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312-5642 Product Link Service Tool Group

SMCS: 1900-038

TOOLOPERATING

MANUAL

NEHS1016

January 2008

R

TOOLOPERATING

MANUAL

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Important Safety Information

Think Safety

Most accidents that involve product operation,maintenance, and repair are caused by failureto observe basic safety rules or precautions.

An accident can often be avoided byrecognizing potentially hazardous situationsbefore an accident occurs. A person must bealert to potential hazards. This person shouldalso have the necessary training, skills, andtools to perform these functions properly.

Improper operation, lubrication,maintenance, or repair o f this product canbe dangerous and could result in injury ordeath.

Do not operate or perform any lubrication,

maintenance, or repair on this product untilyou have read and understood theoperation, lubrication, maintenance, andrepair information.

Safety precautions and warnings are providedin this manual and on the product. If thesehazard warnings are not heeded, bodily injuryor death could occur to you or to otherpersons.

The hazards are identified by the Safety AlertSymbol and followed by a Signal Word suchas DANGER, WARNING, or CAUTION.

The Safety Alert WARNING label is shownbelow.

The meaning of this safety alert symbol is asfollows:

Attention! Become Alert ! Your Safety isInvolved.

The message that appears under the warningexplains the hazard and can be either writtenor pictorially presented.

Operations that may cause product damageare identified by NOTICE labels on theproduct and in this publication.

Caterpillar cannot anticipate every poss iblecircumstance that might involve a potentialhazard. The warnings in this publicationand on the product are, therefore, notall-inclusive. If a tool, procedure, workmethod, or operating technique that is notspecifically recommended by Caterpillar isused, you must satisfy yourself that it issafe for you and for others. You shouldalso ensure that the product wi ll not bedamaged or be made unsafe by theoperation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrationsin this publication are on the basis ofinformation that was available at the time thatthe publication was written. The specifications,torques, pressures, measurements,adjustments, illustrations, and other items canchange at any time. These changes can affectthe service that is given to the product. Obtainthe complete and most current informationbefore you start any job.

When replacement parts are required for thisproduct, Caterpillar recommends usingCaterpillar replacement parts or parts withequivalent specifications including, but notlimited to, physical dimensions, type,strength, and material.

Failure to heed this warning can lead topremature failures, product damage,personal injury, or death.

WARNING

WARNING

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ContentsLiterature Information

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General Information . . . . . . . . . . . . . . . . . . . 3

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 3Safety Icon Nomenclature . . . . . . . . . . . . . . 4

Personal Protection/Important Information 4

Prohibited Action . . . . . . . . . . . . . . . . . . . . 4

Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4

Safety Section

Safety Warnings. . . . . . . . . . . . . . . . . . . . . . 4

General Information Section

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5

References. . . . . . . . . . . . . . . . . . . . . . . . . . 5

Additional Contact Information . . . . . . . . . . 5

Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Required Hardware . . . . . . . . . . 7

Operation Section

Tooling Set-up . . . . . . . . . . . . . . . . . . . . . . . 7

Service Tool Set-up ForPL121 Product Link . . . . . . . . . . . . . . . . . . . 8

PL121 Connection Procedure . . . . . . . . . . 9

Service Tool Set-up ForPL151/201 Product Link. . . . . . . . . . . . . . . 11

PL151/201 Connection Procedure. . . . . . 12

Service Tool Set-up ForPL321 Product Link . . . . . . . . . . . . . . . . . . 15

PL321 Connection Procedure . . . . . . . . . 16

Configuring CAT Electronic Technician . . . 19

Tooling Removal. . . . . . . . . . . . . . . . . . . . . 21

Maintenance Section

Cleaning/Inspection. . . . . . . . . . . . . . . . . . 23

Service Parts . . . . . . . . . . . . . . . . . . . . . . . 23

Literature InformationThis manual should be stored with the toolgroup.

This manual contains safety information,operation instructions, and maintenanceinformation.

Some photographs or illustrations in thispublication show details that can be differentfrom your service tool. Guards and coversmight have been removed for illustrativepurposes.

