 Hard Washer (S) Blanking plug (T) Connect X2011

5. Insert the five 455-3027 Cable Tie (10) into the cab. Refer to Illustration 10.

6. Locate the blanking plug (S) zip tied in a bag to the product link 501-0350 Control Harness As (5). Connect it to the product link controller as shown in Illustration 10.

7. Position the product link 501-0350 Control Harness As (5). Connect X2110 (T) (ET connector) to the product link 501-0361 Bracket As (2) with one terminal 159-9496 Lock washer (7), one terminal 159-9495 Nut (8). Fasten the 501-1119 Dust Cap (9) as shown in Illustration 10.

8. Continue making the appropriate connections as shown in Illustration 10.

9. Mount the previously assembled PL641 communication installation group and the product link 501-0361 Bracket As (2) to the cab using two 8T-4200 Bolt (11) and two 8T-4224 Hard Washer (12). Refer to Illustration 10.

10. Continue to route the product link 501-0350 Control Harness As (5), down the rear of the cab to the engine side area, following the front frame harness.
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    Illustration 11	g06148436
    (5) 501-0350 Control Harness As (U) MS2113 (V) MS729-1 (X) MS2113-3

11. Locate the CAN TEE. Remove the engine harness connector MS729-1 (V) from it and plug into MS2113 (U) of the product link 501-0350 Control Harness As (5). Refer to Illustration 11.

12. Plug the MS2133-3 (X) of the product link 501-0350 Control Harness As (5) into the empty CAN TEE location.

13. Secure the harness and loose legs with tie straps.

14. Install the decals (P) using the dimensions shown in Illustration 8 that were supplied with the PL641 communication installation group.

15. Connect the battery properly.

16. Connect ET to connector X2110 (T) and complete the installation.

17. Install the long upper roof cap cover (B) from the cab that were saved in Step 3.

18. Remove the Do Not Operate Tag on both the ignition key-switch and the steering wheel.

19. Remove the wheel chocks.

20. Place the machine back in service.