Product Link PL-102C System Installation{7606} Caterpillar

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Introduction

This "Special Instruction" is written to provide information for installing the Product Link PL-102C and Caterpillar Service Tool Software for the PL-102C.

Note: Product Link PL-102C uses Caterpillar Service Tool software, not Electronic Technician software. Caterpillar Service Tool must be installed on the computer that is to be used to configure the Product Link PL-102C.

Operation and Maintenance Manual

1. Locate the Operation and Maintenance Manual for the machine that is being serviced.

2. Remove the paper strip on the Operation and Maintenance Manual, REHS2153 supplement in order to expose the adhesive.

3. Insert the Operation and Maintenance Manual, REHS2153 supplement onto the inside of the back cover of the machine Operation and Maintenance Manual.

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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 Caterpillar dealer to determine this structure's limitations without voiding its certification.

ROPS Warning

Required Tools and Parts

SYSTEM OVERVIEW

Illustration 1	g01071821
Product Link PL-102C System Overview

The Product Link PL-102C uses cellular technology and GPS technology. The Product Link PL-102C transmits information regarding service meter hours and the location of the machine. The Product Link PL-102C uses the cellular network system to communicate information. The Product Link PL-102C system uses cellular towers and networks that already exist.

The Product Link PL-102C system is capable of two-way communication between the machine and a remote user. The user can be a dealer or a customer. A user can request updated information from a machine at any time. Also, the system parameters for the Product Link PL-102C module can be changed remotely.

Scheduled Reporting

The PL-102C can be setup to report on a regular schedule to the Equipment Manager system. The schedule can be selected by using Caterpillar Service Tool software for the Product Link PL-102C module. The schedule can be modified by using Equipment Manager or Caterpillar Service Tool software.

Product Watch

Product Watch is a feature of the Product Link PL-102C system. Product Watch can be carried out in three ways:

• Inclusive Product Watch sets up a "virtual fence" around a work site. Once Inclusive Product Watch is activated, the owner of the machine is alerted if the machine leaves the work site area.

• Exclusive Product Watch allows the owner of a machine to set up an area that the machine is not allowed to enter. A technician can set the center point and the radius of the restricted areas. The owner of a machine is alerted if a machine enters a restricted area.

• Time Based Product Watch allows the owner of a machine to choose the time a machine can be operated. An alert is sent to the machine owner if the machine is operated outside of the time that is set for machine operation.

Product Link PL-102C Parts

The Product Link PL-102C can be ordered as a kit. The part number for the kit is 249-6480 Product Link PL-102C . The part numbers for the individual parts of the kit are listed in the table 2.

Illustration 2	g01062216
249-6468 Product Link Module PL-102C

Illustration 3	g01062147
250-1971 Combination GPS/Cellular Antenna

Table 3 lists parts that are sold separately from the Product Link PL-102C kit.

Select a Location for the PL-102C Module

• Do not mount the module in the engine compartment.

• Do not mount the module in battery boxes.

• Do not attach the module to the ROPS.

• The module must be installed so that the connectors of the module point downward.

• The module must be installed on a flat surface.

Note: If self-tapping screws are used to mount the module, the screws must be 3.5 mm (0.138 inch) (#6) screws that are 31.75 mm (1.25 inch) to 38 mm (1.5 inch) long.

For more specific guidelines, refer to Special Instruction, SEHS6929, "Inspection, Maintenance and Repair of Rollover Protective Structures (ROPS) and Attachment Installation Guidelines" as well as any other published guidelines that are specific for a machine serial number.

Select a Location for the Antenna

• Do not mount the antenna to the ROPS. The antenna must be mounted to a flat metal surface with a clear view of the sky. Mounting the antenna to a flat metal surface such as the roof or on the top of the machine cab is preferred. Performance of the antenna is enhanced if the antenna is mounted in the middle of the roof.

• Install the antenna with the base oriented horizontally. For optimal performance, the antenna must be oriented facing up.

Note: The GPS antenna must be mounted with the antenna facing up.

• Mount the antenna more than 30 cm (12 inches) from the operator of the machine in order to comply with FCC regulations for RF human body safety.

• Keep the routing of the cable in mind. Do not route the antenna cable near any source of extreme heat (exhaust). Route the antenna cable so the cable would not be subject to abrasion or pinching. Route the antenna cable using a minimum bend radius of 50 mm (2 inch).

• Secure the antenna cable every 457 mm (18 inches) or shorter if necessary. Coil any excess antenna cable. Properly secure any excess antenna cable to the machine. Shortening the antenna cable could result in inconsistent data transfer.

