REHS9111-11 (en-us)

02 December 2016

Special Instruction
i06882799 Mounting the PL641 Cellular Radio ....................... 11
PL641 Mounting Requirements ......................... 11
Installation Procedure for the PL641 Environmental Information ......................12
Warning Film Installation ...................................12
Pro Product Link TM PL641 and Installing the PL641 ..........................................13
PL631 Systems Mounting a Cellular Radio Without a
Mounting Bracket ........................................14
SMCS Code: 7606 Mounting the Cellular Radio With Optional
425-5729 Bracket Mounting Gp ..................15
Machine Control and Guidance Products Mounting the PL631 Satellite Radio.......................16
PRODUCT LINK (S/N: PL61-UP) PL631 Mounting Requirements .........................16
PL631 Environmental Information ......................17
Warning Film Installation ...................................17
Table of Contents Installing the PL631 ..........................................18
Introduction ...........................................................2 Mounting a Satellite Radio Without a
Mounting Bracket ........................................19
Product Link TM Devices ..........................................2
Mounting the Satellite Radio With Optional
PL641 Cellular Radio with Internal
425-5729 Bracket Mounting Gp ..................20
Antenna ...........................................................2
Isolated Hard Mount Antenna Installation ...........21
PL641 Cellular Radio with External
Connect the Harness to the Radio.........................21
Antenna ...........................................................2
Harness Installation .............................................22
PL631 Satellite Radio with External
Antenna ...........................................................2 Connect the Retrofit Installation Harnesses to
the PL641 Cellular Radio and PL631
Important Safety Information...................................2
Satellite Radio ................................................22
Machine Specific Warnings .................................3
Engine Specific Warnings ...................................3 Wire to the Equipment ......................................22
J1939 Network Connection Group ..................24
Generator Specific Warnings...............................4
J1939 Communications Wiring
Weld Specifications and Qualifications ....................4
Requirements.................................................24
Proper Welding Procedure on Machines and
J1939 Port Characteristics .............................25
Engines with Electronic Controls ........................4
Turn the Equipment Power ON .............................25
Required Parts for Engines.....................................5
Flash the PL641 or the PL631 Using
Contents of the 463-1176 Communication
Winflash ............................................................25
Installation Gp ..................................................5
Upload Configuration File .....................................27
Contents of the 463-1177 Communication
Set the Product ID on the Product Link
Installation Gp ..................................................5
Installation Components Not Included in Device...............................................................28
Set the Machine Serial Number on the PL641 or
Kits ..................................................................5
PL631 Radio......................................................30
Required Parts for Machines...................................6
Contents of the 467-4161 Communication Registering Product Link based on Engine
Serial Number....................................................31
Installation Gp ..................................................7
Registering Product Link based on Product Link
Contents of the 467-4162 Communication
Serial Number....................................................32
Installation Gp ..................................................7
Setting Hours on the Product Link Device ..............32
Contents of the 480-9645 Communication
Check the LED Lights on the Radio .......................32
Installation Gp ..................................................7
Green LED.......................................................32
Installation Components Not Included in
Orange LED.....................................................32
Kits ..................................................................8
Yellow LED ......................................................33
Block Diagram and System Components...............10
Blue LED .........................................................33

1
Connect to the Web Configuration Home Product Link provides location-based features and
Page .................................................................33 event and diagnostic based features through close
Product Link Interface .......................................38 integration of EMCP Genset controllers and machine
Connected Devices ..........................................39 electronics.
Communication Check......................................40
Download All Service Dashboard Data...............41 The PL641 and the PL631 can be subscribed into
Download System Watch ..................................41 either “Product Link TM Web” or VisionLink. Each user
Perform the Communication Check .......................41 interface enables easy access to view the health and
Subscribe the Equipment in the “Dealer status of equipment. The ability to view all the
Services Portal” .................................................41 equipment in a secure web-based application allows
Initial Setup......................................................41 the management of the equipment to be more
Optional Inputs and Hardware ..............................42 efficient.
Digital Inputs ....................................................42
Radio Disable Switch (Optional) ........................45 Product Link TM Devices
Installation Procedure....................................45
Operation .....................................................46 PL641 Cellular Radio with Internal
Device Replacement, Device Swap, Dual-Mode
Upgrade, Device Upgrade, and Device Antenna
Downgrade for the PL641 and PL631
Systems ............................................................46 The PL641 cellular radio records data over the CAN/
PL641 Cellular Radio and PL631 Satellite J1939 datalink, and sends the data to the User
Radio Replacement ........................................46 Interface through the cellular network. No external
Dual-Mode Upgrade .........................................47 antenna is required.
Device Upgrade ...............................................47
Device Downgrade ...........................................47
Replacing Legacy Product Link Systems ...............47 PL641 Cellular Radio with External
Replacing a Product Link PL522 ........................47 Antenna
Replacing a Product Link PL523 ........................47
Replacing a Product Link PL321SR ...................47 The PL641 cellular radio records data over the CAN/
Replacing a Product Link PL321VSR .................48 J1939 datalink, and sends the data to the User
Replacing a Product Link PL121SR ...................48 Interface through the cellular network.
Replacing a Product Link PL421 ........................48
Wiring to Product Link Ready and Legacy
Equipment .........................................................49 PL631 Satellite Radio with External
Wiring to a 12 Position Product Link Antenna
Connector ......................................................49
Wiring to a Six Position Product Link The PL631 satellite radio records data over the CAN/
Connector ......................................................50 J1939 datalink, and sends the data to the User
Wiring to a 70 Position Product Link Interface through the satellite network.
Connector ......................................................51
Connecting a Computer to the Product Link
System..............................................................52 Important Safety Information
Required Software............................................52
Supported Hardware Connections .....................52 Work safely. Most accidents that involve product
Cat ® Electronic Technician (Cat ET) Service operation, maintenance, and repair are caused by
Tool ...............................................................52 failure to observe basic safety rules or precautions.
Status Groups for Cat ET ..................................52 An accident can often be avoided by recognizing
Software installation .........................................52 potentially hazardous situations before an accident
Troubleshooting...................................................52 occurs.

A person must be alert to potential hazards. This

Introduction person must also have the necessary training, skills,
and tools to perform these functions properly.
This Special Instruction will provide instructions for Safety precautions and warnings are provided in this
installing the PL641 and PL631 Product Link instruction and on the product. If these hazard
hardware. warnings are not heeded, bodily injury or death could
occur to you or to other persons.
Product Link TM is a remote monitoring solution that
enables efficient and effective equipment
management. Product Link transmits the information
via a cellular GSM and CDMA network or a satellite
communications network.

2
Caterpillar cannot anticipate every possible Machine Specific Warnings
circumstance that might involve a potential hazard.
The warnings in this publication and on the product
are, therefore, not all inclusive. You must not use this
product in any manner different from that considered
by this manual without first satisfying yourself that you Do not operate or work on this machine unless
have considered all safety rules and precautions you have read and understand the instructions
applicable to the operation of the product in the and warnings in the Operation and Maintenance
location of use, including site-specific rules and Manual. Failure to follow the instructions or heed
precautions applicable to the worksite. If a tool, the warnings could result in injury or death. Con-
procedure, work method, or operating technique that tact any Caterpillar dealer for replacement man-
is not specifically recommended by Caterpillar is uals. Proper care is your responsibility.
used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are
authorized t o perform this work, and that the product
will not be damaged or become unsafe by the
operation, lubrication, maintenance, or repair Sudden movement or accidental starting of the
procedures that you intend to use. The information, machine can cause personal injury or death to
specifications, and illustrations in this publication are persons on or near the machine.
on the basis of information that was available at the
time that the publication was written. The To prevent personal injury or death, perform the
specifications, torques, pressures, measurements, following:
adjustments, illustrations, and other items can
Park the machine on a smooth level surface.
change at any time. These changes can affect the
service that is given to the product. Obtain the Lower the blade and or attachments to the
complete and most current information before you ground.
start any job. Cat dealers have the most current
information available. Stop the engine and engage the parking brake.
Block the wheels and install the steering frame
lock.

Personal injury or death can result when voiding Turn the battery disconnect switch to the OFF po-
this certification. sition and remove the key.

Structural damage, an overturn, modification, al- Place a Special Instruction, SEHS7332, “Do Not
teration, or improper repair can impair the Roll- Operate” tag at the battery disconnect switch lo-
over Protective Structure's (ROPS) protection cation to inform personnel that the machine is
capability thereby voiding this certification. being worked on.

Do not drill holes in the ROPS. Do not weld on the

ROPS unless welding is specified in the proce-
dure. Place welds only at the locations that are Engine Specific Warnings
specified in the procedure.
To avoid possible weakening of this ROPS, con-
sult a Caterpillar dealer before altering this ROPS
in any way. The protection offered by this ROPS Do not operate or work on this engine unless you
will be impaired if it has been subjected to struc- have read and understand the instructions and
tural damage.
warnings in the Operation and Maintenance Man-
Consult a Caterpillar dealer to determine this ual. Failure to follow the instructions or heed the
structure's limitations without voiding its warnings could result in injury or death. Contact
certification. any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

Improper operation of an access platform could

result in injury or death. Operators must carry out
their duties properly and follow all instructions
and guidelines given for the machine and access
platform.

3
 Weld Specifications and
Qualifications
Accidental engine starting can cause injury or
death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative (−) battery ter- Personal injury or death can result from fumes,
minal. Completely tape all metal surfaces of the gases and ultraviolet rays from the weld arc.
disconnected battery cable end in order to pre-
vent contact with other metal surfaces which Welding can cause fumes, burn skin and produce
could activate the engine electrical system. ultraviolet rays.

Turn the battery disconnect switch to the OFF po- Keep your head out of the fumes. Use ventilation,
sition and lockout the battery disconnect switch exhaust at the arc, or both, to keep fumes and
with a safety lock. gases from your breathing area. Wear eye, ear
and body protection before working.
Place a Special Instruction, SEHS7332, “Do Not
Operate” tag at the start switch and battery dis- Protect yourself and others; read and understand
connect location to inform personnel that the ma- this warning. Fumes and gases can be dangerous
chine is being worked on. to your health. Ultraviolet rays from the weld arc
can injure eyes and burn skin. Electric shock can
cause death.
Read and understand the manufacturer's instruc-
Generator Specific Warnings tions and your employer's safety practices. Do
not touch live electrical parts.
See “American National Standard Z49.1, Safety in
Welding and Cutting” published by the American
Do not connect generator to a utility electrical dis- Welding Society.
tribution system unless it is isolated from the sys-
tem. Electrical feedback into the distribution American Welding Society
system can occur and could cause personal in- 2501 N.W. 7th Street
jury or death. Miami, Florida 33125
Open and secure main distribution system switch, See “OSHA Safety and Health Standards, 29 CFR
or if the connection is permanent, install a double 1910”, available from U.S. Department of Labor.
throw transfer switch to prevent electrical feed-
back. Some generators are specifically approved U.S. Department of Labor
by a utility to run in parallel with the distribution Washington, D.C. 20210
system and isolation may not be required. Always
check with your utility as to the applicable
circumstances. Reference: Special Instruction, REHS1841, “General
Welding Procedures” for more welding instructions.

Proper Welding Procedure on Machines

and Engines with Electronic Controls
Only persons with training in electrical installa-
tions must carry connections to the generator. Proper precautions are necessary to prevent damage
to electronic controls. When you weld on a machine
The generator must be wired correctly. A fire or with electronic controls, use the steps that follow:
electrocution could result from wiring that is
incorrect. 1. Turn off the engine. Put the key start switch in the
OFF position.
The generator is capable of generating high vol-
tages. Ensure that the generator is not on while 2. If the machine has a battery disconnect switch,
the connections are being made. Follow these open the switch. If the machine does not have a
steps in order to prevent accidental starting: battery disconnect switch, disconnect the negative
battery cable at the battery.
1. Isolate the machine from all external loads and
sources.
3. Connect the ground cable for the welder directly to
2. Shut off the Engine. the actual machine component that will be welded.
Attach the clamp for the ground cable as close as
3. Disconnect the battery supply lines and tape the possible to the area that is being welded. This
leads. connection will reduce the chance of damage from
welding current to the components that follow:
bearings, hydraulic components, and electrical
components.

