Procedure to Install Truck Payload Measurement System (TPMS) on AD45B (Ejector) Underground Articulated Trucks{1408, 7494} Caterpillar

Introduction

This special instruction covers the procedure to install the Truck Payload Measurement System (TPMS) on AD45B S/N:CXM (Ejector) Underground Articulated Trucks. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

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 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. AVSpare 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 all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by AVSpare. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

ReferenceDisassembly and Assembly, RENR8576, "AD45B Underground Articulated Truck Machine Systems".

ReferenceService Manual, RENR4725, "Underground Articulated Trucks Truck Payload Measurement System".

Parts Required

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

6. Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

Installation Procedure

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes to prevent fluid loss and contaminants from entering the system.

Load Cells and Rear Frame Harness

Reference 253-2736 Monitor Harness As

1. Remove the ejector body. Refer to Disassembly and Assembly, "Ejector Body - Remove".

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Illustration 1	g03721515

2. Remove and discard four pad assemblies (1), four spacers (2), the shims, the bolts, and the washers.

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Illustration 2	g03725182
(3) 246-0053 Shim (4) 246-0054 Shim (5) 246-0055 Shim (6) 316-2826 Pad As (7) 8T-4183 Bolt (8) 8T-4223 Hard Washer (9) 246-0049 Plate (10) 8S-4755 Bolt (11) 5P-8250 Washer (12) 246-0051 Cell (13) 246-0052 Bearing Plate (14) 8T-0668 Bolt (15) 6V-8237 Washer

3. Install Item (3) through Item (15) to both sides of the rear frame.

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Illustration 3	g03725202
View of the left side of the hitch (16) 253-2736 Monitor Harness As (17) 6K-0806 Cable Strap

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Illustration 4	g03725203
View of the right side of the hitch (16) 253-2736 Monitor Harness As (17) 6K-0806 Cable Strap

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Illustration 5	g03725204
View of the rear frame (16) 253-2736 Monitor Harness As (17) 6K-0806 Cable Strap

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Illustration 6	g03725736
View of the rear frame (16) 253-2736 Monitor Harness As (17) 6K-0806 Cable Strap

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Illustration 7	g03725737
Typical example View of the rear of the machine (16) 253-2736 Monitor Harness As (17) 6K-0806 Cable Strap (18) 4P-8134 Clip (19) 4E-5753 Bracket (20) 8T-4137 Bolt (21) 8T-4133 Nut (22) 8T-4121 Hard Washer

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Illustration 8	g03725738
Typical example View of the rear of the machine (16) 253-2736 Monitor Harness As (17) 6K-0806 Cable Strap (23) 8M-2772 Clip

4. Install Item (16) through Item (23). Refer to Illustration 3 through Illustration 8.

   Note: Secure 253-2736 Monitor Harness As (16) using 6K-0806 Cable Straps (17) as required.

5. Connect 253-2736 Monitor Harness As (16) to four 246-0051 Cells (12), installed in Step 3.

Rear Frame to Cab Harnesses

Reference 247-1629 Cab Harness As

Reference 247-1630 Cab Harness As

Reference 247-1633 Monitor Harness As

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Illustration 9	g03725740
View of the left side of the hitch (1) 247-1629 Cab Harness As (2) 6K-0806 Cable Strap (3) 253-2736 Monitor Harness As

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Illustration 10	g03725741
View of the transmission compartment (1) 247-1629 Cab Harness As (2) 6K-0806 Strap

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Illustration 11	g03644625
View of the transmission compartment (1) 247-1629 Cab Harness As (2) 6K-0806 Strap

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Illustration 12	g03644627
View of the engine compartment (1) 247-1629 Cab Harness As (2) 6K-0806 Strap

1. Install 247-1629 Cab Harness As (1) using 6K-0806 Straps (2) as required. Refer to Illustration 9 through Illustration 12.

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Illustration 13	g03644628
View inside the operator station

2. Remove dash panel (4), discard tray (5) .

3. Remove cover (6) and cover (7) .

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Illustration 14	g03644629
View of the engine compartment (1) 247-1629 Cab Harness As (2) 6K-0806 Strap (8) 247-1630 Cab Harness As (9) 119-6105 Grommet

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Illustration 15	g03644637
View inside the operator station (8) 247-1630 Cab Harness As (Connects to indicator) (9) 119-6105 Grommet (10) 8T-9471 Grommet

4. Install 247-1630 Cab Harness As (8), 119-6105 Grommet (9), 8T-9471 Grommet (10), and 6K-0806 Straps (2) as required. Refer to Illustration 14 and Illustration 15.

