Installation of Remote Disable Module (RDM) Kit on Cat<SUP>&reg;</SUP> and Non-Cat Equipment {7606} Caterpillar


Installation of Remote Disable Module (RDM) Kit on Cat® and Non-Cat Equipment {7606}

Usage:

MT700 018


Caterpillar Products
All Machines

Introduction

This Special Instruction provides instructions for installing the Remote Disable Module Kit. Once activated, the RDM will prevent the machine from being started from the key switch in the off position. The RDM will also allow an authorized person in a remote, off board location to enable a disabled machine to start. The RDM will not shut down a running machine.

The system consists of a module and wiring harness to allow connection to the machine key switch, ground, starter circuit, and J1939. The Remote Disable Module System is proposed for use on all machines, both Caterpillar and competitive brands, providing a fleet solution for equipment owners. This kit is offered as an after-market attachment.

Note: It is important to read this entire Special Instruction before beginning the installation of the Remote Disable Module System.

Note: This device is not to be used for "Power Lock and Tagged Out" procedures. Refer to section "Power Locked and Tagged Out" for instructions.



Illustration 1g03879727
Remote disable module (RDM) kit

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 should 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. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Personal injury or death can result from improper assembly procedures.

Do not attempt any assembly until you have read and understand the assembly instructions.


------ WARNING! ------

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 terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.


Power Locked and Tagged Out

Insure that the engine has been disconnected/isolated from the power line and is locked and tagged out. The engine must be on a smooth, level surface that will support the weight of the engine. Turn off the engine with the Key Switch to the OFF position.

Preparing the Machine

  1. The machine must be on a smooth, level surface that will support the weight of the machine.

  2. Turn OFF the engine.


    Illustration 2g00104545

  3. Use proper Lock out and Tag out procedures. Attach a "Do Not Operate" warning tag to the engine start switch or the controls before you perform any service to the engine. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar Dealer.

Electrical Safety

Do not operate or work on a machine unless you have read and understand the instructions and warnings in this Special Instructions. Failure to follow the instructions or heed the warnings could result in injury or death.

Overview

The Remote Disable Module (RDM) allows the owner, from a remote location, the ability to disable a machine from starting.

Applicability

The Remote Disable Module (RDM) is proposed for use on all machines, both Caterpillar and competitive brands, providing a fleet solution for equipment owners. This kit can be retrofitted too many brands and types of equipment and is offered as an after-market attachment. This kit is not certified for Marine applications. This kit is not authorized for use on L,M,N,and O vehicle categories under UNECE Regulation 10.

Electrical Requirements

This control is designed to operate on 12 VDC or 24 VDC, negative ground.

Installation

Installation Procedure

To execute the operational validation of the Remote Disable Module after installation of the system, it is necessary to engage the end customer to administer the feature remotely. Enabling this capability has three prerequisites:

  • VisionLink access to the asset security feature

  • Supporting Product Link device

  • Remote Disable Module

The process for installing this retrofit kit is described briefly here and in detail below. The steps to be followed include:

  • Determine the mounting location of the RDM

  • Mount the RDM

  • Connecting the wiring to the machine

  • Validate the RDM operation

Remote Disable Module Kit Bill of Materials

Table 1
464-7816 Communication Installation Gp and Harness 
Quantity  Part Number  Description 
477-3970  Communication Electronic Control Module 
477-3971  Control Harness As 

Table 2
Mounting Hardware for 464-7816 Communication Installation Gp 
Quantity  Part Number  Part Name  Description 
6V-3940  Bolt  M8×1.25×25, Hex Head 
8T-4224  Hard Washer  Washer, Flat, 8.8ID×16,00D×2.0T 

Table 3
Harness required for PL241 Installations (not included in main kit) 
Quantity  Part Number  Description 
491-7565  Control Harness As 


Illustration 3g06025528


Illustration 4g06025532

Installation of the Remote Disable Module

Given the wide range of machines to which the Remote Disable Module system can be applied, a standardized mounting method is not possible. Some of the considerations to be made when selecting a Remote Disable Module mounting location include:

  • Inconspicuous Location - Not Readily Visible

  • Access to Key Switch

  • Access to battery ground

  • Access to Starter Relay or Starter Solenoid Circuit (or other circuit to be disabled)

  • Access to the machine CAN network

  • Access to ignition circuitry

Key Switch Notes



Illustration 5g06025536
Key switch circuit

Note: The RDM will not function correctly if hooked up on the Accessory Circuit.

