Special Instruction

Installation Procedure for PL241 Cellular

Radio Systems
E Series Mini HEX
305.5E
306E
307E
308E

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Table of Contents
Introduction ................................................................................................................................................... 3
PL241 Cellular Radio ................................................................................................................................... 3
Important Safety Information ....................................................................................................................... 3
Required Parts ............................................................................................................................................... 4
PL241 Cellular Radio................................................................................................................................ 4
Antenna extension coax cable information ............................................................................................... 4
Block Diagram and System Components ..................................................................................................... 6
Mounting the Radio ...................................................................................................................................... 7
PL241 Mounting Requirements ................................................................................................................ 7
PL241 Environmental Information ........................................................................................................... 8
Installing the PL241 ...................................................................................................................................... 8
Pin Definitions ........................................................................................................................................ 10
Antenna Location Guidelines .................................................................................................................. 10
Harness Installation..................................................................................................................................... 13
Wire to the Equipment ............................................................................................................................ 14
Connect the Harness to the PL241 Cellular Radio .................................................................................. 14
Turn the Equipment Power ON .................................................................................................................. 14
Set the Product ID on the Product Link Device .......................................................................................... 14
Upgrading firmware procedure (over the air) ............................................................................................. 15
Subscribe the Equipment in Control ....................................................................................................... 15
Check the LED Lights on the Radio ........................................................................................................... 15
Green LED .............................................................................................................................................. 16
Orange LED ............................................................................................................................................ 16
Yellow LED ............................................................................................................................................ 17
Optional Inputs and Hardware .................................................................................................................... 17
Digital Inputs........................................................................................................................................... 17

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Introduction

This Special Instruction will provide instructions for installing and configuring the PL241 cellular radio
Systems.

PL241 cellular radio is a remote monitoring solution that enables efficient and effective equipment
management. Product Link transmits the information via a cellular GSM network.

PL241 Cellular Radio

PL241 cellular radio that sends data to the user interface over the cellular network. This radio requires the
use of an external antenna in order to transmit data and use GPS location services.

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 in order 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 of a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by
Caterpillar. If used, ensure the safety of the operating personnel and others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation,
lubrication, maintenance, or the repair procedures.

WARNING
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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Accidental machine starting can cause injury or death to personnel working on the equipment.
To avoid accidental machine 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 machine electrical system.

Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a
safety lock.

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.

Required Parts
PL241 Cellular Radio

PL241 installation components

Quantity Part Number
1 444-9619
1 443-8463
1 257-9364
1 256-6803
1 245-7310
1 370-8059
1 307-0047
1 274-4284
Description
PL241 module
Antenna As
Universal Harness As
Harness As
3-pin to Serial
Connector
Serial to USB Cable
Data Broadcast
Worldwide/Self-
propelled
This film, or an equivalent
is required on any vehicle
mounted system that
broadcasts information
RF Warning Portrait
This film, or an equivalent
is required on any vehicle
mounted system that
broadcasts information

Table 1: PL241 Installation components

Antenna extension coax cable information

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 Part Number Description Remarks
Cable As
347-2216 Single mode - 90 degree plug 717mm
Cable As
435-6069 Dual mode - 90 degree plug 914mm
Cable As
349-6083 Single mode - straight plug 1920mm
Cable As
450-2733 Dual mode - straight plug 2100mm
Cable As
Dual mode - wall mount 2166mm
447-8016 (bulkhead) use to traverse machine wall
Cable As
359-4778 Single mode - straight plug 2500mm
Cable As
375-1382 Single mode - 90 degree plug 2633mm
Antenna Cable AS
Single mode - wall mount 3000mm,
373-8970 (bulkhead) use to traverse machine wall
Antenna Cable AS
353-8773 Single mode - straight plug 4000mm

Table 2: Antenna extension Coax Cable Information

Illustration 1: 444-9619 Electronic Control Module (PL241 Cellular radio)

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Block Diagram and System Components

Antenna

GSM connector
PL241 GPS connector
module
12PIN
155-2252

Machine
Illustration 2: Mini HEX PL241 installation

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Mounting the Radio
PL241 Mounting Requirements
Note: Ensure that power is disconnected from the battery during the beginning steps of the installation.

