Nehs1016 WebSite[1]

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TOOL OPERATING MANUAL 312-5642 Product Link Service Tool Group SMCS: 1900-038

NEHS1016 January 2008

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Important Safety Information

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. 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. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

Think Safety 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.

The information, specifications, and illustrations in this publication are on the basis of 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.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

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

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

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. 2

Contents

Literature Information

Literature Information Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Information . . . . . . . . . . . . . . . . . . . 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Icon Nomenclature . . . . . . . . . . . . . . 4 Personal Protection/Important Information 4 Prohibited Action . . . . . . . . . . . . . . . . . . . . 4 Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4 Safety Section Safety Warnings . . . . . . . . . . . . . . . . . . . . . . 4 General Information Section Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5 References. . . . . . . . . . . . . . . . . . . . . . . . . . 5 Additional Contact Information . . . . . . . . . . 5 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 6 Additional Required Hardware . . . . . . . . . . 7 Operation Section Tooling Set-up . . . . . . . . . . . . . . . . . . . . . . . 7 Service Tool Set-up For PL121 Product Link . . . . . . . . . . . . . . . . . . . 8 PL121 Connection Procedure . . . . . . . . . . 9 Service Tool Set-up For PL151/201 Product Link. . . . . . . . . . . . . . . 11 PL151/201 Connection Procedure. . . . . . 12 Service Tool Set-up For PL321 Product Link . . . . . . . . . . . . . . . . . . 15 PL321 Connection Procedure . . . . . . . . . 16 Configuring CAT Electronic Technician . . . 19 Tooling Removal. . . . . . . . . . . . . . . . . . . . . 21 Maintenance Section Cleaning/Inspection . . . . . . . . . . . . . . . . . . 23 Service Parts . . . . . . . . . . . . . . . . . . . . . . . 23

This manual should be stored with the tool group. This manual contains safety information, operation instructions, and maintenance information. Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication. Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.

Safety Section The Safety section lists basic safety precautions. Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section The General Information section describes tooling functions and features. It provides useful information on individual parts, additional tooling, and resources.

Operation Section The Operation section is a reference for the new operator and a refresher for the experienced operator. Photographs and illustrations guide the operator through correct procedures for using the tool group. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.

Maintenance Section The Maintenance section is a guide to equipment care and service parts. 3

Safety Section

Safety Warnings

Safety Icon Nomenclature

WARNING

Personal Protection/Important Information

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools. Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

Read the manual Eye protection Ear protection Face protection

To prevent possible damage to your hearing, always wear ear protection when working around noise-generating tools.

Prohibited Action No liquid around electrical components No smoking

To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

Hazard Avoidance Battery explosion hazard

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area, and clean up all spilled fluids immediately.

Hot surface Pressurized air Safety alert symbol

Personal injuries can occur as a result of using pressurized air. Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressurized air.

Slipping hazard Tripping hazard

Batteries contain sulfuric acid and produce explosive gases that can result in serious injury. Do not stand over the battery when connecting harness clamps. To prevent ignition of gases, avoid sparks and keep other ignition sources away from batteries at all times.

4

The product link service tool group is used with a 12 Volt or 24 Volt external battery power supply and a laptop computer with the most up-to-date version of CAT ET installed.

WARNING Batteries give off flammable fumes that can explode, resulting in personal injury. Do not smoke around batteries and prevent sparks near batteries. Do not allow the battery clips to contact each other or the machine while connected to a battery.

The product link service tool will work with PL121, PL151/201, and PL321 Product Link Systems.

References

Machine engines and related components can be hot. To avoid personal injury, use caution when connecting or disconnecting service tool wiring harness plugs. If possible, allow equipment to cool before connecting the Product Link Service Tool. No liquid components.

around

For more information regarding registration of a Product Link module, or troubleshooting procedures for communication adapters, refer to the following literature. References

electrical

General Information Section

RENR5885

Systems Operation Troubleshooting Testing and Adjusting, Product Link 151/201

RENR7911

Systems Operation Troubleshooting Testing and Adjusting, Product Link 121/321

NEHS0758

Using the 275-5120 Caterpillar Communication Adapter II

NEHS0926

Using the 261-3363 Wireless Communication Adapter

Introduction Additional Contact Information

The 312-5642 Product Link Service Tool Group is used to set-up, test, and troubleshoot the Product Link System. It can be used before, during, and after Product Link System installation. The service tool group verifies proper communication with CAT Electronic Technician (ET), as well as the function of auxiliary digital switch inputs.