Continuing improvement and advancement ofproduct design might have caused changes toyour service tool, which are not included in thispublication.

Whenever a question arises regarding yourservice tool or this publication, please consult

Dealer Service Tools (DST) for the latestavailable information.

Safety Section

The Safety section lists basic safetyprecautions.

Read and understand the basic precautionslisted in the Safety section before operating orperforming maintenance and repair on thisservice tool.


The General Information section describestooling functions and features. It providesuseful information on individual parts,additional tooling, and resources.

Operation Section

The Operation section is a reference for thenew operator and a refresher for theexperienced operator.

Photographs and illustrations guide theoperator through correct procedures for using

the tool group.Operating techniques outlined in thispublication are basic. Skill and techniquesdevelop as the operator gains knowledge ofthe service tool and its capabilities.

Maintenance Section

The Maintenance section is a guide toequipment care and service parts.

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Safety Section

Safety Icon Nomenclature

Personal Protection/Important

Information

Read the manual

Eye protection

Ear protection

Face protection

Prohibited Action

No liquid around electrical components

No smoking

Hazard Avoidance

Battery explosion hazard

Hot surface

Pressurized air

Safety alert symbol

Slipping hazard

Tripping hazard

Safety Warnings

To avoid personal injury or death,carefully read and understand allinstructions before attempting to

operate any equipment or tools.Do not operate or work on a machine unlessyou read and understand the instructionsand warnings in this and all other applicablemanuals. Contact Dealer Service Tools forreplacement manuals. Proper care is yourresponsibil ity. Always follow all State andFederal health and safety laws and/or localregulations.

To prevent possible damage toyour hearing, always wear earprotection when working around

noise-generating tools.

To avoid eye injury,always wear protectiveglasses or face shield.Make sure no one can

be injured by flying objects or debris whenusing tools or working on a component.

Personal injury can resultfrom slips or falls. DONOT leave tools orcomponents laying

around the work area, and clean up allspilled fluids immediately.

Personal injuriescan occur as aresult of usingpressurized air.

Maximum air pressure at the nozzle must bebelow 205 kPa (30 psi) for cleaningpurposes. Wear protective clothing,protective glasses, and a protective faceshield when using pressurized air.

Batteries contain sulfuric

acid and produceexplosive gases that canresult in serious injury. Do

not stand over the battery when connectingharness clamps. To prevent igni tion ofgases, avoid sparks and keep other ignitionsources away from batteries at all times.

WARNING

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Batteries give offflammable fumes that canexplode, resulting inpersonal injury. Do not

smoke around batteries and prevent sparks

near batteries. Do not allow the battery clipsto contact each other or the machine whileconnected to a battery.

Machine engines and relatedcomponents can be hot. To avoidpersonal injury, use caution whenconnecting or disconnecting

service tool wiring harness plugs. Ifpossible, allow equipment to cool beforeconnecting the Product Link Service Tool.

No liquid around electricalcomponents.


Introduction

The 312-5642 Product Link Service ToolGroup is used to set-up, test, and troubleshootthe Product Link System. It can be usedbefore, during, and after Product Link System

installation. The service tool group verifiesproper communication with CAT ElectronicTechnician (ET), as well as the function ofauxiliary digital switch inputs.

The product link service tool group is usedwith a 12 Volt or 24 Volt external battery powersupply and a laptop computer with the mostup-to-date version of CAT ET installed.

The product link service tool will work withPL121, PL151/201, and PL321 Product LinkSystems.

References

For more information regarding registration ofa Product Link module, or troubleshootingprocedures for communication adapters, referto the following literature.

References

RENR5885 Systems Operation Troubleshooting Testing and

Adjusting, Product Link 151/201

RENR7911 Systems Operation Troubleshooting Testing and

Adjusting, Product Link 121/321

NEHS0758 Using the 275-5120 Caterpillar Communication

Adapter II

NEHS0926 Using the 261-3363 Wireless Communication

Adapter

Additional Contact Information

For additional product support questionsconcerning this tool, contact the Caterpillar

Dealer Service Tools Hotline at:

U.S.A.: 1-800-542-8665Illinois: 1-800-541-8665Canada: 1-800-523-8665World: 1-309-675-6277Fax: [email protected]

WARNING

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Nomenclature

The 312-5642 Product Link Service Tool Groupconsists of switch box (1), main harness withbattery power supply clips (2), three servicetool harness assemblies (3,4,5), and storagecase (6) with foam lining (7), not shown.

