Installation Procedure for Product Link PL421 Retrofit for Generator Sets{7606} Caterpillar

Generator Set: All

Introduction

This Special Instruction will provide instructions for installation, configuration, and troubleshooting of the Product Link PL421 on a generator set.

• Cat^® Product Link is a remote monitoring and asset management solution that enables owners to oversee their entire fleet of equipment more efficiently and effectively by providing information about the location, utilization, and condition of their assets .

• PL421 hardware collects GPS positioning and data reported directly off the asset and transmits it off-board through cellular GSM communications networks to the Cat Product Link Service.

• Product Links intuitive, secure web-based user interface, called VisionLink, allows users to quickly and easily view the status and health of all remotely monitored equipment.

• Through PL421 and close integration with the EMCP controller, Product Link also provides features specific to generator sets, including ready to run status.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Structural damage, an overturn, modification, alteration, or improper repair can impair this structure's protection capability thereby voiding this certification. Do not weld on or drill holes in the structure. Consult a Cat dealer to determine this structure's limitations without voiding its certification.

The battery for the PL421 is not a serviceable part but a person must use caution because there is risk of an explosion, if the battery is replaced by an incorrect type. Dispose of used batteries according to the instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

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Only persons with training in electrical installations must carry connections to the generator. The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect. The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these two steps in order to prevent accidental starting: Isolate the DC breaker. Disconnect the DC supply battery.

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Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. 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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Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circumstances.

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Care must be taken in handling lithium batteries. Lithium batteries are not a serviceable part. Personal injury can result from battery exploding. Caution must be used because there is risk of an explosion if the battery is replaced by an incorrect type. Do not dispose of battery or batteries in a fire. The battery is capable of exploding and emitting caustic chemicals. Dispose of used batteries according to federal and local laws.

PL421 Block Diagram and System Components

Table 1

PL421 System Components
Part Number	Description
389-0463	Antenna As
386-3004	Communication Electronic Control Module
390-2764	Holster
394-8813	Communication Wiring Gp

Table 2

396-4284 Communication Installation Gp
Qty	Part Name	Description
4	1H-3244	Lockwasher
4	5C-2890	Nut
4	6V-8214	Bolt
5	7K-1181	Cable Strap
2	7X-2533	Bolt
1	230-1340	Film
1	230-1341	Film
1	386-3004	Communication Electronic Control Module
1	389-0463	Antenna As
1	394-8813	Communication Wiring Gp

Illustration 1	g02998240
386-3004 Communication Electronic Control Module

Illustration 2	g03037496
394-8813 Communication Wiring Gp

Illustration 3	g02998241
389-0463 Antenna As

Illustration 4	g02998236
PL421 Block Diagram

Illustration 5	g02998281
PL421 Connector Diagram

The 14 pin GTC connector is on the enclosure of the PL421.

Table 3

Pin No	GTC Connector Input/Output Signal
1	Battery +
2	Battery -
3	Key Switch
4 (1)	R-Terminal (if equipped)
5	RS232 TX (not populated in harness)
6	RS232 GND (not populated in harness)
7	RS232 RX (not populated in harness)
8	Digital Output 2 / Tamper Switch Output (+ 5 V source)
9	Digital Input 2 / Tamper Switch Input
10	Digital Input 1 / Exception Alert Input (General Purpose)
11	CAN Low
12	CAN High
13	Digital Output 1 / Relay Driver Output
14	Digital Input 3

( 1 )

R-Term Connection Optional - If the generator set is equipped with an EMCP 3 or 4, or a Cat Electronic engine governor, the engine hours are obtained over the EMCP CAN 1 link. If the genset has neither of these, but has a charging alternator with a "Relay terminal" connection, the R-term should be connected to the appropriate R-term on the alternator to determine engine hours.

Generator Set Model Specific Installation Instructions

Table 4

PL421 Feature Availability Matrix for Rental Generator Sets
Generator Set Model	Engine Control Model Type	Tier	Genset Control, EMCP, or PowerWizard	Cellular Communications	DC & Battery Backup	Plug-n-Play Setup	Hours	Fuel
XQ 20	Analog	4	NA	x	x	x	-	-
XQ 20	Electronic	4	NA	x	x	x	-	-
XQ 30	Electronic	4	NA	x	x	x	-	-
XQ 45	Electronic	3	NA	x	x	x	-	-
XQ 60	Electronic	3	NA	x	x	x	-	-
XQ 80	Electronic	3	3.1	x	x	x	x	x
XQ 100	Electronic	3	3.1	x	x	x	x	x
XQ 175	Electronic	3	4001	x	x	x	x	x
XQ 200	Electronic	4	4.2	x	x	x	x	x
XQ 230	Electronic	3	3.2	x	x	x	x	x
XQ 300	Electronic	3	3.2	x	x	x	x	x
XQ 350	Electronic	4	4.2	x	x	x	x	x
XQ 400	Electronic	3	3.2	x	x	x	x	x
XQ 500	Electronic	4	4.4	x	x	x	x	x
XQ 600	Electronic	2	3.3	x	x	x	x	x
XQ 800	Electronic	4	4.4	x	x	x	x	x
XQ 1000	Electronic	2	3.3	x	x	x	x	x
XQ 2000	Electronic	2	3.3	x	x	x	x	x

Table 5

PL421 Feature Availability Matrix for Rental Generator Sets
Generator Set Model	GPS Location	Geo-Fencing	J1939 Diagnostics	Not-Ready-To- Run Alert	Genset Status	Customizable E-mail & Text Alerts
XQ 20	x	x	-	-	-	x
XQ 20	x	x	-	-	x	x
XQ 30	x	x	-	-	x	x
XQ 45	x	x	-	-	x	x
XQ 60	x	x	-	-	x	x
XQ 80	x	x	x	-	x	x
XQ 100	x	x	x	-	x	x
XQ 175	x	x	x	-	x	x
XQ 200	x	x	x	x	x	x
XQ 230	x	x	x	x	x	x
XQ 300	x	x	x	x	x	x
XQ 350	x	x	x	x	x	x
XQ 400	x	x	x	x	x	x
XQ 500	x	x	x	x	x	x
XQ 600	x	x	x	x	x	x
XQ 800	x	x	x	x	x	x
XQ 1000	x	x	x	x	x	x
XQ 2000	x	x	x	x	x	x

Ferrite Beads

In a limited number of genset installations, there have been reports of output voltage spikes caused when the PL421 is introduced into the system. Caterpillar is recommending that ferrite beads be used on all harnessing on voltage regulators. The ferrite bead to be used are 415-4615 Ferrite Bead . The ferrite beads should be placed as close to the voltage regulator as possible. For the CDVR ( 314-7755 Voltage Regulator As or 235-5725 Voltage Regulator As ) 4 ferrite beads are needed. One for the 6-pin and 9-pin harnesses and then two for the the 12-pin harness (split the harness into two 6-wire harnesses). For the R450 ( 352-6019 Voltage Regulator single-phase and 352-5636 Voltage Regulator three-phase) one ferrite bead is needed.