The "Accessory" circuit will go to BAT (+) when the start switch is moved to the "accessory" position, but will lose power when the start switch is moved to "crank". The "accessory" circuit is not usable with the RDM. "Key Switch" is the circuit that goes to BAT (+) when the start switch is in any position other than "OFF". This includes the "accessory" and "crank" positions. Refer to Illustration 5.

Remote Disable Module Mounting



Illustration 6g06025540
Remote disable module mounting diagram

There are two mounting holes for the Remote Disable Module, one at each top corner. Refer to Illustration 6 for the measurements to drill the 2 mounting holes. Use a drill bit to accommodate a size M8 bolt that corresponds to each of the mounting points. Refer to Illustration 6 for dimensions.

Remote Disable Module Connections



Illustration 7g06025538

Remote Disable Module Wiring Setup

Installation Using a PL241 Radio



Illustration 8g06025550
Remote disable module wiring for PL241 radio

If the Remote Disable Module is installed on a machine using a PL241 Radio, refer to Illustration 8 to ensure the correct wiring between the PL241 and the RDM.

Note: 491-7565 Control Harness As is required for the Product Link 241 Radio to function correctly with RDM.

  1. Locate the PL241.

  2. Add the harness in Table 3 directly to the PL241.

  3. Splice the wire from Pin-12 of the PL241 harness to the orange wire from Pin-2 (digital input) of the RDM.

  4. Make the connection between Pin-1 on the connector to BAT (-).

  5. Make the connection between Pin-8 on the connector and the Key Switch signal.

When the above steps are completed, refer to Section "Remote Disable Installation Electrical Validation" to validate the electrical installation of the Remote Disable Module.

RDM to PL6xx Radio Connection Procedure

The following three sections detail the installation for the Remote Disable Module onto a machine with a PL6xx System with:

  • No existing network.

  • Installed in an existing network as a drop.

  • Installed in an existing network as an extension.

Follow the instructions in the section that corresponds to the network of the machine on which the Remote Disable Module will be installed.

Installation with no existing network



Illustration 9g06026013

If the machine has no existing network, route the RDM directly into the Product Link 6xx system using the CAN lines as depicted in Illustration 9. Pin-4 of the RDM should be wired to the Yellow wire and pin-3 of the RDM should be wired to the Green wire. The two 120 ohm terminating resistors should be placed between the RDM and the Product Link 6xx at no greater than a 40 m separation.

Make the connection between pin-1 on the connector to BAT (-) and between pin-8 on the connector and the Key Switch signal as shown in 8.

When the above steps are completed, refer to Section "Remote Disable Installation Electrical Validation" to validate the electrical installation of the Remote Disable Module.

Installation as a drop on an existing network



Illustration 10g06026024

If the machine has an existing network, refer to Illustration 10 for proper wiring. The RDM should be connected to the CAN lines of the existing network. Pin-4 of the RDM should be wired to the F711-YL(Yellow)wire and pin-3 of the RDM should be wired to F712-GN(Green). Make the connection between pin-1 on connector to BAT (-). Make the connection between pin-8 on the connector and the Key Switch signal.

When the above steps are completed, refer to Section "Remote Disable Installation Electrical Validation" to validate the electrical installation of the Remote Disable Module.

Note: Not all CAN networks use these wire numbers. It is important to connect to the same network as the Product Link device.

Installation of RDM as an Extension to Existing Network



Illustration 11g06026026

Illustration 11 represents the network and devices before installing the RDM as an extension to the network.



