Installation and Troubleshooting Procedure for Product LinkTM PLE601 as an EPA Datalogger On Marine Systems {7606, 7610, 7620} Caterpillar

Machine Control and Guidance Products

PRODUCT LINK (S/N: PL61-UP)

Introduction

This Special Instruction is intended for all Caterpillar products. This Special Instruction will provide instructions for installing and configuring the Product LinkPLE601 EPA Datalogger.

Product Link is a remote monitoring solution that enables efficient and effective equipment management. Product Link transmits the information via a cellular GSM network or a satellite communications network. The PLE601 EPA Datalogger is a passive device, which only stores diagnostic codes from the vessel. This device can be upgraded to an Elite Product Link system to create a remote monitoring solution.

The PLE601 EPA Datalogger records EPA required codes from the datalink and stores them for one year. These codes can be seen and downloaded using the ethernet service cable.

Product Link Devices

PLE601 Network Manager

PLE601 Network Manager is a Product Link device that records data from the data link and stores the data. The PLE601 EPA Datalogger is required for Marine Tier 4 applications by EPA. Tier 4 engines will be factory installed with the PLE601 EPA Datalogger. For all other Marine applications, this device is optional.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. Do not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Ensure that you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance, or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result when voiding this certification. Structural damage, an overturn, modification, alteration, or improper repair can impair the Rollover Protective Structure's (ROPS) protection capability thereby voiding this certification. Do not drill holes in the ROPS. Do not weld on the ROPS unless welding is specified in the procedure. Place welds only at the locations that are specified in the procedure. To avoid possible weakening of this ROPS, consult a Caterpillar dealer before altering this ROPS in any way. The protection offered by this ROPS will be impaired if it has been subjected to structural damage. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

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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.

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Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Weld Specifications and Qualifications

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous 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 instructions 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 Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Reference: Special Instruction, REHS1841, "General Welding Procedures" for additional welding instructions.

Proper Welding Procedure on Vessels and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a Vessel with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the vessel has a battery disconnect switch, open the switch. If the Vessels does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual Vessels component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This connection will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components, and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the weld splatter.

Required Parts for the PLE601 EPA Datalogger

The Product Link product line offers several different varieties of installation and hardware options. This publication contains information on how to install and utilize the PLE601 system as a datalogger. Refer to Special Instruction, REHS8850, "Installation Procedure for the Elite Product Link ^TMPLE641 and PLE631 Systems" to upgrade the PLE601 EPA Datalogger to a full telematics solution. Refer to Table 1 for information on kit part numbers for the installation offering for the PLE601 EPA Datalogger on marine applications.

Contents of the 455-5565 Communication Installation Gp

Note: The 455-5565 Communication Installation Gp includes the necessary hardware for a PLE601 Network Manager installation on an engine. The Panel harness is not included in the 455-5565 Communication Installation Gp.

Block Diagram and System Components

General Installation Procedure

The PLE601 EPA Datalogger will be installed at the factory for Marine Tier 4 applications Instructions for installing a PLE601 Network Manager are included as a reference for other Marine Applications or in case the PLE601 Network Manager needs to be replaced.

Some installations may require more mounting hardware to secure the PLE601 Network Manager to a mounting surface. The methods for installation are detailed in the "Shock Mount Installation for the PLE601 Network Manager" section.

Table 3 lists the optional components for mounting the PLE601 Network Manager

Read all instructions prior to installing the hardware. Be sure to consider the length and routing of harnesses when installing the hardware to minimize extra hardware needed.

Note: Ensure that power is disconnected from the battery during the beginning steps of the installation.

Mount the PLE601 Network Manager

PLE601 Network Manager Mounting Requirements

Identify a mounting location for the PLE601 Network Manager. Measure the location to ensure correct spacing for the PLE601 Network Manager "footprint" and the harness routing. The 417-4722 Electronic Control Module (PLE601Network Manager), must be mounted in a location that will not expose the PLE601 Network Manager to temperatures above 85° C (185.00° F). If the temperature at the location is unknown, mount the PLE601 Network Manager in a location that can be properly ventilated. Determine the appropriate mounting method for each specific application. The PLE601 Network Manager must be shock mounted.