 The external antenna must be mounted in a horizontal orientation to the horizon with a clear view
to the sky
 Place the Radio in an area where the Radio is NOT subjected to extreme heat, such as found near
engine compartment or turbo; this applies to wires/harness routed to radio also. Exposure to high
heat may make the Radio inoperable. Do not mount where temperature limitations are exceeded.
Refer to Table 3 for the environmental statistics.

 The module has LEDs to aid in troubleshooting and should be considered when finding a suitable
mounting location.
 The maximum torque for the radio mounting bolts is 3.5 N·m (2.581 lb ft). Use a 129-3178
Locknut if bolting through a surface with a bolt-nut combination or using a welded stud. Use
bolts with pre-applied thread-lock compound if bolting to a boss or weld nut
 Place the Radio in an area, and with an orientation, that the Radio connector is NOT subjected to
high-pressure spray or underwater submersion. Exposure to high-pressure spray or underwater
submersion may compromise the connector seals and lead to connection failure. An option may
be to use a back-shell as 311-8748. A metal deflector plate may also be used.
 Keep a distance between the radio and other antennas that transmit a radio signal. Caterpillar
recommends a distance of at least 1 m (3.28 ft). Keep no less than 500 mm (19.68 inch) between
the radio and other antennas that transmit a radio signal. The lists of radio antennas to maintain a
distance from include the citizen band radio, data radio, and commercial communication radios.
Maximum of 91.4 m (300 ft) of harness length
 Keep in mind the routing of the radio cable. Route the cable such that the cable is not subject to
abrasion or pinching. Do not route the radio harness near any source of extreme heat (exhaust).
Do not mount the radio or the radio harness so that the limitations of temperature are exceeded
 The length of the coax cable should be no more than 4.5 m (14.76 ft).

 Do not mount on a cantilever.

 Do not mount on a flexible surface, <1800 N/mm.
 The Radio must be installed on a flat surface.
 For serviceability purposes, the Radio should be placed in an area that it is easily accessible and
can be serviced in a reasonable amount of time.
 Place the Radio in an area, and with an orientation, that the Radio is not used as a “boot step” or a
fulcrum point for a dealer mechanic or tradesperson. The Radio is made of a high strength plastic
and, although durable, is still breakable.

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  The location for the Radio must allow enough room for the harness assembly. The Radio’s
location must have sufficient clearance for the Radio harness to prevent sharp bends in the Radio
harness.

Illustration 3: Recommended separation distance from edge of antenna enclosure to edge of PL241 cell radio
(assuming internal antenna) is 70 mm

Illustration 4: (Left) Stacked radios blocking additional satellite signal to external antenna (not recommended).
(Right) Correct radio placement.

PL241 Environmental Information

Table 3: PL241 Environmental Information Table

PL241 Environmental Information Table

Parameter Specification
−30° C (−22.00°F)
Operating Temperature Range to 70° C (158.00°F)
Vibration 9.73 Grms
34.5 ± 3.5 kPa
Sealing (5.003 ± 0.507 psi)
Operating Voltage 9 to 32 VDC
Jump Start Voltage 9 to 60 VDC
Non-Destructive Voltage Range -32 to 60 VDC

Installing the PL241

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Illustration 5: 444-9619 Electronic Control Module (PL241 Cellular radio)

1. Radio should be mounted in a cab exposing it to the least amount of extreme environmental
conditions as possible.
 Note: Avoid mounting the radio next to high heat sources such as exhaust stacks

 Note: Keep a distance between the radio and other antennas that transmit a radio signal.
Caterpillar recommends a distance of at least 1 m (3.28 ft). Keep no less than 500 mm (19.68
inch) between the radio and other antennas that transmit a radio signal. The lists of radio antennas
to maintain a distance from include the citizen band radio, data radio, and commercial
communication radios.

 Note: Avoid mounting the radio in transmitted beam of any radar equipment

2. Install the required bolts, washers, and locknuts in order to secure the radio. Tighten the mounting
bolts for the radio to 3.5 N·m +/- 0.5 Nm (2.581 lb ft).

3. Plug in the harness. The harness should extend downward out of the ECM. Harness must be
connected to protect the radio from paint operations. Product servicing guidelines should be followed.

