SERV1797_01_TXT

SERV1797-01June 2006

TECHNICAL PRESENTATION

CATERPILLAR PRODUCT LINK SYSTEM

PL121SR AND PL321SR

Service Training Meeting Guide(STMG)

GLOBAL SERVICE LEARNING

CATERPILLAR PRODUCT LINK PL121SR AND PL321SR

AUDIENCE

Level II - Service personnel who understand the principles of machine system operation,diagnostic equipment, and procedures for testing and adjusting.

CONTENT

This presentation provides information on Caterpillar Product Link module installation. Thepresentation covers the components, system operations, and capabilities of the PL121SR andthe PL321SR product link modules. This presentation may be used for self-paced and self-directed training.

OBJECTIVES

After learning the information in this presentation, the technician will be able to:

1. locate and identify Product Link components;2. explain the operation of various Product Link configurations.

REFERENCES

"Product Link PL121SR and PL300 Installation Guide" REHS 2365"Systems Operation Troubleshooting Testing and Adjusting" RENR 7911

Estimated Time: 2 hoursIllustrations: 45Handouts: 9Form: SERV1797-01Date: 6/06

© 2006 Caterpillar Inc.

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5

PRODUCT LINK COMPONENTS .............................................................................................8PL121SR Radio ......................................................................................................................8Geo-fencing Monitoring .......................................................................................................10PL300 Electronic Control Module (ECM) ...........................................................................11Antennas ...............................................................................................................................12Antenna Bracket ...................................................................................................................13ECM Adapter Plates .............................................................................................................14Wiring Harnesses ..................................................................................................................15

PL121SR LEGACY MACHINES..............................................................................................18

PL321SR LEGACY MACHINES..............................................................................................19

PL121SR PRODUCT LINK READY MACHINES..................................................................21

PL321SR PRODUCT LINK READY MACHINES..................................................................22

PRODUCT LINK ANTENNA: GROUND PLANE..................................................................23

PRODUCT LINK ANTENNA: CORRECT INSTALLATION EXAMPLES...........................24

PRODUCT LINK ANTENNA: INCORRECT INSTALLATION EXAMPLES.......................25

PL321SR MODULE INSTALLATION .....................................................................................26

CAT ET INSTALLATION PARAMETERS SCREEN ..............................................................27PLM Installation Parameters: Machine Serial Number ......................................................28PLM Installation Parameter: DBS Machine Make Code .....................................................29PLM Report Installation Parameters: Dealer Identification Code ......................................30

PLM REPORT CONFIGURATION PARAMETERS ...............................................................31PLM Report Configuration Parameters: Report and Message Interval ..............................31PLM Report Configuration Parameters: Report Start Time................................................32PLM Report Configuration Parameters: Warning Level......................................................33Additional PLM Report Configuration Parameters..............................................................34

DIGITAL INPUT CONFIGURATION ......................................................................................36

SYNCHRONIZE SERVICE METER HOURS..........................................................................38

PLM COMMANDS....................................................................................................................43

SERV1797-01 - 3 - Text Reference6/06

TABLE OF CONTENTS (continued)

PRODUCT LINK STATUS GROUPS.......................................................................................45Product Link Status Group #1 - Queued Messages..............................................................45Product Link Status Group #2 - PLM Operational Status....................................................46Product Link Status Group #3 - Digital Sensors ..................................................................48Product Link Status Group #4 - Geo-fencing.......................................................................49Product Link Status Group #5 - GPS ...................................................................................51Product Link Status Group #6 - Communication.................................................................52

CONCLUSION...........................................................................................................................53

LABORATORY EXERCISES....................................................................................................54

HANDOUTS...............................................................................................................................56

POSTTEST .................................................................................................................................63

ANSWERS .................................................................................................................................65


1


INTRODUCTION

Product Link is a communication device that gathers and wirelessly transmits important datasuch as machine location, hours, and health information to the dealer and machine owner.Product Link provides two-way information flow between the machine on-board systems andthe customer's desktop computer through the Dealer Store Front and Equipment Manager.PL121SR and PL321SR are the new generation of Product Link products using satellitetechnology.

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The PL121SR provides machine operating hours and GPS location through the onboard satellitetransmitter/receiver. Additionally, it will automatically send alerts when machines operatebeyond owner-identified time or location limits.

The PL321SR has all the capabilities of the PL121SR. Additionally, the PL321SR can providemachine health information to identify repair problems before they become costly failures,indicate fuel level and total fuel consumption, and provide condition based events, diagnosticreports, and diagnostic alerts.

The Product Link hardware consists of an antenna, data module, and interconnecting wiring.The antenna unit consists of two separate antennas. One antenna is for receiving locationinformation and transmitting signals from and to a Low-Earth Orbiting (LEO) satellite system.The GPS signal, which provides the location information for the system, is sent to the datamodule from the GPS antenna. The signal is processed by the data module and is transmittedto the LEO satellite through the "whip" antenna. The Service Meter Hours (SMH) signal is sentto the data module where it is processed and transmitted in the same way as the GPSinformation.