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:

U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 [email protected]

5

4. 312-5610 Harness Assembly - Used with 312-5608 Main Harness Assembly, 275-5120 Communication Adapter II or 261-3363 Wireless Communication Adapter, laptop computer, and PL151 or PL201 Module.

Nomenclature The 312-5642 Product Link Service Tool Group consists of switch box (1), main harness with battery power supply clips (2), three service tool harness assemblies (3,4,5), and storage case (6) with foam lining (7), not shown.

5. 312-5611 Harness Assembly - Used with 312-5608 Main Harness Assembly, 275-5120 Communication Adapter II or 261-3363 Wireless Communication Adapter, laptop computer, PL121 Module, and PL300 ECM. 6. 6V-7145 Storage Case. 7. 317-9430 Foam Insert (not shown). The 312-5641 Product Link Service Tool Switch Box has three primary switches (a,b,c) and four auxiliary switches (d) used to test the “Digital Input” feature of the Product Link PL201 module or PL300/321 ECM through CAT ET.

1. 312-5641 Switch Box - Controls power supply and simulates signals for testing the Product Link system. 2. 312-5608 Main Harness Assembly - Used with 312-5641 Switch box, 12 V or 24 V power supply (battery), and other product link service tool harness assemblies.

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

3. 312-5609 Harness Assembly - Used with 312-5608 Main Harness Assembly, laptop computer, and PL121 Module.

b. Key Switch - In the ON position, it provides a valid “key on” signal to the configured modules (simulates the ignition switch in a “run” position).

6

c. Alt. R - Term. Switch - In the ON position, it provides a valid “engine running” signal to configured modules (simulates engine running and accruing hours).

Operation Section Tooling Set-up The 312-5642 Product Link Service Tool Group requires a set-up and connection procedure that varies, depending on the Product Link Group being serviced.

d. Digital Input 1-4 Switches - In the CLOSED position, auxiliary switches provide additional inputs used to test the “Digital Input” feature of the Product Link Module through CAT ET (PL201 and PL300/321 Product Link systems only).

Refer to the appropriate PL121, PL151/201, or PL321 Product Link Service Tool Group section in this manual for specific procedures.

WARNING

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

Batteries give off flammable fumes that can explode, resulting in personal injury. Do not smoke around batteries and prevent sparks near batteries. Do not allow the battery clips to contact each other or the machine while connected to a battery.

Additional Required Hardware To operate the 312-5642 Product Link Service Tool Group, the following additional hardware is required:

Machine engines and related components can be hot. To avoid personal injury, use caution when connecting or disconnecting service tool wiring harness plugs. If possible, allow equipment to cool before connecting the Product Link Service Tool.

• 275-5120 Caterpillar Communication Adapter II or 261-3363 Wireless Communication Adapter • Laptop Computer with CAT ET software installed NOTE: Always make sure the laptop computer has the latest version of CAT ET software installed on it before using the 312-5642 Product Link Service Tool Group.

7

Service Tool Set-up For PL121 Product Link 12 13 10

11 3

312-5608

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1 1016-04

Components (PL121 Product Link) Item

Description

1

312-5641 Switch Box1

2

312-5608 Main Harness Assembly1

3

312-5609 Harness Assembly1

8

12 Volt or 24 Volt Power Supply

10

Laptop Computer2

11

Coaxial Antenna Cables

12

Satellite/GPS Antenna

13

PL121 Radio

1

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

8

PL121 Connection Procedure 1. Make sure all switches on 312-5641 Switch Box are in the OFF and/or OPEN position, as shown.

RM TE RT. AL CH WIT YS KE

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Damage to the harness cable assembly can occur from contact with hot surfaces and/or kinking/pinching/cutting the cable. To avoid damage, do not expose the harness to hot surfaces and route the harness assemblies to avoid contact with sharp edges on the machine.

1 64 ink 2-5 t L ol S 31 duc e To ES N o RN R O Pr ervic HA OWE G S P IN

CT MAIN NE U T ON ITHO ISC E W G/D AT IN PER ED T O OS E C OT CL N NN

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NOTICE

EN OP

WARNING

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Batteries contain sulfuric acid and produce explosive gases that can result in serious injury. Do not stand over the battery when connecting harness clamps. To prevent ignition of gases, avoid sparks and keep other ignition sources away from batteries at all times.

