Installation Procedure for the Elite Product Link PL641 on Certain K-Series Medium Wheel Loaders {7606} Caterpillar

Wheel Loader

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

Introduction

This Special Instruction will provide the parts and procedures to install the Elite Product Link^® PL641 on Certain K-Series Medium Wheel Loaders.

Refer to Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems" for information on how to flash, configure, and register the Product Link PL641.

Reference: Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems"

Reference: Systems Operation, Test and Adjust, UENR5823, "Product Link^® Elite PLE641 and PLE631 Systems".

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. Move the machine to a smooth level area free from obstructions.

2. Turn the machine switch to the OFF position and set the parking brake.

3. Perform lock out / tag out procedure on operator controls in the machine cab.

Required Parts

Reference: Special Instruction, REHS9111, "Required Parts for Machines" for full details on product link installation kits.

Note: A 7/32 drill bit is needed for installation.

Choose the correct Enterprise Product Link Installation Kit. All parts in Table 1 are required.

Note: These instructions only support tethering a PL641 radio to a PL522 or PL523 Electronic Control Module (ECM). To update a Series KMedium Wheel Loader built with PL321 Product Link, you will need to replace the PL321 A4N4 ECM with 351-8490 Electronic Control Module (PL522 ECM) or 351-8492 Electronic Control Module (PL523 ECM).

Note: The 353-8773 Antenna Cable AS (coaxial extension cable) between the antenna and the radio ECM can be reused unless damaged.

Required Software

Note: Cat^® Electronic Technician (Cat ET) Service Tool 2014C or newer is required for this software update. VIMspc is required for this software update.

Note: A VIMS/Ethernet cable 305-5528 Wiring Harness (VIMS SERVICE) or 425-6889 Cable As will be needed for this installation.

Note: Download latest flash files for all ECMs except the ECMs listed in Table 2. These flash files will need to be manually downloaded by software part number.If SIS web directs you to a new part number after entering a software part number from Table 2, use the newer part number. This action means that newer software is available.

Note: The latest Product Link^TM flash files and configuration files can be found at the Product Link Technician's Toolbox on SIS web.

PL522 Machines

Note: Refer to the following steps for machines that have a Product Link 522 Module (ECM serial number ends in RM).

1. Prior to flashing software, download a "Product Status Report" for the PL522 machine.

2. Launch Winflash. Flash the PL522 module with software 497-8978. This software can be downloaded from SIS Web.

3. After the flash is complete, navigate to the configurations in the Cat^® Electronic Technician (Cat ET) Service Tool. Set the "PLM Enable Status (Billing)" configuration to "Disabled". This action effectively turns off the Product Link portion of the PL522 Module.

4. Ensure that there are no new events or diagnostics on the Cat^® Electronic Technician (Cat ET) Service Tool. Proceed to the "Product Link Installation" section of this Special Instruction.

PL523 Machines

Note: Refer to the following steps for machines that have a Product Link 523 Module.

1. Prior to flashing software, download a "Product Status Report" for the PL523 machine.

2. Launch Winflash. Flash the PL523 module with software 476-1912. This software can be downloaded from SIS Web.

3. Launch VIMSpc using the machine Ethernet connection. Select "Connect". Once connected, click "Configure". Load the appropriate configuration file based on the machine model. Refer to Table 2. Software can be downloaded from SIS Web.

4. Once the configuration file is loaded, key off the machine. Turn off the battery disconnect switch. Wait two minutes for the ECMs to power down.

5. Turn the battery disconnect switch back on. Key on the machine. Wait two minutes and then key off the machine. Turn off the battery disconnect switch again. Wait two minutes for the ECMs to power down.

6. Turn on the battery disconnect switch. Key on the machine. Wait two minutes and then connect to VIMSpc again. Go to the "Status" screen and ensure that the flash file and configuration file are correctly loaded.

7. After flash and configuration file loading is complete, navigate to the configurations in theCat^® Electronic Technician (Cat ET) Service Tool. Set the "PLM Enable Status (Billing)" configuration to "Disabled". This action turns off the Product Link portion of the PL523 Module.

8. Ensure that there are no new events or diagnostics on the Cat^® Electronic Technician (Cat ET) Service Tool. Proceed to the "Product Link Installation" section of this Special Instruction

Product Link Installation

Accessing the Cab Electrical Group

Illustration 1	g06088522
(1) Electrical cover (2) Cab arrangement

To access the installation area of the K-Series Medium Wheel Loader Telematics Kit, remove the electrical cover (1) from the cab arrangement (2).