Block Diagram

G P S

Engine Speed = 1200 rpm PL300 ECM239-9954

PL121SR Radio263-9088

RS-232

RS-232

ElectronicTechnician

On-HighwayEngine ECM

Machine or EngineECMs

Machine or EngineECMs

CommAdapter

J1939E

J1939

CDL

ATA

The system is designed to provide four location reports and one SMH report per day. Usershave the ability to obtain additional reports by sending a query from Product Link Web to themodule. The PL121SR and PL321SR modules enable the Web application to display SMH,location, and geo-fencing alarms. The PL321SR also has the ability to report digital switchoutputs, event and diagnostic reporting, and fuel consumption reporting.

The Equipment Manager application has the ability to map machine location online. Themapping function will display the location of each machine and can be used to provide routinginformation to dealer technicians.

Product Link modules are configured and registered using Caterpillar Electronic Technician(Cat ET). After installing the PL data module on the machine, a laptop PC containing Cat ETis connected to the data module. The dealer technician uses Cat ET to setup the module forthat specific machine.


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PRODUCT LINK COMPONENTS

The various Product Link components perform different functions to make the Product Linkcomplete. All the components are necessary for the system to work properly.

PL121SR Radio

The PL121SR Radio provides the customer with several useful Product Link functionsincluding: service meter hour updates, equipment location, integration with internet or PCmapping software, geo-fencing, and cell phone/email/pager alerts. The PL121SR is configuredto work with the embedded Communications Adapter. The antenna attaches to the radiothrough the connectors on the bottom of the unit (Satellite right and GPS left).

To the left side of the PL121 there are three LED lights that will turn on and flash to notedifferent functions. The green LED (1) is on when the engine is on. The orange LED (2)flashes while the GPS receiver searches for GPS satellites. When the system obtains a valid fixusing at least 3 GPS satellites the LED will remain lit. The yellow LED (3) flashes while thePL121 radio antenna searches for additional satellite connections. When the PL121 acquires agood connection with a LEO satellite, the yellow LED will remain lit.

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Service Meter Hours Update: The SMH report eliminates trips or calls for the SMHreadings. These updates also allow the customer to plan there maintenance schedule moreeffectively. Also, the report facilitates accurate and efficient billing. The service meter hoursupdate report is sent daily to the Cat database where it can be viewed on the Dealer Store Front.

Machine Location: This feature of the PL121SR system allows for the efficient use of PMtrucks, non-routine service calls, and other sales and service functions. This feature will alsoreduce transportation costs related to locating a machine as well as delivering or picking up arental machine. The user can view a map showing the location of the machine or fleet.

Geo-fencing Monitoring: Geo-fencing allows the user to monitor the machines in regards tolocation and time. If a machine is operating in a forbidden area or operating at a time when itshould be shut down, a report is sent to the Cat database and an alert is immediately sent to theuser.

Cell Phone/Email/Pager Alerts: The user can designate a specific person to be notified viacell phone,email, or pager when machine violates a geo-fence or a time fence.


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Geo-fencing Monitoring

For Inclusion monitoring, a geo-fence is set up to limit the area the machine should beoperating in. Product Link will report a geo-fence alarm if the machine leaves its designatedoperating area.

For Exclusion monitoring, a geo-fence is set up to exclude an area the machine should not beoperating in. Product Link will report a geo-fence alarm if the machine enters the excludedarea.

For Time Based monitoring, Product Link will report a time based alarm if the machine isoperating outside the designated time period.

NOTE: The blue areas are where/when the machine should not operate and the whiteareas are where/when the machine is scheduled to operate.


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PL300 Electronic Control Module (ECM)

The PL300 Electronic Control Module (ECM) is programmed with a laptop using theCaterpillar Electronic Technician (Cat ET) software version 2004B or newer. ACommunications II Adapter is used to connect the PL300 to Cat ET.

The PL300 is used in combination with the PL121SR radio to form the PL321SR system. ThePL321SR system provides all the capabilities of the PL121SR system with the ability of thePL300 to communicate with other on board ECMs monitor up to 4 additional digital inputs.

The PL321SR gives the customer and dealer the ability to see all events and diagnostic codesremotely. Fuel consumption can be checked on machines where fuel data is provided by theEngine ECM. Four additional digital inputs (On/Off) can be monitored in order to further trackmachine conditions. Product Link can provide customers and dealers with the informationabout the machine health before the machine is serviced.


