Product Link - PL102C Caterpillar

Illustration 1	g01092727
Product Link PL102C Wiring Harness

Problems may occur during the installation of a Product Link PL102C module and wiring harness. Before proceeding, the installation of the wiring should be checked for proper installation. Refer to Illustration 1. The Product Link PL102C module can communicate with a computer that has Caterpillar Service Tool software installed. A serial service cable is used to allow connection between the computer and the PL102C wiring harness. If the serial service cable is not long enough, a serial extension cable is available to be used between the serial service cable and the computer. The Caterpillar Service Tool will be unable to communicate with the Product Link PL102C module if any of the conditions listed below are present:

• The service connector circuits in the Product Link harness are open.

• There is a problem with the power supply circuit for the Product Link PL102C module.

• The service connector circuits in the Product Link module are shorted.

• The serial service cable and/or serial extension cable has failed.

• The Caterpillar Service Tool software is using the incorrect communication port of the computer.

• The Product Link PL102C module has failed.

• If wires for the module are reversed during the installation, the Product Link module will not be shown after connecting Caterpillar Service Tool to the machine.

Test Step 1. VERIFY THE POWER CIRCUIT OF THE PRODUCT LINK PL102C MODULE.

1. Verify that the key start switch is in the OFF position.

2. Turn the disconnect switch to the OFF position.

3. Disconnect the 2-Pin power connector from the Product Link PL102C module.

4. Turn the disconnect switch to the ON position.

5. Turn the key start switch to the ON position.

6. Measure the voltage between pin 1 and 2 pin of the 2-pin power connector.

Expected Result:

The voltage is approximately equal to the system voltage.

Results:

• OK - The voltage is approximately system voltage. Proceed to Test Step 2.

• NOT OK - The voltage is not approximately system voltage.

  Repair: There may be incorrect battery voltage, a blown fuse, and/or a failed harness. Check battery voltage. Check for a blown fuse in the power circuit. If the battery voltage is correct and the fuse is good, repair the harness or replace the PL102C harness.

  Stop.

Test Step 2. CHECK FOR OPEN SERVICE CONNECTOR CIRCUITS.

1. Turn the key start switch to the OFF position.

2. Turn the disconnect switch to the OFF Position.

3. Disconnect the 13-pin connector from the Product Link PL102C module.

4. Disconnect the 4-pin service connector from the machine harness.

5. Measure the resistance between the contacts that are listed below:
   • Contact 1 (Black wire) of the 4-pin service connector and contact 8 of the 13-pin connector of the Product Link PL102C module.

   • Contact 2 (Brown wire) of the 4-pin service connector and contact 9 of the 13-pin connector of the Product Link PL102C module.

   • Contact 3 (orange wire) of the 4-pin service connector and contact 10 of the 13-pin connector of the Product Link PL102C module.

   • Contact 4 (red wire) of the 4-pin service connector and contact 12 of the 13-pin connector of the Product Link PL102C module.

Expected Result:

The resistance is less than 5 ohms for all measurements.

Results:

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

• NOT OK - The resistance is greater than 5000 ohms for any of the measurements. The harness has failed.

  Repair: Repair the circuits that had resistance of greater than 5000 ohms or replace the PL102C harness.

  Stop.

Test Step 3. CHECK FOR SHORTED SERVICE CONNECTOR CIRCUITS.

1. Turn the key start switch to the OFF position.

2. Turn the disconnect switch to the OFF Position.

3. Disconnect the 13-pin connector from the Product Link PL102C module.

4. Disconnect the 4-pin service connector from the machine harness.

5. Measure the resistance between the contacts that are listed below:
   • Contact 8 of the 13-pin connector and contacts 9, 10, 12 of the 13-pin connector.

   • Contact 9 of the 13-pin connector and contacts 10 and 12 of the 13-pin connector.

   • Contact 10 of the 13-pin connector and contact 12 of the 13-pin connector.

Expected Result:

The resistance is greater than 5000 ohms for all the measurements.

Results:

• OK - The resistance is greater than 5000 ohms for all the measurements. Proceed to Test Step 4.

• NOT OK - The resistance is less than 5 ohms for any of the measurements. The harness has failed.

  Repair: Repair the circuits that had resistance of less than 5 ohms or replace the PL102C harness.

  Stop.

Test Step 4. CHECK THE SERIAL SERVICE CABLE AND THE SERIAL EXTENSION CABLE.

1. Reconnect the 2-pin power connector and the 13-pin connector to the Product Link PL102C module.

2. Turn the disconnect switch to the ON position.

3. Turn the key start switch to the ON position.

4. Connect a known good serial service cable and/or a serial extension cable to the 4-pin service connector.

5. Connect the DB9 connector of the service cable and/or serial extension cable to the serial connector on the computer.

6. Attempt to initiate communications between the Caterpillar Service Tool and the Product Link PL102C module.

Expected Result:

The Caterpillar Service Tool and the Product Link PL102C module communicate.

Results:

• OK - The Caterpillar Service Tool and the PL102C module communicate. The service cable and/or the serial extension cable that were previously used have failed.

  Repair: Replace the failed service cable and/or the serial extension cable.

  Stop.

• NOT OK - The Caterpillar Service Tool and the Product Link PL102C module will still not communicate. Proceed to Test Step 5.

Test Step 5. VERIFY THE COMPUTER IS USING THE CORRECT COMMUNICATION PORT.

1. Shut down the computer.

2. Connect a known good service cable and/or serial extension cable to the 4-pin service connector of the PL102C wire harness.

3. Connect the DB9 connector of the service cable and/or serial extension cable to the serial connector on the computer.

4. Reboot the computer.

5. Start the Caterpillar Service Tool application.

6. Select "Options" from the "Tool" menu. This will display a dialog box that allows the user to select the comm port that the "Caterpillar Service Tool" will use to communicate with the Product Link PL102C module.

7. Select the correct comm port for the serial port on the computer.

8. Attempt to initiate communications between the Caterpillar Service Tool and the Product Link PL102C module.

Expected Result:

The Caterpillar Service Tool and theProduct Link PL102C module communicate.

Results:

• OK - The Caterpillar Service Tool and the Product Link PL102C module communicate. The comm port setting was incorrect. Stop.

• NOT OK - The Caterpillar Service Tool and the Product Link PL102C module will not communicate.

  Repair: Try another computer with the Caterpillar Service Tool software installed. If the replacement computer works, the original software or computer may be faulty. If the replacement computer does not work, replace the Product Link PL102C module. If the module is replaced, the proper procedures will need to be used to configure and register the new module. Refer to the System Operation/Test and Adjust, RENR8115, "Configuration" section for information to configure and register the PL102C module.

  Stop.