XQ20, XQ30, XQ45, and XQ60

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Illustration 6	g03423772
Battery Bypass Circuit Diagram

1. Refer to procedures for mounting the PL421 module and the GPS antenna.

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Illustration 7	g03413591

2. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 7 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal and 9X-1056 Receptacle Terminal . (12V Relay: 115-1615, 24V Relay: 3E-5239)

3. Connect the +Battery wire directly to the +Battery terminal of the battery or the battery charger.

4. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

5. If the Engine is not equipped an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal"connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

6. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ80, XQ100, and XQ200

Table 6

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
2	174-0503	Connecting Plug Kit
6	9X-3402	Connector Socket
1	174-3016	Connector Plug As
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
1	9X-1054	Connector Plug As
3	9X-1055	Receptacle Terminal
2	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna.

2. Using 153-2707 Electrical Cable , create short jumper harness using 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket on one end and leaving other end bare wires. Wiring the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

3. Locate CAN1 terminating resistor inserted in terminal blocks in control panel, remove, and discard.

4. Plug one end of the previously created jumper harness into the terminal blocks previously occupied by the CAN1 terminating resistor. Plug the other end of the jumper harness into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 174-3016 Connector Plug As into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2276 Plug Lock Wedge and the 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Wiring the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 8	g03413621

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 8 below using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal and 9X-1056 Receptacle Terminal . (12V Relay - 115-1615, 24V Relay - 3E-5239)

8. Connect the +Battery wire directly to the +Battery terminal of the battery or the battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the engine is not equipped an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a Relay terminal connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ175

Table 7

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
3	174-0503	Connecting Plug Kit
9	9X-3402	Connector Socket
1	140-9442	Adapter Cable As
1	174-3016	Connector Plug As
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
1	9X-1054	Connector Plug AsX-
3	9X-1055	Receptacle Terminal
2	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna.

2. Pull wires from pins F and G from one of the 8T-8736 Connector Receptacle on 140-9442 Adapter Cable As . Cut off the pins and use 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket to make a new connection. Connect the wire from location G to location A and from location F to location B in the plug.

3. Plug the modified 140-9442 Adapter Cable As into the engine diagnostic connector.

4. Plug the previously modified 140-9442 Adapter Cable As into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 174-3016 Connector Plug As into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 9	g03413657

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 9 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal and 9X-1056 Receptacle Terminal . (12V Relay - 115-1615, 24V Relay - 3E-5239)

8. Connect the + Battery wire directly to the +Battery terminal of the battery or battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the Engine is not equipped with an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ230, XQ300, and XQ400

Table 8

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
3	174-0503	Connecting Plug Kit
9	9X-3402	Connector Socket
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
1	9X-1054	Connector Plug As
1	9X-1055	Connector Plug As
1	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna.

2. Using 153-2707 Electrical Cable , create short jumper harness using 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

3. Locate CAN1 terminating resistor in control panel and remove.

4. Plug one end of the previously created jumper harness into the location previously occupied by the CAN1 terminating resistor. Plug the other end of the jumper harness into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 terminating resistor into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 10	g03415298

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in the illustration 10 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal . (12V Relay - 115-1615, 24V Relay - 3E-5239).

8. Connect the +Battery wire directly to the + Battery terminal of the battery or the battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the Engine is not equipped an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ350, XQ500, and XQ800

Table 9

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
3	174-0503	Connecting Plug Kit
9	9X-3402	Connector Socket
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
3	9X-1055	Receptacle Terminal
2	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna.

2. Using 153-2707 Electrical Cable , create short jumper harness using 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

3. Locate CAN1 terminating resistor in control panel and remove.

4. Plug one end of the previously created jumper harness into the location previously occupied by the CAN1 terminating resistor. Plug the other end of the jumper harness into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 terminating resistor into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 11	g03415325

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 11 using the 9X-1054 Connector Plug As , 9X-1055 Receptacle Terminal and 9X-1056 Receptacle Terminal . (12V Relay - 115-1615, 24V Relay - 3E-5239)

8. Connect the + Battery wire directly to the +Battery terminal of the battery or the battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the Engine is not equipped with an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL 421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ600

Table 10

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
2	174-0503	Connecting Plug Kit
6	9X-3402	Connector Socket
1	174-3016	Connector Plug As
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
1	9X-1054	Connector Plug As
3	9X-1055	Receptacle Terminal
2	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna

2. Using 153-2707 Electrical Cable , create short jumper harness using 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket on one end and leaving other end bare wires. Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

3. Locate CAN1 terminating resistor inserted in terminal blocks in control panel, remove, and discard.

4. Plug one end of the previously created jumper harness into the terminal blocks previously occupied by the CAN1 terminating resistor. Plug the other end of the jumper harness into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 174-3016 Connector Plug As into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 12	g03408271

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 12 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal . (12V Relay - 115-1615 Relay As , 24V Relay - 3E-5239 Relay As .

8. Connect the +Battery wire directly to the +Battery terminal of the battery or the battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the engine is not equipped with an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ1000, and XQ2000 with Switchgear

Table 11

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
2	174-0503	Connecting Plug Kit
6	9X-3402	Connector Socket
1	176-9299	Receptacle Kit
3	9X-3401	Connector Pin
1	174-3016	Connector Plug As
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
1	9X-1054	Connector Plug As
3	9X-1055	Receptacle Terminal
2	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna

2. Using 153-2707 Electrical Cable , create short jumper harness using 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket on one end and using 176-9299 Receptacle Kit and 9X-3401 Connector Pin at the other end. Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the connectors.

3. Locate CAN1 terminating resistor in right-hand side of dog house by AC/DC pan, remove, and discard.

4. Plug one end of the previously created jumper harness into the location previously occupied by the CAN1 terminating resistor. Plug the other end of the jumper harness into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 174-3016 Connector Plug As into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 13	g03415352

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 13 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal . (12V Relay - 115-1615 Relay As , 24V Relay - 3E-5239 Relay As .