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Antennas

The new generation of Product Link uses an active antenna. An active antenna consists ofelectrical circuitry powering the antenna to boost the reception. This allows the antenna to befairly small yet get better reception than a larger wire antenna. For example, an 18 inch activeantenna will get better reception than a 30 foot wire antenna. The antenna must be mounted onthe machine with a clear view of the sky. Most of the time the roof of the cab is the best spot.Also, there must be a 3 foot circle of empty space around the antenna. The length of the cable(either 3 meters or 6 meters) should also be taken in to account when mounting the antenna.


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Antenna Bracket

The antenna bracket (arrow) is used when there is not enough available space on top of the cabto mount the antenna and still maintain the necessary clearance. The bracket will be mountedon the top of the cab allowing the antenna to be positioned off of the cab. The bracket is soldseparate from the core hardware kit.


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ECM Adapter Plates

The ECM adapter plates allow a quick switch from the old version of Product Link to the newversion. Upon removing the old module, the adapter plates allow the user to place the newmodule in the same spot. These two plates attach to the back of the PL300 ECM and configurethe ECM to match the mounting of the previous Product Link module.


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Wiring Harnesses

There are several different types of wiring harnesses for Product Link. The type ofconfiguration the user sets up and the type of machine the user has will determine whichharness will be used

Radio Harness: The radio harness (1) consists of a 12 pin plug connector (2), a 2 pinreceptacle connector (3), and 12 pin receptacle connector (4). The radio harness is used in allthe different configurations. The 2 pin receptacle is only used in configurations where thePL300 ECM is used.

ECM Harness: The ECM harness (5) attaches to the PL300 ECM via the 70 pin plugconnector (6). The ECM harness also includes a 2 pin plug connector (7), a 12 pin plugconnector (8), and a 12 pin receptacle connector (9). This harness is only used inconfigurations where the PL300 ECM is involved.


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3 6789

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4

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Legacy Harness: The legacy harness (1) is used to attach Product Link to the machine, incases where the machine is not a Product Link Ready machine. The 12 pin plug connector (3)is used to connect to the radio harness in the PL121SR configuration or the ECM harness in thePL321SR configuration. The 3 pin receptacle connector (4) is used to connect to the serialservice cable. Also the legacy harness is used to connect Product Link to Cat Data Link. TheCat Data Link connector (2) is shown attached to the legacy harness. The legacy harnessallows the user to connect to a machine regardless of the type of machine.

Conversion Harness: The conversion harness (5) serves the same purpose as the legacyharness on Product Link ready machines. This harness simply attaches Product Link to themachine. The 12 pin plug connector (6) connects to the radio harness in the PL121SRconfiguration or the ECM harness in the PL321SR configuration. The 3 pin round receptacleconnector (7) is used to connect to the serial service cable. The other connector is called the 6pin receptacle connector (8).


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5

6 834

7

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Service Cable: The service cable allows the user to have access to all PL121SR configurationsthrough Cat ET. The cable is attached to the PL121SR using the machine service connector (1)and to a laptop using the serial connector (2).


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PL121SR FOR LEGACY MACHINES

The PL121SR Product Link configuration can be mounted to either Product Link readymachines or legacy machines. The main components of the PL121SR legacy configuration arepictured above.

The main components for the PL121SR Legacy Machines are as follows:

- PL121 Radio (1)- Radio Harness (2)- Antenna (3)- Legacy Harness (4)- Service Connector (5)


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2

3

4

5

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PL321SR FOR LEGACY MACHINES

The PL321SR installation is very similar to the the PL121SR installation. The PL300 ECM andthe ECM Harness in addition to the PL121SR components make up the PL321SR for legacymachines. These two components as shown above are simply inserted between the RadioHarness and the legacy harness.

The main components for the PL321SR Legacy Machines are as follows:

- PL121 Radio (1)- Radio Harness (2)- Antenna (3)- ECM Harness (4)- PL300 ECM (5)- Legacy Harness (6)- Service Connector (7)


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The PL121SR Legacy Field Installation Group and the PL300 Legacy Field Installation Groupcan be purchased separately. However, the PL121SR and the PL300 Legacy Field InstallationGroup can be purchased together as a package. The PL321SR Legacy Field Installation Groupcontains all of the components that are in the PL121SR and the PL300 Legacy InstallationGroups. The PL300 Legacy Field Installation Group can be used to upgrade the PL121SRLegacy Field Installation Group to the PL321SR Legacy Field Installation Group.


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PL121SR FOR PRODUCT LINK READY MACHINES

The layout shown above looks very similar to the layout for the PL121SR for legacy machines.The only difference between these two layouts is the cable that connects Product Link to themachine. The legacy machine uses the legacy harness. The Product Link ready machines usethe conversion harness. Both of these configurations have the same capabilities, but the needfor two separate harnesses stem from different connections on Product Link ready machineversus a legacy machine.