Bracket Installation

This section covers the mounting and installation of 479-1915 Bracket As.

Illustration 2	g06088531
(3) Control module (4) Upper bolts/washers (5) Lower bolts/washers (6) 479-1915 Bracket As

1. Remove the upper bolts and washers (4) from the control module (3).

2. Turn the lower bolts and washers (5) of the control module (3) four turns.

3. Slide the 479-1915 Bracket As (6) over the lower bolts and washers (5).

4. With the 479-1915 Bracket As (6), reinstall the upper bolts and washers (4). Tighten the lower bolts and washers (5).

5. Ensure the harness for the control module (3) does not contact the 479-1915 Bracket As (6).

Control Group Installation

Illustration 3	g06088554
(7) 417-4722 Communication Electronics Gp (PLE601 NETWORK MANAGER) (8) 8C-8451 Bolt (9) 9X-6165 Washer (10) 8C-5607 Isolation Mount (11) 8C-5608 Spacer (12) 479-1915 Bracket As (13) Weld Nut (part of 479-1915 Bracket As)

Illustration 3 displays the hardware needed for the mounting and installation of the 417-4722 Communication Electronics Gp (PLE601 NETWORK MANAGER).

Illustration 4	g06088559
(14) 155-2264 Connector Plug As (15) 8T-8737 Seal Plug (16) Mounting location for 440-2105 Communication Radio Gp (PL641E CELLULAR) (17) 440-2105 Communication Radio Gp (PL641E CELLULAR) (18) 8T-4971 Bolt (19) 9X-8256 Washer

Illustration 4 displays the hardware needed for the mounting and installation of the 440-2105 Communication Radio Gp (PL641E CELLULAR). Reference the following steps for the mounting procedure.

1. Place the 440-2105 Communication Radio Gp (PL641E CELLULAR) (17) in the proper mounting location (16).

2. Fasten the 440-2105 Communication Radio Gp (PL641E CELLULAR) using 8T-4971 Bolt (18) and 9X-8256 Washer (19).

3. Install 155-2264 Connector Plug As (14) with 8T-8737 Seal Plug (15) on 440-2105 Communication Radio Gp (PL641E CELLULAR). Refer to Illustration 4.

Antenna Installation

For information regarding the antenna installation, refer to Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems {7606}".

Illustration 5	g06088567
(20) 443-8462 Antenna As (hard-mount antenna) (21) 329-5671 Plate (mounting bracket) (22) Antenna mounting location (top rear right corner of cab)

Illustration 6	g06088573
View showing the connectors attached to 443-8462 Antenna As (23) Satellite cable (White wire) (24) Cellular cable (Brown wire) (25) GPS data (Blue wire)

Note: The existing extension coaxial cable on the machine will be reused.

Illustration 5 shows the connectors attached to the Product Link antenna. For PLE641 cellular installations, connect the cellular data connection (24) and GPS data connection (25) to the existing coaxial extension cable. For PLE631 satellite installations, connect the satellite data connection (23) and the GPS data connection (25) to the coaxial extension cable.

Harness Installation

This section covers the routing and installation of the 484-5891 Harness AS.

Illustration 7	g06089548
(26) Connector, J-C6, 484-5891 Harness As (27) 417-4722 Communication Electronics Gp (PLE601 NETWORK MANAGER) (28) 484-5891 Harness As (29) 440-2105 Communication Radio Gp (PL641E CELLULAR) (30) Connector, J-C6, 484-5891 Harness As (31) Connector, J-C2, 484-5891 Harness As (32) 7K-1181 Cable Strap (15.5-IN)

1. Connect 484-5891 Harness As (J-C6) (26) to 417-4722 Communication Electronics Gp (PLE601 NETWORK MANAGER) (27).

2. Route 484-5891 Harness As (28) up to 440-2105 Communication Radio Gp (PL641E CELLULAR) (29).

3. Connect 484-5891 Harness As (J-C6) (30) to 440-2105 Communication Radio Gp (PL641E CELLULAR) (29).

4. Secure 484-5891 Harness As (28) using the strap cable (32). Refer to Illustration 7.
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   Illustration 8	g06089595
   (31) Connector, J-C2, 484-5891 Harness As (33) 285-5405 Seat Support As (34) 489-3079 Bracket (35) Floor mat (36) 6V-8931 Washer Head Screw

5. Center the 489-3079 Bracket (34) on the left rear 285-5405 Seat Support As (33). Refer to Illustration 8.

6. Drill three pilot holes with a 7/32 drill bit. Use the 489-3079 Bracket (34) as a template for these holes.

7. Fasten the 489-3079 Bracket (34) using three 6V-8931 Washer Head Screw (36).

Electrical Connections

The following section covers the connection of the 484-5891 Harness As to the power supply and data link of the machine.

