Serv1797 01 TXT

SERV1797-01
J une 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. The
presentation covers the components, system operations, and capabilities of the PL121SR and
the 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 hours
Illustrations: 45
Handouts: 9
Form: SERV1797-01
Date: 6/06
2006 Caterpillar Inc.
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................5
PRODUCT LINK COMPONENTS.............................................................................................8
PL121SR Radio......................................................................................................................8
Geo-fencing Monitoring.......................................................................................................10
PL300 Electronic Control Module (ECM)...........................................................................11
Antennas...............................................................................................................................12
Antenna Bracket...................................................................................................................13
ECM Adapter Plates.............................................................................................................14
Wiring 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..............................................................27
PLM Installation Parameters: Machine Serial Number ......................................................28
PLM Installation Parameter: DBS Machine Make Code.....................................................29
PLM Report Installation Parameters: Dealer Identification Code......................................30
PLM REPORT CONFIGURATION PARAMETERS...............................................................31
PLM Report Configuration Parameters: Report and Message Interval ..............................31
PLM Report Configuration Parameters: Report Start Time................................................32
PLM Report Configuration Parameters: Warning Level ......................................................33
Additional PLM Report Configuration Parameters..............................................................34
DIGITAL INPUT CONFIGURATION......................................................................................36
SYNCHRONIZE SERVICE METER HOURS..........................................................................38
PLM COMMANDS....................................................................................................................43
SERV1797-01 - 3 - Text Reference
6/06
TABLE OF CONTENTS (continued)
PRODUCT LINK STATUS GROUPS.......................................................................................45
Product Link Status Group #1 - Queued Messages..............................................................45
Product Link Status Group #2 - PLM Operational Status....................................................46
Product Link Status Group #3 - Digital Sensors..................................................................48
Product Link Status Group #4 - Geo-fencing.......................................................................49
Product Link Status Group #5 - GPS...................................................................................51
Product Link Status Group #6 - Communication.................................................................52
CONCLUSION...........................................................................................................................53
LABORATORY EXERCISES....................................................................................................54
HANDOUTS...............................................................................................................................56
POSTTEST.................................................................................................................................63
ANSWERS.................................................................................................................................65
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INTRODUCTION
Product Link is a communication device that gathers and wirelessly transmits important data
such 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 and
the customer's desktop computer through the Dealer Store Front and Equipment Manager.
PL121SR and PL321SR are the new generation of Product Link products using satellite
technology.
2
The PL121SR provides machine operating hours and GPS location through the onboard satellite
transmitter/receiver. Additionally, it will automatically send alerts when machines operate
beyond owner-identified time or location limits.
The PL321SR has all the capabilities of the PL121SR. Additionally, the PL321SR can provide
machine health information to identify repair problems before they become costly failures,
indicate fuel level and total fuel consumption, and provide condition based events, diagnostic
reports, 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 location
information 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 data
module from the GPS antenna. The signal is processed by the data module and is transmitted
to the LEO satellite through the "whip" antenna. The Service Meter Hours (SMH) signal is sent
to the data module where it is processed and transmitted in the same way as the GPS
information.
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Block Diagram
G P S
Engine Speed = 1200 rpm
PL300 ECM
239-9954
PL121SR Radio
263-9088
RS-232
R
S
-
2
3
2
Electronic
Technician
On-Highway
Engine ECM
Machine or Engine
ECMs
Machine or Engine
ECMs
Comm
Adapter
J1939E
J1939
CDL
ATA
The system is designed to provide four location reports and one SMHreport per day. Users
have the ability to obtain additional reports by sending a query from Product Link Web to the
module. 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 switch
outputs, event and diagnostic reporting, and fuel consumption reporting.
The Equipment Manager application has the ability to map machine location online. The
mapping function will display the location of each machine and can be used to provide routing
information 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 ET
is connected to the data module. The dealer technician uses Cat ET to setup the module for
that specific machine.
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PRODUCT LINK COMPONENTS
The various Product Link components perform different functions to make the Product Link
complete. All the components are necessary for the system to work properly.