• In certain operating environments, the antenna may need to be mounted in a protected location. The antenna must not be covered or surrounded by metal of any kind or thickness. Install the antenna in a location that will protect the antenna from falling debris and accumulated water. The following list includes materials that are allowed to cover or protect the antenna: metal free glass, plastics, fiberglass and most other nonmetal materials

ADDITIONAL NOTES

• If the antenna is a permanently mounted combination antenna, a hole must be drilled in the roof to allow access to the threaded mount on the bottom of the antenna.

• If an individual GPS antenna and an individual cellular antenna are used rather than a combination antenna, the individual antennas can be mounted close together. There is no required minimum distance between the antennas.

• The stealth antenna is a combination style antenna that has a GPS antenna and a cellular antenna. The stealth combination antenna can be mounted using double-sided tape or tie wraps. The guidelines that are listed above should be followed in order to determine a location for the stealth antenna.

Install PL-102C Module

Refer to the mounting template in illustration 10 for the correct hole pattern in order to mount the module. The Product Link PL-102C module must be installed inside a machine cab. The cab of the machine must be shock mount equipped. Refer to the "Select a Location for the PL-102C Module" section for the proper location of the module.

Note: Hardware for mounting the module is included with the kit. Shock mounts are not available for this module.

Connect the Wiring Harness

Illustration 4	g01129276
PL-102C 249-6471 wiring harness

Some machines may already contain a Product Link harness. The Product Link harness that is on the machine can be modified for use with the Product Link PL-102C. Refer to the specific machine schematic for the required connection.

1. De-energize the electrical system. Turn the battery disconnect switch to the OFF position or disconnect the battery.

   Note: If the machine is Product Link Ready, you can attach a 6 pin DT connector to the wire harness and plug the harness directly into the Product Link connector of the machine. Refer to the machines electrical schematic for connections.

2. Connect wire 107- RD of the harness to a fused +Battery supply circuit that is not switched. The power supply to the unit must be fused for 2 amps. An auxiliary fuse circuit can be used to provide a fuse for the module.

   Note: If an existing fuse on the machine is used, verify that the addition of the module does not overload the circuit. The module is 250 mA nominal and 2 amps maximum.

3. Connect wire 229- BK to machine ground. The preferred ground location is a grounding stud.

   Note: The preferred method to establish a good ground connection is to connect the ground wire for the module to the same location as the ground wire of the battery. If you connect the ground wire for the module to a location other than at the same location of the ground wire for the battery, the ground can be unreliable.

4. Connect wire 403- GN from the wire harness to the alternator R-term circuit.

   Note: As an alternative, the green wire can be connected to a switched source such as a key switch ON terminal. However, the key switch should be used only as a last resort.

5. Connect wire 308-YL of the wire harness to any source of battery power that is controlled by the key switch "ON" circuit.

6. Connect the grounding strap to one of the bolts that is used to attach the module to the equipment.

   Note: Make sure that the ground strap is attached to a clean connection. The connection must be free of any paint, oils or other materials that would inhibit a good connection. Make sure that the ground connection is tight.

Additional Notes

When possible, keep all connections in the same location.

If a wire splice must be done, choose a location for the splice that is free from physical stresses on the splice such as heat, contaminants, debris, moisture, sunlight, and excessive motion.

The preferred types of connections are listed in order of preference as follows:

1. Machine DT connectors are preferred if the machine is Product Link Ready.

2. A soldered splice covered with adhesive lined heat shrink.

3. Part number 207-3814 Y splices that are ready made and are available from a Caterpillar dealer.

Confirm Wire Harness Connections

1. Remove the harness connectors from the module.

2. Confirm that the key switch is in the OFF position.

   Note: The wiring harness must remain disconnected from the PL-102C module so voltages can be confirmed.

3. Connect the black (negative) lead of the multimeter to pin 2 of the 2 pin connector.

4. Connect the red (positive) lead of the multimeter to the appropriate pin as shown in table 4.
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   Table 4

   Connector Contact 2 Pin Connector	Connector Contact 13 Pin Connector	12 Volt Machines	24 Volt Machines
   1		0 VDC	0 VDC
   	5	0 VDC	0 VDC
   	6	0 VDC	0 VDC

5. Turn the battery disconnect switch to the ON position.

6. Connect the red lead of the multimeter to the appropriate pin as shown in table 5.
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   Table 5

   Connector Contact 2 Pin Connector	Connector Contact 13 Pin Connector	12 Volt Machines	24 Volt Machines
   1		12 VDC	24 VDC
   	5	0 VDC	0 VDC
   	6	0 VDC	0 VDC