• Module should b oriented vertically +/- 45 degrees

• Harness should extend downward out of the Network Manager

• PLE601 Network Manager ground strap should be connected to chassis ground (mounting stud/bolt)

• PLE601 Network Manager must be mounted within 1 m (3.28 ft) of the CAN/J1939 main trunk when using an installation harness with shielded CAN/J1939 wiring. Refer to Table 7.

• Harness must be connected or the connector must be protected from paint operations

Note: Due to the combination of using multiple harnesses for an "Elite" installation, it is possible to have CAN/J1939 wiring that is longer than the mounting requirements. If the CAN/J1939 wiring exceeds 3 m (9.84 ft) for unshielded or 1 m (3.28 ft) for shielded, shorten the end of the harness that is to be connected directly to the equipment.

The PLE601 Network Manager must be isolation mounted utilizing the appropriate mounting hardware. The PLE601 Network Manager will be fastened utilizing 4 (M6 X 1) bolts or studs, the length can vary depending on the installation. Standard torque specs should be used. The orientation of the module should be vertical +/- 45 degrees such that the 70-pin connector extends out horizontally from the PLE601 Network Manager and the harness extend downward to act as a drip loop. Install the ground strap between the washer and the bolt head/nut on the nearest shock mount. The ground strap must provide a path to chassis ground utilizing the bolt or stud. The location of the PLE601 Network Manager mounting may be limited by the J1939 stub length. Refer to "Harness Installation" for more information. Protect the 70-pin connector during paint operations. If the painting is electrostatic, the harness should be connected to provide proper grounding for the electronics.

PLE601 Network Manager Environmental Information

Shock Mount Installation for the PLE601 Network Manager

There are several different methods to shock mount the PLE601 Network Manager. Select a method that is appropriate for the intended application and environment. The kit includes all of the hardware necessary to install the PLE601 Network Manager in any of the approved shock mounting configurations.

Shock Mount the PLE601 Network Manager with the Use of Bolts and Through Holes

Shock mounting the PLE601 Network Manager by use of through holes will require drilling four clearance holes. Refer to Illustration 1.

1. Place the Network Manager in the desired mounting location. Mark the location for each of the mounting holes.

2. Remove the Network Manager.

3. Drill a 6.35 mm (0.25 inch) hole at each marked location.

4. Mount the Network Manager as shown in Illustration 1.

5. Tighten the bolts to 12 N·m (9 lb ft).

Illustration 1	g01111894
Example of a shock mount with the use of through holes (1) 417-4722 Electronic Control Module "PLE601 Network Manager" (2) 129-3178 Locknut (3) 9X-6165 Washer (4) 8C-5608 Spacer (5) 8C-5607 Mount (6) Mounting plate (7) 8C-8451 Bolt (8) 9X-8256 Washer

Shock Mounting Method Using Weld Bosses or Weld Studs

The method to shock mounts the Network Manager requires the use of weld bosses or weld studs. Refer to Illustrations 2 and 3.

1. Place the Network Manager in the desired location. Mark the location for each of the mounting holes.

2. Remove the Network Manager.

3. Weld the bosses or studs at the marked locations.

4. Mount the Network Manager as shown in Illustration 2 or Illustration 3.

5. Tighten each of the fasteners to 12 N·m (9 lb ft).

Illustration 2	g01111540
Example of the shock mount that uses bolts and weld bosses (1) M6 x 1.00, 40 mm (1.57 inch) 8C-8451 Bolt. (2) 9X-6165 Washer (3) 9X-9896 Mount (4) 8C-5608 Spacer (5) 417-4722 Electronic Control Module (6) M6 x 1.00 Weld Boss, Weld Nut, or Similar Fastener 129-3178 Locknut (7) Mounting Plate

Illustration 3	g01111773
Example of the shock mount that uses weld studs (1) 417-4722 Electronic Control Module (2) 129-3178 Locknut (3) 9X-6165 Washer (4) 9X-9896 Mount (5) M6 x 1.00, 40 mm (1.57 inch) weld stud and 8C-8451 Bolt (6) 8C-5608 Spacer (7) Mounting Plate

Shock Mounting that Uses Bolts and Threaded Holes for Mounting

Shock mounting a Network Manager that use threaded holes will require the use of drilled and tapped holes to mount the Network Manager. Refer to Illustration 4.

