PRODUCT SUPPORT PROGRAM FOR REPLACING PRODUCT LINK PL121 SATELLITE RADIO SYSTEMS ON CERTAIN CATERPILLAR PRODUCTS AND NON-CATERPILLAR PRODUCTS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING PRODUCT LINK PL121 SATELLITE RADIO SYSTEMS ON CERTAIN CATERPILLAR PRODUCTS AND NON-CATERPILLAR PRODUCTS

Usage:

TEBE9135-01

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30Apr2019

(Revised 14May2019)

U-261

A-219

D-230

O-234

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING PRODUCT LINK PL121 SATELLITE RADIO SYSTEMS ON CERTAIN CATERPILLAR PRODUCTS AND NON-CATERPILLAR PRODUCTS
7606 7610 7620		PS46250

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46250" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 30Apr2019 Service Letter. Changes have been made to the Parts Needed, Action Required, and Rework Procedure.

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TERMINATION DATE

31Dec2019

PROBLEM

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PL121/321s will stop sending data after July 28th, 2019. Date codes will appear as if coming from the past so the customer interface (UI) will not recognize those back dated messages and no data will appear in the UI.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C27	DWB00660

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*****Group 2*****
XQ35	JK700144

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3363545	PL121 Satellite Radio
1	5263054	PL240B Cell Radio Field Install Kit
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	3363545	PL121 Satellite Radio
1	5323753	Cable As - 14-pin Svc Port (Alternate to 532-3754)
1	5323754	Cable As - 9-pin Svc Port
1	5325452	Cable As - 12-pin PL-Ready (Alternate to 532-3754
1	5360072	Harness As - 9-Pin Y-Harness (Optional)
1	5368838	Cable As - 8-pin PL-Ready (Alternate to 532-3754
1	5416385	PL542 Cellular Radio Software
1	5429452	Harness As - 14-Pin Y-Harness (Optional)
1	5493131	PL542 Cell Radio Field Install Kit
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

NOTE: Refer to Image1 through Image3 below for a list of all product that may have a Product Link PL121 satellite radio system installed. If a product in question is on the list, this program applies and need to follow the Group 1 Rework Procedure.

NOTE: Refer to Image4 and Image5 below for a list of all product that may have a Product Link PL321 satellite radio system installed. If a product in question is on the list, this program applies and need to follow the Group 2 Rework Procedure.

Note: Affected product in Image5 have reported Active Digital Input messages. If the machine owner wants to continue using these Digital Inputs then only perform Option #1 in the Rework Procedure to update the software on the PL121 Radio. If the machine owner is no longer using the Digital Inputs then Option #1 or Option #2 is available to repair the Product Link radio system.

NOTE: Please file the warranty claim using 99Z00015 as the serial number. Ensure that the Machine Make and Machine Serial Number are included in the Service Letter claim story. Failure to provide this information in the claim story will result in the claim getting rejected.
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Image1

Image2

Image3

Image4

Image5

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-500000 hrs, 0-720 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 1
NOTE: Actual labor hours to perform this PSP repair should be claimed on a labor line, up to Service Letter Allowance. If actual labor hours are less than Service Letter Allowance, Dealer may claim for the difference as a miscellaneous expense line. The claim story should detail the labor hours and the labor rate for the miscellaneous expenses.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-500000 hrs, 0-720 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 2
NOTE: Actual labor hours to perform this PSP repair should be claimed on a labor line, up to Service Letter Allowance. If actual labor hours are less than Service Letter Allowance, Dealer may claim for the difference as a miscellaneous expense line. The claim story should detail the labor hours and the labor rate for the miscellaneous expenses.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Group Number 1

There are 2 repair options in this rework procedure. Repair option #1 is to replace the existing PL121 satellite radio (P/N: 263-9088) with a new PL121 satellite radio (P/N: 336-3545). Repair option #2 is to replace the PL121 satellite radio with a PL240B cellular radio.

NOTE: Only perform one of these repair options.
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********** Repair Option #1: Replace existing PL121 with a new PL121 (P/N: 336-3545) **********

Before going to the Customer Site:

1. Refer to Special Instruction REHS2365 Installation Guide for Product Link PL121SR and PL321, section ?Configure and Register Product Link PL121SR Radio and PL300 ECM?, subsections ?Configuring Installation Parameters (Radio Only)? and ?Registering the System?, for familiarity with the PL121 configuration and registration process.

Note: Cat Electronic Technician (Cat ET) 2019A must be used.

2. Review training materials available for the PL121 replacement, configuration, and registration processes, available at ?https://dealer.cat.com/connectivityoffer? under the tab for ?Technical Training?.

Note: Information provided here will have required training for this process through videos and detailed work instructions. Suggest printing the work instructions as a reference when performing the repair at the machine.

At the Machine (PL121):

Note: If assistance if needed to replace, configure, or register the Product Link hardware, contact the Product Link Hardware Support Hotline. Dial the DSN phone number at 309-636-8500 (Americas - North & South), 65-6828-7080 (EAME, APD), 61-738-03-8160 (Australia) 44-33-40-3660 (India) and select Prompt #2.