8. Connect the +Battery wire directly to the +Battery terminal of the battery or the battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the engine is not equipped with an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

XQ1000, and XQ2000 with GPC module

Table 12

Required Parts
Qty	Part Number	Description
1	133-0970	Connector Receptacle As
2	174-0503	Connecting Plug Kit
6	9X-3402	Connector Socket
1	176-9299	Receptacle Kit
3	9X-3401	Connector Pin
1	174-3016	Connector Plug As
Bulk	153-2707	Electrical Cable
1	3E-5239	Relay As
1	115-1615	Relay As
1	9X-1054	Connector Plug As
3	9X-1055	Receptacle Terminal
2	9X-1056	Receptacle Terminal

1. Refer to procedures for mounting the PL421 module and the GPS antenna

2. Using 153-2707 Electrical Cable , create short jumper harness using 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket on one end and using 176-9299 Receptacle Kit and 9X-3401 Connector Pin at the other end. Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the connectors.

3. Locate CAN1 terminating resistor in control panel, remove, and discard.

4. Plug one end of the previously created jumper harness into the location previously occupied by the CAN1 terminating resistor. Plug the other end of the jumper harness into the 133-0970 Connector Receptacle As .

5. Plug the CAN1 174-3016 Connector Plug As into the 133-0970 Connector Receptacle As .

6. Using a 174-0502 Connector Plug As , 155-2266 Plug Lock Wedge , and 9X-3402 Connector Socket attach the CAN wires from the PL421 harness to the 133-0970 Connector Receptacle As . Connect the yellow wire to location A, the green wire to location B, and the shield wire to location C in the plug.

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Illustration 14	g03415371

7. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 14 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal . (12V Relay - 115-1615 Relay As , 24V Relay - 3E-5239 Relay As .

8. Connect the +Battery wire directly to the +Battery terminal of the battery or the battery charger.

9. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

10. If the engine is not equipped with an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

11. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

General Installation Procedure

Installing the PL421 Module

Location for Mounting the PL421 Unit

1. Insure that the harness wiring is correct and matches the PL421 Connector and Block Diagrams.

2. When mounting the PL421 take the following needs into consideration.
   • The wiring to the CAN connection from the PL421 should not exceed a stub length of 1 m (3.3 ft). Exceeding this length may lead to degradation in communication and hence operation of the PL421 and generator set.

   • Unlike the GPS antenna, the PL421 does not need an uninterrupted view of the sky.

   • The device may be mounted in any orientation.

   • The PL421 is designed to operate within genset enclosure. However, in cases where the cellular signal strength is very weak, the PL421 module may be installed externally in order to get a stronger signal.

3. The location for the PL421 must allow enough room for the antenna cables and for the harness assembly. The PL421s location must have sufficient clearance for the harness to prevent sharp bends in the harness or the antenna cable. The harness has a 60 mm (2.4 inch) bend radius. The coax has a 25 mm (1 inch) bend radius.

4. Orient the device so that the device connector will not be subjected to high-pressure spray or underwater immersion. Exposure to high-pressure spray or underwater immersion may compromise the connector seal, leading to connector failure.

5. Do not mount the device close to a heat source such as the exhaust or engine itself where the unit may be exposed to extreme heat (above 85° C (185.00° F)). Exposure to extreme heat may make the device inoperable.

6. Do not mount the device in an area so that the device could be damaged.

7. The device must be installed on a flat surface.

8. Orient the PL421 to ensure proper cable routing of the main harness as well as the GPS RF Cable Assemblies.

9. For serviceability purposes, the PL421 should be placed in an area that it is easily accessible and can be serviced within a reasonable amount of time.

10. The mounting torque on the mounting bolts is 6 ± 0.5 N·m (53.10 ± 4.425 lb in).

11. Do not mount on a Cantilever.

12. Do not mount on a flexible area.

13. Do not mount near impacts.

14. During install, confirm through Cat ET that the PL421 is receiving a strong cell signal.

Mounting the PL421 Unit

Note: These instructions are for retrofit installation - and are meant to be generic guidelines.

Tools and Supplies

• M6 socket wrench

• Drill with M6 bit

• Tyco pin removal tool

• Tie wraps (at least 4 inches long)

• Circuit tester or Volt Meter/ Ohm Meter

• Wire butt splices (2 per generator set) for 18 Gauge wire

The PL421 has four different mounting options depending on mounting location.

• No holster and three bolts

• Holster and two bolts (preferred)

• Holster w/ three bolts

• Holster w/ adhesive and no bolts

Illustration 15	g02998416
PL421 Mounted inside control panel in enclosure

Illustration 16	g02998418
PL421 Mounted Inside control panel. Using preferred mounting with holster and two bolts.

Note: The mounting hardware is included as a part of part number 396-4284 Communication Installation Gp .

1. Locate the PL421 unit in the desired installation location. Do not stretch the wires, as stretching will cause intermittent operation of the PL421. Mark the hole locations.

2. Remove PL421 to accommodate the drilling operation. 1/8 inch pilot holes are recommended before inserting the 6 self tapping screws.

3. Install the harness and antenna wiring. Secure the PL421 with the self tapping screws or the mounting bolts included with the retrofit kit.

4. If not already installed, install 230-1341 Film on a location on or near the control panel where it will be visible to the operator.

Route the GPS Antenna

Installation of the Antenna

Location for Mounting the Antenna

• Check the list of parts for the Genset.

• Antenna may be mounted under a non-metallic cover, but not a metallic one.

• For outdoor installations, antenna should be mounted in a horizontal orientation to the horizon, or as close to horizontal as possible. The antenna should be exposed to a large portion of the sky. In most cases, the canopy/container roof usually provides an optimal view of the sky with minimal blockages.

• Avoid mounting the antenna next to high heat sources such as exhaust stacks.

• Keep a distance between the PL421 antenna and other antennas that transmit a radio signal. Caterpillar recommends a distance of at least 1 m (3.3 ft). Keep no less than 500 mm (19.4 inch) between the PL421 antenna and other antennas that transmit a radio signal. The lists of radio antennas to maintain a distance from include the citizen band radio, data radio, and commercial communication radios.

• Keep in mind the routing of the antenna cable. Route the cable such that it is not subject to abrasion or pinching. Do not route the antenna cable near any source of extreme heat (exhaust). Do not mount the antenna or the antenna cable so that the limitations of temperature −40° C (−40.0° F) and 85° C (185.0° F) are exceeded.