4. Keep in mind the routing of the radio cable. Route the cable such that the cable is not subject to
abrasion or pinching. Do not route the radio harness near any source of extreme heat (exhaust). Do
not mount the radio or the radio harness so that the limitations of temperature −40° C (−40.00° F) and
85° C (185.00° F) are exceeded

Note: When selecting a fuse for Product Link, place the Product Link radios on independent fuses. This
will allow a dealer to disable Product Link in a blast zone without disabling other key components on the
machine. Having an independent fuse for the gateway will also prevent other key components from being
disabled if Product Link fails. The recommended fuse is a 5A fuse with Caterpillar part number 141-2759.
This is a fast action, non-time delay fuse.

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Note: When running wiring for Product Link, use an un-switched input.

Pin Definitions
The pin definitions for the 12-pin connector are shown in the table below.

7 8 9 10 11 12

Digital
Digital Backup Digital
RS232 RX+ RS232 GND Output(Lamp
Input(STG) +BATT Output(Disable)
Drv)

6 5 4 3 2 1

Digital KEY
RS232 TX+ R-Terminal -BATT +BATT
Input(STG) SWITCH

Table 4: 12-pin connector definitions

Antenna Location Guidelines

 Mount the antennas more than 1000 mm from radiations sources of similar frequencies and more
than 250 mm from radiation sources of other parts of the spectrum.
 Mount the antennas more than 250 mm from any metallic structure above the mounting plane (if
present), including exterior lighting structures.
 Antennas are to be mounted on a flat surface
 Mount further than 500 mm (19.68 inch) from metal structures wider than 40 mm (1.57 inch) and
which are in the radios field of view
 Mount the antenna more than 500 mm (19.68 inch) from the machine operator to comply with
FCC regulations for RF human body safety
 Radio waves will travel through plastic and glass, but not through metal; considerer that tinted
glass may contain metal particles that will considerably degrade radio signals.
 If paint is to be applied over radio, it must be non-metallic or the paint will attenuate signals
significantly
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 Illustration 6: 443-8463 Antenna As (Cellular radio with external antenna)

 For an increased likelihood of successful GPS the antennas must be placed such that the total
blockage on the surface of a hemisphere centered on the RF device itself does not exceed 25% of
the area of this surface above a 10° mask. This blockage must also be distributed such that no
more than 12.5% of it is within any quadrant of this hemisphere. Illustration 7, below, shows an
example of this hemisphere with blockage masks.
 Do not over-tighten the tie-downs on the cable. Damage to the cable may occur. Cable protection
is recommended around the coax cables to avoid physical damage and contact with machine
metal parts. Damage to the cable may occur.
 The length of the coax cable will depend on three factors:
1. Where the Radio placed
2. Where the antenna placed
3. Routing of cable
 Due to low torque on Coax cables, proper thread lock use is required in order to prevent eventual
disconnection.
 GPS antennas must be installed as horizontally as possible; tilting the antenna will cause
additional blockage, as part of the sky will exit the antenna’s field of view. The blockage caused
by tilting the antenna can be approximated by: Blockage = 50*(tilt angle)/75 (in percentage).
Tilting the antenna more than 19 degrees fails the set recommendations even if no other metal
parts add to the blockage.
 Mount the antenna more than 200 mm from the machine operator to comply with FCC
regulations for RF human body safety
 Illustration 8: shows the field of view of the cellular antenna. Even a small portion of the
horizontal 360 will typically allow for the signals to make it through to the radio, and field-trials
have shown that cellular signals will bounce their way to the radio through almost any path.
Following the recommendations for GPS will typically suffice for cellular communications, but
care must be taken not to entirely block the side views.

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The cab roof is typically the highest point on the machine and usually provides an excellent view of the
sky, it also provides a suitable flat surface to mount the radios; however, at times it is impractical to use
this location due to shipping height requirements, the presence of other antennas, routing, or other
metallic object (dump body, large AC unit…). Other locations may need to be considered and specific
guidelines are provided in the next subsections.

Illustration 7: Hemisphere centered on RF device with blockage masks

Illustration 8: Field of view of the cellular antenna

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Harness Installation

Harness Table

Quantity Part Number Description

1 256-6803 Harness As

1 257-9364 Universal harness

As required for
installation

Table: 5: Harness Table

Illustration 9: 257-9364 Universal Harness As. (1) 12 pin connector and (2) 3- pin receptacle

Connect the wires to the machine following the Table 6 below. The 3 pin receptacle will be used to access
Cat ET.

