PTC Solutions Installer (PSI) fails with error message Windchill Loader failed in Windchill PDMLink

• PTC Solutions Installer (PSI) fails with error message:

Windchill Loader failed.

• PSI fails while installing Windchill PDMLink 12.0 with error:

Windchill loader exited with error status = 1

• PSI fails at Loading data into database and PSI log reports following error message:

Running loader command: <Windchill_Home>\Windchill\bin\windchill.exe --java=<Windchill_Home>\Java\bin\java.exe --javaargs=-Dwt.load.installer.serverManagerTimeout=300 wt.load.WindchillLoader -All -Unattended -AbortOnError -IncludeDemo -Locale=en -User=wcadmin -Password=wcadmin   
joining with std out thread  
std out join complete.  
joining with std error thread  
std err join complete.  
Windchill loader exited with error status = 1  
Installation is Aborting.  The installation cannot continue.  
Installation is Aborting.  The installation cannot continue.  
Aborting installation.  Installation is Aborting.  
The installation cannot continue. FATAL Windchill Loader failed.  
FATAL aborting: original exit_code = 2  
FATAL aborting: normalized exit_code = 2  
DEBUG SHUTDOWN REQUESTED  
DEBUG(X) commiting registry  
DEBUG(X) shutting down service manager  
DEBUG(X) cleaning up temporary directories  
DEBUG Exiting with exit code: 2  
DEBUG java.lang.NullPointerException  
DEBUG cleanUp()  
DEBUG calling cleanUpWin32() 

• PSI fails at loading data with below error in WindchillLoader_error.log:

