PRODUCT SUPPORT PROGRAM FOR REPLACING CELLULAR PRODUCT LINK DEVICES ON CERTAIN 770G, 772G, 773G, 775G, AND 777G OFF-HIGHWAY TRUCKS, 725C, 730C, 730C EJ, 740B, 740C EJ, AND 745C ARTICULATED TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CELLULAR PRODUCT LINK DEVICES ON CERTAIN 770G, 772G, 773G, 775G, AND 777G OFF-HIGHWAY TRUCKS, 725C, 730C, 730C EJ, 740B, 740C EJ, AND 745C ARTICULATED TRUCKS

Usage:

TEBE5210-02

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26Oct2016

(Revised 20Apr2017)

U-566

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING CELLULAR PRODUCT LINK DEVICES ON CERTAIN 770G, 772G, 773G, 775G, AND 777G OFF-HIGHWAY TRUCKS, 725C, 730C, 730C EJ, 740B, 740C EJ, AND 745C ARTICULATED TRUCKS
7606 7610 7620 7490 733T		PS45263

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45263" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 26Oct2016 (Revised 19Dec2016) Service Letter. A change has been made to the Termination Date.

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TERMINATION DATE

30Jun2017

PROBLEM

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The 2G network that the cellular Product Link devices are on will be no longer available in October 2016. All devices will stop reporting after this date.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
770G	KDH00203-00204, 215-216, 221-222, 229-234, 238, 247, 251, 265
772G	KEX00121-00122, 130, 136, 169, 176

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*****Group 2*****
773G	JWS00170-00171, 173, 208-209, 244-245, 265-266
773G OEM	T5T00103
775G	MJS00275-00276, 278, 284-286, 310-313, 316, 329, 332, 335-337, 339, 347-348, 352, 354, 372-374, 377, 388-392, 450, 458-459, 461
775G OEM	T5F00101
777G	RDR00109, 111, 166, 184-186, 192-193, 196, 206-207, 210-212, 220, 233-235, 265, 309, 314, 317-321
777G OEM	T5A00115, 119

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*****Group 3*****
725C	TFB00115-00116
730C	LFF00236 TFF00127-00129, 131, 814-815, 825-826
730C EJ	TFH00132
740B	T4R00269, 445, 455, 457, 1260, 1981
740C EJ	TFN00161
745C	LFK00262 TFK00157, 159, 177, 530, 1094

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2G1133	GROMMET
4	2Y5829	NUT-HEX
20	7K1181	STRAP-CABLE (If Needed)
2	7Y5262	BOLT-U
4	8T4121	WASHER-HARD
1	3417961	CABLE AS (If Needed)
1	4438462	ANTENNA AS
1	4502517	PLATE (If Needed)
1	4555563	PL641 Pro Cellular Radio w/ Mounting Hardware Only
1	4559568	CAP AS
1	4932539	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	2G1133	GROMMET
4	2Y5829	NUT-HEX
20	7K1181	STRAP-CABLE (If Needed)
2	7Y5262	BOLT-U
4	8T3844	BOLT-HEX HEAD
4	8T4121	WASHER-HARD
1	3417961	CABLE AS (If Needed)
4	4308829	SPACER
1	4438462	ANTENNA AS
1	4502517	PLATE (If Needed)
1	4555563	PL641 Pro Cellular Radio w/ Mounting Hardware Only
1	4559568	CAP AS
1	4932549	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
8	8T8729	PIN-CONNECTOR
16	8T8737	PLUG-SEAL
1	1028801	KIT-RECEPTACLE
1	1552265	PLUG KIT-CONN
1	2039007	NUT (If Needed)
1	2702679	WASHER-LOCK (If Needed)
1	4674163	PLE601 Network Manager Kit
1	4809645	PL641 Cellular Radio Kit (12V/24V)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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NOTE: This service letter provides for upgrade of Product Link cellular systems from 2G service to 3G service in North America, Costa, Rica, and Honduras. If the machine called out in this service letter is no longer operating in North America, Costa Rica, or Honduras this program does not apply.