257-9364 Universal Harness Splice Information

Wire Information Description Required/Optional
Battery + 125 - OR Required
Battery - 200 - BK Required
Switched Power 308 - YL Required
R –Term 403 - GN Required
CDL + 944 - OR Not Used
CDL - 945 – BR Not Used
RxD Comm #1 N957 – PK Not Used
TxD Comm #1 N960 – OR Not Used
Signal Ground Comm #1 N979 – GN Not Used
CAN - Y794 - OR Not Used

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 CAN + Y795 - GN Not Used
Table 6: 257-9364 Universal Harness Splice Information

Wire to the Equipment

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

The standard harness for the installation is part number 257-9364 Universal Harness. Connect the wires to
the equipment by following Table 6. Only the Battery +, Battery -, Switched Power and the R-term are
needed to connect to the equipment. The rest of the wires should be capped.

Recommended wire splicing practices should be followed for any of the harness splices
Note: Use proper application and installation guide, and schematic of equipment in order to determine the
best place to splice wires for installation.

Connect the Harness to the PL241 Cellular Radio

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

Connect the 12 pin connector to the radio.

Turn the Equipment Power ON

Once the PL241 cellular radio has been connected, and the wires from the harness for battery positive,
battery negative, and key switch power have been connected to the equipment, turn on the power to the
equipment

Set the Product ID on the Product Link Device

The Product Link system will automatically send a registration message to Product Link Web after the
Product ID has been set through Cat ET. The Product Link device will send a registration message in
order to be subscribed in Product Link Web based on the engine serial number. The PL241 system offers
the option for the equipment to be subscribed under a different name or serial number. Use the following
steps in order to change the equipment name or serial number.

1. Connect to the equipment by using the 245-7310 (3-pin to serial) connector and the 370-8059
(serial to USB) cable.
2. Choose the Telematics ECM.
3. Open the configurations screen in Product Link by choosing “Service” and then “Configuration”.
4. The Product ID will show up in the “ECM Identification Parameters” and will be a default of
“CAT00000”. In the “New Value” field enter the serial number of the equipment.

The PL241 will automatically generate a new registration message. Along with the new registration
message the equipment will be subscribed in Product Link Web based off the Product ID entered.

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Note: For equipment not appearing in the “Control Center” tab of Product Link Web.

Upgrading firmware procedure (over the air)

The firmware can only be updated remotely through cellular communication. If you would like to have
your software updated, submit a DSN ticket stating that you would like to have the software on your
PL241 updated, along with acknowledgement of customer consent, and the DSN Tier 2 analysts will have
the software on your radio updated.

Subscribe the Equipment in Control

The PL241 Cellular radio is configured automatically for the services selected in the web-based service
management tool in Product Link Web. Your Caterpillar dealer administrator will be notified when your
device is on-online and ready to have services enabled. Once the dealer selects the desired services, the
configuration will be sent over the air and the device will be configured in order to provide the proper
data at the proper frequency for the service in the “Control Center” tab of Product Link Web.

Consult with your dealer’s Product Link specialist for additional details in assisting you for the right data
service to meet your needs. Service starts with basic equipment management features providing hour,
location monitoring, health and utilization.

Initial Setup

The Caterpillar dealer administrator:

1. Log in to Product Link Web.

2. Select “Control Center” from the primary navigation bar.
3. Select “Services” from the secondary navigation bar.
4. Search for the desired Product Link installed equipment
5. Confirm proper customer ownership
6. Select the desired application to view the equipment in Vision Link or Product Link Web. Select
the level of service the dealer or customer desires. For Visionlink “Basic” or “Cat Essentials” is
available. For Product Link Web, the service levels that are available are “Vitals” and “Aide”.
The dealer level of service is able to be set to a higher level of service than the customer in
Product Link Web. The level of service is the same for the dealer and customer in VisionLink.
For more information refer to https://dealer.cat.com/PL locate Product Link Web for Power Systems and
select “Module 6: Control Center”.

Note: The website https://dealer.cat.com/PL will require a Caterpillar Corporate Web Security (CWS)
user name and password.

Check the LED Lights on the Radio

The PL241cellular radio and the PL631 satellite radio are both equipped with LED lights that function
when the equipment key switch is turned to the on position. The LED lights on the radios from left to
right are green, orange and yellow.