• Route the antenna cable with a minimum bend radius of 25 mm (1 inch). Bend radius depends on the type of cable used. Do not bend the radius any less than ten times the diameter of the cable.

• A clean and flat mounting surface is required for mounting the antenna.

Mounting the Antenna

• Clean the desired mounting surface with an alcohol wipe and allow the area to dry. Remove the tape from the back of the GPS antenna. Press down to secure the antenna to the installation area and route the antenna wire as shown in Illustration 17.

Illustration 17	g02998316
Drill a hole and insert grommet to route the antenna wire.

Illustration 18	g02998317
Mount GPS antenna outside of enclosure.

Record Status

If there is an issue with the installation or a question regarding the status at the time of installation, creating screenshots will greatly aid in beginning the investigation. Create a few screenshots before disconnecting Cat ET and leaving the generator set.

• Connect Communication Adapter and PC with Cat ET. With Key Switch ON, select the PL421 ECM. Allow the PL421 to access satellites and cell phone towers. Accessing the satellites and cell phone towers may take a few seconds.

• Record screen shots of the ECM summary and all three Status Screens. Paste screen shots into Word file. Refer to the "Status Groups for Cat Electronic Technician" section for the available status screens.

Route and Connect the PL421 Harness CAN + and CAN - Wires and Connect to the EMCP Primary CAN Datalink (If Equipped)

Illustration 19	g03036837
(1) Battery +/- (2) CAN 1 +/-

Illustration 20	g03036858
(3) CAN 1+ (4) CAN 1-

Find suitable point in the panel to access the EMCP CAN 1 connection, and the genset +Battery and -Battery.

Note: This will vary from model to model, depending on panel design.

Connect the CAN wires to the system prior to the Battery connections.

If the PL421 is powered on before a CAN signal is present, the onboard firmware may determine that a CAN signal is not present and then go into the wrong mode.

Gensets Not Listed Above

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Illustration 21	g03415382

1. Connect the keyswitch wire from the PL421 harness to the relay as shown in Illustration 21 using the 9X-1054 Connector Plug As and the 9X-1055 Receptacle Terminal . (12V Relay - 115-1615 Relay As , 24V Relay - 3E-5239 Relay As .

2. Connect the +Battery wire directly to the +Battery terminal of the battery or the battery charger.

3. Connect the -Battery wire directly to the -Battery terminal of the battery or the battery charger.

4. If the engine is not equipped with an EMCP 3 or 4, or a Cat Electronic engine governor but the engine has a charging alternator with a "Relay terminal" connection, the R-Term should be connected to the appropriate R-Term on the alternator to determine engine hours.

5. Wiring the genset in this manner, the PL421 will go to low-power mode by bypassing the battery disconnect, only waking up once per day to send an update.

Connect the GPS Wire to the PL421

Illustration 22	g03036860

Connect the GPS harness first to the PL421 connector. The GPS antenna must be on a horizontal surface and have clear line of sight to the sky for a good signal.

Connect the Main Harness Connector to the PL421

Connect the main harness to the PL421. Turn on the battery power to the system after all the connections are made, if it had been shut off previously.

Activation of Subscription Services

1. Verify that the generator set exists in the Cat Equipment Data system. The asset record should use the top-level generator set serial number and be associated to the correct customer account.

2. Log on to the Trimble VisionLink Store. See your Product Link Administrator for assistance.

3. Go to Subscribe Screen.

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Illustration 23	g03036976

4. Enter the generator sets serial number and make in the prompts and select the search button.

5. The VisionLink Store will access the Equipment Data system for asset and ownership information. If the Equipment Data asset record does not exist, an error message will be displayed.

6. If an error message is received, add the asset to Equipment Data.

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Illustration 24	g02998476

7. If validations pass, asset data will be retrieved from Caterpillar and displayed in the VisionLink Store

8. If necessary, enter the PL421 device serial number in the appropriate field. The carrier and SIM serial number will be automatically populated based on the device serial number.

9. Select "Bill To Account" and select or create "Bill To Address".

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Illustration 25	g03004158
Service Selection Screen

10. After reviewing and/or updating the data, click the continue button. In the next window, select OK to verify and proceed.

11. Select the service plans and click the "Add to Cart " button to go to Shopping Cart screen. Proceed with checking out until a confirmation order number is provided.

Update Process

The PL421 is updated Over-the-Air (OTA) only. There is no capability for updating the PL421 Over-the-Wire with Cat ET of WinFlash. Caterpillar with automatically attempt to update all PL421 product Link systems for up to three weeks after a new version of firmware is released. Refer to the following tips on how to ensure Over-theAir firmware update success:

1. Devices running firmware 2.1.9.2 or older must be in Full Power Mode (key switch ON) for at least 15 minutes in order to receive and process the update.

2. Devices running firmware 2.1.9.3 or newer must have unswitched power (main disconnect closed) in order to receive and process the update.

3. Devices must be in an area with adequate cellular coverage in order to receive and process the update.

If a device has run in Full Power Mode twice after the final firmware update was scheduled and fails to process the update, contact VisionLink Support (visit https://dealer.cat.com/PL and click on the "Salesforce Support Access and Training" tab to get information on how to contact VL Support) to have the update rescheduled.

Cat ET Service Tool

Connecting a Computer to the PL421

Required Software

This system requires Cat ET version 2012A or later.

Note: Always update Cat ET to the latest version in order to access all of the available functionality of the PL421.

Supported Hardware Connections

The PL421 is configured with Cat ET and will use the following communications interfaces:

• The 171-4400 Communication Adapter Gp (Cat Communications Adapter II) hardware is connected between the generator set service connector and the PC serial port or parallel port. The Cat ET "Communications Interface Device" is configured for the "Cat Communications Adapter II " (RP1210).

Note: The configuration parameters for the "Communications Interface Device" are found in Cat ET under "Utilities" menu, "Preferences" drop-down menu.

Cat ET is a software program that is used to access data. The service technician can use Cat ET in order to perform maintenance on the generator set. Some of the options that are available with Cat ET are listed below:

• Viewing the status of parameters

• Printing reports

The following list contains some of the diagnostic functions and programming functions that are performed by the service tools.

• The failures of the ECM system are displayed.

• The settings for the ECM are displayed.

• Display the clock hour of the internal diagnostic clock.

• The number of occurrences and the clock hour of the first occurrence and the last occurrence is displayed for each logged diagnostic code.

• The definition for each logged diagnostic code and each event is displayed.