1016-03a

NOTICE 3. Connect the RED (+) and BLACK (-) battery clamps on main harness assembly (2) to an appropriate 12 Volt or 24 Volt power supply (8).

To avoid logging fault codes on Product Link Modules, always turn the switch box MAIN POWER switch OFF before connecting or disconnecting any product link components. 2. Connect the 12-pin plug on 312-5608 Main Harness Assembly (2) to switch box (1) receptacle.

312-5608

8

2 312-5608

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2 64

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(2) 312-5608 Main Harness Assembly. (8) 12 Volt or 24 Volt Power Supply.

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1

1016-14

NOTICE

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

To prevent possible damage to product link tooling or related components, use caution when connecting to the power supply. Always connect the RED (positive) clamp to the POSITIVE terminal first, then the BLACK (ground) clamp to the NEGATIVE terminal last.

9

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

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

3

13

3

312-5608

1016-18

2

1016-16

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

(2) 312-5608 Main Harness Assembly. (3) 312-5609 Harness Assembly

7. Connect the 9-pin serial connector on harness assembly (3) to laptop computer (10) with the latest version of CAT ET installed.

5. Make sure the key switch on the machine is OFF. Disconnect the machine harness 12-pin plug at PL121 Radio (13).

10

13

3

1016-19 1016-17

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

(13) PL121 Radio.

8. Proceed to the Configuring CAT Electronic Technician section in this manual. NOTE: For more information on PL121 Product Link, refer to RENR7911 Systems Operation Troubleshooting Testing and Adjusting, Product Link 121/321.

10

Service Tool Set-up For PL151/201 Product Link 9b

12 14

11 9a

4

10

2 8 312-5608

64

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1 1016-05

Components (PL151/201 Product Link) Item

Description

1


2


4


8


9a

275-5120 Communication Adapter II2

9b

261-3363 Wireless Communication Adapter2

10

Laptop Computer3

11


12


14

PL151/201 Module

1

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

11

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

PL151/201 Connection Procedure

NOTICE To avoid logging fault codes on Product Link Modules, always turn the switch box MAIN POWER switch OFF before connecting or disconnecting any product link components.

312-5608

2 RM TE R-

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1


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

NOTICE

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Damage to the harness cable assembly can occur from contact with hot surfaces and/or kinking/pinching/cutting the cable. To avoid damage, do not expose the harness to hot surfaces and route the harness assemblies to avoid contact with sharp edges on the machine.

1016-03b

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


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


CT MAIN NE U T ON ITHO ISC E W G/D RAT E IN ED CT T OP OS E CL NO NN

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1016-14

312-5608

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2

Y

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8

1016-15 1016-03a


12


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

14

4

4 2 312-5608

1016-23 1016-21

(4) 312-5610 Harness Assembly. (14) PL151/201 Module.

(2) 312-5608 Main Harness Assembly. (4) 312-5610 Harness Assembly.

NOTE: Use either 275-5120 Communication Adapter II (9a) or 261-3363 Wireless Communication Adapter (9b) as a link to laptop computer (10).

5. Make sure the key switch on the machine is OFF. Disconnect the machine harness 24-pin plug at PL151/201 Module (14).

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

14

9b 4 1016-22

(14) PL151/201 Module.

9a 1016-24

(4) 312-5610 Harness Assembly. (9a) 275-5120 Communication Adapter II. (9b) 261-3363 Wireless Communication Adapter.

13

8. If using 275-5120 Communication Adapter II (9a), connect the communication adapter harness 9-pin serial connector to laptop computer (10) with the latest version of CAT ET installed.

10

9a

1016-25

(9a) 275-5120 Communication Adapter II. (10) Laptop Computer

NOTE: 261-3363 Wireless Communication Adapter (9b) uses an 802.11b wireless radio network. There is no hard-wire connection from the wireless communication adapter to the laptop computer. 9. Proceed to the Configuring CAT Electronic Technician section in this manual. NOTE: For more information on PL151/201 Product Link, refer to RENR5885 Systems Operation Troubleshooting Testing and Adjusting, Product Link 151/201. For more information on communication adapters, refer to NEHS0758 Using the 275-5120 Caterpillar Communication Adapter II or NEHS0926 Using the 261-3363 Wireless Communication Adapter.

