Procedure to Install <NOBR>602-6792</NOBR> Work Tool Control and Wiring Kit on Certain Wheel Loaders {1408} Caterpillar


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Procedure to Install <NOBR>602-6792</NOBR> Work Tool Control and Wiring Kit on Certain Wheel Loaders {1408} [M0122275]
ELECTRICAL AND STARTING SYSTEM
WIRING GP
Procedure to Install <NOBR>602-6792</NOBR> Work Tool Control and Wiring Kit on Certain Wheel Loaders {1408}
1.1. Introduction
2.1. Reference Section
3.1. Safety Section
4.1. Required Parts
5.1. Machine Preparation
6.1. Installation Procedure
7.2. Procedure to Install <NOBR>446-9302</NOBR> Wiring Harness on K-Series Wheel Loader
8.2. Procedure to Install <NOBR>446-9302</NOBR> Wiring Harness on M-Series Wheel Loader
9.3. For <B>S/N:</B>LTE, ; <B>S/N:</B>KTG, ; <B>S/N:</B>HEY, and ; <B>S/N:</B>J3R Serial Number prefixes
10.3. For <B>S/N:</B>W5L, ; <B>S/N:</B>F5K, and ; <B>S/N:</B>P5K Serial Number prefixes
11.2. Installing <NOBR>491-2042</NOBR> Work Tool Harness As (Only for M - Series machines)
12.2. Installing the Work Tool Rocker Switch
Wheel Loader
924K (S/N: KW41-UP; ENC1-UP; HJF1-UP; PWR1-UP; SNZ1-UP)
926M (S/N: LTE1-UP; W5L1-UP)
930K (S/N: DYB1-UP; EYE1-UP; FRK1-UP; P3K1-UP; RHN1-UP)
930M (S/N: KTG1-UP; F5K1-UP; HEY1-UP)
938K (S/N: W8K1-UP; SWL1-UP; REP1-UP; XXT1-UP; HFW1-UP)
938M (S/N: P5K1-UP; J3R1-UP)
Work Tool
BA25 (S/N: 7AW1-UP)
BA30 (S/N: 7001-UP)
BP25 (S/N: AEH1-UP)
BROOM - ANGLE (S/N: BCG1-UP; BAW1-UP; H1W1-UP)

Introduction

This Special Instruction describes the necessary procedure to install 602-6792 Work Tool Control and Wiring Kit on the machines listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Specifications, SENR3130, "Torque Specifications"

Safety Section

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

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 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 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 AVSpare.

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! ------

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.


------ WARNING! ------

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.


------ WARNING! ------

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.


------ WARNING! ------

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.


------ WARNING! ------

Personal injury or death can result from sudden movement.

Prevent possible injury by performing the following procedures before work begins:

Move the product or equipment to a smooth, level surface.

When applicable, lower equipment/work tools to the ground.

Engage the parking brake, system brakes and/or hydraulic lockout control. When applicable, stop the engine and remove the ignition key.

Release system pressure from pressurized systems.

If applicable, block the wheels/tracks.

Turn the battery disconnect switch to the OFF position and if applicable, remove the battery disconnect key. If not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. 

Attach a “Do Not Operate” or similar warning tag at the battery disconnect switch location and as defined by site rules and/or local regulations.




Illustration 1g06276183

------ WARNING! ------

Access to this service point may require climbing on the equipment. Slipping or falling while climbing on the equipment could result in personal injury or death. Refer to the Operation and Maintenance Manual, Mounting and Dismounting topic for safety information.


------ WARNING! ------

Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.


------ WARNING! ------

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.


------ WARNING! ------

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.


Required Parts

Table 1
Required Parts of 602-6792 Work Tool Control and Wiring Kit 
Item  Qty  Part Number  Part Name 
446-9302  Harness As 
8T-1890  Clip (2 Piece) 
8T-1889  Clip 
8T-4136  Bolt 
8T-4133  Nut 
8T-4121  Hard Washer 
4P-7581  Clip 
7K-1181  Cable Strap 
446-9304  Plate 
10  7X-7729  Washer 
11  159-9495  Nut 
12  159-9496  Lockwasher 
13  156-1458  Cover 
14  597-9011(1)  Plate 
15  206-2423(1)  Mounting Saddle 
16  491-2042(2)  Work Tool Harness As 
17  443-4062  Rocker Switch As 
18  443-4066  Rocker Switch As 
(1) Only for S/N:W5L1-UP, ; S/N:F5K1-UP, and ; S/N:P5K1-UP
(2) Only for M series machines

Table 2
446-9302 Work Tool Harness As Pin Configuration 
230-5011 Connector Receptacle As "KT-C2" 
Position  Wire Number  Wire Color  Terminal/Plug 
8T-8737 Seal Plug 
200-KT1-BK(Black)  Black  180-9339 Connector Pin 
T970-KT2-GY(Grey)  Gray  180-9339 Connector Pin 
T971-KT3-OR(Orange)  Orange  180-9339 Connector Pin 
T972-KT4 -GN(Green)  Green  180-9339 Connector Pin 
8T-8737 Seal Plug 

Table 3
446-9302 Work Tool Harness As Pin Configuration 
156-1460 Connector Receptacle As "KT-C1" 
Position  Wire Number  Wire Color  Terminal/Plug 
200-KT1-BK(Black)  Black  7T-0093 Connector Pin 
T970-KT2-GY(Grey)  Gray  7T-0093 Connector Pin 
T971-KT3-OR(Orange)  Orange  7T-0093 Connector Pin 
T972-KT4 -GN(Green)  Green  7T-0093 Connector Pin 
8T-8737 Seal Plug 
8T-8737 Seal Plug 
8T-8737 Seal Plug 
8T-8737 Seal Plug 