4
Note: Do NOT use electrical components as a ground Contents of the 463-1177
point for the welder. Do NOT use ground points for Communication Installation Gp
electronic components as a ground point for the
welder. Note: The 463-1177 Communication Installation Gp
includes the necessary hardware for a PL631
4. Protect the wiring harnesses from the weld splatter.
installation on an engine. The PL631 satellite radio
and engine retrofit harnesses are included.
Required Parts for Engines Table 3
Contents of the 463-1177 Communication Installa-
The PL641 and PL631 Product Link devices offer
tion Gp
different varieties of installation, hardware, and
options. There are kit part numbers that can be Quantity Part Number Description
ordered that provide all the part numbers needed for
an installation. This publication contains information Communication In-
1 455-5564
on how to install and utilize PL641 and PL631 stallation Gp
systems. The following installation instructions are for 1 460-5251 Wiring Harness
radio only installations, known as “Pro” . Refer to
Table 1 for information on kit part numbers for retrofit 1 443-8463 Antenna As
and upgrade installation offerings for “Pro” cellular 1 353-8773 Antenna Cable AS
and “Pro” satellite installations on engines. The
harness for engine kits includes shielded CAN/J1939 1 460-5252 Wiring Diagram
wiring.
Table 1
Retrofit Kits and Upgrade Offerings for Engines
Installation Components Not Included in
Kits
Quantity Part Number Description
Table 4
Communication In-
stallation Gp for en- Installation Components Not Included in Kits
1 463-1176
gine “Pro” cellular
Quantity Part Number Description
installations.
Communication In- Bracket Mounting
1 425-5729
stallation Gp for en- Gp
1 463-1177
gine “Pro” satellite
1 443-8462 Antenna As
installations.
1 470-1268 Mounting

Contents of the 463-1176 Harnesses

Communication Installation Gp Optional 425-6889 Cable As

Wiring Harness (1-

Note: The 463-1176 Communication Installation Gp meter radio exten-
Optional (1) 423-7017
includes the necessary hardware for a PL641 sion harness)
installation on an engine. The PL641 cellular radio
and engine retrofit harnesses are included. Wiring Harness (3-
Optional (1) 423-7018 meter radio exten-
Table 2 sion harness)
Contents of the 463-1176 Communication Installa- Wiring Harness (5-
tion Gp Optional (1) 423-7019 meter radio exten-
sion harness)
Quantity Part Number Description
Wiring Harness
Communication In-
1 455-5563 Optional (1) 423-7020 (10-meter radio ex-
stallation Gp
tension harness)
1 460-5251 Wiring Harness
Misc.
1 443-8463 Antenna As Optional 350-3459 Module (Ethernet)
1 353-8773 Antenna Cable AS
Adapter (Ethernet)
Optional 419-5974
1 460-5252 Wiring Diagram six pins

Adapter (Ethernet)
Optional 448-9960
12 pin

(continued)

5
(Table 4, contd)
Installation Components Not Included in Kits

Quantity Part Number Description

Optional 155-2265 Connecting Plug Kit

External Antenna Coax Cable Extensions

Cable As0.7 m
Optional 347-2216 (2.30 ft) (bulkhead,
90 degree, straight)

Cable As0.914 m
Optional 435-6069 (3.00 ft) (bulkhead,
90 degree, straight)

Cable As1.920 m
(6.301 ft) (bulk-
Optional 349-6083
head, 90 degree,
straight)

Cable As2.1 m
Optional 450-2733 (6.89 ft) (bulkhead,
90 degree, straight)
Illustration 1 g03402798
Cable As2.166 m
Optional 447-8016 (7.11 ft) (bulkhead, 425-6889 Cable As (optional service tool)
90 degree, straight)

Cable As2.5 m
Optional 359-4778 (8.20 ft) (bulkhead,
90 degree, straight)

Cable As2.633 m
Optional 375-1382 (8.64 ft) (bulkhead,
90 degree, straight)

Antenna Cable AS
3 m (9.84 ft) (bulk- Illustration 2 g03261220
Optional 373-8970
head, 90 degree, 353-4515 Toggle Switch Gp (radio disable switch)
straight)

Communication Ca-
Optional 476-7003
ble As 15.44 m Required Parts for Machines
(50.66 ft) Cellular /
Satellite Use Only. The PL641 and PL631 Product Link devices offer
different varieties of installation, hardware, and
Communication Ca-
ble As 15.44 m
options. There are kit part numbers that can be
Optional 476-9987 ordered that provide all the part numbers needed for
(50.66 ft) GPS Use
Only. an installation. This publication contains information
on how to install and utilizePL641 and PL631
Radio Disable Switch systems. The following installation instructions are for
1 353-4515 Toggle Switch Gp radio only installations, known as “Pro” . Refer to
Table 5 for information on kit part numbers for retrofit
1 6T-6969 Switch Guard and upgrade installation offerings for “Pro” cellular
1 433-9723 Film and “Pro” satellite installations on machines. The
harness for machine kits includes unshielded CAN/
2 3E-3390 Connector Pins J1939 wiring.
1 102-8803 Receptacle Kit

2 174-0502 Connector Plug As

4 9X-3402 Connector Sockets

(1) Extension Harnesses should be ordered on installation need.

6
Table 5
Retrofit Kits and Upgrade Offerings for Machines Table 7

Quantity Part Number Description Contents of the 467-4162 Communication Installa-

tion Gp
Communication In-
stallation Gp for ma- Quantity Part Number Description
1 467-4162
chine “Pro” satellite
installations. Electronic Control
1 442-7199
Module
Communication In-
stallation Gp for 24v 4 8T-4971 Bolts
1 467-4161
machine “Pro” cellu- 8 9X-8256 Washers
lar installations.
4 129-3178 Locknuts
Communication In-
stallation Gp for 12v 10 7K-1181 Cable Straps
1 480-9645
machine “Elite” cel-
lular installations. 1 433-9722 Film
1 433-9728 Film

Contents of the 467-4161 1 433-9730 Film

Communication Installation Gp 1 443-8463 Antenna As

1 353-8773 Antenna Cable AS

Note: The 467-4161 Communication Installation Gp
includes the necessary hardware for a PL641 cellular 1 452-0543 Wiring Harness
radio installation on a 24v machine. The PL641
1 452-0489 Wiring Diagram
cellular radio, and “Pro” harness for machines is
included.
Table 6
Contents of the 480-9645
Contents of the 467-4161 Communication Installa- Communication Installation Gp
tion Gp

Quantity Part Number Description Note: The 480-9645 Communication Installation Gp

includes the necessary hardware for a PL641 cellular
Electronic Control radio installation on a 12v machine. The PL641
1 440-2105
Module cellular radio, and “Pro” harness for machines is
4 8T-4971 Bolts included.
8 9X-8256 Washers Table 8

4 129-3178 Locknuts Contents of the 480-9645 Communication Installa-

tion Gp
10 7K-1181 Cable Straps
Quantity Part Number Description
1 433-9722 Film
Electronic Control
1 433-9728 Film 1 440-2105
Module
1 433-9730 Film
4 8T-4971 Bolts
1 443-8463 Antenna As
8 9X-8256 Washers
1 353-8773 Antenna Cable AS
4 129-3178 Locknuts
1 452-0543 Wiring Harness
10 7K-1181 Cable Straps
1 452-0489 Wiring Diagram
1 433-9722 Film
1 433-9728 Film

Contents of the 467-4162 1 433-9730 Film

Communication Installation Gp 1 443-8463 Antenna As

1 353-8773 Antenna Cable AS

Note: The 467-4162 Communication Installation Gp
includes the necessary hardware for a PL631 satellite 1 452-0543 Wiring Harness
radio installation on a machine. The PL631 satellite
1 452-0489 Wiring Diagram
radio, and “Pro” harness for machines is included.

7
Installation Components Not Included in (Table 9, contd)
Kits Installation Components Not Included in Kits
Table 9 Quantity Part Number Description
Installation Components Not Included in Kits Cable As2.1 m
Optional 450-2733 (6.89 ft) (bulkhead,
Quantity Part Number Description 90 degree, straight)
Bracket Mounting Cable As2.166 m
1 425-5729
Gp Optional (7.11 ft) (bulkhead,
447-8016
1 443-8462 Antenna As 90 degree, straight)

1 470-1268 Mounting Cable As2.5 m

Optional 359-4778 (8.20 ft)(bulkhead,
Connecting Plug 90 degree, straight)
1 155-2265
Kit
Cable As2.633 m
Control Harness As Optional 375-1382 (8.64 ft) (bulkhead,
Service harness 90 degree, straight)
1 455-0946
forBackhoe
Loaders Antenna Cable AS
3 m (9.84 ft) (bulk-
Harnesses Optional 373-8970
head, 90 degree,
straight)
Optional 425-6889 Cable As
Radio Disable Switch
Wiring Harness (1-
Optional (1) 423-7017 meter radio exten- 1 353-4515 Toggle Switch Gp
sion harness)
1 6T-6969 Switch Guard
Wiring Harness (3-
Optional (1) 423-7018 meter radio exten- 1 433-9723 Film
sion harness) 2 3E-3390 Connector Pins
Wiring Harness (5- 1 102-8803 Receptacle Kit
Optional (1) 423-7019 meter radio exten-
sion harness) 2 174-0502 Connector Plug As

Wiring Harness 4 9X-3402 Connector Sockets

Optional (1) 423-7020 (10-meter radio ex- (1) Extension Harnesses should be ordered on installation need.
tension harness)

Misc.
Optional 350-3459 Module (Ethernet)

Adapter (Ethernet)
six pins for flashing
Optional 419-5974 factory installed-
Product Link on
Skid Steers
Adapter (Ethernet)
Optional 448-9960
12 pin

Antenna Removal
Optional 468-1897
Tool
External Antenna Coax Cable Extensions
Cable As0.7 m
Optional 347-2216 (2.30 ft) (bulkhead,
90 degree, straight)

Cable As0.914 m
Optional 435-6069 (3.00 ft) (bulkhead,
90 degree, straight)

Cable As1.920 m Illustration 3 g03402798

(6.301 ft) (bulk-
Optional 349-6083 425-6889 Cable As (optional service tool)
head, 90 degree,
straight)
Note: The 305-5528 Wiring Harness (optional
service tool) will also work for servicing this product
over ethernet.
(continued)

8
Illustration 4 g03261220
353-4515 Toggle Switch Gp (radio disable switch)

9
Block Diagram and System
Components

Illustration 5 g03731030

10
Illustration 6 g03731029

Mounting the PL641 Cellular Radio • When installing a cellular radio with external
antenna, ensure the external antenna, is mounted
PL641 Mounting Requirements a minimum of 203.2 mm (8 inch) away from any
metal structures that extend above the mounting
• When using the PL641 radio with internal plane. Any metal obstruction for the radio will
antenna, the radio must be mounted in a horizontal create diminished cellular and GPS connectivity.
orientation.
• When using the PL641 radio with external
• When using the PL641 radio with internal antenna, the external antenna must be mounted in
antenna, the radio must be located more than a horizontal orientation.
200 mm (7.87 inch) from the machine operator to
• The radio or antenna needs to have a clear line of
comply with FCC regulations for RF human body
sight of the sky. Usually, the canopy/container roof
safety.
will provide an optimal view of the sky with minimal
• When using the PL641 radio with an external blockages.
antenna, the antenna must be located more than
• To utilize the GPS Signal, the cellular radio or
200 mm (7.87 inch) from the machine operator to
antenna may be mounted under a non-metallic
comply with FCC regulations for RF human body
cover, but not a metallic one.
safety.