(wt.ixb.publicforhandlers.ixbResource/8) wt.ixb.publicforhandlers.LogHelper$IxbException: Problem in export/import process.
Nested exception is: (wt.pom.pomResource/0) wt.pom.PersistenceException: A persistence error occurred. System message follows:
Nested exception is: wt.util.WTException: java.rmi.RemoteException: Unable to register slave cache; nested exception is: 
    java.rmi.ConnectIOException: Exception creating connection to: ####; nested exception is: 
    wt.boot.UnsupportedHTTPTunnelingException: Either Windchill server manager not reachable or RMI over HTTP tunneling not supported with this java version.
Nested exception is: java.rmi.RemoteException: Unable to register slave cache; nested exception is: 
    java.rmi.ConnectIOException: Exception creating connection to: ####; nested exception is: 
    wt.boot.UnsupportedHTTPTunnelingException: Either Windchill server manager not reachable or RMI over HTTP tunneling not supported with this java version.
    at wt.cache.RemoteCacheServer.registerSlaveInternal(RemoteCacheServer.java:244)
    at wt.cache.RemoteCacheServer.lambda$registerSlave$0(RemoteCacheServer.java:177)
    at wt.cache.RemoteCacheServer.callTimeAndLogRemoteCallableLow(RemoteCacheServer.java:683)
    at wt.cache.RemoteCacheServer.callTimeAndLogRemoteCallable(RemoteCacheServer.java:655)
    at wt.cache.RemoteCacheServer.registerSlave(RemoteCacheServer.java:177)
    at wt.cache.CacheManager.reset(CacheManager.java:917)
    at wt.vc.views.ViewCache.reset(ViewCache.java:201)
    at wt.vc.views.StandardViewService$ViewTransactionCommitListener.finishTransaction(StandardViewService.java:154)
    at wt.pom.TransactionManager$FinishTransactionListener.fire(TransactionManager.java:1622)
    at wt.pom.TransactionManager.fireTransactionListener(TransactionManager.java:1582)
    at wt.pom.TransactionManager.finishTransaction(TransactionManager.java:492)
    at wt.pom.TransactionManager.commitTransaction(TransactionManager.java:440)
    at wt.pom.BasicTransactionMonitor.commitTransaction(BasicTransactionMonitor.java:64)
    at wt.pom.PersistentObjectManager.commitTransaction(PersistentObjectManager.java:405)
    at wt.pom.Transaction.commit(Transaction.java:754)
    at wt.ixb.publicforapps.Importer.doRealImport(Importer.java:1364)
    at wt.ixb.publicforapps.Importer.finalizeImport(Importer.java:572)
    at wt.load.StandardLoadService.importData(StandardLoadService.java:818)
    at jdk.internal.reflect.GeneratedMethodAccessor252.invoke(Unknown Source)
    at java.base/jdk.internal.reflect.DelegatingMethodAccessorImpl.invoke(DelegatingMethodAccessorImpl.java:43)
    at java.base/java.lang.reflect.Method.invoke(Method.java:568)
    at wt.method.MethodResultWriter.writeExternal(MethodResultWriter.java:165)
    at wt.method.MethodResult.writeExternal(MethodResult.java:226)
    at java.base/java.io.ObjectOutputStream.writeExternalData(ObjectOutputStream.java:1472)
    at java.base/java.io.ObjectOutputStream.writeOrdinaryObject(ObjectOutputStream.java:1446)
    at java.base/java.io.ObjectOutputStream.writeObject0(ObjectOutputStream.java:1191)
    at java.base/java.io.ObjectOutputStream.writeObject(ObjectOutputStream.java:354)
    at java.rmi/sun.rmi.server.UnicastRef.marshalValue(UnicastRef.java:294)
    at java.rmi/sun.rmi.server.UnicastServerRef.dispatch(UnicastServerRef.java:370)
    at java.rmi/sun.rmi.transport.Transport$1.run(Transport.java:200)
    at java.rmi/sun.rmi.transport.Transport$1.run(Transport.java:197)
    at java.base/java.security.AccessController.doPrivileged(AccessController.java:712)
    at java.rmi/sun.rmi.transport.Transport.serviceCall(Transport.java:196)
    at java.rmi/sun.rmi.transport.tcp.TCPTransport.handleMessages(TCPTransport.java:587)
    at java.rmi/sun.rmi.transport.tcp.TCPTransport$ConnectionHandler.run0(TCPTransport.java:828)
    at java.rmi/sun.rmi.transport.tcp.TCPTransport$ConnectionHandler.lambda$run$0(TCPTransport.java:705)
    at java.base/java.security.AccessController.doPrivileged(AccessController.java:399)
    at java.rmi/sun.rmi.transport.tcp.TCPTransport$ConnectionHandler.run(TCPTransport.java:704)
    at java.base/java.util.concurrent.ThreadPoolExecutor.runWorker(ThreadPoolExecutor.java:1136)
    at java.base/java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:635)
    at java.base/java.lang.Thread.run(Thread.java:842)
Caused by: java.rmi.ConnectIOException: Exception creating connection to: ####; nested exception is: 
    wt.boot.UnsupportedHTTPTunnelingException: Either Windchill server manager not reachable or RMI over HTTP tunneling not supported with this java version.
    at java.rmi/sun.rmi.transport.tcp.TCPEndpoint.newSocket(TCPEndpoint.java:638)
    at java.rmi/sun.rmi.transport.tcp.TCPChannel.createConnection(TCPChannel.java:217)
    at java.rmi/sun.rmi.transport.tcp.TCPChannel.newConnection(TCPChannel.java:204)
    at java.rmi/sun.rmi.server.UnicastRef.invoke(UnicastRef.java:133)
    at java.rmi/java.rmi.server.RemoteObjectInvocationHandler.invokeRemoteMethod(RemoteObjectInvocationHandler.java:215)
    at java.rmi/java.rmi.server.RemoteObjectInvocationHandler.invoke(RemoteObjectInvocationHandler.java:160)
    at jdk.proxy2/jdk.proxy2.$Proxy34.registerSlave(Unknown Source)
    at wt.cache.RemoteCacheServer.registerSlaveInternal(RemoteCacheServer.java:196)
    ... 40 more
Caused by: wt.boot.UnsupportedHTTPTunnelingException: Either Windchill server manager not reachable or RMI over HTTP tunneling not supported with this java version.
    at wt.boot.WTRMIMasterSocketFactory.createSocket(WTRMIMasterSocketFactory.java:236)
    at java.rmi/sun.rmi.transport.tcp.TCPEndpoint.newSocket(TCPEndpoint.java:620)
    ... 47 more

• PSI fails to load base data and xxxxxx_WindchillLoader_error.log shows:

************  Starting to log at Fri Oct 17 17:25:54 CDT 2025************
java.lang.Exception: Unable to complete startup of all Windchill Services
    at wt.load.Installer.checkServiceStartup(Installer.java:686)
    at wt.load.Installer.startServerManager(Installer.java:457)
    at wt.load.Installer.restartServerManager(Installer.java:515)
    at wt.load.BasicLoader.doPostInstall(BasicLoader.java:249)
    at wt.load.BasicLoader.(BasicLoader.java:218)
    at wt.load.WindchillLoader.load(WindchillLoader.java:382)
    at wt.load.WindchillLoader.main(WindchillLoader.java:487)
************ Ending log at Fri Oct 17 20:32:50 CDT 2025************

