Installation Procedure to Retrofit a PL321VSR Electronic Control Module (ECM) With a Pro Product Link PL641 or PL631 or PL542 Systems {7606} Caterpillar

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Introduction

This Special Instruction will provide the parts and procedures to install the Pro Product Link PL641 and PL631 on machines with a PL321VSR (VIMS A4N4).

Reference: Special Instruction, REHS9111, "Installation Procedure for the Pro Product Link^™ PL641 and PL631 Systems".

Reference: Special Instruction, REHS7428, "VIMS 3G Software Installation Guide For Certain Cat^® Product Using VIMSpc 2011A and VIMSpc 2013A".

Reference: Systems Operation, RENR6293, "VIMSpc Software".

Reference: Systems Operation, UENR0769, "VIMS^TM 3G".

Reference: Systems OperationTroubleshootingTesting and Adjusting, M0079294, "Product Link^® PL542 Systems".

Reference: Special Instruction, M0077632, "Installation Procedure for the Product Link^TM PL542 Systems".

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 should also have the necessary training, skills, and tools 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 that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

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

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Personal injury or death can result when voiding this certification. Structural damage, an overturn, modification, alteration, or improper repair can impair the Rollover Protective Structure's (ROPS) protection capability thereby voiding this certification. Do not drill holes in the ROPS. Do not weld on the ROPS unless welding is specified in the procedure. Place welds only at the locations that are specified in the procedure. To avoid possible weakening of this ROPS, consult a Caterpillar dealer before altering this ROPS in any way. The protection offered by this ROPS will be impaired if it has been subjected to structural damage. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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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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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.

Machine Preparation

1. Drive the machine onto a smooth level surface that can support the weight of the machine.

2. Turn off the engine and remove the key from the starting switch.
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   Illustration 1	g00104545

3. Perform lockout tag out procedure by attaching a warning tag to the machine controls.

Note: De-register old Cat^® Product Link system 24 hours prior to visiting the machine and performing hardware retrofit to Product Link hardware.

Note: If Payload Control System equipped machines are set up with Material Lists and Truck Lists, record these lists prior to updating hardware and software. Refer to Systems Operation, RENR6293, "VIMSpc Software" for more information about accessing Material Lists and Truck Lists using VIMSpc.

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

Illustration 2	g06354781
Label with part number and serial number

Note: These instructions only support tethering a PL641 or PL631 radio to a PL321VSR with a A4N4 Electronic Control Module (ECM) including an A4N4 VIMS device 285-1142 Electronic Control Module with suffix "HD". This special instruction does not cover devices with a PL300 285-1133 Electronic Control Module with suffix code "LQ". Refer to Illustration 2.

Note: For machines supporting a PL522 or PL523 Product Link Device outside 2G cellular coverage with the Payload Control System (PCS) installed, follow steps in Special Instruction, M0099440, "Installation Procedure to Retrofit a PL522 or PL523 With a Pro Product Link PL641 or PL631 or PL542 System" and apply to all machines or replace the PL522 or PL523 and install a A4N4 ECM with a VIMS A4N4 285-1142 Electronic Control Module with suffix "HD".

Required Parts

Choose the correct enterprise of Product Link installation kit listed in Table 1.

The additional required parts for installation are listed in Table 2.

Note: Refer to Special Instruction, REHS9111, "Installation Procedure for the Pro Product Link PL641 and PL631 Systems" and refer to section "Required Parts for Machines" for full details on Product Link installation kits.

The required software, compatible device, and machine model are listed in Table 3.

Installation Procedure

Perform the below procedure for Product Link installation:

1. Gain access to where the PL321VSR is located and installed on the machine.

2. Install cellular 440-2105 Electronic Control Module (Communication Radio) or satellite 442-7199 Electronic Control Module (Communication Radio).

3. Reroute existing 353-8773 Communication Cable As to the cellular 440-2105 Electronic Control Module (Communication Radio) or the satellite 442-7199 Electronic Control Module (Communication Radio).

   Note: 353-8773 Communication Cable As (Antenna cable) in 467-4161 Communication Installation Gp or 467-4162 Communication Installation Gp is only required if the existing antenna cable assembly is damaged and needs to be replaced.

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   Illustration 3	g06354860
   Splice end of 452-0543 Wiring Harness for Machines

4. Route and install 8T-8729 Connector Pin to each splice end of 452-0543 Wiring Harness wires, excluding the below three wires.