7. Turn the key switch to the ON position.

8. Connect the red lead of the multimeter to the appropriate pin as shown in table 6.
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   Table 6

   Connector Contact 2 Pin Connector	Connector Contact 13 Pin Connector	12 Volt Machines	24 Volt Machines
   1		12 VDC	24 VDC
   	5	0 VDC	0 VDC
   	6	12 VDC	24 VDC

9. Start the engine.

10. Connect the red lead of the multimeter to the appropriate pin as shown in table 7.
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    Table 7

    Connector Contact 2 Pin Connector	Connector Contact 13 Pin Connector	12 Volt Machines	24 Volt Machines
    1		12 VDC	24 VDC
    	5	Specified Alternator Output Value	Specified Alternator Output Value
    	6	12 VDC	24 VDC

11. Connect the wiring harness to the module if the voltages are approximately the values that are shown in the tables above.

    Note: If the voltages are less than the voltages that are shown in tables above, there is a problem with the wiring harness. Before proceeding, repair the wiring harness. Then, repeat the steps listed above that are in this section.

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Illustration 5	g01075667
230-1340 Warning Film for use within the US

12. Affix the appropriate warning film that is listed in table 2 to the dash or another location within the cab that will allow the film to be visible to the operator during normal operation of the machine. Do not place the film in a location that will obstruct the vision of the operator.

Product Link PL-102C Configuration and Registration

Required Software

Caterpillar Service Tool Software for Product Link PL-102C is required in order to configure and in order to register this product.

Obtaining Software

The software CD is packaged with the 249-6476 Serial Service Cable . The software can also be obtained from the following sources:

• CD-ROM format by using media number EERE5000

• downloaded from the SIS Web internet site from the main page under "Additional Downloads"

• through NACD "Infocast"

Installing the Caterpillar Service Tool Software for Product Link PL-102C on a Laptop Computer

1. Insert the CD that contains the software for Caterpillar Service Tool into the CD-ROM drive.

   Note: If "Auto Play" is enabled on the computer, "Install" may automatically start after the CD is inserted.

2. Click the "Start" button on the Window's desktop. Click the "Run" button.

3. Use Microsoft® Windows Explorer to locate the service tool software.

4. Double click the "setup.exe" file to start the install process.

5. Follow the on screen instructions in order to install the software.

Note: If Caterpillar Service Tool is being installed for the first time on a PC, a software package called Microsoft®.NET Framework will install first. The user must restart the PC after Microsoft®.NET Framework has installed. The user must restart the procedure to install Caterpillar Service Tool. Refer to the preceding steps to install Service Tool after Microsoft .NET Framework has installed.

Configure and Register the Product Link PL-102C

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Illustration 6	g01075747
249-6476 Serial Service Cable

1. Connect the 249-6476 serial service cable to the four pin connector of the 249-6471 wiring harness .

2. Connect the serial service cable to the laptop computer. The laptop computer must have Caterpillar Service Tool software installed.

   Note: If the 249-6476 Serial Service Cable is not long enough, an extension cable is available. The 1U-9484 Serial Extension Cable is 3 m (10 ft.) long. There is also a 237-7547 USB to Serial Adapter that is available. The Serial Adapter will plug into the Serial Service Cable connector and into a USB port on the PC.

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Illustration 7	g01075761
1U-9484 Extension Cable

3. Start the Caterpillar Service Tool.

   Note: The computer will attempt to communicate with the module. A green icon in the upper right hand corner of the screen indicates communication between the computer and the module. If the module does not start communication with the Caterpillar Service Tool within thirty seconds, then select the "Disconnect" option on the "Action" menu. Select "Options" on the "Tools" menu and select the proper communications port. Retry communication with the module by selecting the "Connect" option on the "Action" menu.

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Illustration 8	g01073716
Caterpillar Service Tool Status Tab

4. Click the "Status" tab in the Caterpillar Service Tool software window.

   1. Use the GPS status group in order to verify the number of satellites that are in view. The module must connect with at least four satellites in order to obtain a position fix.

   2. Verify that the RSSI signal strength is greater than -105. The field that shows the signal strength should register the signal in the "green zone".

   3. Use the "Radio Status" field to verify that there is cellular coverage. A green light for "Microburst" parameters indicates a connection.

   4. With the key in the ON position, verify that the "Power Mode" is in the "Full On" mode.

   5. Verify the status of the key switch. Verify that the key switch is actually in one of the three following positions: On position, Run position and Off position.

