26SI Series Alternator – Operating Hours Discrepancy

System Operation Description:

There are problems that could be reported with the Product Link system but the problems are not caused by the Product Link system. The description of the problem is described as a discrepancy of the service meter units. This section contains steps that are used to determine the possible cause. Check for active diagnostic codes for the Product Link. Correct any diagnostic codes before proceeding. The following items should be visually inspected for damage: PL121SR radio, PL300 module, antenna and cables. Verify that there are no loose connections.

The Product Link system depends on several communication links in order to transfer data from the machine to the office. The following procedures assume that these communication links are operating properly. The proper communication links are listed below:

  • The satellite network for VHF communications is operational in the geographic area of concern. The network is operational when messages can travel to the satellite and the messages can travel to the earth and Caterpillar.

  • The Product Link system is correctly configured to communicate on the network for VHF communications.

  • The worldwide network of Caterpillar’s computers is passing messages to software for the Caterpillar Equipmentmanager (EM).

  • The EM is configured properly and the software is functioning.

The PL300 module or the PL121SR radio should not be replaced without verifying that these issues have been investigated. Contact your Caterpillar Technical Communicator for aid in resolving these issues.

Note: The Service Meter Hours that are reported by the Product Link module should approximately match the machine operating hours.

Test Step 1. ACCESS THE PRODUCT LINK THROUGH THE CAT ET SERVICE TOOL.

  1. Connect the Cat ET service tool to the machine.
  1. Verify that the ECM (Product Link) is available.

Expected Result:

The ECM (Product Link) is available.

Results:

  • OK – The ECM (Product Link) is available. Proceed to Test Step 2.

  • NOT OK – The ECM (Product Link) is not present in the screen for Cat ET.

    Repair: Verify that the wiring for the Product Link has been installed correctly. Check the wiring with a multimeter. If the ECM (Product Link) is not available, refer to Systems Operation, Troubleshooting, Testing and Adjusting, “Electronic Service Tool Does Not Communicate with ECM”.

    STOP

Test Step 2. VERIFY THAT THE PRODUCT LINK MODULE IS CONFIGURED PROPERLY.

For PL121 only, perform the following steps:

  1. Go to the “Information” pull-down menu.
  1. Select “Current Totals”.
  1. Verify that the “Product Link Machine Operating Hours” match the machine service meter units.

    For PL321 only, perform the following steps:

    1. Go to the “Service” pull-down menu.
    1. Select “Synchronize Service Meter Hours”.
    1. If Product Link is not the master ECM, verify that the “Product Link SMH” matches the SMH of the master ECM. If Product Link is the master ECM, verify that the Product Link SMH matches the machine service meter units.

Expected Result:

The hours are within 1 percent.

Results:

  • OK – The hours are within 1 percent. The hours are synchronized. The Product Link is operating correctly.STOP

  • NOT OK – ( PL121) The hours are not within 1 percent. Proceed to Test Step 3.

  • NOT OK – ( PL321) The hours are not within 1 percent. In a PL321 system using sync-clock where Product Link is not the master ECM, the Product Link module will automatically sync to the master ECM hours if the difference is not greater than 50 hours. If the difference is greater than 50 hours, a diagnostic will be generated in ET that indicates that a manual sync is required. In that instance, sync the hours (Service/Synchronize Service Meter Hours). Proceed to Test Step 3 unless the master ECM hours are incorrect. If Product Link is not the master ECM, and the hours for the master ECM are not correct, troubleshoot on machine side. Do not replace the Product Link module. STOP.

Test Step 3. VERIFY THAT THE PRODUCT LINK MODULE MONITORS THE “MACHINE RUN STATUS” PROPERLY.

  1. Go to “Status Parameters” for Cat ET.
  1. Verify that the “Alternator Running Input” displays “Engine Off”.
  1. Start the machine.
  1. Verify that the “Alternator Running Input” changes to “Engine Running”.
  1. Verify that the “Key Switch Status” is “On”.

Expected Result:

The “Status” screen for Cat ET changes from “Engine Off” to “Engine Running” when the machine is started. The “Key Switch Status” should be “On”.

Results:

  • OK – The screens for Cat ET are correct. The Product Link is correctly reading the “machine run status”. This allows the Product Link to monitor the machine operating hours correctly.

    Repair: Check the splices for the R-Terminal wire (403-GN) and power wire (308-YL) in order to ensure that there are no intermittent connections.

    STOP

  • NOT OK – On the Cat ET screen, the status did not change from “Engine Off” to “Engine Running”.

    Repair: Verify the Alternator R-Terminal wiring (403-GN). Verify the switched power wire (308-YL). If the problem is not corrected, replace the Product Link module.In a PL321 system where Product Link is not the master ECM, Product Link receives the r-term input from the master ECM. In this instance, do not replace the Product Link module. Instead, troubleshoot the master ECM and the inputs from the master ECM.

    STOP

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