11
• Do not mount the radio or antenna in an area that Warning Film Installation
will expose the radio or antenna to extreme
conditions of heat. Exposure to high heat may
make the radio or antenna inoperable. Refer to
Table 10 .
• The maximum torque for the radio mounting bolts
is 3.5 N·m (2.581 lb ft).
• Locate the radio and antenna so that the radio and
antenna connectors are not exposed to high-
pressure spray or underwater immersion.
Exposure to high-pressure spray or underwater
immersion may compromise the connector seals
and lead to connection failure.
• Keep a distance of no less than 500 mm
(19.68 inch) between the radio and other antennas
that transmit a radio signal. The lists of radio
antennas to maintain a distance from include the
citizen band radio, data radio, and commercial
communication radios.
• Keep in mind the routing of the radio and antenna
cable. Route the cable such that the cable is not Illustration 7 g03356592
subject to abrasion or pinching. Do not route the Film
cable near any source of extreme heat (exhaust).
Do not mount the cable so that the limitations of Install the warning film in Illustration 13 in a location
temperature −40° C (−40.00° F) and 85° C such as the dash or control panel. Ensure that the
(185.00° F) are exceeded. warning film is clearly visible to the operator during
the normal operation of the equipment.
• The coax wiring between the Product Link radio
and the external antenna cannot exceed 4.5 m
(14.76 ft).

• Route the coax antenna cable with a minimum This equipment is equipped with a Cat® Product
bend radius of 49.5 mm (1.94 inch). Bend radius Link communication device. When electric deto-
depends on the type of cable used. Do not bend nators are being used for blasting operations, ra-
the radius any less than ten times the diameter of dio frequency devices can cause interference
the cable. with electric detonators for blasting operations
which can result in serious injury or death. The
Product Link communication device should be
PL641 Environmental Information deactivated within the distance mandated under
Table 10
all applicable national or local regulatory require-
ments. In the absence of any regulatory require-
PL641 Environmental Information Table ments Caterpillar recommends the end user
Parameter Specification perform their own risk assessment to determine
safe operating distance.
−30° C (−22.00° F) to 70° C
Operating Temperature Range (158.00° F) (reduced perform-
ance to 85° C (185.00° F)) The blast site is defined as the area that handles
G
9.8 rms (0.343 oz)
explosive material during loading. Included is the
Vibration
perimeter that is formed by the loaded blast holes.
34.5 ± 3.5 kPa
Sealing If required, the following are suggested methods to
(5.003 ± 0.507 psi)
disable the Caterpillar Product Link communication
Operating Voltage 9 VDC to 32 VDC device:
Jump-Start Voltage 32 VDC to 48 VDC
• Turn theProduct Link radio disable switch to the
Non-Destructive Voltage Range -32 VDC to 180 VDC OFF position.

• Disconnect the Caterpillar Product Link

communication device from the main power
source. This action is performed by disconnecting
the wiring harness at the Product Link radio.

12
Note: If no radio disable switch is installed and the Table 11
equipment will be operating near a blast zone, a radio PL641 Radio 12 Pin Connector
disable switch may be installed. The switch will allow
the Caterpillar Product Link communication device to Pin Location Function
be shut off by the operator from the equipment control Pin 1 Battery Positive
panel. Refer to Special Instruction, REHS7339,
Special Instruction, REHS8850, Special Instruction, Pin 2 Battery Negative
REHS9111, and Special Instruction, REHS9757 for Key Switch
Pin 3
more details and installation instructions.
Pin 4 Backup Battery

Installing the PL641 Pin 5 Ethernet TXD Positive

Pin 6 Ethernet TXD Negative

Pin 7 Ethernet RXD Positive

Pin 8 Ethernet RXD Negative

Pin 9 Wake Up

Pin 10 Ethernet Shield

Pin 11 CAN / J1939 Positive

Pin 12 CAN / J1939 Negative

Table 12
PL641 Radio 8 Pin Connector
Pin Location Function

Pin 1 Digital Input 1

Pin 2 Digital Input 2

Pin 3

Pin 4 Digital Input 4

Pin 5 R-Term
Illustration 8 g03582252
440-2104 Electronic Control Module (PL641 Cellular radio with Pin 6
internal antenna) Pin 7

Pin 8 Digital Input 3

Illustration 9 g03582255
440-2105 Electronic Control Module (PL641 Cellular radio with
external antenna)

13
 Note: Ensure that mounting location does not violate
“Environmental Standards” from Table 10 .
Note: Installations of the adhesive mount external
antenna will have difficulty acquiring the proper
adhesive properties when both the antenna and the
mounting surface are below certain temperatures. For
installations on a metal surface, temperatures under
−6.67° C (20° F) will cause improper adhesion. For
installations on a non-metallic surface, temperatures
under −1.11° C (30° F) will cause improper adhesion.
Increase the temperature of the adhesive mount
external antenna, and the mounting surface prior to
installation if necessary. Apply direct force until the
adhesive mount antenna can hold on its own. Full
adhesion can take over 24 hours in colder climate.
1. Place the radio in the desired mounting location.
Lay out the necessary hole pattern, keeping in
mind the harness must extend outward from the
radio.

Illustration 10 g03582550
Note: Refer to “PL641 Mounting Requirements, and
PL641” when considering the desired mounting
443-8463 Antenna As (Adhesive mount external antenna for
cellular and satellite radios)
location.
2. Lay out the necessary hole pattern.

3. Drill the holes.

4. Install the required bolts, washers, and locknuts to
secure the radio.
5. Tighten the mounting bolts for the radio to 3.5 N·m
(2.581 lb ft).

Note: Do not connect the radio now.

6. Locate a clean dry location where the external
antenna can be mounted horizontally with clear line
of site to the sky.

Note: Ensure that the cable length of the external

antenna is long enough to reach to the mounted
location of the PL641 cellular radio.
7. Install the antenna. For the adhesive mount
antenna, refer to Step 7.a. For the hard mount
antenna, refer to Step 7.b.

Illustration 11 g03725986 a. Remove the adhesive cover tab on the back of

443-8462 Antenna As (Hard mount external antenna for cellular
the 443-8463 Antenna As. This will expose the
and satellite radios) adhesive mounting surface of the external
antenna. Apply the adhesive surface to the
Mounting a Cellular Radio Without a Mounting previously chosen clean dry surface.
Bracket
b. Locate and drill a 19 mm (0.75inch) hole for the
Table 13 443-8463 Antenna As. Install the antenna with
Parts Required for Mounting a Cellular Radio Without the provided hardware.
a Mounting Bracket
Note: For antennas requiring an isolation mount
Quantity Part Number Description refer to “Isolated Hard Mount Antenna Installation”.
4 8T-4971 Bolts 8. Route the external antenna cables back to the
location of the PL641 cellular radio. Connect the
8 9X-8256 Washers coax cables to the external antenna and the PL641
4 129-3178 Locknuts
cellular radio.

14
9. When using a dual-mode external antenna, that
has cellular and satellite connections, it is possible
to connect the antenna backwards. Ensure that the
coax cable with the image of the cellular tower is
connected to the cellular radio. The coax wire color
will be brown for cellular and white for satellite. If
the external antenna is hooked up incorrectly, an
event will become active.

Mounting the Cellular Radio With Optional 425-5729 Bracket Mounting Gp

Illustration 12 g03531602
425-5729 Bracket Mounting Gp

Note: Ensure that mounting location does not violate Note: Installations of the adhesive mount external
“Environmental Standards” from Table 10 . antenna will have difficulty acquiring the proper
adhesive properties when both the antenna and the
Table 14
mounting surface are below certain temperatures. For
Parts Required for Mounting a Cellular Radio with installations on a metal surface, temperatures under
Mounting Bracket −6.67° C (20° F) will cause improper adhesion. For
installations on a non-metallic surface, temperatures
Quantity Part Number Description
under −1.11° C (30° F) will cause improper adhesion.
8 3E-9865 Locknut Increase the temperature of the adhesive mount
external antenna, and the mounting surface prior to
4 7C-6121 Flexible Mount
installation if necessary. Apply direct force until the
8 8T-4205 Hard Washer adhesive mount antenna can hold on its own. Full
1 449-8062 Plate As
adhesion can take over 24 hours in colder climate.

1 449-8063 Bracket 1. Place the mounting bracket in the desired

mounting location. Lay out the necessary holes.

2. Lay out the necessary hole pattern.

3. Drill the holes.

4. Mount the 425-5729 Bracket Mounting Gp.

15
 5. Install the required bolts, washers, and locknuts to • Ensure the external antenna, is mounted a
secure the radio. minimum of 203.2 mm (8 inch) away from any
metal structures that extend above the mounting
6. Tighten the mounting bolts for the radio to 3.5 N·m plane. Any metal obstruction for the radio will
(2.581 lb ft). create diminished satellite and GPS connectivity.
Note: Do not connect the radio now. • Ensure the external antenna, is located more than
7. Locate a clean dry location where the external 200 mm (7.87 inch) from the machine operator to
antenna can be mounted horizontally with clear line comply with FCC regulations for RF human body
of site to the sky. safety.

Note: Ensure that the cable length of the external • To utilize the GPS Signal, the antenna may be
antenna is long enough to reach to the mounted mounted under a non-metallic cover, but not a
location of the PL641 cellular radio. metallic one.

8. Install the antenna. For the adhesive mount • Do not mount the radio or antenna in an area that
antenna, refer to Step 8.a. For the hard mount will expose the radio or antenna to extreme
antenna, refer to Step 8.b. conditions of heat. Exposure to high heat may
make the radio or antenna inoperable. Refer to
a. Remove the adhesive cover tab on the back of Table 15 .
the 443-8463 Antenna As. This will expose the
adhesive mounting surface of the external • The maximum torque for the radio mounting bolts
antenna. Apply the adhesive surface to the is 3.5 N·m (2.581 lb ft).
previously chosen clean dry surface.
• Locate the radio and antenna so that the radio and
b. Locate and drill a 19 mm (0.75inch) hole for the antenna connectors are not exposed to high-
443-8463 Antenna As. Install the antenna with pressure spray or underwater immersion.
the provided hardware. Exposure to high-pressure spray or underwater
immersion may compromise the connector seals
Note: For antennas requiring an isolation mount and lead to connection failure.
refer to “Isolated Hard Mount Antenna Installation”.
• Keep a distance of no less than 500 mm
9. Route the external antenna cables back to the (19.68 inch) between the radio and other antennas
location of the PL641 cellular radio. Connect the that transmit a radio signal. The lists of radio
coax cables to the external antenna and the PL641 antennas to maintain a distance from include the
cellular radio.
citizen band radio, data radio, and commercial
10. When using a dual-mode external antenna, that communication radios.
has cellular and satellite connections, it is possible
to connect the antenna backwards. Ensure that the • Keep in mind the routing of the radio and antenna
coax cable with the image of the cellular tower is cable. Route the cable such that the cable is not
connected to the cellular radio. The coax wire color subject to abrasion or pinching. Do not route the
will be brown for cellular and white for satellite. If cable near any source of extreme heat (exhaust).
the external antenna is hooked up incorrectly, an Do not mount the cable so that the limitations of
event will become active.
temperature −40° C (−40.00° F) and 85° C
(185.00° F) are exceeded.
Mounting the PL631 Satellite Radio • The coax wiring between the Product Link radio
and the external antenna cannot exceed 4.5 m
PL631 Mounting Requirements (14.76 ft).

Note: When possible, the satellite radio should be • Route the coax antenna cable with a minimum
installed at a time when it has clear line of site to the bend radius of 49.5 mm (1.94 inch). Bend radius
sky. A situation can occur for radios installed indoors, depends on the type of cable used. Do not bend
where several messages can be created before the the radius any less than ten times the diameter of
registration messages, and once the machine is the cable.
moved outside, there can be a significant delay of an
hour or more for the other messages to transmit first
prior to the registration messages being transmitted.
• The antenna must be mounted in a horizontal
orientation to the horizon.