PL121SR Radio
The PL121SR Radio provides the customer with several useful Product Link functions
including: service meter hour updates, equipment location, integration with internet or PC
mapping software, geo-fencing, and cell phone/email/pager alerts. The PL121SR is configured
to work with the embedded Communications Adapter. The antenna attaches to the radio
through 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 note
different 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 fix
using at least 3 GPS satellites the LEDwill remain lit. The yellow LED(3) flashes while the
PL121 radio antenna searches for additional satellite connections. When the PL121 acquires a
good connection with a LEO satellite, the yellow LED will remain lit.
1
2
3
Service Meter Hours Update: The SMH report eliminates trips or calls for the SMH
readings. These updates also allow the customer to plan there maintenance schedule more
effectively. Also, the report facilitates accurate and efficient billing. The service meter hours
update 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 PM
trucks, non-routine service calls, and other sales and service functions. This feature will also
reduce transportation costs related to locating a machine as well as delivering or picking up a
rental 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 to
location and time. If a machine is operating in a forbidden area or operating at a time when it
should be shut down, a report is sent to the Cat database and an alert is immediately sent to the
user.
Cell Phone/Email/Pager Alerts: The user can designate a specific person to be notified via
cell 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 be
operating in. Product Link will report a geo-fence alarm if the machine leaves its designated
operating area.
For Exclusion monitoring, a geo-fence is set up to exclude an area the machine should not be
operating in. Product Link will report a geo-fence alarm if the machine enters the excluded
area.
For Time Based monitoring, Product Link will report a time based alarm if the machine is
operating outside the designated time period.
NOTE: The blue areas are where/when the machine should not operate and the white
areas 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 the
Caterpillar Electronic Technician (Cat ET) software version 2004B or newer. A
Communications 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. The
PL321SR system provides all the capabilities of the PL121SR system with the ability of the
PL300 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 codes
remotely. Fuel consumption can be checked on machines where fuel data is provided by the
Engine ECM. Four additional digital inputs (On/Off) can be monitored in order to further track
machine conditions. Product Link can provide customers and dealers with the information
about 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 of
electrical circuitry powering the antenna to boost the reception. This allows the antenna to be
fairly small yet get better reception than a larger wire antenna. For example, an 18 inch active
antenna will get better reception than a 30 foot wire antenna. The antenna must be mounted on
the 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 cab
to mount the antenna and still maintain the necessary clearance. The bracket will be mounted
on the top of the cab allowing the antenna to be positioned off of the cab. The bracket is sold
separate 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 new
version. Upon removing the old module, the adapter plates allow the user to place the new
module in the same spot. These two plates attach to the back of the PL300 ECM and configure
the 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 of
configuration the user sets up and the type of machine the user has will determine which
harness will be used
Radio Harness: The radio harness (1) consists of a 12 pin plug connector (2), a 2 pin
receptacle connector (3), and 12 pin receptacle connector (4). The radio harness is used in all
the different configurations. The 2 pin receptacle is only used in configurations where the
PL300 ECM is used.
ECM Harness: The ECM harness (5) attaches to the PL300 ECM via the 70 pin plug
connector (6). The ECM harness also includes a 2 pin plug connector (7), a 12 pin plug
connector (8), and a 12 pin receptacle connector (9). This harness is only used in
configurations where the PL300 ECM is involved.
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1
2
3
6
7
8 9
5
4
10
Legacy Harness: The legacy harness (1) is used to attach Product Link to the machine, in
cases 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 the
PL321SR configuration. The 3 pin receptacle connector (4) is used to connect to the serial
service cable. Also the legacy harness is used to connect Product Link to Cat Data Link. The
Cat Data Link connector (2) is shown attached to the legacy harness. The legacy harness
allows 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 legacy
harness on Product Link ready machines. This harness simply attaches Product Link to the
machine. The 12 pin plug connector (6) connects to the radio harness in the PL121SR
configuration or the ECM harness in the PL321SR configuration. The 3 pin round receptacle
connector (7) is used to connect to the serial service cable. The other connector is called the 6
pin receptacle connector (8).