• While loading base data manually from Windchill shell through below command fails with error:

windchill wt.load.WindchillLoader -All -Unattended

java.lang.Exception: Unable to complete startup of all Windchill Services

• Despite this error, windchill method Server is able to start and the UI may be accessible as well
• ServerManager logs reports following error(s):

WARN  [main] wt.server.manager.startup -  ----------------------------------------------------------

WINDCHILL CONFIGURATION ASSISTANT (WCA) HAS NOT BEEN USED! PERFORMANCE ISSUES MAY RESULT FROM FAILING TO USE WCA! FOR OPTIMAL PERFORMANCE, WCA SHOULD BE USED PRIOR TO PRODUCT USAGE.

------------------------------------------------------------------------------- 

INFO  [wt.jmx.core.SharedScheduledExecutor.worker] wt.summary.general - JVMName=5064@SACNT1215, HeapMemoryUsage=15272992, NonHeapMemoryUsage=26285480, Uptime=16941, ProcessCpuTime=7456847800, JITCTime=1869, GarbageCollectors=[PS MarkSweep,PS Scavenge], GCTime=[237,123], GCCount=[2,11], Classes=3776, Threads=25, TotalStartedThreadCount=27, PermGenPercentCollUsage=5.3025767008463545, PermGenPercentUsage=5.309075249565972, CodeCachePercentUsage=2.5058746337890625, SystemLoadAverage=-1.0 ERROR [MethodServerMonitor] wt.manager.ServerManagerImpl - Start of MethodServer timed out. WARN  [MethodServerMonitor] wt.manager.ServerManagerImpl - Invoking taskkill [with task filter 'windowtitle eq MethodServer-1@5064'] in an attempt to ensure MethodServer has truly stopped MethodServerMonitor] wt.manager.ServerManagerImpl - taskkill output for MethodServer: SUCCESS: Sent termination signal to the process with PID 5216. INFO  [MethodServerMonitor] wt.manager.ServerManagerImpl - taskkill /f output for MethodServer: INFO: No tasks running with the specified criteria. ERROR [MethodServerMonitor] wt.server.manager.startup - Unable to launch 1 MethodServer instance wt.util.WTRemoteException: Unable to get server; nested exception is:     (wt.manager.managerResource/3) wt.util.WTException: Start of MethodServer timed out.     at wt.manager.ServerManagerImpl.getServer(ServerManagerImpl.java:318)     at wt.manager.RemoteServerManager$2.call(RemoteServerManager.java:290)     at wt.manager.RemoteServerManager$2.call(RemoteServerManager.java:285)     at wt.manager.RemoteServerManager.remoteInvoke(RemoteServerManager.java:509)     at wt.manager.RemoteServerManager.getServer(RemoteServerManager.java:283)     at wt.manager.StandardServerMonitor$ServerMonitor.startServers(StandardServerMonitor.java:319)     at wt.manager.StandardServerMonitor$ServerMonitor.run(StandardServerMonitor.java:198) INFO  [MethodServerMonitor] wt.server.manager.startup - Starting 1 additional MethodServer instance INFO  [wt.jmx.core.SharedScheduledExecutor.worker] wt.summary.general - JVMName=5064@SACNT1215, HeapMemoryUsage=18308680, NonHeapMemoryUsage=32505776, Uptime=617191, ProcessCpuTime=17550112500, JITCTime=7129, GarbageCollectors=[PS MarkSweep,PS Scavenge], GCTime=[624,212], GCCount=[4,22], Classes=4475, Threads=26, TotalStartedThreadCount=36, PermGenPercentCollUsage=6.29963853624132, PermGenPercentUsage=6.29963853624132, CodeCachePercentUsage=5.5240631103515625, TotalActiveUserCount=0, SystemLoadAverage=-1.0 ERROR [MethodServerMonitor] wt.manager.ServerManagerImpl - Start of MethodServer timed out. WARN  [MethodServerMonitor] wt.manager.ServerManagerImpl - Invoking taskkill [with task filter 'windowtitle eq MethodServer-2@5064'] in an attempt to ensure MethodServer has truly stopped INFO  [MethodServerMonitor] wt.manager.ServerManagerImpl - taskkill output for MethodServer: SUCCESS: Sent termination signal to the process with PID ****