• The antenna must have a clear line of sight of the

sky. Usually, the canopy/container roof usually
provides an optimal view of the sky with minimal
blockages.

16
PL631 Environmental Information
Table 15
This equipment is equipped with a Cat® Product
PL631 Environmental Information Table
Link communication device. When electric deto-
Parameter Specification nators are being used for blasting operations, ra-
dio frequency devices can cause interference
−30° C (−22.00° F) to 70° C with electric detonators for blasting operations
Operating Temperature Range (158.00° F) (reduced perform-
which can result in serious injury or death. The
ance to 85° C (185.00° F))
Product Link communication device should be
Vibration 9.8 Grms (0.343 oz) deactivated within the distance mandated under
all applicable national or local regulatory require-
34.5 ± 3.5 kPa
Sealing ments. In the absence of any regulatory require-
(5.003 ± 0.507 psi)
ments Caterpillar recommends the end user
Operating Voltage 9 VDC to 32 VDC perform their own risk assessment to determine
safe operating distance.
Jump-Start Voltage 32 VDC to 48 VDC

Non-Destructive Voltage Range -32 VDC to 180 VDC

The blast site is defined as the area that handles
explosive material during loading. Included is the
perimeter that is formed by the loaded blast holes.
Warning Film Installation
If required, the following are suggested methods to
disable the Caterpillar Product Link communication
device:
• Turn theProduct Link radio disable switch to the
OFF position.

• Disconnect the Caterpillar Product Link

communication device from the main power
source. This action is performed by disconnecting
the wiring harness at the Product Link radio.
Note: If no radio disable switch is installed and the
equipment will be operating near a blast zone, a radio
disable switch may be installed. The switch will allow
the Caterpillar Product Link communication device to
be shut off by the operator from the equipment control
panel. Refer to Special Instruction, REHS7339,
Special Instruction, REHS8850, Special Instruction,
REHS9111, and Special Instruction, REHS9757 for
more details and installation instructions.

Illustration 13 g03356592
Film

Install the warning film in Illustration 13 in a location

such as the dash or control panel. Ensure that the
warning film is clearly visible to the operator during
the normal operation of the equipment.

17
Installing the PL631 (Table 17, contd)
Pin 6
Pin 7

Pin 8 Digital Input 3

Illustration 14 g03582255
442-7199 Electronic Control Module (PL631 Satellite radio)

Table 16
PL631 Radio 12 Pin Connector
Illustration 15 g03582550
Pin Location Function 443-8463 Antenna As ( Adhesive mount external antenna for
cellular and satellite radios)
Pin 1 Battery Positive

Pin 2 Battery Negative

Pin 3 Key Switch

Pin 4 Backup Battery

Pin 5 Ethernet TXD Positive

Pin 6 Ethernet TXD Negative

Pin 7 Ethernet RXD Positive

Pin 8 Ethernet RXD Negative

Pin 9 Wake Up

Pin 10 Ethernet Shield

Pin 11 CAN / J1939 Positive

Pin 12 CAN / J1939 Negative

Table 17
PL631 Radio 8 Pin Connector
Pin Location Function
Illustration 16 g03725986
Pin 1 Digital Input 1
443-8462 Antenna As (Hard mount external antenna for cellular
Pin 2 Digital Input 2 and satellite radios)

Pin 3

Pin 4 Digital Input 4

Pin 5 R-Term

(continued)

18
Mounting a Satellite Radio Without a Mounting
Bracket a. Remove the adhesive cover tab on the back of
the 443-8463 Antenna As. This will expose the
Table 18 adhesive mounting surface of the external
Parts Required for Mounting a Satellite Radio Without antenna. Apply the adhesive surface to the
a Mounting Bracket previously chosen clean dry surface.
Quantity Part Number Description b. Locate and drill a 19 mm (0.75inch) hole for the
4 8T-4971 Bolts 443-8463 Antenna As. Install the antenna with
the provided hardware.
8 9X-8256 Washers
4 129-3178 Locknuts Note: For antennas requiring an isolation mount
refer to “Isolated Hard Mount Antenna Installation”.
Note: Ensure that mounting location does not violate 8. Route the external antenna cables back to the
“Environmental Standards” from Table 13 . location of the PL631 satellite radio. Connect the
coax cables to the external antenna and the PL631
Note: Installations of the adhesive mount external satellite radio.
antenna will have difficulty acquiring the proper 9. When using a dual-mode external antenna, that
adhesive properties when both the antenna and the has cellular and satellite connections, it is possible
mounting surface are below certain temperatures. For to connect the antenna backwards. The coax wire
installations on a metal surface, temperatures under color will be brown for cellular and white for
−6.67° C (20° F) will cause improper adhesion. For satellite. If the external antenna is hooked up
installations on a non-metallic surface, temperatures incorrectly, an event will become active.
under −1.11° C (30° F) will cause improper adhesion.
Increase the temperature of the adhesive mount
external antenna, and the mounting surface prior to
installation if necessary. Apply direct force until the
adhesive mount antenna can hold on its own. Full
adhesion can take over 24 hours in colder climate.
1. Place the radio in the desired mounting location.
Lay out the necessary hole pattern, keeping in
mind the harness must extend outward from the
radio.

Note: Refer to “PL631 Mounting Requirements, and

PL631” when considering the desired mounting
location.
2. Lay out the necessary hole pattern.

3. Drill the holes.

4. Install the required bolts, washers, and locknuts to
secure the radio.
5. Tighten the mounting bolts for the radio to 3.5 N·m
(2.581 lb ft).

Note: Do not connect the radio now.

6. Locate a clean dry location where the external
antenna can be mounted. The external antenna for
the PL631 satellite radio must be located with a
clear line of site to the sky to communicate.
Note: Ensure that the cable length of the external
antenna is long enough to reach to the mounted
location of the PL631 satellite radio.
7. Install the antenna. For the adhesive mount
antenna, refer to Step 7.a. For the hard mount
antenna, refer to Step 7.b.

19
Mounting the Satellite Radio With Optional 425-5729 Bracket Mounting Gp

Illustration 17 g03531602
425-5729 Bracket Mounting Gp

Note: Ensure that mounting location does not violate 1. Place the mounting bracket in the desired
“Environmental Standards” from Table 15 . mounting location. Lay out the necessary holes.
Table 19 Note: Refer to “PL631 Mounting Requirements, and
Parts Required for Mounting a Satellite Radio with PL631” when considering the desired mounting
Mounting Bracket location.
Quantity Part Number Description 2. Lay out the necessary hole pattern.
8 3E-9865 Locknut 3. Drill the holes.
4 7C-6121 Flexible Mount
4. Mount the 425-5729 Bracket Mounting Gp.
8 8T-4205 Hard Washer
5. Install the required bolts, washers, and locknuts to
1 449-8062 Plate As
secure the radio.
1 449-8063 Bracket
6. Tighten the mounting bolts for the radio to 3.5 N·m
(2.581 lb ft).
Note: Installations of the adhesive mount external
antenna will have difficulty acquiring the proper Note: Do not connect the radio now.
adhesive properties when both the antenna and the
mounting surface are below certain temperatures. For 7. Locate a clean dry location where the external
installations on a metal surface, temperatures under antenna can be mounted. The external antenna for
the PL631 satellite radio must be located with a
−6.67° C (20° F) will cause improper adhesion. For clear line of site to the sky to communicate.
installations on a non-metallic surface, temperatures
under −1.11° C (30° F) will cause improper adhesion. Note: Ensure that the cable length of the external
Increase the temperature of the adhesive mount antenna is long enough to reach to the mounted
external antenna, and the mounting surface prior to location of the PL631 satellite radio.
installation if necessary. Apply direct force until the
adhesive mount antenna can hold on its own. Full 8. Install the antenna. For the adhesive mount
adhesion can take over 24 hours in colder climate. antenna, refer to Step 8.a. For the hard mount
antenna, refer to Step 8.b.

20
 4. Install the plastic washer, new flat steel washer,
a. Remove the adhesive cover tab on the back of and the retained nut from Step 1 in that order.
the 443-8463 Antenna As. This will expose the Tighten nut to 5 N·m (44.25 lb in).
adhesive mounting surface of the external
antenna. Apply the adhesive surface to the
previously chosen clean dry surface. Connect the Harness to the Radio
b. Locate and drill a 19 mm (0.75inch) hole for the
443-8463 Antenna As. Install the antenna with
the provided hardware.

Note: For antennas requiring an isolation mount

refer to “Isolated Hard Mount Antenna Installation”.
9. Route the external antenna cables back to the
location of the PL631 satellite radio. Connect the
coax cables to the external antenna and the PL631
satellite radio.
10. When using a dual-mode external antenna, that
has cellular and satellite connections, it is possible
to connect the antenna backwards. The coax wire
color will be brown for cellular and white for
satellite. If the external antenna is hooked up
incorrectly, an event will become active.

Isolated Hard Mount Antenna Installation

Use the following Steps when there is a need to
install the 470-1268 Mounting. Illustration 19 g03730732

1. Remove the nut and star washer from the antenna The 460-5251 Wiring Harness is required for a “Pro” installation
assembly. Retain the nut and discard the star on an engine.
washer.

Illustration 20 g03730752

Illustration 18 g03822786 The 452-0543 Wiring Harness is required for a “Pro” installation
on a machine.
2. Place the plastic mounting plate on the bottom of
the antenna. Verify that the rubber gasket is on the For a full electrical schematic of the system, refer to
bottom of the mounting plate. Schematic, UENR6000, “Product Link TM PLE601,
PLE631 and PLE641,, PL631 and PL641 Electrical
3. Place the antenna through the previously drilled System”.
hole.

21
Note: When not using the eight-pin connector on the Note: For installing the PL641 or PL631 Product Link
radio for R-Term or the digital switches, the connector hardware on a piece of equipment that already has a
can be plugged with one 155-2265 Connecting Plug Product Link device, refer to “Replacing Legacy
Kit and eight 8T-8737 Seal Plugs. Product Link Systems” and “Wiring to Product Link
Ready and Legacy Equipment”.

Harness Installation The standard harness for machine installation is part

number 452-0543 Wiring Harness.
Table 20
The standard harness for engine installation is part
Harness Table
number 460-5250 Wiring Harness.
Quantity Part Number Description
Recommended wire splicing practices should be
Wiring Harness followed for any of the harness splices.
Required for “Pro” in-
1 452-0543
stallation on If using the R Terminal wiring with the 452-0543
machines. Wiring Harness, the 452-0543 Wiring Harness will
Wiring Harness need to be modified. Use the following Steps for
1 460-5251 Required for “Pro” in- 452-0543 Wiring Harness modifications:
stallation on engines.
1. On the 452-0543 Wiring Harness, remove the
three wires from the 12-pin connector that only has
Connect the Retrofit Installation three wires.
Harnesses to the PL641 Cellular Radio 2. Install the removed wires into the optional
and PL631 Satellite Radio 155-2265 Connecting Plug Kit.

Note: Ensure that the equipment power is OFF, and a. Install the403-GN(Green)into position five.
the battery disconnect is engaged when installing
harnesses. b. Install the893-GN(Green)into position six.

c. Install the892-BR(Brown)into position seven.

3. Connect the 155-2265 Connecting Plug Kit into

the radio.
4. Connect the R-Terminal wire from the harness to
the 403-GN(Green)R-Terminal wire from the
equipment if one is provided.
If there is not an R Terminal wire provided, add the
terminal to the equipment to record engine starts and
engine stops. The voltage provided to the PL641 or
the PL631 on the R Terminal circuit needs to have
system voltage when the engine is running. Often this
voltage can be provided from the alternator.
If engine start and engine stops are not being
recorded properly from the machine, measure voltage
on the R Terminal wire.
If the input signal is a DC voltage, a minimum of 9V is
required to detect engine running status properly on a
12V machine. On a 24V machine a minimum of 18V
Illustration 21 g03730806
is required to detect engine running status. If the input
signal is a square wave, a minimum frequency of
Connect the 12-pin connector to the chosen radio. 50Hz is required to detect engine running status.
Refer to Illustration 21.