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1
2
5
6
8 3
4
7
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Service Cable: The service cable allows the user to have access to all PL121SR configurations
through 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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1
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PL121SR FOR LEGACY MACHINES
The PL121SR Product Link configuration can be mounted to either Product Link ready
machines or legacy machines. The main components of the PL121SR legacy configuration are
pictured 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 and
the ECM Harness in addition to the PL121SR components make up the PL321SR for legacy
machines. These two components as shown above are simply inserted between the Radio
Harness 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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2
3
4
5
6
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The PL121SR Legacy Field Installation Group and the PL300 Legacy Field Installation Group
can be purchased separately. However, the PL121SR and the PL300 Legacy Field Installation
Group can be purchased together as a package. The PL321SR Legacy Field Installation Group
contains all of the components that are in the PL121SR and the PL300 Legacy Installation
Groups. The PL300 Legacy Field Installation Group can be used to upgrade the PL121SR
Legacy 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 the
machine. The legacy machine uses the legacy harness. The Product Link ready machines use
the conversion harness. Both of these configurations have the same capabilities, but the need
for two separate harnesses stem from different connections on Product Link ready machine
versus 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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1
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 Link
ready machines for users who want the maximum Product Link capabilities. The PL321SR
system 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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2
3
4
5
6
Without Ground Plane
P L 1 2 1
Without an RF reflective surface, some of
the radio energy is reflected downward
With Ground Plane
P L 1 2 1
Metal cab roof reflects RF
energy 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 conductive
surface that serves as a reference ground in a circuit. The ground plane reflects the Radio
Frequency (RF) energy upward and outward. Without a ground plane, some of the RF energy
is reflected downward causing the signal to weaken. The roof of the cab works well for a
ground plane. If it is not possible to have a ground plane, the use of a braided ground strap is
recommended.
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PL121SR and PL321SR PRODUCT LINK ANTENNA: CORRECT INSTALLATION
EXAMPLE
The above illustrations are both examples of good antenna installations. Both pictures show
the antenna mounted on the roof of the cab or ROPS. Generally, the cab roof is the best place
to mount the antenna. The roof is typically the highest point on the machine and it also
provides a suitable ground plane.
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19
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PL121SR and PL321SR PRODUCT LINK ANTENNA: INCORRECT INSTALLATION
EXAMPLE
The above illustrations are examples of poor installations. Illustration 20 shows an antenna
mounted on the ROPS of a backhoe loader. At first, this antenna may seem to be installed in a
good 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 seem
to be in a good location because it is in an open area and there is a large ground plane
surrounding 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 can
also cause some interference with the signal. In addition, the antenna is not at the highest point
on the machine. The antenna is mounted on the hood rather than the roof of the cab. Mounting
antennas on the highest point of the machine will ensure the best possible reception.
20
21
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PL321SR MODULE INSTALLATION
The PL121SR and PL300 modules should be mounted in a secure location. The modules
should 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 include
behind 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 and
result in damage. For security purposes, the modules should be in a location that can be locked
when 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 machine
and dealer. Installation parameters need to be set at the time Product Link is installed. Product
Link 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 report
configuration screen when the PL121SR is used alone.
If the machine's information is already in the Dealer Business System (DBS) or Equipment
Data (the Equipment Manager database), the installation parameters must match the existing
information or the registration will fail.
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PLMInstallation Parameters: Machine Serial Number
The Machine Serial Number is the serial number of the machine on which the module is
installed. This value is utilized by Product Link for routing and displaying information. Verify
that the correct machine serial number is entered on any new or transferred installation. To
change the machine serial number, enter the machine serial number in the box. On Caterpillar
machines with a 17-character PIN, the last eight characters are used for the serial number. Do
not 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 which
Product Link is installed. "AA" represents a machine built by Caterpillar and is the default
value. Individual dealers determine codes for non-Caterpillar machines. The two digit code
used here needs to be mapped to an appropriate three digit code in DBS. If the two digit
Machine Make Code is not "mapped" in Equipment Data to an appropriate Dealer Identification
Code, 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 is
registered. The code entered should be the Dealer Identification Code for the main branch of
the dealership rather than the sub-branch code.