Configure Computer Interface Communications for Cat ET

1. Use the Communication Adapter Gp to connect a computer with the required Cat ET software to the serial service connector of the wiring harness.

2. Select "Utilities" on the tool bar.

3. From the drop-down menu, select "Preference".

4. From the "Communications" tab, click the drop-down menu and select "Caterpillar Communications Adapter II".

Click the "Connect" icon or click "File" on the menu bar. Click "Connect" from the pull-down menu in order to establish communication with the PL421.

Status Groups for Cat ET

In order to access the status groups, follow the procedure that is listed below.

1. Select the "Information" tab on the menu bar in Cat ET.

2. Click "Status" or click the "Status" icon on the tool bar.

The status groups should be used in order to verify that the installation of the PL421 module has been successful.

There are only four screens available in Cat ET for verifying and servicing the PL421 system.

Illustration 26	g02998596
ECM Information screen

Illustration 27	g02998597
ECM Connection Screen

Illustration 28	g02998598
Status Parameters screen

Connected to PL421 showing status. The PL421 "Status Parameters" screens show the current operational status of the PL421. Refer to Illustration 28.

Table 13

Status Information for PL421
PL421 Information	Description
GPS Receiver	Functional: The hardware for the GPS receiver is functional
	Not Functional: The hardware for the GPS receiver is not functional
Possible Device Power Disconnection	Yes: The PL421 has missed reports due to a power loss. This value is reset automatically after the status reported to the office
	No: The PL421 has not missed any scheduled reports due to power loss.

Illustration 29	g02998636
GPS Information screen

The PL421 "GPS Information" screen shows the status of the GPS. Refer to Illustration 29. Refer to Table 14 for an explanation of the GPS-related parameters.

Table 14

GPS Information Parameters
Status	Description
PC Current Date/Time	The current Date and Time of the host PC is displayed.
GPS Position Status	Valid: The Product Link Module has previously calculated a valid fix.
	Invalid: The Product Link Module has not calculated a previous fix.
GPS Time Stamp	The time stamp from the last fix is displayed. The time can be compared to the Current Date/Time to verify that the time since the last position was calculated.
GPS Latitude	The last valid GPS Latitude is displayed.
GPS Longitude	The last valid GPS Longitude is displayed.
Number of GPS Satellites	The number of GPS satellites currently in use by the GPS receiver (1).
GPS Antenna	GPS Antenna Operational - The antenna is operational.
	GPS Antenna Fault - There is an issue with the antenna.
	GPS Antenna is not installed - The antenna is not installed or is disconnected.

( 1 )

Three or more satellites are needed to get an updated position fix.

Illustration 30	g02998657
GSM Information Screen

Table 15

Cellular Information Parameters
Status	Description
Cellular network coverage status	In Coverage - Attached to network Out of coverage - Not attached to network. Check Trimble Store subscriptions and SIM activation. Network Not Allowed - No coverage in the area from the SIM provider (or partner)
Cellular Signal Quality	Display percent age values (0 percent, 5 percent, 25 percent, 50 percent, 75 percent, and 100 percent) - If a value is shown, a cell tower can be seen. The Higher the percentage value the better the signal strength.
Cellular Device Data Network Registration Status	Searching - Device is currently trying to attach or searching a network to register Not Attached - Device is not attached to the network and is not searching a network to register Attached Home - Device is registered to a home network Attached Roaming - Device is registered to a roaming network Registration Denied - Device is not allowed to attach to the network. Authentication failure or GRPS service is not active. Unknown - Unknown error in registration process
Cellular Packet Data Protocol (PDP) Context Activation Status	Active - Can communicate Not Active - Cannot communicate. Likely incorrect APN or network denied Missing or Unknown APN - Possible pasteboard problem
SIM Card Status Active - Functional.	Active - Functional Not Active - Contact DSN to have the SIM activated Not Detected - Modem cannot detect the SIM card Failure - Check activation with network. Possible failed SIM card Need PIN - Obtain security PIN from SIM provider Need PUK - SIM card is blocked. Need PUK from SIM provider to unlock SIM
SIM Card Number	Unique identifier for the SIM card
Cellular Service Provider Name	SPN (Ex: AT&T, T-Mobile)
Cellular Network Disconnection Timestamp	Last time the cellular modem lost connection with the cellular network
International Mobile Equipment Identity Number	A unique 15-digit code or 17-digit code used to identify a GSM device to the GSM network. IMEI number is used by the GSM network to identify valid devices.

PL421 Firmware

Once the PL421 has been provisioned it is good practice to connect with the Service Tool (ET) and verify you are using the latest PL421 firmware (check SIS for the latest firmware) Note: If you are not using 2.1.9.3.2 or newer all genset specific features related to the PL421 will not work.

VisionLink

Accessing the Product Link User Interface

Contact your dealer Product Link Administrator for a user name and password to access Product Link's web-based remote monitoring user interface, called VisionLink.

Through VisionLink, view all your remotely monitored equipment at once with street and satellite view mapping features, see current hour and fuel information as well as track utilization. Monitor equipment health through visibility to fault codes and ready to run status. Set up alerts to be notified via e-mail or SMS text when a condition occurs that needs immediate attention.

See videos and more information on features at www.cat.com/productlink. Access detailed training and reference information on www.dealer.cat.com/pl.

Product Link's web-based remote monitoring user interface, VisionLink, provides users powerful tools to transform data from their entire fleet of equipment into essential information required to increase productivity and reduce costs. The VisionLink application is a mixed fleet solution that enables customers to monitor their Cat generator sets and other equipment, regardless of make, in one easy to use application.

Users can monitor and analyze asset information through any computer with internet access using a secure account and password. Contact your Dealer Product Link Administrator to obtain a log-in account. Within the application, alerts can be configured to notify those who need to know via e-mail or SMS text message when something occurs that needs immediate attention. In addition, VisionLink provides exclusive features for Cat equipment with easy access to other Cat data through integration with Cat applications, like PartStore^TM for on-line parts ordering.

Through the VisionLink interface, the Product Link solution provides location, hour and fuel usage, health codes and more, allowing insight into the operation, health, and utilization of equipment:

• Manage the location and the basic usage of generator sets.

• Use location to manage rental fleets, invoicing, and service.

• Schedule planned maintenance and major repairs more effectively.

• Manage diagnostic and event codes reported in real time.

• Detect problematic health conditions before they cause a major component failure.

• Increase generator set availability and productivity by avoiding unexpected downtime for repairs.