1. 312-5641 Switch Box - Controls powersupply and simulates signals for testing theProduct Link system.

2. 312-5608 Main Harness Assembly - Usedwith 312-5641 Switch box, 12 V or 24 Vpower supply (battery), and other productlink service tool harness assemblies.

3. 312-5609 Harness Assembly - Used with

312-5608 Main Harness Assembly, laptopcomputer, and PL121 Module.

4. 312-5610 Harness Assembly - Used with312-5608 Main Harness Assembly,275-5120 Communication Adapter II or261-3363 Wireless Communication Adapter,laptop computer, and PL151 or PL201Module.

5. 312-5611 Harness Assembly - Used with

312-5608 Main Harness Assembly,275-5120 Communication Adapter II or261-3363 Wireless Communication Adapter,laptop computer, PL121 Module, andPL300 ECM.

6. 6V-7145 Storage Case.

7. 317-9430 Foam Insert (not shown).

The 312-5641 Product Link Service Tool SwitchBox has three primary switches (a,b,c) andfour auxiliary switches (d) used to test theDigital Input feature of the Product LinkPL201 module or PL300/321 ECM throughCAT ET.

a. Main Power Switch - In the ON position,power is provided to the modules beingtested.

b. Key Switch - In the ON position, it providesa valid key on signal to the configuredmodules (simulates the ignition switch in arun position).

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c. Alt. R - Term. Switch - In the ON position, itprovides a valid engine running signal toconfigured modules (simulates enginerunning and accruing hours).

d. Digital Input 1-4 Switches - In the CLOSEDposition, auxiliary switches provideadditional inputs used to test the Digital

Input feature of the Product Link Modulethrough CAT ET (PL201 and PL300/321Product Link systems only).

NOTE: The PL121 SR Radio and PL151Product Link Module are not configured forauxiliary inputs. The four digital input switches(d) are not used with PL121 or PL151 ProductLink System testing.

Addit ional Required HardwareTo operate the 312-5642 Product Link ServiceTool Group, the following additional hardwareis required:

275-5120 Caterpillar CommunicationAdapter II or 261-3363 WirelessCommunication Adapter

Laptop Computer with CAT ET softwareinstalled

NOTE: Always make sure the laptopcomputer has the latest version of CAT ETsoftware installed on it before using the312-5642 Product Link Service Tool Group.

Operation Section

Tooling Set-up

The 312-5642 Product Link Service Tool Grouprequires a set-up and connection procedurethat varies, depending on the Product Link

Group being serviced.Refer to the appropriate PL121, PL151/201, orPL321 Product Link Service Tool Group sectionin this manual for specific procedures.

Batteries give offflammable fumes that canexplode, resulting inpersonal injury. Do not

smoke around batteries and prevent sparksnear batteries. Do not allow the battery clipsto contact each other or the machine whileconnected to a battery.

Machine engines and relatedcomponents can be hot. To avoidpersonal injury, use caution whenconnecting or disconnecting

service tool wiring harness plugs. Ifpossible, allow equipment to cool beforeconnecting the Product Link Service Tool.

WARNING

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Components (PL121 Product Link)

Item Description

1 312-5641 Switch Box1

2 312-5608 Main Harness Assembly1

3 312-5609 Harness Assembly1

8 12 Volt or 24 Volt Power Supply

10 Laptop Computer2

11 Coaxial Antenna Cables

12 Satellite/GPS Antenna

13 PL121 Radio

1 Part of 312-5642 Product Link Service Tool Group.2 Loaded with latest version of CAT ET.

8

Service Tool Set-up For PL121 Product Link

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PL121 Connection Procedure

1. Make sure all switches on 312-5641 SwitchBox are in the OFF and/or OPEN position,as shown.

NOTICE

To avoid logging fault codes on Product LinkModules, always turn the switch box MAINPOWER switch OFF before connecting ordisconnecting any product link components.