1. Place the Network Manager in the desired mounting location. Mark the location for each of the mounting holes.

2. Remove the Network Manager.

3. Drill a 5 mm (3/16 inch) hole at each marked location.

4. Tap each hole with a M6 x 1.00 tap to provide the threaded holes for the M6 x 1.00 bolts.

5. Mount the Network Manager as shown in Illustration 4.

6. Tighten the bolts to 12 N·m (9 lb ft).

Illustration 4	g01111821
Example of the shock mount that uses threaded mounting holes (1) M6 x 1.00, 40 mm (1.57 inch) 8C-8451 Bolt. (2) 9X-6165 Washer (3) 9X-9896 Mount (4) 8C-5608 Spacer (5) 417-4722 Electronic Control Module (6) Mounting Plate

Harness Installation

Illustration 5	g03868655
441-7508 Panel Harness As

Connect the Retrofit Installation Harnesses to the PLE601 Network Manager

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

Illustration 6	g01458173

Connect the 70-pin connector to the network manager. Refer to Illustration 6.

Wire to the Equipment

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

Recommended wire splicing practices should be followed for any of the harness splices.

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 implement the PLE601 Network Manager communication ECMs J1939 to Modbus feature. Reference the "J1939 Communications Wiring Requirements" section for specific wiring requirements. The CAN A or CAN 1 is the correct CAN wiring to splice into for data access. CAN B or CAN 2 is not to be used to access the data from the gensets.

J1939 Communications Wiring Requirements

The J1939 communications connection provides a connection between the PLE601 Network Manager communication ECM and the J1939 network. 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 7 shows the parameters for the J1939 network.

The 441-7508 Panel Harness As 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 they are connected to the CAN 1 / Local CAN wires on the equipment. Some pieces of equipment will have other connections labeled CAN 2 / Global CAN. If the Product Link device is connected to the wrong CAN connection, the proper data will not be recorded and sent to user interface.

J1939 Port Characteristics

Illustration 7	g01157211
Typical J1939 communications network layout

Turn the Equipment Power ON

Once the network manager has been connected, and the wires from the retrofit harness for battery positive, battery negative, and key switch power have been properly connected to the equipment, turn on the power to the equipment.

Update the PLE601 Network Manager Using Winflash

Note: Flash Files are located at the link below:

Perform the following procedure to flash the ECM. The ECM is flashed to upgrade the software. Flash programming of the ECM must also be done if the ECM has been replaced. TheCaterpillar Electronic Technician (Cat ET) contains the program WinFlash. WinFlash is used to load software into the ECM. The following procedure is used to flash software into the ECM.

1. Connect the 425-6889 Cable As to the laptop and 9-pin service port connector on the PLE601 Network Manager harness.

   Note: This procedure is only done through the 425-6889 Cable As and not a 317-7484 Communication Adapter Gp.

   1. Open Cat ET.
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      Illustration 8	g03395278

   2. Inside "Utilities" select "Preferences" then "Modify".
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      Illustration 9	g03396624

   3. Select the "Communications" tab and choose "Ethernet Direct Connection".
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      Illustration 10	g03396549

   4. The drop-down under "Ethernet Direct Connection" will have multiple options based on the laptop being used. Select the option based on the laptops wired Ethernet connection.

   5. Open and use WinFlash to load the software.

Note: Typical software flash can take up to 15 minutes, and may appear to stop at 45 percent. The flash will continue on its own. Actual flash times may vary.

Note: After the flash is complete reset the preferences that were changed in Step 1.c.

Upload Configuration File

For equipment that has a configuration file created, it will be already installed on the product that was built with a PLE601 Network Manager at the factory. A configuration will need to be installed if one of the following have been performed.