The main components for the PL121SR Product Link Ready Machines are as follows:

- PL121 Radio (1)- Radio Harness (2)- Antenna (3)- Conversion Harness (4)


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2

3

4

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PL321SR FOR PRODUCT LINK READY MACHINES

The PL321SR configuration layout is pictured above. This layout is used on Product Linkready machines for users who want the maximum Product Link capabilities. The PL321SRsystem allows the user to get the full potential out of Product Link.

The main components for the PL321SR Product Link Ready Machines are as follows:

- PL121 Radio (1)- Radio Harness (2)- Antenna (3)- ECM Harness (4)- PL300 ECM (5)- Conversion Harness (6)


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Without Ground Plane

P L 1 2 1

Without an RF reflective surface, some ofthe radio energy is reflected downward

With Ground Plane

P L 1 2 1

Metal cab roof reflects RFenergy upward and outward

PL121SR and PL321SR PRODUCT LINK ANTENNA: GROUND PLANE

The product link antenna requires a ground plane. A ground plane is an electrically conductivesurface that serves as a reference ground in a circuit. The ground plane reflects the RadioFrequency (RF) energy upward and outward. Without a ground plane, some of the RF energyis reflected downward causing the signal to weaken. The roof of the cab works well for aground plane. If it is not possible to have a ground plane, the use of a braided ground strap isrecommended.

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PL121SR and PL321SR PRODUCT LINK ANTENNA: CORRECT INSTALLATIONEXAMPLE

The above illustrations are both examples of good antenna installations. Both pictures showthe antenna mounted on the roof of the cab or ROPS. Generally, the cab roof is the best placeto mount the antenna. The roof is typically the highest point on the machine and it alsoprovides a suitable ground plane.

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PL121SR and PL321SR PRODUCT LINK ANTENNA: INCORRECT INSTALLATIONEXAMPLE

The above illustrations are examples of poor installations. Illustration 20 shows an antennamounted on the ROPS of a backhoe loader. At first, this antenna may seem to be installed in agood place because it is protected, however an antenna should never be mounted horizontally.Illustration 21 is of an antenna mounted on the hood of a motor grader. This antenna may seemto be in a good location because it is in an open area and there is a large ground planesurrounding the antenna. The slow moving vehicle (SMV) sign and the rear work light,however, are blocking part of the radio signal. The filler necks surrounding the antenna canalso cause some interference with the signal. In addition, the antenna is not at the highest pointon the machine. The antenna is mounted on the hood rather than the roof of the cab. Mountingantennas on the highest point of the machine will ensure the best possible reception.

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PL321SR MODULE INSTALLATION

The PL121SR and PL300 modules should be mounted in a secure location. The modulesshould be in a place where they will protected from the elements, large amounts of dirt,vibration, heat sources, and other hazards. Possible mounting location for the modules includebehind the operator's seat, in the tool box, and under access plates in the operator station floor.The modules need to be mounted with the wires running downward so dirt does not collect andresult in damage. For security purposes, the modules should be in a location that can be lockedwhen the machine is not in use.


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CAT ET INSTALLATION PARAMETERS SCREEN

The Product Link Module Installation Parameters are general information about the machineand dealer. Installation parameters need to be set at the time Product Link is installed. ProductLink will queue a registration message 15 minutes after the installation parameters are set.

The above illustration is for the PL321SR. The installation screen is combined with the reportconfiguration screen when the PL121SR is used alone.

If the machine's information is already in the Dealer Business System (DBS) or EquipmentData (the Equipment Manager database), the installation parameters must match the existinginformation or the registration will fail.


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PLM Installation Parameters: Machine Serial Number

The Machine Serial Number is the serial number of the machine on which the module isinstalled. This value is utilized by Product Link for routing and displaying information. Verifythat the correct machine serial number is entered on any new or transferred installation. Tochange the machine serial number, enter the machine serial number in the box. On Caterpillarmachines with a 17-character PIN, the last eight characters are used for the serial number. Donot abbreviate the serial number. Do not use an uppercase "O" instead of a zero "0".

NOTE: The serial number cannot start with a space.


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PLM Installation Parameters: DBS Machine Make Code

The Dealer Business System Machine Make Code signifies the make of the machine on whichProduct Link is installed. "AA" represents a machine built by Caterpillar and is the defaultvalue. Individual dealers determine codes for non-Caterpillar machines. The two digit codeused here needs to be mapped to an appropriate three digit code in DBS. If the two digitMachine Make Code is not "mapped" in Equipment Data to an appropriate Dealer IdentificationCode, the registration will fail.

NOTE: Only two upper-case alpha-numeric characters are allowed for this value.


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PLM Report Installation Parameters: Dealer Identification Code

The Dealer Identification Code identifies the dealer to which the Product Link module isregistered. The code entered should be the Dealer Identification Code for the main branch ofthe dealership rather than the sub-branch code.