2. Connect the 12-pin plug on 312-5608 MainHarness Assembly (2) to switch box (1)receptacle.

(1) 312-5641 Switch Box. (2) 312-5608 Main Harness

Assembly.

NOTICE

Damage to the harness cable assembly canoccur from contact with hot surfaces and/orkinking/pinching/cutting the cable. To avoiddamage, do not expose the harness to hot

surfaces and route the harness assemblies toavoid contact with sharp edges on the machine.

Batteries contain sulfuricacid and produceexplosive gases that canresult in serious injury. Do

not stand over the battery when connectingharness clamps. To prevent igni tion of

gases, avoid sparks and keep other ignit ionsources away from batteries at all times.

3. Connect the RED (+) and BLACK (-) batteryclamps on main harness assembly (2) to anappropriate 12 Volt or 24 Volt power supply(8).

(2) 312-5608 Main Harness Assembly.

(8) 12 Volt or 24 Volt Power Supply.

NOTICE

To prevent possible damage to product linktooling or related components, use cautionwhen connecting to the power supply. Alwaysconnect the RED (positive) clamp to thePOSITIVE terminal first, then the BLACK(ground) clamp to the NEGATIVE terminal last.

312-5608

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4. Connect the 8-pin receptacle on 312-5609Harness Assembly (3) to the matching8-pin plug on main harness assembly (2).


(3) 312-5609 Harness Assembly

5. Make sure the key switch on the machine isOFF. Disconnect the machine harness12-pin plug at PL121 Radio (13).

(13) PL121 Radio.

6. Connect the 12-pin plug on harnessassembly (3) to PL121 Radio (13).

(3) 312-5609 Harness Assembly. (13) PL121 Radio.

7. Connect the 9-pin serial connector onharness assembly (3) to laptop computer

(10) with the latest version of CAT ETinstalled.

(3) 312-5609 Harness Assembly. (10) Laptop Computer.

8. Proceed to the Configuring CAT ElectronicTechnician section in this manual.

NOTE: For more information on PL121Product Link, refer to RENR7911 SystemsOperation Troubleshooting Testing and

Adjusting, Product Link 121/321.

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10

3

3

13

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1016-17

13

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3

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Components (PL151/201 Product Link)

Item Description





9a 275-5120 Communication Adapter II2

9b 261-3363 Wireless Communication Adapter2

10 Laptop Computer3



14 PL151/201 Module

1 Part of 312-5642 Product Link Service Tool Group.2 Select either 9a or 9b communication adapter.3 Loaded with latest version of CAT ET.

11

Service Tool Set-up For PL151/201 Product Link

312-5608

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2

8

4

14

12

11

9b

9a

10

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PL151/201 Connection Procedure

NOTICE

To avoid logging fault codes on Product LinkModules, always turn the switch box MAIN

POWER switch OFF before connecting ordisconnecting any product link components.



(1) Switchbox. (2) 312-5608 Main Harness Assembly.

NOTICE

Damage to the harness cable assembly canoccur from contact with hot surfaces and/orkinking/pinching/cutting the cable. To avoiddamage, do not expose the harness to hotsurfaces and route the harness assemblies toavoid contact with sharp edges on the machine.

3. Connect the RED (+) and BLACK (-) batteryclamps on main harness assembly (2) to anappropriate 12 Volt or 24 Volt power supply(8).



312-5608

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(4) 312-5610 Harness Assembly.

5. Make sure the key switch on the machine isOFF. Disconnect the machine harness24-pin plug at PL151/201 Module (14).

(14) PL151/201 Module.

6. Connect the 24-pin plug on harnessassembly (4) to PL151/201 Module (14).


(14) PL151/201 Module.

NOTE: Use either 275-5120 Communication

Adapter II (9a) or 261-3363 WirelessCommunication Adapter (9b) as a link tolaptop computer (10).