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 Off Blinking @ 1Hz Solid
Power ON (Only
comes on when the
device has both main
Green No Power Fault power and keyswitch)
GPS
Orange Fault Searching / No Lock GPS Fix
Cell Searching/ Cell Data Connection
Yellow Fault No Connection established

Green LED
The purpose of the green LED is to indicate when the radio is powered ON or OFF

Note: When the battery disconnect is turned ON, the green light will appear for two or three minutes
while the radio powers up, even if key switch power is not present. The radio will power up, find a GPS
location, determine if a connection needs to be made to the back office, and shut itself down.

Green LED OFF: The green LED will be OFF when there is no power on the battery positive pin or the
key switch is in the OFF position. While the radio is starting up, the green LED will be OFF, and the
yellow and orange LEDs will be ON indicating the radio is in startup mode. Startup mode should not
occur for more than 30 seconds. Once the radio has properly started up, the green LED should turn ON
solid, while the other lights perform other functions. If green LED does not turn solid on after more than
two minutes after startup, refer to System Operation Testing and Adjusting, UENR5824, “Cellular Radio
Does Not Communicate”.

Green LED Blinking – The green LED will blink when a fault has been detected that will prevent the
application firmware from running. If the green LED is blinking, refer to System Operation Testing and
Adjusting, UENR5824, “Cellular Radio Does Not Communicate”.

Green LED ON – Indicates that the radio is powered properly and is ON.

Orange LED
The purpose of the orange LED is to indicate whether a GPS fix has been made.

Orange LED OFF – The orange LED will be OFF when a GPS antenna is not found by the radio. For
radios with an external antenna, check the connection of the external antenna. If that does not resolve any
issue, refer to System Operation Testing and Adjusting, UENR5824, “User Interface Does Not Update
GPS Location”.

Orange LED Blinking – The orange LED will have a constant blinking status when the GPS Antenna is
working properly, however not enough GPS satellites are viewable to get a good GPS location fix. If a
blinking orange LED persists, ensure that the antenna has clear line of site to the sky. If that does not
resolve any issues, refer to System Operation Testing and Adjusting, UENR5824, “User Interface Does
Not Update GPS Location”.

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Orange LED ON – The GPS Antenna is working properly, and can see enough GPS satellites to
determine a good location fix.

Yellow LED
The purpose of the yellow LED is to indicate that a satellite or cellular connection, is being attempted.
This does not indicate that there is an appropriate signal to make a satellite or cellular connection, only
that the hardware is working properly, and is capable of making a connection given that a signal is
present.

Yellow LED OFF – The yellow LED should be OFF when an external antenna is not present or when an
external antenna has been connected backwards. If the green LED is ON, and the yellow LED is OFF,
refer to System Operation Testing and Adjusting, UENR5824, “Cellular Radio Does Not Communicate”.

Yellow LED Blinking – The yellow LED will blink when the cellular radio, or satellite radio is trying to
make a connection. If a cellular radio continues to blink for longer than five minutes, and is in an area
known to have a good cellular signal, check the installation of the external antenna if equipped. If that
does not resolve the situation, refer to System Operation Testing and Adjusting, UENR5824, “Cellular
Radio Does Not Communicate” or System Operation Testing and Adjusting, UENR5824, “Satellite Radio
Does Not Communicate” depending on the radio displaying this symptom. If the satellite radio has a
yellow LED that blinks for greater than five minutes, check the installation of the external antenna. Check
that the external antenna has been connected properly, and has clear line of site to the sky. Satellite radios
can only make a satellite connection when they have clear line of site to orbiting satellites. If the situation
is not resolved, refer to System Operation Testing and Adjusting, UENR5824, “Cellular Radio Does Not
Communicate”.

Yellow LED ON – The yellow LED will be ON when a good connection through either cellular or
satellite communication is detected, depending on the radio type.

Optional Inputs and Hardware

Digital Inputs
Note: Digital inputs can only be configured through the User Interface. Currently VisionLink supports the
configuration of digital switches on the PL241. The User Interface Product Link Web does not currently
support the configuration of digital switches on the PL241. For more information on how to configure the
digital switches from the User Interface.

The PL241 cellular radio provides two digital switch to ground type inputs that can be used for alerting
functions in a Product Link installation. This feature allows the PL241 to monitor a pressure, temperature,
or level that is not normally provided through the equipment ECM. The pin position on the 12 pin
connector of the PL241 cellular radio that supports digital inputs are “6” and “9”.

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