Illustration 12g06026028

The Remote Disable Module can be installed as an extension to an existing network with devices as depicted in Illustration 12. The bold dashed box in Illustration 12 represents the RDM addition to the network. The new items are the remote disable module and the Tee 133-0970 Connector Receptacle As. Reference Illustration 11, Illustration 12, and the following instructions:

  1. Remove the 120 ohm terminating resistor from the end of the network.

  2. Install the three-way adapter in place of the resistor.

  3. Connect the Remote Disable Module to the second port of the three-way connector.

  4. Install the 120 ohm resistor in the third port of the three-way connector.

  5. Make the connection between pin-1 on connector to BAT (-). Make the connection between pin-8 on the connector and the Key Switch signal.

When the above steps are completed, refer to Section "Remote Disable Installation Electrical Validation" to validate the electrical installation of the Remote Disable Module.

Remote Disable Installation Electrical Validation

  1. Starting condition: 8-pin plug is wired to the machine as indicated in Illustration 8, Illustration 10, Illustration 11, and Illustration 12.

  2. Disconnect Harness from Remote Disable Module for electrical validation.

  3. Battery is connected.

  4. Key Switch is off.

  5. The resistance between pin-3 and pin-4 of the connector should be between 60 ± 5 ohms. This is the parallel resistance of the two terminating resistors on the CAN backbone.

    1. There should be continuity (near 0 ohms) between pin-3 (CAN(-)) and every green CAN (-) wire that is part of the network.

    2. There should be continuity between pin-4 (CAN(+)) and every yellow CAN (+) wire that is part of the network.

  6. The resistance from pin-1 to BAT(-) should be less than 10 ohms.

  7. Turn on the Key Switch to Accessory - DO NOT start engine.

  8. The voltage from pin-8 to BAT(-) should be within 2 V of BAT(+).

  9. Turn Key Switch off.

  10. Insert 8-pin plug connector into the Remote Disable Module connector.

  11. Check the continuity between the two 12AWG wires - should be open circuit (infinite resistance).

  12. Turn on the Key Switch, but DO NOT start the engine. Check the continuity between the two 12 AWG wires - should be closed circuit (near 0 ohms).

  13. Turn off the Key Switch and disconnect the battery.

Once the Remote Disable Module electrical installation has been validated, proceed to Section "Configuration of Installed System" to finish the installation of the remote disable module.

Configuration of Installed System

The Remote Disable Module (RDM) has an internal relay, which is configured mainly by a command from a Caterpillar Telematics device. Ultimately, it will be up to the installation technician to determine the best way to prevent the system from starting. Use your best judgement for which circuit to interrupt while the system is in a "DISABLED" state.

There are two possible options to connect the RDM. Choose one option, then remove wires from the other option. If not using 12 AWG wires, they should be terminated with waterproof heat-shrink tube to prevent shorts. If not using the wires going to pins 6 & 7, remove them from the connector, and insert seal plugs where they were removed.

Option 1, shown below, will detail potential configurations to interrupt the Starter Motor circuit with the 12AWG wires coming from the side of the RDM. Option 2 will demonstrate how to use the wires from Pins 6 & 7 to interrupt the low current circuit that will go to the start relay on a mechanical machine, or to an ECM which controls the start relay on an electronic machine.

Note: Do not connect the RDM using both the configurations. The internal circuitry will connect the circuits together, and may cause shorts in the system, or prevent the machine from starting in any state.

Option 1: Starter Motor Configuration



    Illustration 13g06351003
    Connection in the Machine before installing RDM

  1. This configuration involves interrupting the high-power line from the starter relay to the starter motor S terminal. This will be a thick 12AWG wire and intended to carry 13-20A current.

  2. The starter circuit can be interrupted at the positive terminal or using the wire that goes from the starter to the battery.


    Illustration 14g06350980
    Wire disconnected from starter, and connected to the RDM

  3. Connect the disconnected wire to a black 12 AWG wire from the RDM.


    Illustration 15g06350982
    RDM completing starter circuit with 12 AWG wires

  4. Connect the 2nd black 12 AWG from the RDM to the end where the wire was disconnected from Illustration 15.

  5. To validate the connection, refer to "VisionLink Administration".

Option 2: Starter Relay Configuration

Note: If option 1 is not used, trim the two black 12AWG wires down to a short length. Tape off the wires using insulation tape, so that they do not contact each other.

Use option 2 to connect RDM using the starter relay configuration. There are 2 cases to install the RDM into the starter relay circuit, which is dependent upon the location of the required components of the circuit.