Wire to the Equipment

Note: Ensure that the equipment power is OFF, and
the battery disconnect is engaged when installing
harnesses.

22
Most alternators have two terminals that provide
signals that can be used as an R- Terminal input to
the PL641 or the PL631. A D+ Terminal usually
provides a DC voltage at or slightly higher than the
battery system voltage. A W- Terminal usually
provides a square wave signal that goes from 0V to
the battery system voltage or slightly higher. The
frequency of the signal on the W- Terminal will vary
with engine RPM. When the engine is idling, the
frequency of the W- Terminal signal must be at least
50Hz for the PL641 or the PL631 to detect engine
running status.

Illustration 23 g03791813
Splice end of the 452-0543 Wiring Harness for machines.

Table 21
452-0543 Wiring Harness For Machines Splice
Information
Wire Information Description
101-RD(Red) Battery +

200-BK(Black) Battery -

308-YL(Yellow) Switched Power

Illustration 22 g06024626
403-GN(Green) R-Term
If an adequate DC voltage or square wave signal is
not possible to obtain that can be used to indicate 893-GN(Green) CDL +
engine running status, other methods to obtain an 892-BR(Brown) CDL -
adequate DC voltage can be used. For example, a
relay or an oil pressure switch can be added to the F711-YL(Yellow) CAN +
machine to provide a source of battery voltage to the
F712-GN(Green) CAN -
R- Terminal input of the PL641 or the PL631.
The oil pressure switch-on many engines acts as a
switch-to-ground and cannot be used as an R-
Terminal input. If the existing oil pressure switch does
not provide a source of battery voltage when the
engine is running, a second oil pressure switch can
be added to provide battery voltage to the W-
Terminal input of the PL641 or the PL631 when the
engine is running. Refer to Table 24 for some
examples of recommended pressure switches.
Note: When installing the relay, a controlling voltage
that is only active when the engine is running must be
used.
Recommended wire splicing practices should be
followed for any of the harness splices.

Note: Use proper application and installation guide,

and schematic of equipment to determine the best
place to splice wires for installation.

23
 J1939 Communications Wiring
Requirements
The J1939 communications connection provides a
connection between the PL641 cellular radio or the
PL631 satellite radio and the CAN/J1939 datalink on
the equipment being install on. The J1939 network
contains a bus along with wiring to connect the nodes
to the bus. The bus is terminated on each end to
complete the network. Table 23 shows the
parameters for the J1939 network.

The 452-0543 Wiring Harness for machine

installations uses unshielded CAN / J1939 wiring.

The 460-5251 Wiring Harness for engine

installations uses shielded CAN / J1939 wiring.
Note: When connecting the J1939 / CAN wires from
the Product Link device to the piece of equipment,
ensure that the wires are connected to the CAN 1 /
Local CAN wires on the equipment. Some pieces of
Illustration 24 g03788636 equipment will have other connections labeled CAN 2
Splice end of the 460-5251 Wiring Harness for engines. / Global CAN. If the Product Link device is connected
to the wrong CAN connection, the proper data will not
Table 22 be recorded and sent to the user interface.
460-5251 Wiring Harness For Engines Splice Table 23
Information
J1939 Port Characteristics
Wire Information Description
Value
101-RD(Red) Battery +
Shielded (SAE Unshielded
200-BK(Black) Battery - Parameter J1939 -11) (SAE J1939 -15)
308-YL(Yellow) Switched Power Maximum Nodes (n) 30 10
403-GN(Green) R-Term Maximum length of
40 m (131.23 ft)
the Bus (L
893-GN(Green) CDL +
Maximum length of
892-BR(Brown) CDL - 1 m (3.28 ft) 3 m (9.84 ft)
the Stub Wire (S)
F711-YL(Yellow) CAN + Node Distance (d) 0.1 m (0.328 ft) to 40 m (131.23 ft)
F712-GN(Green) CAN - Minimum Distance to
201 Shield-BK(Black) CAN Shield Terminating Resistor 0.0 m (0.000 ft)
(d)

Terminating Resistors 120 Ohm, 0.4 W

Note: Use proper application and installation guide,
and schematic of equipment of installation to
determine the best place to splice wires for
installation.
J1939 Network Connection Group

The J1939 network connection group provides a

standard “CAN” bus connection operating at a
250,000 baud rate. The J1939 network connection
group must be connected to allow the PL641 and
PL631 radios to communicate with the equipment
over the CAN/J1939 data link. Reference the “J1939
Communications Wiring Requirements” section for
specific wiring requirements. When connecting to the
J1939 datalink on the machine or engine, connect to
the CAN 1 port of the machine or engine.

24
J1939 Port Characteristics

Illustration 25 g01157211
Typical J1939 communications network layout

Turn the Equipment Power ON Perform the following procedure to flash the radio.
The radio is flashed to upgrade the software. Flash
Note: To avoid possible registration issues, do not programming of the radio must also be done if the
apply power to the system until all hardware has been radio has been replaced. The Cat Electronic
installed and all electrical connections are made. Technician (Cat ET) contains the program WinFlash.
WinFlash is used to load software into the radio. The
Once the radio has been connected, and the wires following procedure is used to flash software into the
from the retrofit harness for battery positive, battery radio.
negative, and key switch power have been properly
connected to the equipment, turn on the power to the 1. Connect the 425-6889 Cable As to the laptop and
equipment. 9-pin service port connector on the Product Link
harness.

Note: This procedure is only done through the

Flash the PL641 or the PL631 425-6889 Cable As and not a 466-6258
Using Winflash Communication Adapter Gp.

Note: Flash Files are at https://dealer.cat.com/PL in

the “Service Technicians Toolbox” section. a. Open Cat ET.

Note: For radios pre-flashed with 2016A or later

firmware from the factory or Morton parts system,
they should not be flashed backwards to 2015 or
older software. As Product Link continues to update
the operating system, and other software versions on
the Product Link hardware, there are some
backwards compatibility issues. For that reason, any
radios coming pre-flashed with 2016A or newer
versions should not be flashed back to 2015 or older
versions. If you have a situation where you believe
that older software is necessary, submit your situation
through the DSN before flashing backwards.

25
Illustration 26 g03395278

b. Inside “Utilities” select “Preferences” then

“Modify” .

Illustration 27 g03396624

c. Select the “Communications” tab and choose

“Ethernet Direct Connection” .

26
Illustration 28 g03396549

Configuration files can be found on SISweb by

d. The drop-down under “Ethernet Direct searching for the product serial number in the
Connection” will have multiple options based on “Service Software Files” section of SISweb. If you are
the laptop being used. Select the option based unsure of what configuration file you need for a retrofit
on the laptops wired Ethernet connection. installation, your TC can enter a Product Technology
service request through the PSCRM system.
e. Open and use WinFlash to load the software.
Complete the following steps to install the
Note: Typical software flash can take up to 15 configuration file.
minutes, and may appear to stop at 45 percent. The
flash will continue on its own. Actual flash times may 1. Connect to the “Web Configuration” home page
vary. using Cat ET, or the Cat ECM Finder. For
instructions on how to use Cat ET or the Cat ECM
Note: After the flash is complete reset the Finder, refer to “Connect to the Web Configuration
preferences that were changed in Step 1.c. Home Page” in this document.

Upload Configuration File

Note: Not all equipment has a standard Configuration
File. All configuration file part numbers are at https://
dealer.cat.com/PL. If there is not a configuration file
listed for your product, a Configuration File is not
needed.

For equipment that has a configuration file created, it

will be already installed on the product that was built
with a PL641 or PL631 Radio at the factory. A
configuration will need to be installed if one of the
following have been performed.
• Replaced a failed PL641 or PL631 Radio

• Retrofit kit installation

27
Illustration 29 g03824579

2. Once connected to the “Web Configuration” home The Product Link system will automatically send a
page, under the Product Link drop down, select registration message to Product Link Web when
“Upload / Delete Config” . This page allows you to installed on a piece of Caterpillar equipment, if the
upload new config files or delete existing config Product Link device detects a Caterpillar engine on
files. Refer to Illustration 29. the datalink. The Product Link device will send a
registration message to be subscribed in Product Link
Note: Older versions of the PL641 or PL631 Radio Web based on the engine serial number. The PL641
Software, required the technician to type in the full or PL631 system offers the option for the equipment
URL of the “Config Upload” page. Flash the PLE601 to be subscribed under a different name or serial
Network Manager with the latest software, and load number. Use the following steps to change the
the configuration file through the “Service Dashboard” equipment name or serial number.
button.
1. Connect to the equipment service port connector
3. Choose the “Browse” button to upload the
using your Caterpillar Communication Adapter.
configuration file that is already stored on your
computer.
2. Choose the “Telematics ECM” .
4. Select the “Upload” button to upload the
configuration file.
Note: The Radio will need to power cycle before the
configuration file part number is displayed in the
“Product Link Interface” .

Set the Product ID on the Product

Link Device
Note: The Product ID should always be set for
Caterpillar machines. The Product ID should be the
serial number of the prime product. The Product ID
must follow the standard 8-digit Caterpillar serial
number format. For OEM equipment that does not
follow that format, Refer to “Set the Machine Serial
Number on the PL641 or PL631 Radio, PL641, and
PL631”.

28
Illustration 30 g03514804

3. Open the configurations screen by choosing

“Service” and then “Configuration” . Refer to
Illustration 30.

Illustration 31 g03705400

4. The Product ID will show up in the “ECM Note: For Caterpillar machines, it should be the serial
Identification Parameters” and will be a default of number of the machine. For stand alone engines, it
“CAT00000” . In the “New Value” field enter the should be the serial number of the engine. Package
serial number of the equipment. Refer to Illustration serial number should be used for Electric Power
31.
Generators.
The PL641 or PL631 will automatically generate a
new registration message. Along with the new Note: For equipment not appearing in the “Dealer
registration message the equipment will be Services Portal” , verify that the Product Link ECM
subscribed in Product Link Web based off the can be viewed by using a Com Adapter on the
Product ID entered. equipment service port connector. The equipment will
need to be detected on the CAN data link to appear in
the “Dealer Services Portal” .

29
Set the Machine Serial Number on
the PL641 or PL631 Radio
Note: The machine serial number should be set any
time the desired serial number to be seen in the user
interface is not a standard Caterpillar serial number.
The machine serial number is predominantly for OEM
equipment. The machine serial number can be up to
17 characters long, and cannot contain any special
characters.
The Product Link system will automatically send a
registration message to Product Link Web when
installed on a piece of equipment. The Product Link
device will send a registration message to be
subscribed in Product Link Web based on the engine
serial number. The Product Link system offers the
option for the equipment to be subscribed under a
different name or serial number. Use the following
steps to change the equipment name or serial
number:
1. Connect to the equipment service port connector
using your Caterpillar Communication Adapter.

2. Choose the Telematics ECM.

Illustration 32 g03794992

3. Open the configurations screen by choosing

“Service” and then “Configuration” . Refer to
Illustration 32.