Illustration 31	g03090997
Fleet Summary

The Fleet Summary displays top-level fleet information at a glance, including last known status, hours and number of open alerts. Users can quickly filter to the assets they need to see and customize the information displayed on the screen. Easily navigate street, satellite, and hybrid mapping to view a group of equipment or zoom in to see the location last reported by a specific asset.

Double-clicking on a given asset will open the Asset Details window.

Illustration 32	g03090998
Asset details dashboard tab

The dashboard tab shows a summary of the assets main details. Updates on status information, hour meter, and fuel usage are provided at least once per hour while the generator set is on. When a generator set changes state or a fault code occurs (where supported - dependant upon control system version support), updates are sent real time.

Illustration 33	g03090999
Asset Details - Alerts Tab

The alerts tab shows all alerts created for the asset and their status for the selected period - you can view open alerts and alert history. An alert provides notification of specific conditions detected that need attention and can be configured to send e-mails or SMS text messages to those who need to know.

To configure and customize automated alert notifications, access the Administration tab on the fleet level view to manage alerts.

Types of alerts that can be created using the VisionLink include:

• A generator set has arrived to a site boundary.

• A generator set has left a site boundary.

• Equipment is due for maintenance.

• A generator set has started.

• A generator set has stopped.

• A specific event code has occurred.

• A high severity diagnostic code has occurred (where supported by compatible systems).

• A standby generator set is Not Ready to Run.

Note: The Not Ready to Run alert was created for Cat standby power systems specifically. Any condition which would prevent the generator set from automatically starting and providing power will trigger the Not Ready to Run alert. The alert can be enabled or disabled through the VisionLink interface.

Illustration 34	g03091000
Asset Details - Health Tab

The health tab shows a list of all events and diagnostics that have occurred on the generator set. Fault codes are available through integration with the EMCP 3 and EMCP 4 systems. When a code is detected by the EMCP controller, it is reported off-board by the PL421 device and displayed within VisionLink. E-mail and text message alerts can be customized to provide notification of a fault code detected by the EMCP based on severity level or specific codes of interest.

For more training on using the VisionLink interface, click the Help link from within the application after logging in. See videos and more information on features at www.cat.com/productlink. Access additional reference information on www.dealer.cat.com/pl.

Instant Notification of Critical Events

Illustration 35	g03091001
SMS text message alerts

The VisionLink application makes setting up automated alert notifications fast and easy. The user is guided step by step on how to configure e-mail or text alerts that notify the people who need to know without requiring a user to log into a system.

Alerts can be set up for when preventive maintenance is due, diagnostic, and event codes occur, a generator goes to a certain status, site boundaries are entered or exited and more.

Instructions on Configuring R-Term and R-Term Service Hour Meter with VisionLink

1. Connect to VisionLink.

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Illustration 36	g03415399

2. Under the "Administration" tab select "Device Configuration".

3. Choose Device Type as PL421.

4. On the "Reporting Configuration" tab select asset and click on "Configure Devices".

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Illustration 37	g03415410

5. A Reporting Configuration window will appear. Refer to Illustration 37.

6. For the Service Meter Hour/Odometer Configuration you can select 1 of 3 options
   • Datalink

   • R-Term-AC

   - 30Hz

   - 50Hz (Default)

   - 70Hz

   • R-Term-DC

   - 4 seconds (Default)

   - 6 seconds

7. Select Send to program.

8. On the Reporting Configuration Tab select asset and click on Configure Devices.

9. A Reporting Configuration window will appear and this time the Odometer miles and Hour Meter will not be grayed out.

10. Enter the Odometer miles.

11. Enter the Hour Meter.

12. Select Send to program.

Instruction on Configuration Digital Inputs

1. Connect to VisionLink.

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Illustration 38	g03415399

2. Under the Administration tab select Device Configuration. Refer to the above Illustration.

3. Choose Device Type as PL421.

4. On the Switches Tab select asset and click on Configure Devices.

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Illustration 39	g03415431

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Illustration 40	g03415433

5. A Switch Configuration window will appear. Refer to Illustration 40.

6. For the Switch Configuration the following options exists for switches 1 and 3.
   • Enabled or Disabled

   • Switch Name

   • Switch Closed - Text that will show in the asset history report.

   • Switch Open - Text that will show in the asset history report.

   • Sensitivity (seconds) - 2.0 default.

7. Select Send to program.

Note: Alerts are not yet available as of VL 2.7 with Digital Inputs.

Troubleshooting - Symptoms and Procedures

Cat ET Does Not Communicate with ECM

System Operation Description

During the installation of a PL421 system, the wiring harness is connected to the existing EMCP Data Link wiring on the Genset. If the installation is not done properly, the continuity of the Cat Data Link wiring may be open intermittently. This condition may not be apparent immediately. Improper installation will cause a problem when you are trying to connect the Cat ET service tool to the generator set.

• Cat ET may report that no ECM has been found.

• Cat ET may not report every ECM that is on the generator set.

• Cat ET may report an ECM but the ECM will not have any data.

If the Data Link wires for the PL421 are reversed, the ECM will not appear after connecting Cat ET.

Test Step 1. VERIFY THAT THE CAN WIRES ARE NOT REVERSED

A. Check that the CAN High wire (Yellow) in the wiring harness for the PL421 is connected to the wire of the wire harness for the generator set.

B. Check that the CAN Low wire (Green) in the wiring harness for the PL421 is connected to the CAN Low wire of the wire harness for the generator set.

Expected Result:

The Data Link wires are properly connected.

Results:

• OK - The wires for the Data Link are properly connected. Proceed to "Test Step 2".

• NOT OK - The wires for the Data Link are reversed.

Repair

Reinstall the Data Link wires correctly and check the operation of the PL421 module by using Cat ET.

STOP

Test Step 2. CHECK THE WIRING WITH A MULTIMETER

A. Turn off the generator set and turn the disconnect switch to the OPEN position.

B. Measure the resistance of the CAN Low wire from the service connector (contact "F") to the location for the spliced CAN wire. Note the resistance.

C. Measure the resistance of the CAN High wire from the service connector (contact "G") to the location for the spliced CAN wire. Note the resistance.

Expected Result:

The resistance in both wires is less than 5 ohms.

Results:

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

• NOT OK - The resistance is greater than 5 ohms.

Repair

Repair the wiring harness. After repairing, resume the PL421 installation setup procedures.

STOP

Test Step 3. VERIFY THAT THE WIRING FOR CAN IS PROPERLY CONNECTED

A. Check the spliced connections for CAN that were made during the installation. Verify that all connections are clean and tight.