Case 1: Interrupt the Power Side



    Illustration 16g06351005
    Starter Relay coil circuit in the Machine before installing RDM


    Illustration 17g06350986
    Starter Relay coil circuit in the Machine with the RDM connected

  1. In this case, the RDM is connected on the power side of the coil circuit of the starter relay. It involves interrupting the signal line from the keyswitch/ECM to the starter relay coil. This will be 16AWG/18AWG wire and intended to carry low voltage signals.

  2. Break the relay coil circuit – either at the relay coil or at the device that drives the relay coil. The device could be starter switch directly or the ECM that signals the actuation of the starter relay.

  3. Connect pins 6 and 7 across the break in the circuit, refer to Illustration 17.

  4. To validate the connection, refer to "VisionLink Administration".

Case 2: Interrupt the Ground Side



    Illustration 18g06350988
    Starter Relay coil circuit in the Machine before installing RDM


    Illustration 19g06351006
    Starter Relay coil circuit in the Machine with the RDM connected

  1. If the power side is not feasible to be tapped, an alternate method of connecting the RDM is to break the ground side of the starter relay. It involves interrupting the signal line from the starter relay coil to ground. This will be 16AWG/18AWG wire and intended for grounding.

  2. Break the relay coil circuit - either at the relay coil or at the ground connection.

  3. Connect pins 6 and 7 across the break in the circuit, refer to Illustration 19.

  4. To validate the connection, refer to "VisionLink Administration".

VisionLink Administration

Asset Security Administration

Before beginning the operational validation of this device, it is important that the user be familiar with the Asset Security Administrator Guide on below link.

https://dealer.cat.com/pl


Illustration 20g06365636


Illustration 21g06365637

Features

The RDM is designed to be in a disabled state until the Product Link device commands it to be in the enabled state.



Illustration 22g06365638

Once installed, refer to the Asset Security Administrator Guide to enable security (Security Mode = Active) and allow machine to start (Security Status = Normal Operation).

Verification

Power Requirements

  1. Check power pins with key off and with key on. If power is constant, then the system will not work:

    • RDM, Pin 8 is Batt + (Machine Key)

    • RDM, Pin 1 is Batt - (Machine Ground)

J1939 Connections



Illustration 23g06365639

  1. Check continuity between RDM and Service Port:

    • RDM, Pin 4 to Service Port, Pin G (9-pin)

    • RDM, Pin 4 to Service Port, Pin C (14-pin)

    • RDM, Pin 3 to Service Port, Pin F (9-pin)

    • RDM, Pin 3 to Service Port, Pin D (14-pin)

  2. Verify in VisionLink - ECM Information tab will show "CAT_RDM" for both ECM Serial Number and Software Part Number

Note: There is no support for the RDM in Cat® Electronic Technician (Cat ET).

Current Status



    Illustration 24g06365640

  1. Verification in ET – Security System Status in Telematics Status Parameters screen.


    Illustration 25g06365641

  2. Verification in VisionLink.

  3. On a powered system, check continuity between pins 6 & 7 of the RDM. If continuous, RDM is ENABLED. If Open, RDM is DISABLED.

Machine Installation

  1. Remove power from RDM (should not start).

  2. Disconnect 8 pin and try to start machine (should not start).

Operational Validation

Refer to the Asset Security Administrator Guide to manage the starting capability of your asset.

Basic steps to ensure commands are successful:

  1. Ensure asset has been powered, with key on, for at least five minutes.

  2. Use VisionLink to send command.

  3. Wait five minutes for command to reach the asset.

  4. Cycle power:

    • key off

    • wait for Telematics to shut down

    • key on

    • wait for Telematics to wake up

  5. Command should have taken effect. Refer to Verification of Current Status to confirm.

Useful Information while managing security:

  1. Telematics devices do not reflect security state until a full power cycle has occurred.

  2. RDM will enact command on next RDM power cycle (ie. A disable command will go into effect after key goes off, then on again).

  3. Telematics devices can take five minutes to shut down.

  4. Telematics devices take up to five minutes to fully power up and connect to a cellular network.

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