NOTE: If the wrong Dealer Identification Code is entered, Product Link will not beable to register the machine. The information for the machine will not be available orvisible to the personnel at the dealership.


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PLM REPORT CONFIGURATION PARAMETERS

PLM Report Configuration Parameters: Report and Message Interval

The Event/Diagnostic Report Interval determines how soon the Product Link module willrecord the reoccurrence of an event or diagnostic code. The default value for theEvent/Diagnostic Report Interval is 20 hours, and the minimum value for the Event/DiagnosticReport Interval is 4 hours. The Event/Diagnostic Report Interval is based on machine operatinghours. In the above illustration the Event/Diagnostic Report Interval is set to 20 hours, so itwill only record the occurrence of a particular event or diagnostic code every 20 hours ofmachine operating time.

The Event/Diagnostic Message Interval is the amount of Real Time (RT) or calendar hoursbetween the Event or the Diagnostic code messages. The Report Start Time is used as thestarting reference for when messages are sent. In the above illustration the Event/DiagnosticMessage Interval is set to 168 hours. Product Link will send any current event and diagnosticcodes to the dealership every 168 hours of real time.


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PLM Report Configuration Parameters: Report Start Time

The Report Start Time is used as the initial report time. All other reports are based off of thistime. The time entered will be the time that the Product Link module will attempt to send itsfirst report and will be the basis for calculating all location reports and message intervals.Messages may not arrive at the exact report start time but the messages will arrive close to theentered time.

NOTE: If the machine is powered down at the first report start time, Product Link willnot send the scheduled message as expected.


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PLM Report Configuration Parameters: Warning Level

The Warning Level Report Configuration controls how the Product Link module will deliverevents from other Electronic Control Modules (ECMs) on the machine. Product Link does notgenerate events. It only reports the events it receives from other Machine ECMs.

The choices for the Warning Level Report Configuration are:

- Report Immediately: Events are sent immediately upon their occurrence. Recommendedfor Level 2 and Level 3 Events. In immediate mode, a reoccurrence of the event is onlysent once the event/diagnostic report interval has expired.

- Report at Next Scheduled: Events are sent at the next scheduled message interval.Recommended for Level I Events.

- Never Report: Events are not reported.


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Additional PLM Report Configuration Parameters

The Diagnostic Report Configuration Status controls when Product Link reports diagnosticevents from the other ECMs. The Diagnostic Report Configuration Status has the same choicesas the warning levels.

The Operating Hours Report Configuration Status configures Product Link to display themachine's operating hours in Equipment Manager if it is set to "ON".

The Number of Daily Machine Location Message Configuration parameter is the number oftimes during a 24 hour period that the machine's location is reported to the office. Theminimum value is 0 and the maximum value is 4. The first location report will be sent at theReport Start Time. A position report will still come through with the daily standard messageeven if this value is set to zero. Product Link will not report the machine's location if themachine has not moves at least 200 meters since the last report.

The Fuel Consumed Report Configuration Status configures Product Link to send a fuelconsumption report if it is set to "ON". A fuel consumption report can only be sent if theEngine ECM or Machine ECM is capable of making one available.


The Global Gram Enable Status configures Product Link to communicate properly when asatellite ground station is not available to the satellite. The default setting is "Disabled". TheGlobal Gram Enable Status should only be set to "Enabled" if there is not a satellite groundstation available. At this time, Global Gram is predominately used in areas such as NewZealand and Australia. Global Gram can be used anywhere where ground station coverage islimited. However, there are significant delays associated with Global Gram "Enabled" andshould only be used where it is appropriate.


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DIGITAL INPUT CONFIGURATION

Extra digital inputs are available on the PL321SR. They are not available when the PL121SRis used alone. Digital Input Configuration is used to configure additional inputs. Up to fouradditional digital input can exist.

Digital Sensor Type:

- Not Installed: The factory default is "Not Installed" and cannot be set by the user.

- Not Configured: The input is connected but not configured.

- Normally open: The input is a normally open (or high) type.

- Normally closed: The input is a normally closed (or low) type.


Digital Input Monitoring Condition:

- All Conditions: The input will be monitored regardless of the key switch position or theengine status.

- Key Off/Engine Off: The digital input will be monitored only if the key and the engineare off.

- Key On/Engine Off: The digital input will only be monitored when the key is in the ONposition with the engine off.

- Key On/Engine On: The digital input will only be monitored when the key and theengine are both on.

- Digital Input Description: The description for the digital input can be up to 24characters. The default description is Digital Input 1.

- Digital Input Delay Time: The time an input must be in the opposite of the normal statebefore an alarm is recorded and sent to the geo-fencing application. The minimum valueis 0.1 seconds and the maximum value is 1200 seconds.


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SYNCHRONIZE SERVICE METER HOURS

Before the Product Link Module can be registered, the Service Meter Hours (SMH) must be setto the Machine SMH. Choose Synchronize Service Hour Meters from the Service drop downmenu.