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Illustration 16	g03645320
View inside the operator station

5. Remove retainer (11), retainer (12), and radio (13) .

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Illustration 17	g03644636
View inside the operator station (2) 6K-0806 Strap (14) 247-1633 Monitor Harness As (Connects to indicator)

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Illustration 18	g03645324
View inside the operator station (2) 6K-0806 Strap (14) 247-1633 Monitor Harness As

6. Install 247-1633 Monitor Harness As (14) using 6K-0806 Straps (2) as required. Refer to Illustration 17 and Illustration 18.

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Illustration 19	g03645333
View of the right side rear of the operator station (14) 247-1633 Monitor Harness As (15) 247-1625 Antenna (16) 247-1634 Transmitter (17) 153-8001 Bolt (18) 5C-8312 Nut

7. Install 247-1625 Antenna (15) to 247-1634 Transmitter (16) .

8. Install 247-1634 Transmitter (16) using two 153-8001 Bolts (17) and two 5C-8312 Nuts (18) .

9. Connect 247-1633 Monitor Harness As (14) to 247-1634 Transmitter (16) .

10. Install retainer (11), retainer (12), and radio (13) that were removed in Step 5.

Panel Harness

Reference 247-1631 Panel Harness As

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Illustration 20	g03645999
Steering wheel removed for illustration purposes only

1. Remove dash panel (1) .

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Illustration 21	g03645345
247-1631 Panel Harness As (2) To cab harness (12 pin) (3) Fuse receptacle (6 pin) (4) To indicator (6 pin) (5) Connector (3 pin) (6) Connector (2 pin) (7) Splice Receptacle (8 pin) (8) To indicator (12 pin)

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Illustration 22	g03646000
Steering wheel removed for illustration purposes only (2) To cab harness (12 pin) (3) Fuse receptacle (6 pin) (4) To indicator (6 pin) (5) Connector (3 pin) (6) Connector (2 pin) (7) Splice Receptacle (8 pin) (8) To indicator (12 pin) (9) 247-1631 Panel Harness As (10) 6K-0806 Strap

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Illustration 23	g03646003
Steering wheel removed for illustration purposes only (6) Connector (2 pin) (9) 247-1631 Panel Harness As (11) Cab harness connector (2 pin) 707B-PU

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Illustration 24	g03652036
Steering wheel removed for illustration purposes only (5) Connector (3 pin) (9) 247-1631 Panel Harness As (12) Cab harness connector (3 pin) C533A-PU, A251A-BK, and C534A-YL

2. Install 247-1631 Panel Harness As (9) using 6K-0806 Straps (10) as required. Refer to Illustration 21 through Illustration 24.

   Note: Connector (6) connects to cab harness connector (11). Refer to Illustration 23.

   Note: Connector (5) connects to cab harness connector (12). Refer to Illustration 24.

3. Install dash panel (1) that was removed in Step 1.

4. Install dash panel (4), cover (6), and cover (7) that were removed in Step 2 and Step 3 of ""Rear Frame to Cab Harnesses" ".

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Illustration 25	g03646620
(13) 3E-8766 Switch (14) 165-5674 LED Lamp (15) 441-4014 Actuator As (16) 468-4662 Indicator (17) 247-2041 Screw

5. Remove and discard the plug from the dash panel. Install Item (13) through Item (15). Refer to Illustration 25.

6. Install 468-4662 Indicator (16) using four 247-2041 Screws (17). Refer to Illustration 25.

   Note: Connect 468-4662 Indicator (16) to the 247-1630 Cab Harness As , the 247-1633 Monitor Harness As and the 247-1631 Panel Harness As connectors. Refer to Illustration 15, Illustration 17, and Illustration 22.