Illustration 9	g06089616
(37) Wires from 484-5891 Harness As (38) Partial view of 484-5891 Harness As (39) Connector, J-C4, 484-5891 Harness As (40) Wires from the Cab Harness As (41) Cab Harness Connector, C-C2 (42) Cab Harness Connector, C-C52

Note: Each connector on 484-5891 Harness As is labeled. The label is formatted as "J-C#".

1. Remove the wires from the existing Cab Harness Connector (41). Refer to Illustration 9 and Table 3.
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   Table 3

   Cab Harness Connector (C-C2) (41)	Wires from Cab Harness As (40)
   C-C2, Position 32	F711-C293 YL
   C-C2, Position 33	F712-C279 GN

2. Insert the wires from 484-5891 Harness As (37) into the existing Cab Harness Connector (41). Refer to Illustration 9 and Table 4.
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   Table 4

   Cab Harness Connector (C-C2) (41)	Wires from 484-5891 Harness As (37)
   C-C2, Position 34	F712-J35 GN
   C-C2, Position 35	F711-J30 YL

3. Insert the wires from the Cab Harness As (40) into the 484-5891 Harness As connector (J-C4) (39). Refer to Illustration 9 and Table 5
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   Table 5

   Connector (J-C4) on the 484-5891 Harness As (39)	Wires from the Cab Harness As (40)
   J-C4, Position 1	F711-C293 YL
   J-C4, Position 2	F712-C279 GN

   Note: Step 4 provides the power, ground, and key switch to the new K-Series Medium Wheel Loader Telematics Kit.

4. Connect J-C5 of the 484-5891 Harness As (38) to the Cab Harness Connector (C-C52) (42) "Power Connection".

Illustration 10	g06089651
K-Series Medium Wheel Loaders 484-5891 Harness As (43) Connects to Machine Harness C-C52 (44) Wires are inserted into the Cab Harness Connector C-C2 (45) Wires removed from the Cab Harness Connector C-C2 are inserted into J-C4

System Installation Verification

Electrical Validation

Turn on the power to the equipment once the following have been properly connected:

• Network manager

• Wires from the retrofit harness for battery positive, battery negative, and key switch power

Software Validation

1. Use Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems", Flash the PLE641 or PLE631 Product Link System Using Winflash for the procedure to flash the Product Link ECMs through Winflash.

2. Use Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems", Upload Configuration File to upload the configuration file 484-3319. This procedure is used to upload the configuration file to the Telematics ECM (network manager) using the Ethernet cable and the newly installed VIMS service port.

3. Follow the procedure in Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems", Set the Product ID on the PLE601 Network Manager. This procedure programs the machine serial number into the Product ID field using the Cat^® Electronic Technician (Cat ET) Service Tool and the Communications Adapter.

4. Launch the Cat^® Electronic Technician (Cat ET) Service Tool with the Communications Adapter. Connect to the Product Link ECM. Synchronize service meter hours across the ECMs. The transmission ECM should have the master machine hours on a K-Series Medium Wheel Loader.

5. In the Cat^® Electronic Technician (Cat ET) Service Tool, set the ECM Date/Time to the current local time on the PLE641, PL522/532, and Transmission ECM.

   Note: Setting the current date/time requires selecting each ECM individually and editing the parameter.

6. Refer to Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link^™ PLE601, PLE641, and PLE631 Systems" for information about subscribing the Product Link using the Dealer Service Portal and checking for connectivity.

   Note: The subscription in the VisionLink store for the previously subscribed machine must be canceled prior to any subscription being created through the Dealer Service Portal.

   Note: The machine will no longer show as a PL522/523 machine. The machine will appear as a PLE641 machine. With this retrofit, the PL522 is for the payload data collection and functionality only. The PLE641 will take care of the Product Link functionality.

7. Resolve any active codes. Clear logged events and diagnostics before gathering a final "Product Status Report".