• Replaced a failed network manager.

• Retrofit kit installation.

Configuration File part numbers can be found in the below link:

If you are unsure of what configuration file you need for a retrofit installation, contact the DSN.

Complete the following steps to install the configuration file.

1. Open WinFlash but do not flash any software. Refer to System Operation Troubleshooting Testing and Adjusting, UENR5823, "Electronic Control Module (ECM) - Flash Program" for more information.

2. Once WinFlash is connected, open any web browser.
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   Illustration 11	g03516179

3. Connect to the "Service Dashboard". Under the Product Link drop down, select "Config File Upload". Refer to Illustration 11.

   Note: Older versions of the PLE601 Network Manager Software, required the technician to type in the full URL of the "Config Upload" page. Flash the PLE601 Network Manager with the latest software, and load the configuration file through the "Service Dashboard" button.

4. Choose the "Browse" button to upload the configuration file that is already stored on your computer.

5. Select the "Upload" button to upload the configuration file.

   Note: The Network Manager will need to power cycle before the configuration file part number is displayed in the "Product Link Interface".

Required Application to Connect to the PLE601 EPA Datalogger

Prior to connecting to the PLE601 EPA Datalogger, download the Cat ECM finder application. This software is required to access the codes from the PLE601 EPA Datalogger.

1. Go to https://dealer.cat.com/PL/Toolbox, under the required software section, download the Cat ECM Finder application (standalone version).

   The "Web Configuration" home page is accessed by attaching the 425-6889 Cable As to the PLE601 harness, and a laptop. Once a connection is made, the user can use the following Steps to access the "Web Configuration" home page. There are two ways to connect to the "Web Configuration" home page, the first is through the "Browse Network Devices" option in 2014C or newer Cat ET.

Connect to the PLE601 EPA Datalogger

The "Web Configuration" home page is accessed by attaching the 425-6889 Cable As to the PLE601 harness and a laptop. Once a connection is made, the user can use the following steps to access the "Web Configuration" home page.

1. Connect to the Product Link device with the 425-6889 Cable As.

2. Open the Cat ECM Finder application
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   Illustration 12	g06028302

3. In the "Network Devices" drop-down menu, select your laptop’s wired Ethernet port. This selection may vary based on the operating system and laptop.

4. Once the ECMs are detected, select an ECM and then click the "Launch" button. This will launch the "Web Configuration" home page into your preferred network browser.
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   Illustration 13	g06128725

5. Click "Product Link" to get to the Product Link Interface.

   The "Product Link Interface" page supplies basic system information about PLE601 Network Manager device installed.

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   Illustration 14	g06128727

6. Click "EPA Logger" to navigate to the EPA Datalogger tab.

   User will be prompted to retrieve EPA Information. Select "Yes" to view the information.

Illustration 15	g06128728

The EPA logger tab will display the reporting ECM address, Diagnostic and Failure Mode Identifier, ECM Source Address and the date the diagnostic was active.

In the EPA Logger page, the user may download the displayed information by clicking the "Download" button.

The PLE601 EPA Datalogger will store six codes required by EPA for one year. The codes and their descriptions are listed in Table 8.

Troubleshooting

Not able to see Data Logger Tab

Perform the following steps if data logger tab is not viewable:

1. Connect to the Web Configuration page using the 425-6889 Cable As.

2. Ensure that the appropriate configuration file is loaded by checking the Product Link Home tab.

3. If the appropriate configuration file is not loaded, the "EPA Logger" tab will not be displayed. Load the appropriate configuration file.

Power Wiring

Perform the following steps for power wiring:

1. Ensure that the engine and the PLE601 EPA Datalogger are powered.

2. To ensure that the EPA Datalogger is powered, check the power wiring. Check voltage on pin 53 (Battery positive), pin 70 (keyswitch), and pin 67 (ground).

3. If the wiring is correct and the PLE601 EPA Datalogger will not power up, replace the PLE601 EPA Datalogger.

4. For any other issues, download the Service Dashboard and System watch files. Contact DSN and submit a DSN ticket.