7. Connect the 9-pin round plug on harnessassembly (4) to the 9-pin round receptacleon 275-5120 Communication Adapter II(9a) or 261-3363 Wireless CommunicationAdapter (9b).


(9a) 275-5120 Communication Adapter II.

(9b) 261-3363 Wireless Communication Adapter.

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4

9b

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8. If using 275-5120 Communication AdapterII (9a), connect the communication adapterharness 9-pin serial connector to laptopcomputer (10) with the latest version of CATET installed.


(10) Laptop Computer

NOTE: 261-3363 Wireless CommunicationAdapter (9b) uses an 802.11b wireless radionetwork. There is no hard-wire connectionfrom the wireless communication adapter tothe laptop computer.


NOTE: For more information on PL151/201Product Link, refer to RENR5885 SystemsOperation Troubleshooting Testing andAdjusting, Product Link 151/201. For moreinformation on communication adapters, referto NEHS0758 Using the 275-5120 CaterpillarCommunication Adapter II or NEHS0926 Usingthe 261-3363 Wireless CommunicationAdapter.

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9a

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Components (PL321 Product Link)

Item I.D. Description





9a 275-5120 Communication Adapter II2

9b 261-3363 Wireless Communication Adapter2

10 Laptop Computer3



13 PL121 Radio

15 PL300 ECM

1 Part of 312-5642 Product Link Service Tool Group.2 Select either 9a or 9b communication adapter.3 Loaded with latest version of CAT ET.

15

Service Tool Set-up For PL321 Product Link

312-5608

9b

9a

10

1

2

8

11

5

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PL321 Connection Procedure

NOTICE





(1) 312-5641 Switch Box. (2) 312-5608 Main Harness

Assembly.

NOTICE

Damage to the harness cable assembly canoccur from contact with hot surfaces and/orkinking/pinching/cutting the cable. To avoiddamage, do not expose the harness to hotsurfaces and route the harness assemblies toavoid contact with sharp edges on the machine.

3. Connect the RED (+) and BLACK (-) batteryclamps on main harness assembly (2) to anappropriate 12 Volt or 24 Volt power supply

(8).


(8) 12 Volt or 24 Volt Power Supply

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5. Make sure the key switch on the machine isOFF. Disconnect the machine harness70-pin plug at PL300 ECM (15).

(15) PL300 ECM.

6. Connect the 70-Pin plug on harnessassembly (5) to PL300 ECM (15).

(5) 312-5611 Harness Assembly. (15) PL300 ECM.

7. Connect the 12-pin plug on harnessassembly (5) to PL121 Radio (13).

(13) PL121 Radio. (15) PL300 ECM.

NOTE: Use either 275-5120 CommunicationAdapter II (9a) or 261-3363 Wireless

Communication Adapter (9b) as a link tolaptop computer (10).

8. Connect the 9-pin round plug on harnessassembly (5) to the 9-pin round receptacleon 275-5120 Communication Adapter II(9a) or 261-3363 Wireless CommunicationAdapter (9b).



(9b) 261-3363 Wireless Communication Adapter.

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9a

9b 5

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9. If using 275-5120 Communication AdapterII (9a), connect the communication adapterharness 9-pin serial connector to laptopcomputer (10) with the latest version of CATET installed.


(10) Laptop Computer.

NOTE: 261-3363 Wireless CommunicationAdapter (9b) uses an 802.11b wireless radionetwork. There is no hard-wire connectionfrom the wireless communication adapter tothe laptop computer.


NOTE: For more information on PL321Product Link, refer to RENR7911 SystemsOperation Troubleshooting Testing andAdjusting, Product Link 121/321. For moreinformation on communication adapters, referto NEHS0758 Using the 275-5120 CaterpillarCommunication Adapter II or NEHS0926 Usingthe 261-3363 Wireless CommunicationAdapter.

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Configuring CAT Electronic Technician

1. Place MAIN POWER (a) and KEY SWITCH(b) rocker switches to the ON position, asshown.

(a) MAIN POWER Rocker Switch.

(b) KEY SWITCH Rocker Switch.