LED Lamps

Reference 338-6588 Lighting Harness As

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Illustration 26	g03647269
(1) 247-1635 Plate As (2) 9X-8256 Washer (3) 7G-7053 Grommet (4) 9X-2480 Bolt (5) 6V-7743 Locknut (6) 247-1632 Led Lamp As

1. Assemble Item (1) through Item (6) .

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Illustration 27	g03725759
Typical example View of the right side of the machine (7) 8T-4136 Bolt (8) 8T-4121 Hard Washer (9) 8T-4133 Nut (10) 338-6588 Lighting Harness As (11) 8S-0023 Clip (12) 8S-0024 Clip

2. Install the LED lamp assembled in Step 1 using Item (7) through Item (12) .

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Illustration 28	g03647276
View of the left side of the operator station (6) 247-1632 Led Lamp As (13) 9X-2046 Screw (14) 119-6105 Grommet

3. Install 247-1632 Led Lamp As (6) using four 9X-2046 Screws (13) and 119-6105 Grommet (14) .

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Illustration 29	g03647277
View through the rear window of the operator station (15) Harness

4. Connect 247-1632 Led Lamp As (6) to harness (15) .

Payload Pivot Pins

Reference 246-0048 Pivot Pin

1. Install the ejector body using two 246-0048 Pivot Pins . Refer to Disassembly and Assembly, "Ejector Body - Install" and the instruction that follows.

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Illustration 30	g03647278
View of the right side payload pivot pin (1) 8W-8456 Plate (2) 8T-4223 Hard Washer (3) 8T-4183 Bolt (4) 246-0047 Plate (5) 246-0048 Pivot Pin (6) 247-1628 Monitor Harness As (7) 5P-2228 Bolt (8) Elbow (9) 124-9014 Thrust Washer (10) 203-0593 Thrust Washer (11) 7D-7488 Thrust Washer

2. Install Item (1) through Item (11) to both the left side and the right side.

Calibration Procedure

1. Disconnect the harness connectors from the two payload pivot pins, the right side rear load cell, and from the two left side load cells.

2. Turn the key start switch and the battery disconnect switch to the ON position.

3. Record the reading on the TPMS indicator for the right side front load cell. Refer to Table 2.
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   Table 2

   First Attempt
   Load Cell	Body Down	Body Up	Difference	Action
   Right side front
   Right side rear
   Left side front
   Left side rear

4. Disconnect the harness connector from the right side front load cell. Connect the harness connector to the right side rear load cell.

5. Record the reading on the TPMS indicator for the right side rear load cell. Refer to Table 2.

6. Disconnect the harness connector from the right side rear load cell. Connect the harness connector to the left side front load cell.

7. Record the reading on the TPMS indicator for the left side front load cell. Refer to Table 2.

8. Disconnect the harness connector from the left side front load cell. Connect the harness connector to the left side rear load cell.

9. Record the reading on the TPMS indicator for the left side rear load cell. Refer to Table 2.

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Illustration 31	g03656859
(1) Pin assembly

10. Remove two pin assemblies (1) in order for the ejector body to be lifted off the load cells.

11. Using a suitable lifting device, raise the front of the ejector body approximately 500 mm (20.0 inch). The weight of the ejector body and ejector plate combined is approximately 10000 kg (22050 lb).

    Note: If required, move the ejector plate to the rear of the machine in order to reduce the lifted weight.

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Illustration 32	g03725762
Location where support block is to be installed

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Illustration 33	g03725763
Location where support block is to be installed

12. Install two suitable 450 mm (18.0 inch) thick support blocks. Refer to Illustration 32 and Illustration 33.

13. Lower the ejector body onto the support blocks.

14. Repeat Step 1 through Step 9.

15. Calculate the difference by subtracting the "Body Up" reading from the "Body Down" reading. Refer to Table 2.

16. For correct calibration, the two calculations in Step 15 will be within 5000 kg (11000 lb) of each other.

17. Remove or install shims in order to obtain the correct calibration. Refer to Step 16.

18. Using a suitable lifting device, raise the front of the ejector body in order to remove the support blocks. The weight of the ejector body and ejector plate combined is approximately 10000 kg (22050 lb).

19. Lower the ejector body onto the load cells and install two pin assemblies (1). Refer to Illustration 31.

20. Connect the harness connectors to all four load cells and to the two payload pivot pins.

21. Perform a tare calibration. Refer to Underground Articulated Trucks Truck Payload Measurement System, "Calibration".

22. Perform a span calibration. Refer to Underground Articulated Trucks Truck Payload Measurement System, "Calibration".

Data Download

Illustration 34	g03653436
(1) 247-2042 Monitor Harness As (2) Service port

Use 247-2042 Monitor Harness As in order to connect a Personal Computer (PC) to the machine service port.

The EASYLOG software must be installed on the PC in order to download the stored data from the payload system.

The EASYLOG software CD is located at the rear of Service Manual, RENR4725, "Underground Articulated Trucks Truck Payload Measurement System".

For more information on downloading data from the payload system refer to Service Manual, "Down Loading Data".