   • 403-GN

   • 892-BR

   • 893-GN

5. Secure the below mentioned unused wires of 452-0543 Wiring Harness.

   • 403-GN

   • 892-BR

   • 893-GN
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   Illustration 4	g06355721
   Wiring Connections

6. Insert the five pinned wires from 452-0543 Wiring Harness into 102-8805 Receptacle Kit (A) in pin locations as mentioned below. Refer to Illustration 4.

   • Pin 1 - 101-RD - Batt +

   • Pin 2 - 200-BK - Batt -

   • Pin 3 - 308-YL - Key Sw

   • Pin 4 - F711-YL - CAN High

   • Pin 5 - F712-GN - CAN Low

   • Pin 6 - No connection

7. Remove the following five wires, one at a time from the VIMS A4N4 ECM and insert the socket pin ends into 155-2274 Connecting Plug Kit (B) in the following order. Refer to Illustration 4.

   • Pin 1 - from 52 - Orange 125 - Batt+

   • Pin 2 - from 65 - Black 200 - Batt -

   • Pin 3 - from 70 - Yellow 308 - Key Switch

   • Pin 4 - from 50 - Orange Y794 - CAN High

   • Pin 5 - from 34 - Green Y765 - CAN Low

   • Pin 6 - No connection

8. Locate the five 207-3814 Wire As ("Y" Splice) having one end with two socket pins and one end with one connector pin.

9. Insert the five pinned ends from 207-3814 Wire As into 102-8805 Receptacle Kit kit (D) in locations as shown in Illustration 4.

10. Connect 155-2274 Connecting Plug Kit (B) connector to 102-8805 Receptacle Kit (C) connector as shown in Illustration 4.

11. Insert the socket ends of the five 207-3814 Wire As splice wires with one socket connected to the A4N4 VIMS ECM and the corresponding socket end into 155-2274 Connecting Plug Kit (D) in locations as follows:

    • A4N4 pin 52 to pin 1 of 155-2274 Connecting Plug Kit

    • A4N4 pin 65 to pin 2 of 155-2274 Connecting Plug Kit

    • A4N4 pin 70 to pin 3 of 155-2274 Connecting Plug Kit

    • A4N4 pin 50 to pin 4 of 155-2274 Connecting Plug Kit

    • A4N4 pin 34 to pin 5 of 155-2274 Connecting Plug Kit

    • No Connection to pin 6 of 155-2274 Connecting Plug Kit

12. Then connect 155-2274 Connecting Plug Kit (D) connector to 102-8805 Receptacle Kit (A) connector. Refer to Illustration 4.
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    Illustration 5	g06355730
    (1) Satellite cable (white wire) (2) Cellular cable (Brown wire) (3) GPS Data (Blue wire)

13. Replace the antenna on top of the cab with 443-8462 Antenna As (hard mount).

    Note: The adhesive mount antenna in 467-4161 Communication Installation Gp and 467-4162 Communication Installation Gp can be discarded.

14. Attach the following antenna connections to the coaxial extension cable.

    - For PL641 cellular installations:

    • Connect cellular cable (2) (Brown wire)

    • Connect GPS data (3) (Blue wire)

    - For PL631 satellite installations:

    • Connect satellite cable (1) (White wire)

    • Connect GPS data (3) (Blue wire)

15. Plug 12-pin connector in 452-0543 Wiring Harness into 440-2105 Electronic Control Module or 442-7199 Electronic Control Module.

16. Seal the unused 8-pin connector port on 440-2105 Electronic Control Module (ECM) using 155-2265 Connecting Plug Kit and 8T-8737 Seal Plug.

PL321VSR Software Update Instruction and Configuration

Perform the below steps for PL321VSR software update instruction and configuration:

1. Connect "Comm Adapter 3" to the service port of the machine.

2. Using the Cat^® Electronic Technician (Cat ET) Service Tool 2015C or newer, download the software for the VIMS A4N4 ECM to the software specified in Table 3.
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   Illustration 6	g06355756
   Preferences Tab

3. Open Cat ET 2015C or newer, select "Utilities" -> "Preferences" -> "Modify" and set connection to "Caterpillar Comm Adapter 3 (RP1210)", defaults to "J1939 Baud Rate 250k" and select "OK". Refer to Illustration 6.
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   Illustration 7	g06355759

4. Click on "Winflash" icon.

5. Select the ECM labeled "VIMS A4:N4 Main" in the WinFlash ECM list and load the software. Follow software availability from SIS web "VIMS Software & Current Releases". Refer to Table 5 (VIMS Compatibility Software Matrix).

