Product Link 151/201 Caterpillar

There are problems that could be reported with the Product Link System but the problems are not caused by the Product Link Module. The following section describes the problems. The section contains steps that are used to determine the possible cause. Check for active diagnostic codes for the Product Link. Correct any diagnostic codes before proceeding. The module, the antenna, and cables should be visually inspected for damage. Verify that there are no loose connections.

Description of the Problem:

• Reports or messages are not received in the office.

The Product Link system depends on several communication links in order to transfer data from the machine to the office. The following procedures assume that these communication links are operating properly. The proper Communication links are listed below:

• The Orbcomm satellite network is operational in the geographic area of concern. The network is operational when messages can travel to the satellite and the messages can travel to the earth and Caterpillar.

• The Product Link module is correctly configured to communicate on the Orbcomm network. This was verified during manufacturing tests.

• The worldwide network of Caterpillar's computers is passing messages to the software ("CPLS-PC: Caterpillar Product Link System - PC Software").

• The CPLS is configured properly and the software is functioning.

The Product Link module should not be replaced without verifying that these issues have been investigated. Contact the Service System Support Center for aid in resolving these issues.

In "power mode 1", four position reports and one SMU/Fuel report are transmitted. This transmission occurs one time in 24 hours. Fewer messages are sent in power mode 2 and power mode 3. If messages are not available, proceed with the following steps in order to determine the cause.

Test Step 1. CHECK THE LED INDICATORS.

Check the LED indicators on the Product Link.

Expected Result:

The red LED is OFF.

Results:

• RED LED OFF - The red LED is OFF. There are no diagnostic codes. Proceed to Test Step 2.

• RED LED BLINKING - There is a diagnostic code.

  Repair: There is a diagnostic code. First correct the diagnostic code. See Troubleshooting, "Diagnostic Capabilities" for more information.

  Stop.

• RED LED ALWAYS ON - The red LED is always ON. The Product Link has failed.

  Repair: Replace the Product Link.

  Stop.

Test Step 2. ACCESS THE PRODUCT LINK THROUGH THE ELECTRONIC TECHNICIAN.

1. Connect the Electronic Technician to the machine.

2. Verify that the ECM (Product Link) is available.

Expected Result:

The ECM (Product Link) is available.

Results:

• OK - The ECM (Product Link) is available. Proceed to Test Step 3

• NOT OK - The ECM (Product Link) is not present in the Electronic Technician screen.

  Repair: Verify that the wiring for the Product Link has been installed correctly. See Systems Operation, "System Installation". Near the end of the installation procedure, Step 13 checks the wiring with a multimeter. If the ECM (Product Link) is not available, see Troubleshooting, "Electronic Service Tool Does Not Communicate with ECM - Troubleshoot"

  Stop.

Test Step 3. VERIFY THAT THE PRODUCT LINK MODULE IS CONFIGURED PROPERLY.

1. Go to the "Configuration" screen. See Testing and Adjusting, "Installation Parameters - Configure" for more information.

2. Verify that the "PLM Enable Status" is configured as "Enabled".

3. Verify that the "Dealer Identification Code" is configured with the correct code for the Dealer.

4. Verify that the "DBS Machine Make Code" is configured correctly.

5. Verify that the "Machine Serial Number" is configured with the correct machine serial number.

6. Verify that "Maintenance Mode" is configured as "Off".

Expected Result:

All settings are correct.

Results:

• OK - The Product Link is configured correctly. Proceed to Test Step 4

• NOT OK - The Product Link is not configured correctly.

  Repair: Correct the configuration of the Product Link. The "PLM Enable Status" and "PLM Registration Status" can be verified in the "ET Status Group 2".

  Stop.

Test Step 4. VERIFY THAT THE PRODUCT LINK MODULE HAS NOT BEEN TURNED OFF.

1. Go to "ET Status Group 2 - PLM Operational Status".

2. Verify that " the Possible Device Power Disconnection" is labelled as "No".

Expected Result:

"Possible Device Power Disconnection" is labelled as "No".

Results:

• OK - The "Possible Device Power Disconnection" is labelled as "No". The Product Link has operated since successfully transmitting the last report. Proceed to Test Step 5.

• NOT OK - The "Possible Device Power Disconnection" is labelled as "Yes". The Product Link has been disconnected from power and transmissions have been prevented. This could explain the failure to get any messages. Proceed to Test Step 5.

Test Step 5. VERIFY THAT THE PRODUCT LINK MODULE HAS BEEN IN AN AREA OF BLOCKED COMMUNICATIONS.

1. Go to "ET Status Group 2 - PLM Operational Status".

2. Verify that the "Possible Periods of Communications Blockage" is "No".

Expected Result:

The Electronic Technician shows that the "Possible Periods of Communications Blockage" is "No".

Results:

• OK - The Product Link has seen satellites since the transmission of the last report. Verify that the machine has a clear view of the sky. Proceed to Test Step 6.

• NOT OK - The Product Link has experienced blocked communications. Transmissions have been prevented. This could explain the failure to get any messages. Verify that the machine has a clear view of the sky. Proceed to Test Step 6.

Test Step 6. VERIFY THAT THE PRODUCT LINK IS IN POWER MODE 1.