2. With the laptop computer turned ON, openCAT Electronic Technician (ET) and select(click on) the STOP CONNECT icon toprevent ET from searching for anon-configured communication adapter.

3. Open the Utilities menu, then select (clickon) the Preferences tab.

4. In the Preferences pane, select(click on) the Communications tab.

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5. In the Communications pane, use the pulldown menu to select (click on) thecommunication adapter 275-5120Communication Adapter II (a) or 261-3363Wireless Communication Adapter (b)connected to the harness assembly.

(a) 275-5120 Communication Adapter II.

(b) 261-3363 Wireless Communication Adapter.

6. In the same pane, use pull down menu (c)to select the port that the communicationadapter is configured to and then clickOK (d).

(c) Port Selection Pull Down Menu. (d) OK.

7. On the main toolbar select (click on) theConnect icon to connect CAT ET to theProduct Link system.

8. Once CAT ET has connected to the ProductLink module, it is possible to:

Use the laptop computer to proceed withset-up and registration of the module inCAT ET

View the status of the key switch,alternator, and digital switch inputs bygoing to the laptop computer STATUSscreen

NOTE: Digital switch inputs are not availablewith PL121SR Radio or PL151 Product Linkmodule. For PL201 and PL321 Product Link,the digital inputs must be activated in theConfiguration Screen.

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Tool ing Removal

NOTICE




2. Make sure the machine key switch is in theOFF position.

3. Close all programs on laptop computer(10). If using 275-5120 CommunicationAdapter II (9a), disconnect from the laptop

computer when it is safe to do so.


(10) Laptop Computer.

10

9a

1016-33

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Batteries contain sulfuricacid and produceexplosive gases that canresult in serious injury. Do

not stand over the battery when

disconnecting harness clamps. To preventignition of gases, avoid sparks and keepother ignition sources away from batteries atall times.

NOTICE

To prevent possible damage to product linktooling or related components, use cautionwhen disconnecting the power supply. Alwaysremove the BLACK (ground) clamp first, thenremove the RED (positive) terminal last.

4. Disconnect the RED (+) and BLACK (-)battery clamps on main harness assembly(2) from 12 Volt or 24 Volt power supply (8).



5. Disconnect harness assembly (3), (4), or(5) connectors from Product Link radio (13),module (14), and/or ECM (15), as required.

(3),(4),(5) Harness Assembly Connectors.

(13) Product Link Radio. 14) Product Link Module.

(15) Product Link ECM.

6. Disconnect main harness assembly (2)from harness assembly (3), (4), or (5), notshown, and from switch box (1).

(1) Switch Box. (2) Main Harness Assembly.

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WARNING

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7. Neatly coil up harness assemblies andstore with switch box in 6V-7145 StorageCase.

Maintenance Section

Cleaning/Inspection

1. Avoid allowing oil, grease, or other fluids tocome in contact with the 312-5641 SwitchBox and other components. Clean theswitch box with a clean, dry cloth, asneeded.

No liquid around electricalcomponents.

2. Inspect harness assemblies. Make sureconnectors are clean and there are nokinks, breaks, or heat damage to the

harness. Replace damaged harnessassemblies.

3. Inspect the battery clamps on the mainharness. Make sure they are clean and freefrom corrosion.

4. When not in use, store this tool group in thefoam-lined case in a clean, dry location.

Service Parts

312-5642 Service Parts

Item No. Part No. Description

1 312-5641 Switch Box

2 312-5608 Main Harness Assembly

3 312-5609 Harness Assembly

(PL121 Product Link)


(PL151/201 Product Link)


(PL321 Product Link)

6 6V-7145 Storage Case

7 317-9430 Foam Insert (not shown)

WARNING

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2008 Caterpillar NEHS1016

For information on service tools or shop supplies,

contact Dealer Service Tools on:

Dealer Service Tools

501 S. W. Jefferson

Peoria, IL U.S.A. 61630-2125

U.S.A.: 1-800-542-8665

Illinois: 1-800-541-8665

Canada: 1-800-523-8665

World: 1-309-675-6277

Fax: 1-309-494-1355

[email protected]

Documents

Nehs1016 WebSite[1]