   6. Verify the status of the input for "engine running". Verify whether or not the engine is running.

      Note: There is a 30 second delay in detecting the transition from engine is running to engine not running.

   7. Verify that the voltage is at the appropriate level. The status bar may not be calibrated if the system voltage configuration parameter has not been set.

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Illustration 9	g01073753
Caterpillar Service Tool Configuration Tab

5. Click the "Configuration" tab.

   1. In the "Time Zone" field of the "Module Properties" area, select the time zone in which the machine will be operated.

   2. In the "System Voltage" field, select the system voltage.

   3. Enter the DBS Machine Make Code in the "DBS Machine Make Code" field.

      Note: The "DBS Machine Make Code" is a two letter code. An example of the code is AA, which is used for Caterpillar machines. The two letter code is used to indicate the type of machine that the Product Link PL-102C module is being installed in.

   4. Enter the dealer identification code for the Caterpillar dealership that is installing the unit.

   5. In the "Machine Serial Number" field, enter the serial number of the machine.

   6. If the Product Link PL-102C is being installed on a machine that is already in service, then enter the number of hours that is shown on the machine hour meter in the "Total Operating Hours" field.

   7. Go to the "Report Schedule" field. Select the appropriate schedule from the list in order to send data to Equipment Manager.

      Note: If "None" is selected, no data will be provided to Equipment Manager. The reporting period that is chosen will affect the billing costs. Contact your Caterpillar dealer for information about billing rates.

   8. Go to the "Engine Running Indicator" field. Either select "Alternator R-Term" if the wire that provides input to the module is connected to the alternator R-Term or select "Steady State Signal" if the wire that provides input to the module is connected to the key switch or another steady voltage supply.

Setup Inclusive Product Watch

To use "Inclusive Product Watch":

1. Click the "Configuration" tab.

2. Select a radius in the "Radius" field of the "Inclusive Product Watch" portion of the window.

Note: Setting the radius does not activate Product Watch. Activation is through the use of Equipment Manager. The center point of the radius will be established based on the location of the machine at the time "Inclusive Product Watch" is activated.

Setup Exclusive Product Watch

To set up Exclusive Product Watch:

1. Click the "Configuration " tab.

2. Enter the latitude and the longitude into the correct fields of the "Exclusive Product Watch" field.

3. Select the desired radius in the "Radius" field.

Note: Selecting the radius and the center point does not activate "Exclusive Product Watch". Activation is achieved through the use of Equipment Manager. In order to obtain an accurate center point, a longitude coordinate and latitude coordinate must be entered. The suggested method in order to obtain the desired coordinates is the use of dynamic mapping system software that is PC-based.

Setup Time Based Product Watch

To set up Time Based Product Watch:

1. Click the "Configuration" tab.

2. From the "Active Time" field in the "Time" based "Product Watch" field, select the time range for allowable operating hours of the machine.

Note: Selecting the time range does not activate "Time Based Product Watch". Activation is obtained through the use of Equipment Manager. If the machine is operated outside of the selected time range, an alarm is sent to Equipment Manager.

Finish Configuration and Registration of the Module

Click the "Register" button in order to register the installation and configuration data with Equipment Manager. After the data has successfully been transmitted, a "Transmitted Successfully" message will be displayed.

Note: Registration is required in order to activate the PL-102C module and to begin scheduled reporting.

Finish the Installation

1. Verify that the mounting hardware is secure.

2. Verify that all of the cable connections are tight.

3. Verify that all of the of the cables and wires have been properly secured.

4. Verify that all machine plates and guards that were removed for the installation procedure are put back on the machine

5. Verify warning film is attached properly.

6. Verify that the machine operates properly.

7. Verify that the OMM supplement has been placed in the machine OMM.

"PLM STATUS" PARAMETERS

"PLM Status" Section

Refer to table 8 for an explanation of the "PLM Status" parameters.

"Radio Status" Section

Refer to table 9 for an explanation of the "Radio Status" parameters.

Product Watch Status

Product Watch allows tracking of a machines' movement. Product Watch can report if a machine moves into a specified area. Product Watch can generate a report if a machine moves out of a specified area. Also, if a machine is operated outside of a specified time period a report will be sent.

Product Watch can be configured through the Caterpillar Service Tool or through Equipment Manager. Refer to table 10 for an explanation of the parameters for the Product Watch section.

GPS Status

Refer to table 11 for an explanation of the parameters for GPS Status.

Product Link PL-102C Module Template

Illustration 10	g01073344
Mounting Template for 249-6468 Product Link PL-102C Module .