6. Once the download is complete, select "File", and select "Return to Cat ET", and select "VIMS Main Module", and then select "OK".
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   Illustration 8	g06355765
   Configuration Screen

7. Select "Service" -> "Configuration Screen".
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   Illustration 9	g06355783

8. Select "VIMS Main Module" -> "General Information" "PLM Enable Status (Billing)". Refer to Illustration 9.

   Note: If the "PLM Enable Status (Billing)" is not seen in General Information as shown in Illustration 9, then select "File" -> "Switch Data Link".

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   Illustration 10	g06355815

9. Set the "PLM Enable Status (Billing)" configuration to "Disabled". Refer to Illustration 10.

   Note: This action effectively disables the 2G cellular radio in the PL121 satellite radio. Harness to the PL121 radio should remain connected to the PL121. If PL121 radio is not connected user will receive an active code 1250-9 Remote Communication Module: Abnormal Update Rate. With some installations, code 1250-9 Remote Communication Module: Abnormal Update Rate will be inactive if the PL121 is connected. 1250-9 Remote Communication Module: Abnormal Update Rate will only be visible with Cat ET. This nuisance code is not shown on operator display and does not limit functionality of the system. GPS and Satellite LED’s will continue to blink when machine is power cycled on. Green LED will be on solid only if R-Term is used and engine is running.

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   Illustration 11	g06355821

10. Within the Configuration screen, select "ECM Identification Parameters" -> "Product ID" enter the "Product ID" into the "VIMS Main Module" as shown in Illustration 11.

VIMS Main Module A4:N4 Configuration File Upload

1. A configuration file is required for VIMS A4N4 ECM. Connect 305-5528 Wiring Harness (VIMS 3G Service Cable) to the VIMS Service Port.

2. To install the VIMS config file follow instructions outlined in Special Instruction, REHS7428, "VIMS 3G Software Installation Guide For Certain Cat^® Product Using VIMSpc 2011A and VIMSpc 2013A".

PL641 / PL631 Software Update Instructions

1. Connect 305-5528 Wiring Harness (VIMS 3G Service Cable) to the service port on 452-0543 Wiring Harness (Product Link harness).

2. Follow the instruction in Special Instruction, REHS9111, "Installation Procedure for the Pro Product Link PL641 and PL631 Systems" refer to section "Flash the PL641 or the PL631 Using WinFlash" to flash the product link radio.

3. Follow the instruction in Special Instruction, REHS9111, "Installation Procedure for the Pro Product Link PL641 and PL631 Systems", refer to section "Upload Configuration File" to upload the configuration file into the PL641 or PL631 radio.

   Note: Only the PL641 cellular radio can be flashed over the air.

   Note: A configuration file may be required for the PL641 or PL631 on certain machines. Follow software availability from SIS web. "VIMS Software & Current Releases" (VIMS Compatibility Software Matrix).If not, follow software availability from SIS web. "Product Link Technician's Toolbox".(Current Firmware Part Numbers: PL121SR, PL321SR, PL420, PL421, PL522, PL542, PLE601, PL241, PL631 & PL641) Refer to Table 5.

4. Follow the instructions in Special Instruction, REHS9111, "Installation Procedure for the Pro Product Link PL641 and PL631 Systems", refer to section "Set the Product ID on the Product Link Device" to program the Product ID into the PL641 or PL631 radio.

5. Cycle the power on the machine after loading the configuration file and programming the product ID before testing the connection.

6. Follow Special Instruction, REHS9111, "Installation Procedure for the Pro Product Link PL641 and PL631 Systems" to test the connection and register the Product Link system.

PCS and VIMS Data Download

Note: If the machine is equipped with Payload Control System, Material Lists and Truck Lists were set up prior to this update. These lists will need to be reprogrammed using VIMSpc.

Refer to Systems Operation, RENR6293, "VIMSpc Software" for more information about accessing and updating Material Lists and Truck Lists using VIMSpc.

Note: After the Product Link update is complete, data from Payload Control System (PCS) and VIMS will continue to be downloaded using the VIMS service port, 305-5528 Wiring Harness (VIMS 3G Service Cable), and VIMSpc software. The location of the VIMS service port in the cab of the K-Series Medium Wheel Loader.

Follow System Operation, UENR0769, "VIMS^TM 3G" for more information about connecting VIMSpc software to a K-Series Medium Wheel Loader.

PL542 Installation Procedure

Procedure to install a PL542 on machines equipped with a PL321VSR (VIMS A4N4)

Note: De-register old Cat^® Product Link system 24 hours prior to visiting the machine and performing hardware retrofit to Product Link hardware.

Required Parts

The additional required parts if no service port is available for installation are listed in Table 4.