3. Using a Serial Service Cable, 245-7310, and USB-to-Serial Adapter, 370-8059, connect to the asset?s 3-pin PL121 Service Connector.

4. On the PC start Cat Electronic Technician (Cat ET) and connect to the PL121 using the ?Caterpillar Embedded Communications Adapter? setting.

5. In Cat ET click on the ?Information? menu and select the ?Product Status Report? menu item. Click the ?Create Report? button at the bottom of the screen.

Note: This step is critical to recording parameters for configuring and registering the new PL121 radio after hardware replacement.
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6. Turn the key start switch and the disconnect switch to the OFF position.

7. Disconnect the 12-pin harness connector and the 2 antenna coaxial connectors from the PL121. Unbolt and remove the PL121 radio from the asset. Retain the mounting hardware for installing the new radio.

8. Install the new PL121 radio (P/N: 336-3545-xx) using the existing hardware. Connect the 12-pin harness connector and the 2 antenna coaxial connectors to the new PL121.

9. Turn the disconnect switch to the ON position. Turn the asset?s Key Switch on and reconnect Cat ET.

10. In Cat ET click on the ?Service? menu and select the ?Product Link Registration? menu item. Using the Product Status Report (PSR) created in step # 5 update the parameters as follows:

a. Machine Make Code: - Copy from the PSR ?DBS Machine Make Code?
b. Machine Serial Number: - Copy from the PSR ?Machine Serial Number?
c. Primary Dealer Code: - Select the Dealer Code for the dealer performing the repair
d. Confirmation Email Address: - Enter the email address where the confirmation email is get sent
e. Service Hour Meter Value: - Copy form the PSR ?Total Operating Hours?

11. In Cat ET click on the ?Service? menu and select the ?Configuration? menu item. Click on the ?Expand All? button at the bottom of the page. Using the Product Status Report (PSR) created in step # 5 compare and update as needed the parameters as follows:

a. Report Start Time
b. Operating Hours Report Configuration
c. Number of Daily Machine Location Messages Configuration
d. Position Report Minimum Location Change
e. Global Gram Enable Status
f. GPS Fix Validity Time Duration

Note: Registration of the device can take 15-60 minutes. It is recommended to monitor the machine to verify it does begin to communicate again. To confirm registration is complete monitor through Cat ET ?Status? tab. The PLM Registration status will change from ?Pending? to ?Registered?. If you see ?Failed? you need to review your settings and retry. Refer to RENR911, Troubleshooting section, for additional guidance.

12. Check with your PL Admin to confirm subscription of the new device to the machine.
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********** Repair Option #2: Replace PL121 satellite Radio with PL240B Cellular Radio **********

Before going to the Customer Site:

1. Refer to M0081260 installation instructions for all tools required to perform the radio PL240B installation.

At the machine:

2. Locate the existing Product Link PL121 device and completely remove prior to installing the Product Link PL240B radio system.

Note: Complete removal of an existing PL121 is required along with properly sealing and securing unused wiring. If the PL121 is left on-board and accidently re-enabled by the customer, or another service technician, then conflicting information will get sent from both the old and newly installed device to the back office.

Note: If assistance if needed to replace Product Link hardware, contact the Product Link Hardware Support Hotline. Dial the DSN phone number at 309-636-8500 (Americas - North & South), 65-6828-7080 (EAME, APD), 61-738-03-8160 (Australia) 44-33-40-3660 (India) and select Prompt #2.

3. Perform M0081260 installation instructions in full for the Product Link PL240B radio system.

4. Make sure to follow the entire process until the device performs a successful communication check.

NOTE: The comm check will have to be performed from the back office through the Dealer Service Portal, as it cannot be done from the machine.

5. If the device is not communicating, refer to UENR6983 to troubleshoot the PL240B installation. Please complete a successful communication check before leaving the machine.

6. Power Up the machine and let it run. Registration can be done remotely using CAT Activate Phone application. Open Cat Activate and Scan the QR code or search the radio SN. Follow the setup steps on the CAT activate app to set Product ID and Subscription level. For additional instruction on using the CAT activate app please refer to M0077270.

Note: If subscription assistance is needed, the PL administrator may leverage Cat Connect Support services to subscribe assets. Please submit assets to be subscribed via email using the template below. The template is available for download at ?https://dealer.cat.com/connectivityoffer? under the Dealer Toolkit tab. Cat Connect Support can be reached via phone (866 228 2111 - toll free US & Canada or +1 513 830 1809 - international) or email (CatConnectSupport@cat.com).

Group Number 2

There are 2 repair options in this rework procedure. Repair option #1 is to replace the existing PL121 satellite radio (P/N: 263-9088) with a new PL121 satellite radio (P/N: 336-3545). Repair option #2 is to replace the PL321 satellite radio with a PL542 cellular radio.

NOTE: Only perform one of these repair options.
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6. Turn the key start switch and the disconnect switch to the OFF position.