30
Illustration 33 g03837279

4. The machine serial number will show up in the Registering Product Link based on
“ECM Identification Parameters” and will not have
a value as default . In the “New Value” field enter Engine Serial Number
the serial number of the equipment. Refer to
Illustration 33. The Product Link device will automatically register
based on the serial number of the engine on the
The PL641 or PL631 Radio will automatically datalink, either CDL or CAN/J1939. The Product Link
generate a new registration message. Along with device must be connected to the datalink in order for
the new registration message, the equipment will
the Product Link device to register based on the serial
be subscribed in the User Interface based off the
machine serial number entered. number of the engine. The engine on the datalink
must be a Caterpillar engine in order for the Product
Note: To reset the machine serial number to its Link device to register based on the engines serial
default value, enter 17 pound signs number. This is an auto detect field only, and cannot
(#################). Users may encounter an be programmed. If the equipment is registered based
error stating that special characters are not allowed, on the engine serial number, the product ID, or
but the reset will be successful. machine serial number can be set remotely from the
“Dealer Services Portal” . If the product ID or machine
serial number are set, they will override any engine
serial number that is detected on the datalink. The
equipment will then be found in “Dealer Services
Portal” based on the product ID or machine serial
number.

31
Registering Product Link based on Green LED OFF – The green LED will be OFF when
there is no power on the battery positive pin or the
Product Link Serial Number key switch is in the OFF position. While the radio is
starting up, the green LED will be OFF, and the yellow
If the product ID and machine serial number are not and orange LEDs will be ON indicating the radio is in
set, and there is not a Caterpillar engine on the startup mode. Startup mode should not occur for
datalink for the Product Link device to register, the more than 30 seconds. Once the radio has properly
Product Link device will send a registration message started up, the green LED should turn ON solid, while
with the Product Link device information. This will the other lights perform other functions. If green LED
allow the user to search the serial number of the does not turn solid on after more than 2 minutes after
Product Link device in the “Dealer Services Portal” , startup, refer to System Operation Testing and
and then set either the product ID, or the machine Adjusting, UENR5824, “Cellular Radio Does Not
serial number remotely. Communicate” or System Operation Testing and
Adjusting, UENR5824, “Satellite Radio Does Not
Communicate” depending on the radio displaying this
symptom.
Setting Hours on the Product Link
Device Green LED Blinking – The green LED will blink
when a fault has been detected that will prevent the
application firmware from running. If the green LED is
To ensure that the Product Link device is reporting blinking, refer to System Operation Testing and
accurate service meter hours values, navigate to the Adjusting, UENR5824, “Cellular Radio Does Not
“Synchronize Service Hour Meters” page within Cat Communicate” or System Operation Testing and
ET and validate that the hours currently set on the Adjusting, UENR5824, “Satellite Radio Does Not
Product Link device are correct. For more Communicate” depending on the radio displaying this
information, refer to UENR5823, Setting Service Hour symptom.
Meters.
Green LED ON – Indicates that the radio is powered
properly and is ON.
Check the LED Lights on the Radio
Orange LED
The purpose of the orange LED is to indicate whether
a GPS fix has been made.
Orange LED OFF – The orange LED will be OFF
when a GPS antenna is not found by the radio. For
radios with an external antenna, check the connection
of the external antenna. If that does not resolve any
issue, refer to System Operation Testing and
Adjusting, UENR5824, “User Interface Does Not
Update GPS Location”.
Orange LED Blinking – The orange LED will have a
constant blinking status when the GPS Antenna is
working properly, however not enough GPS satellites
Illustration 34 g03738018 are viewable to get a good GPS location fix. If a
blinking orange LED persists, ensure that the antenna
The PL641 cellular radio and the PL631 satellite radio has clear line of site to the sky. If that does not resolve
are both equipped with LED Lights that function when any issues, refer to System Operation Testing and
the equipment key switch is turned to the on position. Adjusting, UENR5824, “User Interface Does Not
The LED lights on the radios from left to right are Update GPS Location”.
green, orange, yellow, and blue. Orange LED ON – The GPS Antenna is working
properly, and can see enough GPS satellites to
Green LED determine a good location fix.
The purpose of the green LED is to indicate when the
radio is powered ON or OFF.
Note: When the battery disconnect is turned ON, the
green light will appear for 2 to 3 minutes for radio
power-up, even if key switch power is not present.
The radio will power up, find a GPS location,
determine if a connection needs to be made to the
back office, and shut itself down.

32
Yellow LED blinking. If the blue LED blinks on a regular, continual
basis, and does not appear to be transmitting data
The purpose of the yellow LED is to indicate that a properly, contact the Dealer Solutions Network for
connection to the communication network, either via next steps.
satellite or cellular connection, is being attempted.
This does not indicate that there is an appropriate
signal to make a satellite or cellular connection, only
that the hardware is working properly, and is capable Connect to the Web Configuration
of making a connection given that a signal is present. Home Page
Yellow LED OFF – The yellow LED should be OFF The “Web Configuration” home page is accessed by
when an external antenna is not present or when an
attaching the 425-6889 Cable As to the pro
external antenna has been connected backwards. If
the green LED is ON, and the yellow LED is OFF, harness, and a laptop. Once a connection is made,
refer to System Operation Testing and Adjusting, the user can use the following Steps to access the
UENR5824, “Cellular Radio Does Not Communicate” “Web Configuration” home page.
or System Operation Testing and Adjusting,
UENR5824, “Satellite Radio Does Not Communicate” There are two ways to connect to the “Web
depending on the radio displaying this symptom. Configuration” home page, the first is through the
“Browse Network Devices” option in 2014C or newer
Yellow LED Blinking – The yellow LED will blink Cat ET. The other is through the Cat ECM Finder
when the cellular radio, or satellite radio is trying to
make a connection. If a cellular radio continues to application that can be downloaded from https://
blink for longer than 5 minutes, and is in an area dealer.cat.com/PL.
known to have a good cellular signal, check the
installation of the external antenna if equipped. If that 1. Connect to the Product Link device with the
425-6889 Cable As.
does not resolve the situation, refer to System
Operation Testing and Adjusting, UENR5824, 2. Open Cat ET.
“Cellular Radio Does Not Communicate” or System
Operation Testing and Adjusting, UENR5824,
“Satellite Radio Does Not Communicate” depending
on the radio displaying this symptom. If the satellite
radio has a yellow LED that blinks for greater than 5
minutes, check the installation of the external
antenna. Check that the external antenna has been
connected properly, and has clear line of site to the
sky. Satellite radios can only make a satellite
connection when they have clear line of site to
orbiting satellites. If the situation is not resolved, refer
to System Operation Testing and Adjusting,
UENR5824, “Cellular Radio Does Not Communicate”
or System Operation Testing and Adjusting,
UENR5824, “Satellite Radio Does Not
Communicate”.
Yellow LED ON – The yellow LED will be ON when a
good connection through either cellular or satellite
communication is detected, depending on the radio
type.

Blue LED
The purpose of the blue LED is to determine when
Ethernet or CAN datalinks are present. In the case of
the “Elite” system, the radio will be detecting if it can
see a Network Manager on the Ethernet connection.
In the case of the “Pro” system, the radio will be
detecting if it can see any traffic on the CAN Datalink.
Blue LED OFF – The blue LED will be OFF when no
information is present on the data link. For the “Elite”
system, check the Ethernet wiring from the Network
Manager. or the “Pro” system, check the CAN wiring
that is connected to the equipment being monitored.
Blue LED ON – The blue LED will turn ON when the
radio is receiving data, and will turn OFF when not
receiving data. This should not be confused with

33
Illustration 35 g03795013

3. In the “Utilities” option, select “Browse Product

Network Devices” . Refer to Illustration 35.
4. In the “Network Devices” drop-down menu, select
your laptops wired Ethernet port. This selection
may vary based on operating system and laptop.

Illustration 36 g06154290

5. Detect ECMs on the Ethernet Datalink by using the

“Detect” button. Refer to Illustration 36.

34
Illustration 37 g03794772

6. Once ECMs are detected, select an ECM and then

click the “Launch” button. The “Web Configuration”
home page will launch into your preferred network
browser.
To access the “Web Configuration” home page
through the Cat ECM Finder application, use the
following steps.
Note: The Cat ECM Finder application can be
downloaded from https://dealer.cat.com/PL in the
“Service Technicians Toolbox” link.
1. Open the Cat ECM Finder application.

2. In the “Network Devices” drop-down menu, select

your laptops wired Ethernet port. This selection
may vary based on operating system and laptop.

35
Illustration 38 g06154360

3. Detect ECMs on the Ethernet Datalink by using the

“Detect” button. Refer to Illustration 38.

36
Illustration 39 g03794772

4. Once ECMs are detected, select an ECM and then

click the “Launch” button. The “Web Configuration”
home page will launch into your preferred network
browser.

37
Product Link Interface

Illustration 40 g03824586

The “Product Link Interface” page supplies basic

system information about the Product Link device that
is installed.

38
Connected Devices

Illustration 41 g03824619

The “Connected Devices” section of the Service

Dashboard “Home” screen indicates which devices
are connected properly on the Ethernet port of the
Product Link device. Refer to Illustration 41.

39
Communication Check

Illustration 42 g03703642

Illustration 43 g03703643

The “Communication Check” is an end to end test

that verifies back-office server network. Once the
“Communication Check” link is selected, the test
automatically begins. The test will check end to end
communication for up to 3 minutes. Once the test is
complete, the user will receive a message that the
test passed or failed. Refer to Illustration 42 and
Illustration 43.

40
Download All Service Dashboard Data Perform the Communication Check
Once all the hardware is installed, perform the
“Communication Check” through the Service
Dashboard. If the “Communication Check” is
successful, the Service Dashboard will display
“Communication Successful” icon. A successful
communication check signifies a successful 2-way
communication link between the device and the back-
office network.
If the “Communication Check” fails for error code 22,
the unit is provisioning. Wait 5 minutes, and attempt
another “Communication Check” . If the
“Communication Check” failure for error code 22
persists for greater than 20 minutes, or if it fails for an
error code other than 22, refer to Systems Operation
Troubleshooting Testing and Adjusting, UENR5824,
“Cellular Radio Does Not Communicate, or Satellite
Radio does not Communicate”.

Subscribe the Equipment in the

Illustration 44 g03394916 “ Dealer Services Portal””
The “Download Service Dashboard” link allows you to Note: If a piece of equipment was previously
save all information in the “Service Information subscribed through the VisionLink Store, the
Screen” into a single file. This file is useful when subscription in the VisionLink Store must be
submitting a DSN ticket to Caterpillar for Canceled prior to any subscription being created
troubleshooting purposes. Choose “Save” file, and through the “Dealer Services Portal” .
locate the file in a location you are familiar with.
The PL641 cellular radio or the PL631 satellite radio
is configured automatically for the services selected
Download System Watch in the web-based service management tool in Product
Link Web. Your Caterpillar dealer administrator will be
notified when your device is on-line and ready to have
services enabled. Once the dealer selects the desired
services, the configuration will be sent over the air
and the device will be configured to provide the
proper data at the proper frequency for the service in
the “Control Center” tab of Product Link Web.
Consult with your dealers Product Link specialist for
more details in assisting you for the right data service
to meet your needs. Service starts with basic
equipment management features providing hour,
location monitoring, health, and utilization.

Initial Setup
The Caterpillar dealer administrator:

1. Log in to “Dealer Services Portal” .

Illustration 45 g03394924

The “Download System Watch” link allows you to

save the “System Watch File” which is used for
troubleshooting. Submit this file with any DSN ticket
that is opened. Choose “Save” file, and locate the file
in a location you are familiar with.