Table 4
491-2042 Work Tool Harness As Pin Configuration 
230-5011 Connector Receptacle As "CA-C1" 
Position  Wire Number  Wire Color  Terminal/Plug 
M939-CA1-OR(Orange)  Orange  144-1636 Connector Pin 
T969-CA2-YL(Yellow)  Yellow  144-1636 Connector Pin 
T970-CA3-GY(Grey)  Gray  144-1636 Connector Pin 
T971-CA4-OR(Orange)  Orange  144-1636 Connector Pin 
T972-CA5-GN(Green)  Green  144-1636 Connector Pin 
8T-8737 Seal Plug 

Table 5
491-2042 Work Tool Harness As Pin Configuration 
228-5856 Connector "CA-C2" 
Position  Wire Number  Wire Color  Terminal/Plug 
T971-CA4-OR(Orange)  Orange  104-1995 Blade Terminal 
M939-CA6-OR(Orange)  Orange  104-1995 Blade Terminal 
T972-CA5-GN(Green)  Green  104-1995 Blade Terminal 

Table 6
491-2042 Work Tool Harness As Pin Configuration 
228-5856 Connector "CA-C3" 
Position  Wire Number  Wire Color  Terminal/Plug 
T969-CA2-YL(Yellow)  Yellow  104-1995 Blade Terminal 
M939-CA7-OR(Orange)  Orange  104-1995 Blade Terminal 
T970-CA3-GY(Grey)  Gray  104-1995 Blade Terminal 

Machine Preparation

Refer to Operation and Maintenance Manual, Prepare the Machine for Maintenance for your host machine.

Installation Procedure

Procedure to Install 446-9302 Wiring Harness on K-Series Wheel Loader



    Illustration 2g06596266
    View inside right frame
    (D) Existing plate

  1. Remove existing plate (D).


    Illustration 3g06596262
    (E) Existing hardware
    (1) 446-9302 Harness As
    (2) 8T-1890 Clip
    (3) 8T-1889 Clip
    (4) 8T-4136 Bolt
    (5) 8T-4133 Nut
    (6) 8T-4121 Hard Washer
    (7) 4P-7581 Clip
    (8) 7K-1181 Cable Strap
    (9) 446-9304 Plate
    (10) 7X-7729 Washer
    (11) 159-9495 Nut
    (12) 159-9496 Lockwasher
    (13) 156-1458 Cover

    Note: Cut harness assembly (1) to required length, then add back terminals and auxiliary hydraulic connector.

  2. Install harness assembly (1) using hardware as shown in Illustration 3.

    Note: Reuse existing hardware (E) to install clip (7) as shown in Illustration 3.

  3. Connect harness assembly (1) to the auxiliary hydraulic connector on the machine.

  4. Secure harness assembly (1) using three cable straps (8). Refer to Illustration 3.

  5. Install plate (4) on block using two bolts (4) and two washers (7). Refer to Illustration 3.

  6. Secure connector end of the harness assembly (1) into the plate (9) using nut (11), lock washer (12), and cover (13). Refer to Illustration 3.

Procedure to Install 446-9302 Wiring Harness on M-Series Wheel Loader

For S/N:LTE, ; S/N:KTG, ; S/N:HEY, and ; S/N:J3R Serial Number prefixes

For the installation of 446-9302 Wiring Harness, refer to Step 1 through Step 6 under Section "Procedure to Install 446-9302 Wiring Harness on K-Series Wheel Loader".

For S/N:W5L, ; S/N:F5K, and ; S/N:P5K Serial Number prefixes



    Illustration 4g06614444
    (14) 597-9011 Plate

  1. Loosen the nuts holding the fittings and slide plate (14) under the nuts. Tighten nuts to a standard torque. Refer to Illustration 4.

    Note: Refer to Specifications, SENR3130, "Torque Specifications"



    Illustration 5g06614479
    (1) 446-9302 Harness As
    (8) 7K-1181 Cable Strap
    (11) 159-9495 Nut
    (12) 159-9496 Lockwasher
    (13) 156-1458 Cover
    (14) 597-9011 Plate
    (15) 206-2423 Mounting Saddle

  2. Install and secure harness assembly (1) using eight cable straps (8) and four mounting saddles (15) as shown in Illustration 5.

  3. Connect harness assembly (1) to the auxiliary hydraulic connector on the machine.

  4. Secure connector end of the harness assembly (1) into the plate (9) using nut (11), lock washer (12), and cover (13). Refer to Illustration 5.

Installing 491-2042 Work Tool Harness As (Only for M - Series machines)



    Illustration 6g06188561
    (F) Panel

  1. To install harness assembly, remove the existing panel (F) inside the cab.


    Illustration 7g06188576
    (G) Existing Plug
    (H) Receptacle

  2. Plug the harness assembly into the main cab harness by connecting the plug of harness assembly to receptacle (H) of the main cab harness.

    Route the harness assembly past the key switch up to two existing plugs (G) on dash.

Installing the Work Tool Rocker Switch



    Illustration 8g06188600
    View of console
    (J) Screw

  1. Remove switch bezel by removing seven screws (J) and save the screws.


    Illustration 9g03539748
    View of console
    (G) Plug

  2. Release the tabs to remove two plugs (G) as shown in Illustration 7.


    Illustration 10g06597232
    View of console
    (J) Screw
    (17) 443-4062 Rocker Switch As
    (18) 443-4066 Rocker Switch As

  3. Connect rocker switch (17) to jumper harness connector "CA-C3" as shown in Illustration 10.

  4. Connect rocker switch (18) to jumper harness connector "CA-C2" as shown in Illustration 10.

  5. Install switch bezel using seven screws (J) which were saved in Step 1 of Section "Installing the Work Tool Rocker Switch".

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