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If there is a "Master" ECM present on the machine, synchronize Product Link with the "Master" ECM. To synchronize Product Link to the "Master" ECM, click the "Synchronize"button on the lower left corner of the window.


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When the "Synchronize" button is clicked, a confirmation screen will appear. Click "Yes" tosynchronize the SMUs of Product Link to the Machine "Master" ECM.


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If the machine does not have a "Master" ECM, you will have to set the hours for the ProductLink Module. Click "Set Master Hours" on the lower left corner of the window.


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A new window will appear asking for the new value of the hours. Enter the SMH value in bothlines and click "OK".


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PLM COMMANDS

Registration: The registration message can be manually queued if you do not want to wait 15minutes after all of the Installation Parameters are entered. Choose PLM Commands =>Registration from the Service drop down menu.

De-Registration: The PLM should only be de-registered if it is being removed from a machineor if the machine is changing dealerships. Select PLM Commands => De-Registration from theService drop down menu. When a machine is de-registered, all of the installation parametervalues and report configuration settings will be returned to their default values.

Status Message: The Status Message command queues a report containing the SMH, location,and fuel consumption.

Position, Geo-fencing, and SMH Report: Selecting one of the report commands queues areport.


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When the registration command is used, a new window will appear asking to confirm sendingthe registration message. Click "Yes" to send the registration message. After selecting "Yes" tosend the registration message, monitor "Status Group #1" and verify the "Queued RegistrationMessages" value has changed from a "1" to a "0" (zero) indicating the registration message hasbeen sent.


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PRODUCT LINK STATUS GROUPS

Product Link Status Group #1 - Queued Messages

The Product Link Group 1 Status screen shows a current count of the messages that are pendingto be sent by the PLM. The following list gives the possible values for the types of messages.

- Status Messages 0 or 1

- Registration Messages 0 or 1

- De-Registration Messages 0 or 1

- Service Meter Change >= 0

- Position Report 0 or 1

- SMH Report 0 or 1


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Product Link Status Group #2 - PLM Operational Status

The Product Link Group 2 Status screen shows the current operational status of the PLM.

PLM Registration Status:

- Registered: The PLM is properly registered on the communications system. The PLMmust be registered for messages to be transmitted.

- De-Registered: The PLM is not registered on the communications system and will nottransmit any messages except a Registration command.

Primary Communications Link:

- On-Line: A communications satellite is in view allowing the PLM to send and receivemessages.

- Off-Line: There are no communications satellites in view allowing the PLM to send andreceive messages.


Power Mode Status:

- Power Mode 1: The machine has operated in the last 48 hours.

- Power Mode 2: The machine has not operated for greater than 48 hours but less than 1week. The PLM will wake up every 6 hours to send and receive messages. Positionmessages will only be sent if the machine has changed position by greater than 200meters.

- Power Mode 3: The machine has not operated for more than 1 week. The PLM willwake up every 24 hours to send and receive messages. Position messages will only besent if the machine has changed position by greater than 200 meters.

Alternator Running Input:

- Engine Running: The alternator R-Terminal reflects the engine is currently running.

- Engine Off: The alternator R-Terminal reflects the engine is not currently running.

GPS Receiver:

- Functional: The GPS receiver has generated a fix since the PLM last powered up.

- Not Functional: The GPS receiver has not generated a fix since the PLM last poweredup.

Key Switch Status:

- On: The machine key start switch is in the "ON" state. The PLM will be powered up.

- Off: The machine key start switch is in the "OFF" state. The PLM will periodicallypower up to send and receive messages depending on the power mode.

Possible Periods of Communications Loss:

- Yes: The PLM has not seen a communications satellite for an extended period of timecausing scheduled reports to be missed. This value is reset automatically after the statusis reported to the office.

- No: The PLM has not experienced a loss of communications and has beencommunicating as scheduled.

Possible Device Power Disconnection:

- Yes: The PLM has missed reports due to a power loss. This value is reset automaticallyafter the status is reported to the office.

- No: The PLM has not missed any scheduled reports due to power loss.


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Product Link Status Group #3 - Digital Inputs

The Product Link Group 3 Status screen shows the current status of the Product Link DigitalSensors. The Digital Sensor Inputs Screen is only available on PL321SR.

Digital Sensor Inputs:

- Not Configured: Default setting signifying there is no sensor attached at this time.

- Active: If this type of sensor is configured as the normally open sensor, an active sensorwould be closed to ground. If the sensor is configured as a normally closed sensor, andactive sensor would be open to ground. In both cases, the sensor will not become activeuntil the delay time has expired.

- Inactive: When this type of sensor is configured as a normally open sensor, an inactivesensor will not be closed to ground. The sensor is open. If the sensor is configured as anormally closed sensor, and inactive sensor will not be open. The sensor is closed. Inboth cases, the sensor will not become active until the delay time has expired.