41
Illustration 46 g03823699

2. Select “My Worklist” tab. Refer to Illustration 46. For more information refer to https://dealer.cat.com/
PL select (using the Corporate Web Security – CWS
3. Search for the specific asset in the “Search” box, or user name and password). Locate the Product Link
select the “Number of Assets” link associated with Web training for “Energy and Transportation
the appropriate “Work List” queue reason. Systems” , select “Module 7: Dealer Services Portal” .
4. After successfully finding and confirming proper
customer ownership for the asset for which
services are to be assigned, select the desired Optional Inputs and Hardware
application. View the equipment in VisionLink or
Product Link Web. Select the level of service the Digital Inputs
dealer or customer desires. For VisionLink, “Basic”
or “Cat Essentials” is available and the level of
service is the same for the dealer and customer in Note: Any time a Product Link device is replaced, or
VisionLink. For Product Link Web, the service swapped on a piece of equipment, the new Product
levels that are available are “Vitals” , “Aide” (with or Link device will not carry over the same “Digital Input
without “Rapid Reporting” ), and “Advisor” (with or Configurations” . The Digital Input information will
without “Rapid Reporting” ). The dealer level of need resent from the User Interface to the Product
service can be set to a higher level of service than Link Device.
the customer in Product Link Web.
Note: Digital switches can only be configured through
5. When assigning a level of service to an OEM: the User Interface. VisionLink and Product Link Web
• Verify that the information is correct in the both support the configuration of digital switches on
“Equipment Data” section and take note of the the PL641 and the PL631. For more information on
“Make Code” section. how to configure the digital switches from the User
Interface, refer to the Help menus within VisionLink
• In the “Dealer Services Portal” , verify the and Product Link Web.
“Asset Type” (which is an edit-able field on the
yellow ribbon) is the same as the “Make Code”
in the “Equipment Data” section.
The “Make Code” and the “Asset Type” need to be
the same. If the “Asset Type” is not the same,
simply edit the “Asset Type” and then click the
“Sync” button. Once the “Make Code” and the
“Asset Type” are the same, the service level can
be chosen. When the service level is chosen, the
asset will show in the appropriate program,
VisionLink, or Product Link Web.

42
Illustration 47 g03726048
Any circuit can be wired as normally open or normally closed. Examples shown on circuits “1” and “4” .

The PL641 cellular radio provides 4 digital switches to

ground type inputs that can be used for alerting
functions in a Product Link installation. This feature
allows the PL641 to monitor a pressure, temperature,
or level that is not normally provided through the
equipment ECM. The pin positions on the eight-pin
connector of the PL641 cellular radio that supports
digital inputs are “1” , “2” , “4” , and “8” .

Illustration 48 g03726051
Any circuit can be wired as normally open or normally closed. Examples shown on circuits “1” and “4” .

43
The PL631 satellite radio provides four digital
switches to ground type inputs that can be used for
alerting functions in a Product Link installation. This
feature allows the PL631 to monitor a pressure,
temperature, or level that is not normally provided
through the equipment ECM. The pin positions on the
eight-pin connector of the PL631 satellite radio that
supports digital inputs are “1” , “2” , “4” , and “8” .
Table 24 , Table 25 , and Table 26 show common
sensors that can be used to alert on various
pressures, levels, and temperatures.
Table 24
Pressure Switches
Part Number Actuation Pressure Deactuation Port Fitting Connector Type Normal State
Pressure
168-7557 13780 kPa (1998.6 psi) 10335 (±689) kPa 9/16 - 18 THD 2-PIN DT REC NC

140-9669 1206 kPa (174.92 psi) 700 (±103) kPa 3/4 - 16 THD 3-PIN DT REC NC or NO

3E-7675 2550 kPa (369.85 psi) 1800 (±175) kPa 9/16 -18 THD 3-PIN DT REC NC

173-7252 75 kPa (10.88 psi) 35 kPa 9/16 -18 THD 2-PIN DT REC NO

107-0611 93 ± 21 kPa 70 ± 21 kPa 1/8 - 27 NPTF THD 2-PIN DT REC NO

(13.49 ± 3.05 psi) (10.15± 3.05 psi)

3E-2033 640 kPa (92.82 psi) 530 ± 40 kPa 1/4 - 18 NPTF THD 2-PIN DT REC NO
(76.87 ± 5.8 psi)

3E-2026 60 kPa (8.7 psi) 38 ± 20 kPa 1/4 - 18 NPTF THD 2-PIN DT REC NO
(5.5 ± 2.9 psi)

115-7103 93 ± 20.8 kPa 68.9 ± 20.8 kPa 9/16 - 18 NPTF THD 3-PIN DT REC NO or NC
(13.49 ± 3 psi) (10 ± 3 psi)

Table 25
Level Switches
Part Number Connector Type Mounting Rating Mounting Wire Length Normal State
Position Fitting
146-8437 None Top -40-85 1/2 NPT 169 mm NO or NC
(6.6535 inch)

141-0374 DT-3 Side -40-85 1/8 - 27 NPTF 250 mm

(9.8425 inch)

174-1821 NONE Top -40-85 1/8 - 27 NPTF 155 mm NO

(6.1 inch)

1V-2727 NONE Top -40-85 1/8 - 27 NPTF 850 mm NO

(33.46 inch)

7C-6930 NONE Top -40-85 1/8 - 27 NPTF 2250 mm NC

(88.58 inch)

Table 26
Temperature Switches

Part Number Actuation Deactuation Port Fitting Tube Length Connector Normal State
Degrees Degrees
3E-7298 21.11° C (70° F) 12.78° C (55° F) 3/8 -18 NPT 31 mm (1.22 inch) 2-PIN DT REC NC

124-8274 25° C (77° F) 15° C (59° F) 3/4 - 16 STO 17 mm (0.67 inch) 2-PIN DT REC NC

(continued)

44
(Table 26, contd)
Temperature Switches

Part Number Actuation Deactuation Port Fitting Tube Length Connector Normal State
Degrees Degrees
104-7843 38° C (100.4° F) 27° C (80.6° F) M16 X 1.5 STO 28 mm (1.11 inch) 2-PIN DT REC NC

3E-6449 38° C (100.4° F) 27° C (80.6° F) 3/4 - 16 STO 28 mm (1.11 inch) 2-PIN DT REC NC

3E-9350 52° C (125.6° F) 43° C (109.4° F) 3/4 - 16 STO 28 mm (1.11 inch) 2-PIN DT REC NC

155-8998 65° C (149° F) 21.8° C 3/4 - 16 STO 21.8 mm 2-PIN DT REC NO

(71.24° F) (0.858 inch)

3E-6240 65° C (149° F) 57° C (134.6° F) 1/2 - 14 NPT 35 mm 2-PIN DT REC NC

(1.378 inch)

146-1762 68.3° C (155° F) 59.3° C 3/4 - 16 STO 100 mm 2-PIN DT REC NC

(138.74° F) (3.94 inch)

107-4927 82° C (179.6° F) 74° C (165.2° F) 3/4 - 16 STO 28 mm (1.1 inch) 2-PIN DT REC NO

184-7245 92° C (197.6° F) 83° C (181° F) 3/8 - 18 STO 18 mm (0.7 inch) 2-PIN DT REC NO

177-2313 100° C (212° F) 92° C (197.6° F) 3/4 - 16 STO 64.3 mm 2-PIN DT REC NC
(2.53 inch)

131-4135 102° C (215.6° F) 90° C (194° F) 3/4 - 16 STO 18 mm (0.71 inch) 2-PIN DT REC NC

114-9235 107° C (224.6° F) 97° C (206.6° F) 1/2-14 NPT 28 mm (1.1 inch) 2-PIN DT REC NO

3E-6451 107° C (224.6° F) 93° C (199.4° F) 3/4 - 16 STO 28 mm (1.1 inch) 2-PIN DT REC NC

118-5144 107° C (224.6° F) 95° C (203° F) 3/4 - 16 STO 18 mm (0.71 inch) 2-PIN DT REC NO

3E-2028 107° C (224.6° F) 93° C (199.4° F) 3/8 -18 NPT 31 mm (1.22 inch) 2-PIN DT REC NC

3E-7504 107° C (224.6° F) 98° C (208.4° F) 3/4 - 16 STO 28 mm (1.1 inch) 2-PIN DT REC NO

111-3194 108° C (226.4° F) 100° C (212° F) 1/2 - 14 NPT 28 mm (1.1 inch) 2-PIN DT REC NO

130-5453 110° C (230° F) 102° C (215.6° F) 3/4 - 16 STO 18 mm (0.71 inch) 2-PIN DT REC NC

130-3015 110° C (230° F) 96° C (204.8° F) 3/4 - 16 STO 18 mm (0.71 inch) 2-PIN DT REC NC

177-2314 115° C (239° F) 106° C (222.8° F) 3/4 - 16 STO 64.3 mm 2-PIN DT REC NC
(2.53 inch)

113-8240 115° C (239° F) 106° C (222.8° F) 3/4 - 16 STO 28 mm (1.1 inch) 2-PIN DT REC NC

155-8999 124° C (255° F) 117° C (242.6° F) 3/4 - 16 STO 64.3 mm 2-PIN DT REC NC
(2.53 inch)

9X-5602 125° C (257° F) 117° C (242.6° F) 3/4 - 16 STO 64.3 mm 2-PIN DT REC NO
(2.53 inch)

104-3007 129° C (264° F) 112° C (233.6° F) 3/4 - 16 STO 28 mm (1.1 inch) 2-PIN DT REC NO

3E-6453 129° C (264° F) 118° C (244.4° F) 3/4 - 16 STO 28 mm (1.1 inch) 2-PIN DT REC NC

149-8292 −0.5° C (31.1° F) −1.7° C -15.25 17.3 mm 3-PIN DT REC NO

(28.94° F) (0.68 inch)

139-6826 65° C (149° F) 56° C (132.8° F) 3/4 - 18 THD 100 mm 3-PIN DT REC NC
(3.94 inch)

Radio Disable Switch (Optional) Installation Procedure

The Radio Disable switch is used to disable power to Note: Ensure that power is disconnected from the
the cellular or satellite radio when transmitting a radio battery during the beginning steps of the installation.
signal is not desired.
1. Place the main disconnect in the OFF position.

45
 a. For installations using the 460-5251 Wiring b. Install the wires with the 9X-3402 Connector
Harness, continue to Step 5. Socket into positions “B” and “C” in one
174-0502 Connector Plug As.
b. For installations using the 452-0543 Wiring
Harness or another installation harness not c. Install the wires with the 3E-3390 Connector
utilizing a three-pin connector for the radio Pin into positions “B” and “C” in one 102-8803
disable switch, continue to Step 2. Receptacle Kit.

2. Cut the 101-RD(Red)wire right before the d. Route and plug the newly created jumper
452-0543 Wiring Harness plugs into the radio. harness into the 353-4515 Toggle Switch Gp
and three-pin radio disable switch connectors on
3. Put one 9X-3402 Connector Socket onto each the harness.
end of the 101-RD(Red)wire that was cut.
9. Install the 6T-6969 Switch Guard over the switch.
4. Put each end of the 101-RD(Red)wire into position
“B” and “C” on the 174-0502 Connector Plug As. 10. Place the main disconnect switch in the ON
position.
5. Determine a suitable location for the radio disable
switch near the operator station or at ground level 11. Turn the key switch to the ON position.
that can easily be reached.
12. Verify that the radio is ON.

13. Move the Radio Disable switch to the OFF position.

14. Verify that the radio is OFF.

15. Return the Radio Disable switch to the ON position.

Operation

To use the radio disable switch, perform the following

steps:

1. Raise the Switch Guard.

2. Place the switch in the OFF position.

3. Return the switch to the ON position when

conditions are appropriate.

4. Lower the Switch Guard to protect the switch.

Illustration 49 g03270016 Device Replacement, Device Swap,

6. Drill pattern template for the 353-4515 Toggle Dual-Mode Upgrade, Device
Switch Gp (radio disable switch). Upgrade, and Device Downgrade
7. Mount the 353-4515 Toggle Switch Gp (radio for the PL641 and PL631 Systems
disable switch) in a convenient location. Place the
433-9723 Film near the switch. PL641 Cellular Radio and PL631 Satellite
8. Plug the 353-4515 Toggle Switch Gp into the Radio Replacement
174-0502 Connector Plug As that came installed
on the harness or was installed on the harness in Note: If the steps for the radio replacement are not
the previous steps. If the 174-0502 Connector followed properly, subscription services in the Dealer
Plug As does not reach the 353-4515 Toggle Services Portal can be canceled.
Switch Gp, continue to Step 8.a to create a jumper
harness. 1. Remove the radio from the installation.

a. Determine the distance needed between the 2. If the replacement radio is a swap, set the Product
harness and the 353-4515 Toggle Switch Gp. ID on the radio back to default value of “CAT00000”
. Refer to Special Instruction, REHS9111, “Set the
Get two lengths of electrical wire at the distance Product ID on the Product Link Device”.
needed. Install one 9X-3402 Connector Socket
and one 3E-3390 Connector Pin on the end of 3. Install the replacement radio.
each wire.