Required Software

The required software, compatible device, and machine model are listed in Table 5.

Note: Cat^® Electronic Technician (Cat ET) Service Tool 2015C or newer is required for this software update.

Note: Download latest flash files for all ECMs. These flash files will need to be manually downloaded by software part number. SIS web directs you to part number. Go to the address mentioned below and select from the Software and Releases tab (VIMS Compatibility Software Matrix).

Refer to Special Instruction, REHS7428, "VIMS 3G Software Installation Guide For Certain Cat^® Product Using VIMSpc 2011A and VIMSpc 2013A".

Product Link Installation Procedure

1. Gain access to where the PL321VSR is located and installed on the machine.

2. Remove the existing 353-8773 Communication Cable As and Antenna.

3. Refer to Special Instruction, M0077632, "Installation procedure for the Product Link^™ PL542 Systems" for installation and mounting of the PL542 system.

If no service port is available on machine perform the following steps:

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Illustration 12	g06356300
538-2641 Wiring Harness wires

1. Route and attach to each splice end of 538-2641 Wiring Harness wires with 8T-8729 Connector Pin excluding the following five wires:

   • Black w/white stripe

   • Purple

   • Purple w/white stripe

   • Orange

   • Orange w/white stripe

2. Secure the following unused wires:

   • Black w/white stripe

   • Purple

   • Purple w/white stripe

   • Orange

   • Orange w/white stripe
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   Illustration 13	g06356658
   Wiring Connections

3. Insert the six pinned wires from 538-2641 Wiring Harness into 102-8805 Receptacle Kit (A) in pin locations as follows.

   • Pin 1 - Red - Batt +

   • Pin 2 - Black - Batt -

   • Twisted Pairs: Pin 3 - Yellow - J1939 High and Pin 4 - Green - J1939 Low

   • Twisted Pairs: Pin 5 - Green - CDL High and Pin 6 - Blue - CDL Low

4. Remove the following six (6) wires, one at a time from the VIMS A4N4 ECM and insert the socket pin ends into 155-2274 Connecting Plug Kit (B) in the following order:

   • Pin 1 - from 52 - Orange 125 - Batt+

   • Pin 2 - from 65 - Black 200 - Batt -

   • Pin 3 - from 34 - Orange Y794 - CAN High

   • Pin 4 - from 50 - Green Y765 - CAN Low

   • Pin 5 - from 8 - Orange 944 - CDL High

   • Pin 6 - from 9 - Brown 945 - CDL Low

5. Locate the six 207-3814 Wire As ("Y" Splice) having one end with two socket pins and one end with one connector pin.

6. Insert the six pinned ends from 207-3814 Wire As into 102-8805 Receptacle Kit (C) in locations as shown in Illustration 13.

7. Then connect 155-2274 Connecting Plug Kit to 102-8805 Receptacle Kit.

8. Insert the socket ends of the six 207-3814 Wire As splice wires with one socket connected to the A4N4 VIMS ECM and the corresponding socket end into 155-2274 Connecting Plug Kit (D) in locations as follows:

   - A4N4 pin 52 to pin 1 of 155-2274 Connecting Plug Kit

   - A4N4 pin 65 to pin 2 of 155-2274 Connecting Plug Kit

   - A4N4 pin 34 to pin 3 of 155-2274 Connecting Plug Kit

   - A4N4 pin 50 to pin 4 of 155-2274 Connecting Plug Kit

   - A4N4 pin 8 to pin 5 of 155-2274 Connecting Plug Kit

   - A4N4 pin 9 to pin 6 of 155-2274 Connecting Plug Kit

9. Then connect 155-2274 Connecting Plug Kit (D) to 102-8805 Receptacle Kit (A).

PL321VSR Software Update Instruction and Configuration

Perform the below steps for PL321VSR software update instruction and configuration:

1. Connect "Comm Adapter 3" to the service port of the machine.

2. Using the Cat^® Electronic Technician (Cat ET) Service Tool 2015C or newer, download the software for the VIMS A4N4 ECM to the software specified in Table 5.
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   Illustration 14	g06355756
   Preferences Tab

3. Open Cat ET 2015C or newer, select "Utilities" -> "Preferences" -> "Modify" and set connection to "Caterpillar Comm Adapter 3 (RP1210)", defaults to "J1939 Baud Rate 250k" and select "OK". Refer to Illustration 14.
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   Illustration 15	g06355759

4. Click on "Winflash" icon.

5. Select the ECM labeled "VIMS A4:N4 Main" in the WinFlash ECM list and load the software. Follow software availability from SIS web "VIMS Software & Current Releases". Refer to Table 5 (VIMS Compatibility Software Matrix).