NOTE: If the wrong Dealer Identification Code is entered, Product Link will not be
able to register the machine. The information for the machine will not be available or
visible 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 will
record the reoccurrence of an event or diagnostic code. The default value for the
Event/Diagnostic Report Interval is 20 hours, and the minimum value for the Event/Diagnostic
Report Interval is 4 hours. The Event/Diagnostic Report Interval is based on machine operating
hours. In the above illustration the Event/Diagnostic Report Interval is set to 20 hours, so it
will only record the occurrence of a particular event or diagnostic code every 20 hours of
machine operating time.
The Event/Diagnostic Message Interval is the amount of Real Time (RT) or calendar hours
between the Event or the Diagnostic code messages. The Report Start Time is used as the
starting reference for when messages are sent. In the above illustration the Event/Diagnostic
Message Interval is set to 168 hours. Product Link will send any current event and diagnostic
codes 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 this
time. The time entered will be the time that the Product Link module will attempt to send its
first 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 the
entered time.
NOTE: If the machine is powered down at the first report start time, Product Link will
not 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 deliver
events from other Electronic Control Modules (ECMs) on the machine. Product Link does not
generate 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. Recommended
for Level 2 and Level 3 Events. In immediate mode, a reoccurrence of the event is only
sent 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 PLMReport Configuration Parameters
The Diagnostic Report Configuration Status controls when Product Link reports diagnostic
events from the other ECMs. The Diagnostic Report Configuration Status has the same choices
as the warning levels.
The Operating Hours Report Configuration Status configures Product Link to display the
machine's operating hours in Equipment Manager if it is set to "ON".
The Number of Daily Machine Location Message Configuration parameter is the number of
times during a 24 hour period that the machine's location is reported to the office. The
minimum value is 0 and the maximum value is 4. The first location report will be sent at the
Report Start Time. A position report will still come through with the daily standard message
even if this value is set to zero. Product Link will not report the machine's location if the
machine has not moves at least 200 meters since the last report.
The Fuel Consumed Report Configuration Status configures Product Link to send a fuel
consumption report if it is set to "ON". A fuel consumption report can only be sent if the
Engine ECM or Machine ECM is capable of making one available.
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The Global Gram Enable Status configures Product Link to communicate properly when a
satellite ground station is not available to the satellite. The default setting is "Disabled". The
Global Gram Enable Status should only be set to "Enabled" if there is not a satellite ground
station available. At this time, Global Gram is predominately used in areas such as New
Zealand and Australia. Global Gram can be used anywhere where ground station coverage is
limited. However, there are significant delays associated with Global Gram "Enabled" and
should 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 PL121SR
is used alone. Digital Input Configuration is used to configure additional inputs. Up to four
additional 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.
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Digital Input Monitoring Condition:
- All Conditions: The input will be monitored regardless of the key switch position or the
engine status.
- Key Off/Engine Off: The digital input will be monitored only if the key and the engine
are off.
- Key On/Engine Off: The digital input will only be monitored when the key is in the ON
position with the engine off.
- Key On/Engine On: The digital input will only be monitored when the key and the
engine are both on.
- Digital Input Description: The description for the digital input can be up to 24
characters. The default description is Digital Input 1.
- Digital Input Delay Time: The time an input must be in the opposite of the normal state
before an alarm is recorded and sent to the geo-fencing application. The minimum value
is 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 set
to the Machine SMH. Choose Synchronize Service Hour Meters from the Service drop down
menu.
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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" to
synchronize 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 Product
Link 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 both
lines and click "OK".
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PLM COMMANDS
Registration: The registration message can be manually queued if you do not want to wait 15
minutes 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 machine
or if the machine is changing dealerships. Select PLM Commands =>De-Registration from the
Service drop down menu. When a machine is de-registered, all of the installation parameter
values 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 a
report.
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When the registration command is used, a new window will appear asking to confirm sending
the registration message. Click "Yes" to send the registration message. After selecting "Yes" to
send the registration message, monitor "Status Group #1" and verify the "Queued Registration
Messages" value has changed from a "1" to a "0" (zero) indicating the registration message has
been 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 pending
to 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 PLM
must be registered for messages to be transmitted.