46
4. Set the Product ID on the replacement radio to the 4. To connect the “Pro” harness directly to the
Prime Product serial number. Refer to Special equipment, refer to Special Instruction, REHS9111,
Instruction, REHS9111, “Set the Product ID on the “Installation Procedure for the Pro Product Link®
Product Link Device”. PL641 and PL631 Systems”
Note: There is no need to resubscribe the asset, as 5. Connect the radio to the equipment.
the device will download all necessary parameters
from the back-office. The configurations for digital 6. Set the Product ID on the Radio to the highest level
switches will also be carried over, as long as the Caterpillar serial number. Refer to Special
device is a like-to-like replacement (PL641 to PL641 Instruction, REHS9111, “Set the Product ID on the
or PL631 to PL631 replacement). Product Link Device”.
7. Edit the subscription on the asset if desired. There
is no need to resubscribe the asset as the device
Dual-Mode Upgrade will download all necessary parameters from the
back office. Any subscriptions not supported by a
Dual-Mode upgrade is only available for “Elite” “Pro” system will automatically be downgraded.
Installations. Refer to Special Instruction, REHS8850,
"Installation Procedure for the Elite Product Link
PLE641 and PLE631 Systems" for more information Replacing Legacy Product Link
on Dual-Mode.
Systems
Device Upgrade Replacing a Product Link PL522
A device upgrade is when you add a PLE601 Network When replacing a Product Link PL522, remove the
Manager to an existing “Pro” Installation. 351-8490 Electronic Control Module. If the asset
has a Product Link harness, remove the harness. The
1. Unplug the radio from the system. PL522 harness cannot be reused for the PL641 or
PL631 installation. The 353-8773 Antenna Cable
2. Install a PLE601 Network Manager to the AS for the PL522 is the same coax assembly used
equipment. Refer to Special Instruction, with the PL641 and PL631 systems and may be
REHS8850, "Installation Procedure for the Elite reused.
Product Link® PLE641 and PLE631 Systems".

3. Set the Product ID on the Network Manager to the

highest level Caterpillar serial number. Refer to Replacing a Product Link PL523
Special Instruction, REHS8850, “Set the Product
ID on the PLE601 Network Manager”. When replacing a Product Link PL523, remove the
351-8492 Electronic Control Module. If the asset
4. Install the radio onto the PLE601 Network has a Product Link harness, remove the harness. The
Manager. PL523 harness cannot be reused for the PL641 or
PL631 installation. The 353-8773 Antenna Cable
5. Edit the subscription on the asset if desired. There AS for the PL523 is the same coax assembly used
is no need to resubscribe the asset as the device with the PL641 and PL631 systems and may be
will download all necessary parameters from the
back office. reused. The 346-9376 Antenna As for the PL523 is
compatible with the PL641 and may be reused, if
desired.
Device Downgrade
A device downgrade is when you take a PLE641 or Replacing a Product Link PL321SR
PLE631 “Elite” system and remove the PLE601
Network Manager. When replacing a Product Link PL321SR, remove the
285-1133 Electronic Control Module, and the
1. Unplug the radio from the system. 336-3545 Communication Radio Gp or 263-9088
Communication Radio Gp. If the asset has a Product
2. Set the Product ID on the Network Manager back Link harness, remove the harness. The PL321SR
to default value of “CAT00000” . Refer to Special harness cannot be reused for the PL641 or PL631
Instruction, REHS8850, “Set the Product ID on the installation. The PL321SR antenna is not compatible
PLE601 Network Manager”. with the PL641 or PL631 system. Remove the
PL321SR antenna. If the asset has a 353-8773
3. Remove the PLE601 Network Manager and the Antenna Cable AS, the 353-8773 Antenna Cable
PLE601 Network Manager harness from the AS is the same coax assembly used with the PL641
installation.
and PL631 systems and may be reused, if desired.

47
Replacing a Product Link PL321VSR
When replacing a Product Link PL321VSR, remove
the 285-1142 Electronic Control Module and the
336-3545 Communication Radio Gp. If the asset
has a Product Link harness, remove the harness. The
PL321VSR harness cannot be reused for the PL641
or PL631 installation. The PL321VSR antenna is not
compatible with the PL641 or PL631 system. Remove
the PL321VSR antenna. If the asset has a 353-8773
Antenna Cable AS, the 353-8773 Antenna Cable
AS is the same coax assembly used with the PL641
and PL631 systems and may be reused, if desired.

Replacing a Product Link PL121SR

When replacing a Product Link PL121SR, remove the
336-3545 Communication Radio Gp, or 263-9088
Communication Radio Gp. If the asset has a Product
Link harness, remove the harness. The PL121SR
harness cannot be reused for the PL641 or PL631
installation. The PL121SR antenna is not compatible
with PL641 or PL631 system. Remove the PL121SR
antenna. If the asset has a 353-8773 Antenna
Cable AS, the 353-8773 Antenna Cable AS is the
same coax assembly used with the PL641 and PL631
systems and may be reused, if desired.

Replacing a Product Link PL421

When replacing a Product Link PL421, remove the
386-3004 Communication Electronic Control
Module. The PL421 harness is not compatible with
the PL641 or PL631 system, remove the PL421
harness. The 389-0463 Antenna As is not
compatible with the PL641 or PL631 system. Remove
the 389-0463 Antenna As.

48
Wiring to Product Link Ready and
Legacy Equipment
Wiring to a 12 Position Product Link Connector

Illustration 50 g03736119

1. Refer to the schematic of the asset in SISWeb and

locate the 12 position Product Link ready
connector.
2. Review the wiring of the 12 position connector and
note the signal or circuit going into each position of
the connector.
3. Crimp an 8T-8729 Connector Pin onto each wire
of the 452-0543 Wiring Harness.

4. Install a 12 pin 102-8801 Receptacle Kit onto the

452-0543 Wiring Harness. Ensure that each wire
location matches the corresponding wire locations
on the 12-pin Product Link ready connector on the
asset.
5. Insert 8T-8737 Seal Plugs into the unused
locations in the 102-8801 Receptacle Kit.

6. Insert the 102-8801 Receptacle Kit onto the 12-

pin Product Link ready connector on the asset.

7. Connect “C1” of the 452-0543 Wiring Harness

the 12-pin connector on the radio.

49
Wiring to a Six Position Product Link Connector

Illustration 51 g03736134

1. Refer to the asset schematic and locate the six

position Product Link ready connector.

2. Review the wiring of the six position connector and

note the signal or circuit going into each position of
the connector.
3. Crimp an 8T-8729 Connector Pin onto each wire
of the 452-0543 Wiring Harness.

4. Install a 155-2273 Connector Plug As six-pin

receptacles onto the 452-0543 Wiring Harness.
Ensure that each wire location matches the
corresponding wire locations on the six-pin Product
Link ready connector on the asset. The six-pin
Product Link ready connector does not have J1939
wires.
5. The two CAN/J1939 wires in the 452-0543 Wiring
Harness might not be used. The PL641 and PL631
only connect over CAN/J1939 so these must be
connected separately.
Note: If there is one or more ECMs on the asset that
only support CDL and information from these ECMs
are required, an “Elite” Product Link installation with a
Network Manager is required. Refer to Special
Instruction, REHS8850, "Installation Procedure for
Product Link PLE641 and PLE631 Systems".

6. Insert the 155-2273 Connector Plug As onto the

six-pin Product Link ready connector on the asset.

7. Connect “C1” of the 452-0543 Wiring Harness to

the 12-pin connector on the radio.

50
Wiring to a 70 Position Product Link Connector

Illustration 52 g03736139

Note: If the asset has a 70 position Product Link (Table 27, contd)
connector that branches directly off the machine Position Wire
harness and connects to a legacy Product Link ECM,
the wires in the 70 position connector can be used to 4 R-Term
connect the 452-0543 Wiring Harness. 5 CDL positive

1. Remove the end bell from the 70 position Product 6 CDL negative
Link connector.
7 J1939 positive
2. Remove the following eight wires from the 70
8 J1939 negative
position Product Link connector:
• Battery positive. 4. Insert 8T-8737 Seal Plugs into the unused
locations in the 155-2252 Connector Plug As.
• Battery negative.
5. Crimp an 8T-8729 Connector Pin onto each wire
• Key switch. of the 452-0543 Wiring Harness.
• R-Term. 6. Install a 102-8801 Receptacle Kit onto the
452-0543 Wiring Harness as shown in Table 28 .
• CDL positive.
Table 28
• CDL negative. Position Wire

• J1939 positive. 1 Battery positive 125-RD(Red).

2 Battery negative200-BK(Black).
• J1939 negative.
3 Key switch 308-YL(Yellow).
3. Insert the wires from Step 2 into a 155-2252
Connector Plug As as shown in Table 27 . 4 R-Term 403-GN(Green).
Table 27 5 CDL positive 893-GN(Green).
Position Wire
6 CDL negative 892-BR(Brown).
1 Battery positive
7 J1939 positive F711-YL(Yellow).
2 Battery negative
J1939 negative
8 F712-GN(Green).
3 Key switch

7. Insert 8T-8737 Seal Plugs into the unused

(continued) locations in the 102-8801 Receptacle Kit.

51
8. Insert the 102-8801 Receptacle Kit onto the • The definition for each logged diagnostic code and
155-2252 Connector Plug As on the asset. each event is displayed
9. Connect “C1” of the 452-0543 Wiring Harness to
the 12-pin connector on the radio. Status Groups for Cat ET
To access the status groups, follow the procedure
Connecting a Computer to the that is listed below.
Product Link System 1. Select the “Information” tab on the menu bar in Cat
ET.
Required Software
2. Click “Status” or click the “Status” icon on the tool
® bar.
This system requires Cat Electronic Technician (Cat
ET) version 2014A or later. The status groups should be used to verify that the
installation of the Product Link device module has
Note: Caterpillar recommends that Cat ET to be
been successful. There are only four screens
updated to the latest version to access all the
available in Cat ET for verifying and servicing the
available functionality in this Product Link TM system.
Product Link system.

Supported Hardware Connections Software installation

The Product Link device is configured with Cat ET
For procedure for installing software on to the Product
using the following communications interfaces:
Link radio refer to Testing and Adjusting, UENR5824,
• The 171-4400 Communication Adapter Gp or “ECM Software - Install”.
466-6258 Communication Adapter Gp is
connected between the machine service connector
and the PC serial port or parallel port. Troubleshooting
• The Cat ET Communications Interface Device is Refer to Systems Operation Troubleshooting Testing
configured for Cat Communications Adapter II and Adjusting, UENR5824, "Product LinkTM PL641
(RP1210) or Cat Communication Adapter 3 and PL631 Systems"
(RP1210).
■
Note: The configuration parameters for the
“Communications Interface Device” are found in Cat
ET under “Utilities” , in the “Preferences” drop-down
menu.

Cat ® Electronic Technician (Cat ET)

Service Tool
Cat ET is a software program that is used to access
data. The service technician can use Cat ET to
perform maintenance on the generator set. Some of
the options that are available with Cat ET are listed
below:

• Viewing the status of parameters

• Printing reports

• The failures of the ECM system are displayed

• The settings for the ECM are displayed

• Display the clock hour of the internal diagnostic

clock
• The number of occurrences and the clock hour of
the first occurrence and the last occurrence is
displayed for each logged diagnostic code

52
53
REHS9111 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

54 02 December 2016