B. Reconnect the harness connectors that were disturbed during the installation. Ensure that all of the pins are correctly seated in the sockets.

C. Reconnect the cable from the service tool connector. Attempt to access the Data Link by using Cat ET

Expected Result:

Reconnect the cable from the service tool connector. Attempt to access the Data Link by using Cat ET.

Results:

• OK - Cat ET lists the electronic control modules that are available on the generator set. The ECM for the PL421 can be accessed. Resume the setup procedures for the installation of the PL421. STOP

• NOT OK - The Cat ET does not list the electronic control modules that are installed on the generator set. The PL421 ECM cannot be accessed. Proceed to "Test Step 4".

Test Step 4. CHECK FOR PROPER INSTALLATION OF J1939 CAN TERMINATOR RESISTOR

If there is no J1939 CAN data link on the generator set, other than the CAN wires from the PL421, inspect the CAN wires near the service tool connector and verify that a J1939 Terminator Resistor was properly installed across the "CAN High" and "CAN Low" wires.

Expected Result:

The generator set has no J1939 CAN network other than the PL421 CAN wires and a J1939 CAN Terminator Resistor was properly installed across the "CAN High" and "CAN Low" wires near the service tool connector.

Results:

• OK - The generator set has no J1939 CAN network other than the PL421 CAN wires and a J1939 CAN Terminator Resistor was properly installed. Proceed to "Test Step 4".

• OK - The generator set had a J1939 CAN network before installing the PL421, the PL421 CAN wires were properly spliced onto the existing generator set CAN wires, and no J1939 Terminator Resistor was added. Proceed to "Test Step 5".

• NOT OK - The generator set has no J1939 CAN network other than the PL421 CAN wires and a J1939 CAN Terminator Resistor was not properly installed.

• NOT OK - The generator set had a J1939 CAN network before installing the PL421, the PL421 CAN wires were spliced onto the existing generator set CAN wires, and a J1939 Terminator Resistor was added.

Repair

If the generator set had no J1939 CAN network before installing the PL421, install a J1939 CAN Terminator Resistor. Refer to section "J1939 Terminator Resistor Installation". After installation, resume the PL421 installation setup procedures.

Test Step 5. CHECK FOR A DIAGNOSTIC CODE FOR CAN

Check the monitoring system for a diagnostic code for CAN.

Expected Result:

There is a diagnostic code for CAN.

Results:

• YES - There is a diagnostic code for CAN.

• No - There are no diagnostic codes for CAN. Proceed to "Test Step 6".

Repair

Perform the troubleshooting procedure for that diagnostic code that is found in the service manual for that ECM.

STOP

Test Step 6. RETURN THE WIRING TO THE ORIGINAL CONDITION

A. Return the CAN wires to the original condition. Remove any splices that were made and reconnect the wiring harness.

B. Connect Cat ET to the service connector. Verify that all of the appropriate electronic control modules are present. The ECM for the PL421 will not be present.

Expected Result:

All of the appropriate electronic control modules are present.

Results:

• YES - All of the appropriate electronic control modules are present. The wiring is correct. Return to the installation procedure for the PL421 and reinstall the wiring for CAN. Continue with the setup of the PL421. STOP

• NO - All of the appropriate electronic control modules are not present.

Repair

A problem still exists with the CAN wiring. This problem does not relate to the installation of the PL421. Troubleshoot the entire CAN circuit to all available electronic control modules. After the problem is found and corrected, return to the installation procedure for the PL421. Reinstall the wiring for CAN. Continue with the setup of the PL421.

STOP

Reports and Messages Not Available

System Operation Description

There are problems that could be reported with the PL421 system but the problems are not caused by the PL421 system. Check for active diagnostic codes for the PL421. Correct any diagnostic codes before proceeding. Visually inspect the following for damage: module, antenna, and cables. Verify that there are no loose connections.

The PL421 system depends on several communication links in order to transfer data from the generator set to the office. The following procedures assume that these communication links are operating properly. The proper communication links are listed below:

• The cellular network for communications is operational in the geographic area of concern. The network is operational when messages can travel to the cell tower and then to Caterpillar.

• The PL421 system is correctly configured to communicate on the network for cellular communications. Correct configuration was verified during manufacturing tests.

• The PL421 is configured properly and the software is functioning. The PL421 module should not be replaced without verifying that these issues have been investigated. Contact your Caterpillar Technical Communicator for aid in resolving these issues.

• Subscriptions to the PL421 module must be up to the current date.

If reports and messages are not available, perform the following steps in order to determine the cause.

Test Step 1. ACCESS THE PL421 THROUGH CAT ELECTRONIC TECHNICIAN

A. Connect Cat ET to the generator set.

B. Verify that the PL421 is present.

Expected Result:

The PL421 is present.

Results:

• OK - The PL421 is available. Proceed to "Test Step 4".

• NOT OK - The PL421 is not present in the Cat ET screen.

Repair

Verify that the wiring for the PL421 has been installed correctly. Check the wiring with a multimeter. If the PL421 is not present, refer to "Electronic Service Tool Does Not Communicate with ECM". STOP

Test Step 2. VERIFY THAT THE PL421 MODULE HAS NOT BEEN DISABLED

A. Go to the "Cellular Information" screen in Cat ET.

B. Verify that the "Cellular Network Coverage Status" is "In Coverage".

Expected Result:

The "Cellular Network Coverage Status" module is "In Coverage", PL421 is reporting.

Results:

• OK - The "Cellular Network Coverage Status" for PL421 is "In Coverage". Go to "Test Step 4".

• NOT OK - The "Cellular Network Coverage Status" for PL421 is "Out of Coverage". Go to "Test Step 4".

• NOT OK - The "Cellular Network Coverage Status" for PL421 is "Network Not Allowed". Go to "Test Step 5".

Test Step 3. VERIFY THAT THE PL421 IS RECEIVING CELLULAR SIGNALS

A. Go to the "Cellular Information" status screen in Cat ET.

B. Verify that the "Cellular Signal Quality" is greater than 25 percent.

C. Verify that the antenna is correctly installed.

D. Verify that the unit is in cellular map coverage of the provider.

Expected Result:

The "Cellular Signal Quality" detected is greater than 25 percent.

Results:

• OK - There is cell coverage in the area and the antenna is correctly installed. Proceed to "Test Step 6".

• NOT OK - Either the unit is out of cell coverage or antenna is installed incorrectly. Verify that the unit is in cellular map coverage of the provider. Proceed to "Test Step 7" to check antenna installation.