Note: 770G, 772G, 773G, 775G, and 777G Off-Highway Trucks require that the PL523 hardware remain installed in the machine to support VIMS, TKPH, TPMS, and RAC. The final installation will include the PL522 or PL523 ECM and the PL641 Product Link Pro radio.

Caterpillar Electronic Technician (ET) 2015B and VIMSpc 2011A or newer should be used to perform any software updates.

Note: Create a full Product Status Report (PSR) and ECM replacement files for the machine before performing the updates as some configurations and settings could be erased during the software installation process. This will allow a point of reference to restore the settings of the machine after the update.

Refer to the attached Rework Procedures.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-500000 hrs, 0-720 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 1
NOTE: Actual labor hours to perform this PSP repair should be claimed on a labor line, up to Service Letter Allowance. If actual labor hours are less than Service Letter Allowance, Dealer may claim for the difference as a miscellaneous expense line. The claim story should detail the labor hours and the labor rate for the miscellaneous expenses.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-500000 hrs, 0-750 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 2
NOTE: Actual labor hours to perform this PSP repair should be claimed on a labor line, up to Service Letter Allowance. If actual labor hours are less than Service Letter Allowance, Dealer may claim for the difference as a miscellaneous expense line. The claim story should detail the labor hours and the labor rate for the miscellaneous expenses.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-500000 hrs, 0-720 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 6.0-hour job for Group 3
NOTE: Actual labor hours to perform this PSP repair should be claimed on a labor line, up to Service Letter Allowance. If actual labor hours are less than Service Letter Allowance, Dealer may claim for the difference as a miscellaneous expense line. The claim story should detail the labor hours and the labor rate for the miscellaneous expenses.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Group Number 1

Note: 770G, 772G, 773G, 775G, and 777G Off-Highway Trucks require that the PL523 hardware set remain installed in the machine to support VIMS, TKPH, TPMS, and RAC. The final installation will include the PL523 ECM and the PL641 Product Link Pro radio.

Note: PL523 ECM's require an ECM configuration file. Reference Special Instruction, M0072766 section, "Required Software", for more information on required configuration files.

770G, 772G, 773G, 775G, and 777G Off-Highway Truck ECM's may require updates to firmware to work properly with the new PL641 radio system. Reference Special Instruction, M0072766, section "Required Software", for more information on required flash files.

Before going to the Customer Site:

1. Review Special Instruction, M0072766 for all the tools required to perform the 2G-3G upgrade from a legacy Product Link to a PL641.

2. Download all required ECM flash files and configuration files as shown in Special Instruction, M0072766, section "Required Software".

Note: An Ethernet (425-6889) service tool is required to flash the telematics device and radio.

At the machine:

3. Perform the installation instructions in Special Instruction, M0072766 in full.

Note: Follow these instructions EXACTLY to avoid rendering an ECM inoperable.

4. Make sure to follow the entire process until the device performs a successful communication check.

5. If the device is not communicating, refer to UENR5824. Please complete a successful communication check before leaving the machine.

6. After the installation is complete, connect up to the machine using Cat ET, and take a Product Status Report (PSR).

7. Once the installation is completed please send all required documents to your PL Technical Communicator and make sure the Radio MAC address is among that documentation.

8. Contact your local PL administrator to deactivate the current legacy device by canceling the subscription from the VisionLink store.

9. Wait one hour after the subscription is canceled and machine history is canceled. The PL Administrator must then subscribe their new Telematics device. Log into the Dealer Service Portal and validate the equipment serial number and ownership in the Equipment Data System. Locate the equipment by the machine Serial Number. Confirm the customer, equipment data, and desired subscription level. Additional information and training can be located at www.dealer.cat.com/pl

Note: The wait time may vary during different times of the day.