1. Go to "ET Status Group 2 - PLM Operational Status".

2. Verify that the "Power Mode Status" is "Power Mode 1". Verify that the "Key Switch Status" is "On".

Expected Result:

The ET screen shows that the machine is in "Power Mode 1" and "Key Switch On".

Results:

• OK - The ET screen is correct. The Product Link should daily send four position reports and one SMU/Fuel report. Proceed to Test Step 8.

• NOT OK - The Electronic Technician shows "Power Mode 2" or "Power Mode 3". A report of the position is sent in "Power Modes 2" and in "Power Mode 3" when the machine moves more than 200 m (656 ft). Fuel reports are sent in "Power Mode 1" only. Even if this explains the current reports that are arriving at the office, proceed to Test Step 7.

Test Step 7. VERIFY THAT THE PRODUCT LINK MODULE MONITORS THE MACHINE RUN STATUS PROPERLY.

1. Go to "ET Status Group 2 - PLM Operational Status".

2. Start the machine.

3. Verify that the "Power Mode Status" changes to "Power Mode 1".

4. Verify that the "Alternator Running Input" changes to "Engine On".

5. Verify that the "Key Switch Status" is "On".

Expected Result:

The ET Status screen changes to "Power Mode 1" and "Engine On". The "Key Switch Status" should be "On".

Results:

• OK - The Electronic Technician screens are correct. The Product Link should send four position reports and one SMU/Fuel report daily until the Power Mode changes to "mode 2". The power mode can be viewed in CPLS. Stop.

• NOT OK - ENGINE OFF - Electronic Technician screen shows "Engine Off".

  Repair: Verify that the Alternator R-Terminal wiring has not been damaged. It is likely that the machine's SMU and Product Link's SMU no longer match. Refer to Troubleshooting, "Operating Hours Discrepancy".

  Stop.

• NOT OK - POWER MODE 2 OR 3 - Electronic Technician shows "Power Mode 2" or "Power Mode 3".

  Repair: Verify that the wiring for the switched power 308-YL has not been damaged. Repair the wiring.

  Stop.

Test Step 8. SEND A TEST MESSAGE IN ORDER TO VERIFY THE TRANSMISSION.

1. Go to the drop-down menu in the ET and select "Service". Then select "PLM Commands" and "Position Report".

2. Go to "ET Status Group 1 - Queued Messages".

3. Verify that the "Queued Position Report" equals 1.

4. Go to "ET Status Group 2 - PLM Operational Status".

5. Verify the "Primary Communication Link" switches to "On-Line" within 15 minutes.

6. Go to "ET Status Group 1 - Queued Messages".

7. Verify that the Queued Position Report changes to 0 within 15 minutes. This signifies that the message has been successfully transmitted.

Expected Result:

The "Primary Communication Link" switches to "On-Line" and the "Queued Position Report" is transmitted within 15 minutes.

Results:

• OK - The Product Link appears to be operating properly. Verify that the message was successfully received at the office. Remember that the delay time is dependent on the configuration of the software at the office. Stop.

• NOT OK - There is a problem with the antenna or with the module. Do not replace the module until the antenna and cable are verified. Proceed to Test Step 9.

Test Step 9. VERIFY THAT THE CENTER CONDUCTOR OF THE ANTENNA HAS NOT SHORTED TO THE SHIELD.

1. Disconnect the connection of the GPS antenna at the module.

2. Measure the resistance from the shield of the antenna cable to the conductor at the center of the cable. The shield is the threaded part of the connector.

Expected Result:

The resistance is 1 to 10 megohms.

Results:

• OK - The resistance is 1 to 10 megohms. The resistance is correct. Proceed to Test Step 10

• NOT OK - The resistance is less than 300 ohms. The resistance is incorrect.

  Repair: The antenna cable or the antenna has a short from the center conductor to the outer shield. Disconnect the cable from the antenna in order to isolate the short. Replace the cable or the antenna. Verify that the module is operating correctly.

  Stop.

Test Step 10. CHECK THE INSTALLATION OF THE ANTENNA.

Observe installation of the antenna for the Product Link. Verify that the antenna is installed with a clear view of the sky. The antenna must be in a location that is free from interference. Examples of interference include the following items: Devices on the roof of the machine that emit power, Other antennas that are close to the antenna for the Product Link, indoor machine, machine under large signs that are lighted and machine under power lines

Expected Result:

The antenna is installed on the highest point on the machine. There is a clear view of the sky.

Results:

• OK - The antenna for the Product Link is installed properly. Verify that all of the connections for the antenna are tight. Proceed to Test Step 11.

• NOT OK - The installation of the antenna is not optimal.

  Repair: Accept the current performance of the communication or reinstall the antenna at a superior location.

  Stop.

Test Step 11. VERIFY THE WIRING OF THE ANTENNA.

1. Disconnect the connector for the antenna at the module.

2. Measure the resistance from the conductor at the center of the cable to the connector for the antenna.

Expected Result:

The resistance should be less than 10 ohms.

Results:

• OK - The resistance is correct.

  Repair: Verify that all of the connections are tight. If the problem persists, replace the antenna first. Then, replace the cable. Replace the Product Link Module last.

  Stop.

• NOT OK - The cable for the antenna or the antenna has an open circuit.

  Repair: Disconnect the cable from the antenna. Test each component. Replace the cable or replace the antenna. Verify that the Product Link module operates correctly.

  Stop.