Procedure for Installing Continuous Telematics Power Retrofit (CTPR) for Electric Power{7606} Caterpillar

Electric Power Generation: All

Machine Control and Guidance Products:

PRODUCT LINK (S/N: PL61-UP)

Introduction

This Special Instruction outlines the procedure for installing Continuous Telematics Power Retrofit (CTPR) which is a retrofit option that can be installed on an asset to provide continuous reporting from the Product Link system regardless of the state of the master disconnect switch of the asset.

When the master disconnect switch of the asset is turned OFF (opened), all power is removed from the Product Link system. On a standard Product Link installation this action will completely disable the device, so the device can no longer determine asset location or communicate with Product Link Web.

To allow the Pro and Elite systems to continue reporting when the master disconnect switch of the asset is turned OFF (opened), the Continuous Telematics Power Retrofit option can be installed. This retrofit option involves bypassing the master disconnect switch of the generator set package to provide continuous power to the Product Link system.

Do not perform any procedure in this Special Instruction until you have read this entire Special Instruction and you understand this information

Note: This procedure applies only to the Product Link Pro (PL641/PL631) and Elite (PLE641/PLE631) systems. Caterpillar is not responsible for data loss, damage to the Product Link, or damage to the generator set package if this procedure is used with any Product Link System other than the Pro and Elite systems.

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.

Show/hide table

Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

Show/hide table

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. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Required Common Components/Connectors

The required common components/connectors are listed in Table 1.

Installation Procedure

Perform the following procedure for installing the Continuous Telematics Power Retrofit:

Show/hide table



Illustration 1	g03782497
CTPR schematic

1. Cut a length of black 16 AWG wire of sufficient length to reach from Pro harness open-end wires to the master disconnect switch.

2. Splice one end of the black 16 AWG wire from Step 1 to the 200-BK "-Battery Input" wire coming from the Pro harness.

3. Terminate the other end of the black 16 AWG wire from Step 1 with an 8T-8730 Connector Socket and insert the socket into location "2" of 155-2269 Connector Plug As .

4. Cut a length of black 16 AWG wire of sufficient length to reach from 155-2269 Connector Plug As to the master disconnect terminal lug that goes to the "Negative Battery Terminal" of the starter battery.

5. Terminate one end of the black 16 AWG wire from Step 4 with an 8T-8730 Connector Socket and insert the socket into location "1" of the 155-2269 Connector Plug As from Step 3.

Show/hide table



Illustration 2	g03782521
Progress by end of step 6 (in black)

6. Terminate the opposite end of the black 16 AWG wire from Step 4 with the appropriate size ring terminal and attach to the master disconnect terminal lug that goes to the "Negative Battery Terminal" of the starter battery.

7. Cut a length of black 16 AWG wire approximately 250 mm (9.8 inch) long and terminate both ends with 8T-8729 Connector Pins .

Show/hide table



Illustration 3	g03782525
Loop created to prevent losing Telematics disable connector

8. Loop the black wire from Step 7 around the wiring assembly and insert the pins into locations "1 and 2" of a 3E-3364 Receptacle to prevent losing the Receptacle when not connected.

   Note: The 3E-3364 Receptacle in 3 allows power to be removed from the Product Link system.

9. Connect the 3E-3364 Receptacle to the 155-2269 Connector Plug As in Step 3.

10. Cut a length of red 16 AWG wire of sufficient length to reach from Pro harness open-end wires to "Positive Battery Source".

    An example would be terminal location 101 on an XQ800.

11. Splice one end of the red 16 AWG wire from Step 10 to the 101-RD "+ Battery Input" wire coming from the Pro harness.

12. Splice the opposite end of the red 16 AWG wire from Step 10 to a 304-5284 Fuse Holder .

    Note: Do not insert fuse into the fuse holder at this time.

13. Cut a length of red 16 AWG wire of sufficient length to reach from 304-5284 Fuse Holder from Step 12 to the "Positive Battery Source" identified in Step 10.

Show/hide table



Illustration 4	g03782527
9X-1056 Receptacle Terminal and 308-YL wire (1) Hole "1" (2) Hole "2" (3) 9X-1056 Receptacle Terminal (4) Hole "4" (5) Hole "5" (6) 308-YL wire

14. Insert the 308-YL "Switched Power" wire (6) from the Pro harness through hole "1" (1) of a 9X-1054 Connector Plug As and then terminate with a 9X-1056 Receptacle Terminal (3). Secure the receptacle terminal into hole "1" (1) .

15. Cut two identical lengths of red 16 AWG wire of sufficient length to reach from 9X-1054 Connector Plug As to "Positive Battery Source" in Step 10.

Show/hide table



Illustration 5	g03782529
9X-1054 Connector Plug As and red 16 AWG wire (1) Hole "1" (2) Hole "2" (3) 9X-1056 Receptacle Terminal (4) Hole "4" (5) Hole "5"

16. Insert one red 16 AWG wire from Step 15 through hole "5" (5) of 9X-1054 Connector Plug As and then terminate with a 9X-1056 Receptacle Terminal (3). Secure the receptacle terminal into hole "5" (5) .

17. Insert the other red 16 AWG wire from Step 15 through hole "4" (4) of 9X-1054 Connector Plug As and then terminate with a 9X-1056 Receptacle Terminal (3). Secure the receptacle terminal into hole "4" (4) .

18. Take the other end of the two identical red 16 AWG wires from Step 15 and connect to "Positive Battery Source" identified in Step 10.

19. Cut a length of black 16 AWG wire of sufficient length to reach from 9X-1054 Connector Plug As to a "Negative Battery Source" on the Control ECMs side of the master disconnect terminal lug.

    An example would be terminal location 202 on an XQ800.

Show/hide table



Illustration 6	g03782535
9X-1054 Connector Plug As and black 16 AWG wire (1) Hole "1" (2) Hole "2" (3) 9X-1056 Receptacle Terminal (4) Hole "4" (5) Hole "5"

20. Insert the black 16 AWG wire from Step 19 through hole "2" (2) of 9X-1054 Connector Plug As and then terminate with a 9X-1056 Receptacle Terminal (3). Secure the receptacle terminal into hole "2" (2) .

21. Take the other end of the black 16 AWG wire from Step 19 and connect to "Negative Battery Source" identified in Step 19.

22. Plug the Relay As (12/24VDC) into 9X-1054 Connector Plug As . Mount the Relay As if desired.

23. Insert a 15 A fuse in the 304-5284 Fuse Holder from Step 12.

Operational Verification of the Product Link

Before leaving the site, complete the following procedure to verify that the Product Link system is operating normally after installing the Continuous Telematics Power Retrofit option:

1. Turn the master disconnect switch to the OFF (open) position.

2. Verify that the green LED in PL641/PL631 viewing window is still illuminated.

3. Turn the master disconnect switch to the ON (closed) position.

4. Connect to the Product Link system with Caterpillar Electronic Technician (Cat ET) and verify normal operation.