6. Once the download is complete, select "File", and select "Return to Cat ET", and select "VIMS Main Module", and then select "OK".
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   Illustration 16	g06355765
   Configuration Screen

7. Select "Service" -> "Configuration Screen".
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   Illustration 17	g06355783

8. Select "VIMS Main Module" -> "General Information" -> "PLM Enable Status (Billing)". Refer to Illustration 17.

   Note: If the "PLM Enable Status (Billing)" is not seen in "General Information" as shown in Illustration 17, then select "File" -> "Switch Data Link".

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   Illustration 18	g06355815

9. Set the "PLM Enable Status (Billing)" configuration to "Disabled". Refer to Illustration 18.

   Note: This action effectively disables the 2G cellular radio in the PL121 satellite radio. Harness to the PL121 radio should remain connected to the PL121. If PL121 radio is not connected user will receive an active code 1250-9 Remote Communication Module: Abnormal Update Rate. With some installations, code 1250-9 Remote Communication Module: Abnormal Update Rate will be inactive if the PL121 is connected. 1250-9 Remote Communication Module: Abnormal Update Rate will only be visible with Cat ET. This code is not shown on operator display and does not limit functionality of the system. GPS and Satellite LED’s will continue to blink when machine is power cycled on. Green LED will be on solid only if R-Term is used and engine is running.

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   Illustration 19	g06355821

10. Within the Configuration screen, select "ECM Identification Parameters" -> "Product ID" enter the Product ID into the "VIMS Main Module" as shown in Illustration 19.

VIMS Main Module A4:N4 Configuration File Upload

1. A configuration file is required for VIMS A4N4 ECM. Connect 305-5528 Wiring Harness (VIMS 3G service cable) to the VIMS Service Port.

2. To install the VIMS config file follow instructions outlined in Special Instruction, REHS7428, "VIMS 3G Software Installation Guide For Certain Cat^® Product Using VIMSpc 2011A and VIMSpc 2013A".

Instruction for PL542 Software Update

Connecting to the PL542 with Cat ET

1. With the PL542 connected to the service port on the machine, users are unable to connect to the PL542 with Cat ET without a "Y" harness. For machines with a standard 9-pin service port connector, use 140-9442 Adapter Cable As.

2. 140-9442 Adapter Cable As allows the PL542, and Cat ET to be on the datalink at the same time.

3. The Product ID can be set locally with Cat ET. If the PL542 does not automatically sync hours to a master ECM, then the PL542 hours can be set locally with Cat ET as well.

Note: For machines where local service is not possible, hours can be set in the "Administration" tab of VisionLink.

Note: Local service is not required for the PL542. All required steps for installation can either be done remotely from the "Dealer Services Portal", or through Cat Activate.

Follow Special Instruction, M0077632, "Installation Procedure for the Product Link^TM PL542 Systems" for setting the Product ID or Machine Serial Number of the PL Device, How to Register with Cat Activate, Setting Hours on the Product Link Device, and Subscribe in Dealer Service Portal.

Note: The PL542 software cannot be flashed locally. The only way to update the software is over the air. To update the software on the PL542, submit a DSN ticket with the following: The list of Product IDs and machine serial numbers to be updated, information that the customer has consented to update their PL542 devices over the air.

Note: The PL542 actions are transparent to the machine operation, and the software can be updated over the air while the machine is running. When a DSN ticket is submitted, the file will be put in the queue for the device to download the file. The file will be downloaded and flashed the next time the PL542 makes a connection to the Caterpillar back office.

PCS and VIMS Data Download

Note: If the machine is equipped with Payload Control System, Material Lists and Truck Lists were set up prior to this update. These lists will need to be reprogrammed using VIMSpc.

Refer to Systems Operation, RENR6293, "VIMSpc Software" for more information about accessing and updating Material Lists and Truck Lists using VIMSpc.

Note: After the Product Link update is complete, data from Payload Control System (PCS) and VIMS will continue to be downloaded using the VIMS service port, 305-5528 Wiring Harness (VIMS 3G Service Cable), and VIMSpc software. The location of the VIMS service port in the cab of the K-Series Medium Wheel Loader.

Refer to Systems Operation, UENR0769, "VIMS^TM 3G" for more information about connecting VIMSpc software to a K-Series Medium Wheel Loader.

Troubleshooting

Refer to Systems OperationTroubleshootingTesting and Adjusting, M0079294, "Product Link^® PL542 Systems".