- De-Registered: The PLM is not registered on the communications system and will not
transmit any messages except a Registration command.
Primary Communications Link:
- On-Line: A communications satellite is in view allowing the PLM to send and receive
messages.
- Off-Line: There are no communications satellites in view allowing the PLM to send and
receive messages.
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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 1
week. The PLM will wake up every 6 hours to send and receive messages. Position
messages will only be sent if the machine has changed position by greater than 200
meters.
- Power Mode 3: The machine has not operated for more than 1 week. The PLM will
wake up every 24 hours to send and receive messages. Position messages will only be
sent 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 powered
up.
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 periodically
power 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 time
causing scheduled reports to be missed. This value is reset automatically after the status
is reported to the office.
- No: The PLM has not experienced a loss of communications and has been
communicating as scheduled.
Possible Device Power Disconnection:
- Yes: The PLM has missed reports due to a power loss. This value is reset automatically
after 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 Digital
Sensors. 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 sensor
would be closed to ground. If the sensor is configured as a normally closed sensor, and
active sensor would be open to ground. In both cases, the sensor will not become active
until the delay time has expired.
- Inactive: When this type of sensor is configured as a normally open sensor, an inactive
sensor will not be closed to ground. The sensor is open. If the sensor is configured as a
normally closed sensor, and inactive sensor will not be open. The sensor is closed. In
both 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-fencing
is 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 is
not currently activated.
Geographical Exclusion Activation Status:
- Active: Geographical Exclusion Geo-fencing has been properly configured and is
currently activated.
- Not Active: There is currently no Geographical Exclusion Geo-fencing properly
configured and/or it is not currently activated.
6/06
Geographical Inclusion Activation Status:
- Active: Geographical Inclusion Geo-fencing has been properly configured and is
currently activated.
- Not Active: There is currently no Geographical Inclusion Geo-fencing properly
configured 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.
6/06
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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 previously
calculated 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 to
the 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.
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Product Link Status Group #6 - Communication
The Product Link Group 6 Status screen shows the current status of satellite communication
with the module.
If the Product Link Module is communicating with the satellites, the Satellite Communication
Status value will be established.
Satellite Network Control Center Communication Status will display "Established" if the
satellite communicating with the Product Link Module is also communicating with a ground
station. Otherwise, "Not Established" will be displayed.
Average Wireless Communication Error Count is the number of times an error has occurred.
6/06
45
6/06
CONCLUSION
This presentation has covered Product Link components and configurations. An understanding
of Product Link can assist the user with diagnostic, troubleshooting, and programming. Always
use the latest Service Information to ensure that the most current specifications and test
procedures 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 open
circuit 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 circuit
is interrupted. A normally closed circuit will have less than 5 ohms of resistance. The
following procedure explains the test for an open circuit:
Reference: For a complete electrical schematic, refer to the Electrical System Schematic for
the machine that is being serviced.
Test for an Open Circuit.
1. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical
System 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 the
resistance 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 the
resistance is greater than 5000 ohms, there is an open in the machine harness. Repair or
replace the machine harness.
SERV1797-01 - 54 - Laboratory Exercise
6/06
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 the
wires in a circuit for a lamp produces too much current in the wires but no current is felt at the
lamp. The lamp is shorted out. The resistance in a normal circuit can vary, but the resistance
between a particular circuit and other unrelated circuits is always greater than 5000 ohms. The
following procedure explains the test for a short circuit:
Reference: For a complete electrical schematic, refer to Electrical System Schematic for the
machine that is being serviced.
Test for an Short Circuit.
1. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical
System 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 on
the contact of the suspect wire.
5. Use the other multimeter probe to check the resistance across all other contacts in the
connector(s) of the ECM and frame ground.