14

Service Tool Set-up For PL321 Product Link 9b 13

12

15 5

9a

11

10

2 8

312-5608

64

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1 1016-06

Components (PL321 Product Link) Item I.D.

Description

1


2


5


8


9a

275-5120 Communication Adapter II2

9b

261-3363 Wireless Communication Adapter2

10

Laptop Computer3

11


12


13

PL121 Radio

15

PL300 ECM

1

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

15

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

PL321 Connection Procedure

NOTICE To avoid logging fault codes on Product Link Modules, always turn the switch box MAIN POWER switch OFF before connecting or disconnecting any product link components.

312-5608

2 RM TE R-


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TA IN -S MA ADY TE RN TU ND S ED YS CH A OS A L C LW WIT K

1


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

EN OP

EN OP

S EY

EN OP

NOTICE Damage to the harness cable assembly can occur from contact with hot surfaces and/or kinking/pinching/cutting the cable. To avoid damage, do not expose the harness to hot surfaces and route the harness assemblies to avoid contact with sharp edges on the machine.

1016-03b



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A

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


CT MAIN NE U T ON ITHO ISC E W G/D RAT E IN ED P O CT OS CL

NE NOT ON ILL EC LW TS OR IGNA PU S EF L IN D F B ATOR F A O IT SE RN R TE DIG CLO WE E AL T PO

TA IN -S MA ADY TE RN TU ND S ED YS CH A OS A L C LW WIT K

1016-14

312-5608

EN OP

EN OP

S EY

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2

1016-03a

8

1016-15

(2) 312-5608 Main Harness Assembly. (8) 12 Volt or 24 Volt Power Supply

16


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

13 5 5

2 8065-213

1016-30 1016-27

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

(2) 312-5608 Main Harness Assembly. (5) 312-5611 Harness Assembly.

NOTE: Use either 275-5120 Communication Adapter II (9a) or 261-3363 Wireless Communication Adapter (9b) as a link to laptop computer (10).

5. Make sure the key switch on the machine is OFF. Disconnect the machine harness 70-pin plug at PL300 ECM (15).

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

9b

5

15 1016-28

(15) PL300 ECM.

9a 6. Connect the 70-Pin plug on harness assembly (5) to PL300 ECM (15).

1016-31

(5) 312-5611 Harness Assembly. (9a) 275-5120 Communication Adapter II. (9b) 261-3363 Wireless Communication Adapter.

5 15

1016-29

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

17

9. If using 275-5120 Communication Adapter II (9a), connect the communication adapter harness 9-pin serial connector to laptop computer (10) with the latest version of CAT ET installed.

9a 10

1016-32

(9a) 275-5120 Communication Adapter II. (10) Laptop Computer.

NOTE: 261-3363 Wireless Communication Adapter (9b) uses an 802.11b wireless radio network. There is no hard-wire connection from the wireless communication adapter to the laptop computer. 10. Proceed to the Configuring CAT Electronic Technician section in this manual. NOTE: For more information on PL321 Product Link, refer to RENR7911 Systems Operation Troubleshooting Testing and Adjusting, Product Link 121/321. For more information on communication adapters, refer to NEHS0758 Using the 275-5120 Caterpillar Communication Adapter II or NEHS0926 Using the 261-3363 Wireless Communication Adapter.

18

3. Open the “Utilities” menu, then select (click on) the “Preferences” tab.

Configuring CAT Electronic Technician 1. Place MAIN POWER (a) and KEY SWITCH (b) rocker switches to the ON position, as shown.

b

a

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CT MAIN NE U T ON ITHO ISC E W G/D RAT ED TIN OPE C OS NE NOT CL ON ILL E C AL W TS N OR PU EF R SIG IN B L F TO D OF RNA ITA SE R TE DIG CLO WE E AL T PO

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4. In the “Preferences” pane, select (click on) the “Communications” tab. 1016-07

(a) MAIN POWER Rocker Switch. (b) KEY SWITCH Rocker Switch.

2. With the laptop computer turned ON, open CAT Electronic Technician (ET) and select (click on) the “STOP CONNECT” icon to prevent ET from searching for a non-configured communication adapter.

19

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

7. On the main toolbar select (click on) the “Connect” icon to connect CAT ET to the Product Link system.

(a) 275-5120 Communication Adapter II. (b) 261-3363 Wireless Communication Adapter.