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Product Link Status Group #4 - Geo-fencing

The Product Link Group 3 Status screen shows the current status of Geo-fencing. Geo-fencingis configured via the "Caterpillar Product Link PC Software".

Time Based Activation Status:

- Active: Time Base Geo-fencing has been properly configured and is currently activated.

- Not Active: There is currently no Time Base Geo-fencing properly configured and/or it isnot currently activated.

Geographical Exclusion Activation Status:

- Active: Geographical Exclusion Geo-fencing has been properly configured and iscurrently activated.

- Not Active: There is currently no Geographical Exclusion Geo-fencing properlyconfigured and/or it is not currently activated.


Geographical Inclusion Activation Status:

- Active: Geographical Inclusion Geo-fencing has been properly configured and iscurrently activated.

- Not Active: There is currently no Geographical Inclusion Geo-fencing properlyconfigured and/or it is not currently activated.

Time Based Alarm:

- On: There is an active Time Based Alarm.

- Off: There is not an active Time Based Alarm.

Geographical Exclusion Boundary Alarm:

- On: There is an active Geographical Exclusion Boundary Alarm.

- Off: There is not an active Geographical Exclusion Boundary Alarm.

Geographical Inclusion Boundary Alarm

- On: There is an active Geographical Inclusion Boundary Alarm.

- Off: There is not an active Geographical Inclusion Boundary Alarm.


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Product Link Status Group #5 - GPS

The Product Link Group 5 Status screen shows the current status of the Product Link GPS.

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, or the previouslycalculated fix has not updated in at least 60 minutes.

GPS Time Stamp: The time stamp from the last fix is displayed. The time can be compared tothe Current Date/Time to verify 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: Displays the number of GPS Satellites used to determine location.


44

Product Link Status Group #6 - Communication

The Product Link Group 6 Status screen shows the current status of satellite communicationwith the module.

If the Product Link Module is communicating with the satellites, the Satellite CommunicationStatus value will be established.

Satellite Network Control Center Communication Status will display "Established" if thesatellite communicating with the Product Link Module is also communicating with a groundstation. Otherwise, "Not Established" will be displayed.

Average Wireless Communication Error Count is the number of times an error has occurred.


45


CONCLUSION

This presentation has covered Product Link components and configurations. An understandingof Product Link can assist the user with diagnostic, troubleshooting, and programming. Alwaysuse the latest Service Information to ensure that the most current specifications and testprocedures are used.

LAB A: WIRING HARNESS (OPEN CIRCUIT) - TEST

An open is a failure of an electrical circuit that results in no flow of electrical current. An opencircuit is usually caused by failed electrical wires or a poor connection of electrical connectors.If an electrical wire or a connection is broken, the flow of electrical current through the circuitis interrupted. A normally closed circuit will have less than 5 ohms of resistance. Thefollowing procedure explains the test for an open circuit:

Reference: For a complete electrical schematic, refer to the Electrical System Schematic forthe machine that is being serviced.

Test for an Open Circuit.

1. Identify the connectors and the wire numbers of the suspect circuits. Use the ElectricalSystem Schematic of the machine to identify the circuits.

2. Turn the key start switch and the disconnect switch to the OFF position.

3. Disconnect the component and the ECM from the wiring harness.

4. At one of the disconnected harness connections, place a jumper wire to frame ground.

5. At the other connector of machine harness, use the multimeter probes to measure theresistance from the contact wire of the suspect wire to frame ground.

Expected Result: If the resistance is less than 5 ohms, then the harness circuit is okay. If theresistance is greater than 5000 ohms, there is an open in the machine harness. Repair orreplace the machine harness.

SERV1797-01 - 54 - Laboratory Exercise6/06

LAB B: WIRING HARNESS (SHORT CIRCUIT) - TEST

A short circuit is a failure of an electrical circuit that results in undesired electrical current.Usually, a short circuit is a bypass of the circuit across a load. For example, a short across thewires in a circuit for a lamp produces too much current in the wires but no current is felt at thelamp. The lamp is shorted out. The resistance in a normal circuit can vary, but the resistancebetween a particular circuit and other unrelated circuits is always greater than 5000 ohms. Thefollowing procedure explains the test for a short circuit:

Reference: For a complete electrical schematic, refer to Electrical System Schematic for themachine that is being serviced.

Test for an Short Circuit.

1. Identify the connectors and the wire numbers of the suspect circuits. Use the ElectricalSystem Schematic of the machine to identify the circuits.

2. Turn the key start switch and the disconnect switch to the OFF position.

3. Disconnect the component and the ECM from the wiring harness.

4. At the machine harness connector for the ECM, place one of the multimeter probes onthe contact of the suspect wire.

5. Use the other multimeter probe to check the resistance across all other contacts in theconnector(s) of the ECM and frame ground.