Test Step 4. VERIFY THAT THE PL421 MODULE IS CONFIGURED PROPERLY

A. Go to the "APN Configuration" screen.

B. Verify that the "APN Cellular Carrier" is configured to the correct cellular service provider.

C. Verify that the "APN Username" is configured to the correct cellular network. Refer to cellular provider for correct APN information.

D. Verify that the "APN Password" is configured with the correct password for cellular network. Refer to cellular provider for correct APN information.

E. Verify that the "APN SIM PIN" is configured with the correct SIM Card PIN. Refer to SIM Card Provider to determine and program SIM PIN.

Expected Result:

All settings are correct.

Results:

• OK - The PL421 module is configured correctly. Proceed to "Test Step 5".

• NOT OK - The PL421 module is not configured correctly.

Repair

Correct the configuration of the PL421module. The "APN Configuration" can be verified in the "Cellular Network Coverage Status" within "GSM Information" of the service tool.

STOP

Test Step 5. VERIFY THAT THE PL421 MODULE HAS NOT BEEN TURNED OFF

A. Go to "Status Parameters" of Cat ET.

B. Verify the "Possible Device Power Disconnection" is Labeled as "No".

Expected Result:

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

Results:

• OK - The "Possible Device Power Disconnection" is Labeled as "No". The PL421 has operated since successfully transmitting the last report. Proceed to "Test Step 7".

• NOT OK - The "Possible Device Power Disconnection" is Labeled as "Yes". The PL421 has been disconnected from power and transmissions have been prevented. The power loss could explain the failure to get any messages.

Repair

Turn on the unit.

STOP

Test Step 6. CHECK FOR "ACTIVE" AND/OR "LOGGED" CODES FOR THE PL421 ECM

A. Follow the steps in "Connecting a Computer to the PL421" in order to connect a laptop computer to the PL421 system.

B. Go to the menu bar for Cat ET. Select the "Diagnostics" tab. From the drop-down menu, choose the type of code. Choose "Active Codes" or "Logged Codes".

Results:

• OK - There are no "active" or "logged" diagnostic codes. Proceed to "Test Step 8".

• NOT OK - An "active" or "logged" diagnostic code exists.

Repair

Refer to the Systems Operation, Troubleshooting, & Testing and Adjusting, REHS8143, "Diagnostic Code List", in order to correct possible problems.

STOP

Test Step 7. CHECK THE INSTALLATION OF THE DEVICE

Observe installation of the PL421. Verify that the device is not enclosed in metal. The devices must be in a location that is free from interference. Examples of interference include the following items:

• Other communication antennae that are close to the PL421.

• The PL421 is inside a metal enclosure or another similar structure.

• The generator set is under large signs that are lighted.

• The generator set is under power lines

Note: Refer to "Installation of the PL421" for additional details on optimal installation of the antenna.

Expected Result:

The PL421 is not enclosed in metal completely.

Results:

• OK - The PL421 is installed properly. Verify that all of the connections for the PL421 are tight. Proceed to "Test Step 8".

• NOT OK - The installation of the PL421 is not optimal.

Repair

Accept the current performance of the communication or reinstall the PL421 at a superior location.

STOP

Test Step 8. VERIFY THAT THE PL421 HAS AN ACTIVE SUBSCRIPTION

Log in to Trimble Store and verify that subscriptions are listed for the PL421 and generator set.

Expected Result:

The PL421 has an active subscription.

Results:

• OK - Replace the PL421 with a known good PL421. Verify that communication is reestablished.

• NOT OK - The PL421 does not have an active subscription.

Repair

Order subscription using the "To Subscribe to Services for a New PL421" section.

STOP

Position Reports Not Available

System Operation Description

This section contains steps that can be used to help determine the possible cause of erratic reports of interval. Check for active diagnostic codes for the PL421. Correct any diagnostic codes before proceeding. Visually inspect the following items for damage: PL421 module, antenna, and cables. Verify that there are no loose connections

The PL421 system depends on several communication links in order to transfer data from the generator set to the office. The following procedures assume that these communication links are operating properly. The proper communication links are listed below:

• The network for cellular communications 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 PL421 system is correctly configured to communicate on the network for cellular communications. Correct configuration was verified during manufacturing tests.

• VisionLink is configured properly and the software is functioning. The PL421 module should not be replaced without verifying that these issues have been investigated. Contact the Caterpillar Technical Communicator for aid in resolving these issues. The unit is likely to have been configured correctly if the SMH report is received.

There is a probability that the system GPS has failed. Proceed with the following steps in order to determine the cause.

Test Step 1. ACCESS THE PL421 THROUGH CAT ELECTRONIC TECHNICIAN

A. Connect the Cat ET service tool to the generator set.

B. Verify that the PL421is present.

Expected Results:

The PL421 is present.

Results:

• OK - The PL421 is present. Proceed to "Test Step 3".

• NOT OK - The PL421 is not present in the Cat ET screen.

Repair

Verify that the wiring for the PL421 has been installed correctly. Check the wiring with a multimeter. If the PL421 is not present, refer to "Electronic Service Tool Does Not Communicate with ECM".

STOP

Test Step 2. VERIFY IF THE GENERATOR SET HAS MOVED

A. Select "GPS Information" for Cat ET.

B. Verify that the "GPS Position Status" is "Valid".

C. The "GPS Time Stamp" can be compared to the "PC Current Date/Time" in order to calculate the time since the last calculation of the position.

D. Verify "GPS Antenna" states "Operational".

E. Select "Status Parameters". Verify "GPS Receiver" states "Functional".

Expected Results:

The "GPS Position Status" is "Valid". The "GPS Antenna" is "Operational".

Results:

• OK - The indications on the Cat ET screen are correct. The GPS Receiver and Antenna are functioning properly. Proceed to "Test Step 3".

• NOT OK - The indications on the "GPS Information" are incorrect. Proceed to "Test Step 3".

• NOT OK - The indications on the "GPS Receiver" are not "Functional". Proceed to "Test Step 3".

Test Step 3. VERIFY THAT THE ANTENNA IS NOT DAMAGED

A. Visually inspect the antenna.

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

Expected Results:

The antenna has no physical damage.

Results:

• OK - Replace the antenna with a known good antenna. Verify that communication is reestablished.

• NOT OK - Damage is found.

Repair

Replace the antenna assembly. Verify that the module is operating correctly.

STOP

Note: VisionLink and the VisionLink - Powered by Trimble logo are trademarks of Trimble Navigation Limited