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

6. In the same pane, use pull down menu (c) to select the port that the communication adapter is configured to and then click “OK” (d).

• Use the laptop computer to proceed with set-up and registration of the module in CAT ET • View the status of the key switch, alternator, and digital switch inputs by going to the laptop computer STATUS screen NOTE: Digital switch inputs are not available with PL121SR Radio or PL151 Product Link module. For PL201 and PL321 Product Link, the digital inputs must be activated in the Configuration Screen.

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

20

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

Tooling Removal NOTICE

3. Close all programs on laptop computer (10). If using 275-5120 Communication Adapter II (9a), disconnect from the laptop computer when it is safe to do so.

To avoid logging fault codes on Product Link Modules, always turn the switch box MAIN POWER switch OFF before connecting or disconnecting any product link components.

9a 10

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IN MA

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R WE PO


CT MAIN NE U T ON ITHO ISC E W G/D RAT ED TIN PE OS EC OT O CL N NN L

O IL EC LW TS OR IGNA PU S EF L IN D F B TOR OF RNA ITA OSE R E T DIG CL WE E AL O P TAT

IN -S MA ADY TE RN TU ND S ED YS H A OS WA ITC CL A L Y SW KE

EN OP

EN OP

1016-33 EN OP

(9a) 275-5120 Communication Adapter II. (10) Laptop Computer.

1016-03b



IN MA

R WE PO

KE

CT MAIN NE U T ON ITHO ISC E W G/D AT IN PER ED T OS E C OT O CL N NN

O ILL EC LW TS OR IGNA PU S EF L IN D F B TOR OF RNA ITA OSE R IG L TE E D L C W A PO TATE

IN -S MA ADY TE RN TU ND S ED YS H A OS WA ITC CL A L Y SW


EN OP

EN OP

EN OP

1016-03a

21

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

WARNING Batteries contain sulfuric acid and produce explosive gases that can result in serious injury. Do not stand over the battery when disconnecting harness clamps. To prevent ignition of gases, avoid sparks and keep other ignition sources away from batteries at all times.

15 5

13 4

NOTICE To prevent possible damage to product link tooling or related components, use caution when disconnecting the power supply. Always remove the BLACK (ground) clamp first, then remove the RED (positive) terminal last.

14 3 1016-35

(3),(4),(5) Harness Assembly Connectors. (13) Product Link Radio. 14) Product Link Module. (15) Product Link ECM.

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

6. Disconnect main harness assembly (2) from harness assembly (3), (4), or (5), not shown, and from switch box (1).

312-5608

2

8 312-5608

1016-34

2


T. AL

MA

IN

PO

R WE

RM TE R-


IN TIN MA EC NN HOUT CO DIS ATE WIT G/ ED TIN OPER OS T EC CL NN L NO

H ITC Y SW KE CO WIL L S RE UT FO SIGNA L INP F BE TOR ED OF NA ITA R ER DIG CLOS WE ALT PO ATE IN -ST MA DY EN RN STEA OP TU D ED YS H AN OS WA ITC CL AL Y SW

EN OP

KE

EN OP

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

22

1016-36

7. Neatly coil up harness assemblies and store with switch box in 6V-7145 Storage Case.

Service Parts

Maintenance Section Cleaning/Inspection 1. Avoid allowing oil, grease, or other fluids to come in contact with the 312-5641 Switch Box and other components. Clean the switch box with a clean, dry cloth, as needed.

312-5642 Service Parts

WARNING No liquid components.

around

electrical

2. Inspect harness assemblies. Make sure connectors are clean and there are no kinks, breaks, or heat damage to the harness. Replace damaged harness assemblies. 3. Inspect the battery clamps on the main harness. Make sure they are clean and free from corrosion. 4. When not in use, store this tool group in the foam-lined case in a clean, dry location.

23

Item No.

Part No.

Description

1

312-5641

Switch Box

2

312-5608

Main Harness Assembly

3

312-5609

Harness Assembly (PL121 Product Link)

4

312-5610

Harness Assembly (PL151/201 Product Link)

5

312-5611

Harness Assembly (PL321 Product Link)

6

6V-7145

Storage Case

7

317-9430

Foam Insert (not shown)

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 [email protected]

©2008 Caterpillar All Rights Reserved

NEHS1016 Printed in U.S.A.

Nehs1016 WebSite[1]

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