Group Number 2

Note: 770G, 772G, 773G, 775G, and 777G Off-Highway Trucks require that the PL523 hardware set remain installed in the machine to support VIMS, TKPH, TPMS, and RAC. The final installation will include the PL523 ECM and the PL641 Product Link Pro radio.

Note: PL523 ECM's require an ECM configuration file. Reference Special Instruction, M0072768 section, "Required Software", for more information on required configuration files.

Note: 770G, 772G, 773G, 775G, and 777G Off-Highway Truck ECM's may require updates to firmware to work properly with the new PL641 radio system. Reference Special Instruction, M0072768, section "Required Software", for more information on required flash files.

Before going to the Customer Site:

1. Review Special Instruction, M0072768 for all the tools required to perform the 2G-3G upgrade from a legacy Product Link to a PL641.

2. Download all required ECM flash files and configuration files as shown in Special Instruction, M0072768, section "Required Software".

Note: An Ethernet (425-6889) service tool is required to flash the telematics device and radio.

At the machine:

3. Perform the installation instructions in Special Instruction, M0072768 in full.

Note: Follow these instructions EXACTLY to avoid rendering an ECM inoperable.

4. Make sure to follow the entire process until the device performs a successful communication check.

5. If the device is not communicating, refer to UENR5824. Please complete a successful communication check before leaving the machine.

6. After the installation is complete, connect up to the machine using Cat ET, and take a Product Status Report (PSR).

7. Once the installation is completed please send all required documents to your PL Technical Communicator and make sure the Radio MAC address is among that documentation.

8. Contact your local PL administrator to deactivate the current legacy device by canceling the subscription from the VisionLink store.

9. Wait one hour after the subscription is canceled and machine history is canceled. The PL Administrator must then subscribe their new Telematics device. Log into the Dealer Service Portal and validate the equipment serial number and ownership in the Equipment Data System. Locate the equipment by the machine Serial Number. Confirm the customer, equipment data, and desired subscription level. Additional information and training can be located at www.dealer.cat.com/pl

Note: The wait time may vary during different times of the day.

Group Number 3

Before going to the Customer Site:

1. Refer to the installation instructions REHS8850 for all tools required to perform the 2G-3G upgrade from a legacy Product link to a 3G radio system. Carefully check the required parts listed under each group.

Note: An Ethernet (425-6889) service tool is required to flash the telematics device and radio.

2. Download the flash files and configuration files to your PC for updating the PL641 radio and PLE601 Network Manager:
.

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3. Please check the parts required very carefully for each machine. Research the machine prefix in SIS and take a look at all associated service magazines and service letters that have been published.

Note: For B & C series AT machines reference the section 'Wiring to a 70 position product link connector' in the special instruction REHS8850 and REHS9111 and replace the existing Secondary Service Port with the Ethernet Service Port supplied with the new harness.

At the machine:

4. Perform installation instructions REHS8850 when replacing a PL522 with a PLE641. Carefully check the required parts listed under each group.

5. Make sure to follow the entire process until the device performs a successful communication check.

6. If the device is not communicating, refer to UENR5823 to troubleshoot a PLE641. Please complete a successful communication check before leaving the machine.

7. After the installation is complete, connect up to the machine using Cat ET, and take a Product Status Report (PSR).

8. Once the installation is completed please send all required documents to your PL Technical Communicator and make sure the Radio MAC address is among that documentation.

9. Contact your local PL administrator to deactivate the current legacy device by canceling the subscription from the VisionLink store.

10. Wait one hour after the subscription is canceled and machine history is canceled. The PL Administrator must then subscribe their new Telematics device. Log into the Dealer Service Portal and validate the equipment serial number and ownership in the Equipment Data System. Locate the equipment by the machine Serial Number. Confirm the customer, equipment data, and desired subscription level. Additional information and training can be located at www.dealer.cat.com/pl

Note: The wait time may vary during different times of the day.