Expected Result: If the resistance is greater than 5000 ohms for all the measurements, then
the harness circuits are okay. If the resistance is less than 5 ohms, there is a short in the
machine harness. The short is located between the suspected wire and the wire with the lowest
resistance measurement. Repair or replace the machine harness
SERV1797-01 - 55 - Laboratory Exercise
6/06
COMPONENT IDENTIFICATION
Directions: The following pages contain images of the components that are contained in
Product Link. First identify the component itself. Next identify the specific parts of the
component. The Service Manual may be used as a reference for the more specific parts.
Component Name: ___________________________________
1. __________________________________________________
2. __________________________________________________
3. __________________________________________________
4. __________________________________________________
5. __________________________________________________
SERV1797-01 - 56 - Handout No. 1
6/06
1
2
3
4
5
Component Name: ____________________________________
1. ___________________________________________________
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Component Name: ___________________________________
1. __________________________________________________
2. __________________________________________________
3. __________________________________________________
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2
3
Component Name: ___________________________________
1. __________________________________________________
2. __________________________________________________
3. __________________________________________________
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2
3
Component Name: ___________________________________
1. __________________________________________________
2. __________________________________________________
3. __________________________________________________
4. __________________________________________________
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2
3
4
Component Name: ___________________________________
1. __________________________________________________
2. __________________________________________________
3. __________________________________________________
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2
3
Component Name: ___________________________________
1. __________________________________________________
2. __________________________________________________
6/06
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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 configuration
B. PL121SR Product Link Ready Legacy configuration
C. PL321SR Product Link Ready configuration
D. all of the above
E. both A and C
2. The PL121SR systems connect to Cat ET using:
A. an embedded communications adapter
B. a wireless communications adapter
C. a communications II adapter
D. none of the above
E. any of the above
E. any of the above
4. Which wiring harness connects the PL300 ECM to the Product Link system?
A. the conversion harness
B. the gateway harness
C. the legacy harness
D. the radio harness
5. Which version of Cat ET must be used with the Product Link system?
A. Cat ET 2003
B. Cat ET 2004 A
C. Cat ET 2004B
D. any of the above
SERV1797-01 - 63 - Posttest
6/06
6. Which of the following configurations do not include the radio harness?
B. PL321SR Product Link Ready configuration
C. PL121SR Legacy configuration
D. PL321SR Legacy configuration
E. none of the above
7. As a rule of thumb how many feet of clear space must the antenna have surrounding it?
A. 3 feet
B. 4 feet
C. 5 feet
D. 6 feet
8. The service is used to connect the PL300 ECM to the machine.
A. True
B. False
9. In addition to all the functions of the PL121 system, the PL321 system can also track
what number of digital inputs?
A. 2
B. 3
C. 4
D. 6
10. Which of the following categories of machines can product link be mounted on?
A. Legacy Machines
B. Product Link Ready Machines
C. Non-Cat Machines
D. all of the above
SERV1797-01 - 64 - Posttest
6/06
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?
B. PL121SR Product Link Ready Legacy configuration
C. PL321SR Product Link Ready configuration
D. all of the above
E. both A and C
E. any of the above
E. any of the above
4. Which wiring harness connects the PL300 ECM to the Product Link system?
A. the conversion harness
B. the gateway harness
C. the legacy harness
D. the radio harness
5. Which version of Cat ET must be used with the Product Link system?
A. Cat ET 2003
B. Cat ET 2004 A
C. Cat ET 2004B
D. any of the above
SERV1797-01 - 65 - Answers
6/06
6. Which of the following configurations do not include the radio harness?
B. PL321SR Product Link Ready configuration
C. PL121SR Legacy configuration
D. PL321SR Legacy configuration
7. As a rule of thumb how many feet of clear space must the antenna have surrounding it?
A. 3 feet
B. 4 feet
C. 5 feet
D. 6 feet
8. The service cable is used to connect the PL300 ECM to the machine.
A. True
B. False
9. In addition to all the functions of the PL121 system, the PL321 system can also track
what number of digital inputs?
A. 2
B. 3
C. 4
D. 6
10. Which of the following categories of machines can product link be mounted on?
A. Legacy Machines
B. Product Link Ready Machines
C. Non-Cat Machines
D. all of the above
SERV1797-01 - 66 - Answers
6/06

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