7. Disconnect the 12-pin harness connector and the 2 antenna coaxial connectors from the PL121. Unbolt and remove the PL121 radio from the asset. Retain the mounting hardware for installing the new radio.

8. Install the new PL121 radio (P/N: 336-3545-xx) using the existing hardware. Connect the 12-pin harness connector and the 2 antenna coaxial connectors to the new PL121.

9. Turn the disconnect switch to the ON position. Turn the asset?s Key Switch on and reconnect Cat ET.

10. In Cat ET click on the ?Service? menu and select the ?Product Link Registration? menu item. Using the Product Status Report (PSR) created in step # 5 update the parameters as follows:

a. Machine Make Code: - Copy from the PSR ?DBS Machine Make Code?
b. Machine Serial Number: - Copy from the PSR ?Machine Serial Number?
c. Primary Dealer Code: - Select the Dealer Code for the dealer performing the repair
d. Confirmation Email Address: - Enter the email address where the confirmation email is get sent

11. In Cat ET click on the ?Service? menu and select the ?Configuration? menu item. Click on the ?Expand All? button at the bottom of the page. Using the Product Status Report (PSR) created in step # 5 compare and update as needed the parameters as follows:

a. Report Start Time
b. Operating Hours Report Configuration
c. Number of Daily Machine Location Messages Configuration
d. Position Report Minimum Location Change
e. Global Gram Enable Status
f. GPS Fix Validity Time Duration

Note: Registration of the device can take 15-60 minutes. It is recommended to monitor the machine to verify it does begin to communicate again. To confirm registration is complete monitor through Cat ET ?Status? tab. The PLM Registration status will change from ?Pending? to ?Registered?. If you see ?Failed? you need to review your settings and retry. Refer to RENR911, Troubleshooting section, for additional guidance.

12. Check with your PL Admin to confirm subscription of the new device to the machine.
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********** Repair Option #2: Replace PL321 satellite Radio with PL542 Cellular Radio **********

Before going to the Customer Site:

1. Refer to M0077632 installation instructions for all tools required to perform the radio installation.

Note: The PL542 radio requires a harness to complete the installation. Check the service port in machine schematic to determine if a 9-pin service connector or a 14-pin service connector is installed on the machine. Some machines may have a 12-Pin Product Link Ready Connector in the machine harness. Select the proper harness assembly for that machine installation as shown in Image 2.4.1.

Note: If using the Cat 12-Pin Product Link Ready connector harness option note that some machines do not follow the Product Link Ready Standard pinout. Compare the pinouts between the machine schematic and the harness pinout as shown in Image 2.4.2. If any differences are noticed then move sockets in the machine harness plug as needed in order to make the proper connections.

Note: A ?Product Link(TM) Pro Series PL542 Machine Compatibility Reference? is available showing for most machine models the necessary harness used for a PL542 installation. The web link is: ?https://dealer.cat.com/PL/PL542InstallationRef?. This link is case sensitive, so you will need to type in the link exactly as shown.
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Image2.4.1

Image2.4.2

At the machine:

2. Locate the existing Product Link PL321 device and completely remove prior to installing the Product Link PL542 radio system.

Note: Complete removal of an existing PL321 is required along with properly sealing and securing unused wiring. If the PL321 is left on-board and accidently re-enabled by the customer, or another service technician, then conflicting information will get sent from both the old and newly installed device to the back office.

Note: If assistance if needed to replace Product Link hardware, contact the Product Link Hardware Support Hotline. Dial the DSN phone number at 309-636-8500 (Americas - North & South), 65-6828-7080 (EAME, APD), 61-738-03-8160 (Australia) 44-33-40-3660 (India) and select Prompt #2.

3. Perform M0077632 installation instructions in full for the Product Link radio system.

4. Make sure to follow the entire process until the device performs a successful communication check.

5. If the device is not communicating, refer to M0079294 to troubleshoot the PL542 installation. Please complete a successful communication check before leaving the machine.

6 Register the device using CAT Activate Phone application. Open Cat Activate and Scan the QR code or search the radio SN. Follow the setup steps on the CAT activate app to set Product ID and Subscription level. For additional instruction on using the CAT activate app please refer to M0077270.

Note: If the Product ID or the Machine SN is not set on the device, the device will register as its own Serial number.

Note: If subscription assistance is needed, the PL administrator may leverage Cat Connect Support services to subscribe assets. Please submit assets to be subscribed via email using the template below. The template is available for download at ?https://dealer.cat.com/connectivityoffer? under the Dealer Toolkit tab. Cat Connect Support can be reached via phone (866 228 2111 - toll free US & Canada or +1 513 830 1809 - international) or email (CatConnectSupport@cat.com).

7. The PL542 radio device may not have the latest software on-board. Please use Caterpillar's Product Support Customer Relations Management (PSCRM) system to create a ?System Technology? event type service request (SR). The Inquiry Type needs to be Product Technologies with the Workgroup/Subsystem = Product Link. In the description field, please use ?FOTA Request? and the PL542 software needs to be updated. This will require acknowledgment of Customer consent to proceed with the FOTA prior to submitting to Caterpillar.