Expected Result: If the resistance is greater than 5000 ohms for all the measurements, thenthe harness circuits are okay. If the resistance is less than 5 ohms, there is a short in themachine harness. The short is located between the suspected wire and the wire with the lowestresistance measurement. Repair or replace the machine harness

SERV1797-01 - 55 - Laboratory Exercise6/06

COMPONENT IDENTIFICATION

Directions: The following pages contain images of the components that are contained inProduct Link. First identify the component itself. Next identify the specific parts of thecomponent. The Service Manual may be used as a reference for the more specific parts.

Component Name: ___________________________________

1. __________________________________________________

2. __________________________________________________

3. __________________________________________________

4. __________________________________________________

5. __________________________________________________

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1

2

3

4 5

Component Name: ____________________________________

1. ___________________________________________________

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1

Component Name: ___________________________________

1. __________________________________________________

2. __________________________________________________

3. __________________________________________________

SERV1797-01 - 58 - Handout No. 36/06

1

2

3

Component Name: ___________________________________

1. __________________________________________________

2. __________________________________________________

3. __________________________________________________

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1

2

3

Component Name: ___________________________________

1. __________________________________________________

2. __________________________________________________

3. __________________________________________________

4. __________________________________________________

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1

2

3

4

Component Name: ___________________________________

1. __________________________________________________

2. __________________________________________________

3. __________________________________________________

SERV1797-01 - 61 - Handout No. 66/06

1

2

3

Component Name: ___________________________________

1. __________________________________________________

2. __________________________________________________

SERV1797-01 - 62 - Handout No. 76/06

1 2

POSTTEST: PRODUCT LINK SYSTEM

Directions: Circle the correct letter indicating the best answer for each question.

1. Which of the following are Product Link configurations?A. PL121SR Product Link Ready configurationB. PL121SR Product Link Ready Legacy configurationC. PL321SR Product Link Ready configurationD. all of the aboveE. both A and C

2. The PL121SR systems connect to Cat ET using:A. an embedded communications adapterB. a wireless communications adapterC. a communications II adapterD. none of the aboveE. any of the above


4. Which wiring harness connects the PL300 ECM to the Product Link system?A. the conversion harnessB. the gateway harnessC. the legacy harnessD. the radio harness

5. Which version of Cat ET must be used with the Product Link system?A. Cat ET 2003B. Cat ET 2004 AC. Cat ET 2004BD. any of the above

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6. Which of the following configurations do not include the radio harness?A. PL121SR Product Link Ready configurationB. PL321SR Product Link Ready configurationC. PL121SR Legacy configurationD. PL321SR Legacy configurationE. none of the above

7. As a rule of thumb how many feet of clear space must the antenna have surrounding it?A. 3 feetB. 4 feetC. 5 feetD. 6 feet

8. The service is used to connect the PL300 ECM to the machine.A. TrueB. False

9. In addition to all the functions of the PL121 system, the PL321 system can also track what number of digital inputs?A. 2B. 3C. 4D. 6E. none of the above

10. Which of the following categories of machines can product link be mounted on?A. Legacy MachinesB. Product Link Ready MachinesC. Non-Cat MachinesD. all of the aboveE. none of the above

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ANSWERS: PRODUCT LINK SYSTEM

Directions: Circle the correct letter indicating the best answer for each question.

1. Which of the following are Product Link configurations?A. PL121SR Product Link Ready configurationB. PL121SR Product Link Ready Legacy configurationC. PL321SR Product Link Ready configurationD. all of the aboveE. both A and C



4. Which wiring harness connects the PL300 ECM to the Product Link system?A. the conversion harnessB. the gateway harnessC. the legacy harnessD. the radio harness

5. Which version of Cat ET must be used with the Product Link system?A. Cat ET 2003B. Cat ET 2004 AC. Cat ET 2004BD. any of the aboveE. none of the above

SERV1797-01 - 65 - Answers6/06

6. Which of the following configurations do not include the radio harness?A. PL121SR Product Link Ready configurationB. PL321SR Product Link Ready configurationC. PL121SR Legacy configurationD. PL321SR Legacy configurationE. none of the above

7. As a rule of thumb how many feet of clear space must the antenna have surrounding it?A. 3 feetB. 4 feetC. 5 feetD. 6 feet

8. The service cable is used to connect the PL300 ECM to the machine.A. TrueB. False

9. In addition to all the functions of the PL121 system, the PL321 system can also track what number of digital inputs?A. 2B. 3C. 4D. 6E. none of the above

10. Which of the following categories of machines can product link be mounted on?A. Legacy MachinesB. Product Link Ready MachinesC. Non-Cat MachinesD. all of the aboveE. none of the above

SERV1797-01 - 66 - Answers6/06

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