Field Installation of the Payload Monitor Gp Kits{7494} Caterpillar


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Field Installation of the Payload Monitor Gp Kits{7494} [REHS4511]
OPERATOR STATION
MONITOR GP
1.1. Introduction
2.1. Field Installation of the 301-6923 Payload Monitor Gp (Kit) for the 938H Wheel Loader
3.2. Installation of PCS Switch for Machines that Are Equipped with Levers
4.2. Installation of PCS Switch for Machines that Are Equipped with a Joystick
5.2. Install the Wiring Group for the Payload Control System
6.2. Installation of the Pressure Sensor and Mounting Gp for the Lift Cylinder Oil
7.2. Installation of the Position Sensor
8.2. Software and Password
Wheel Loader:
938H (S/N: MJC1-UP)

Introduction

The information that is contained in this publication is for the field installation of the following kit:

  • 301-6923 Payload Monitor Gp (Kit) for the 938H

A complete listing of the parts that is contained in this kit is listed in the Parts Manual, SEBC1531. This supplemental product support literature should be used with the appropriate Service Manual that is available for the standard machine. Refer to System Operation, RENR6293, "Medium Wheel Loaders Payload Control System".

Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Field Installation of the 301-6923 Payload Monitor Gp (Kit) for the 938H Wheel Loader

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

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine.

To prevent personal injury or death, perform the following:

Park the machine on a smooth, level surface.

Lower the work tool to the ground and engage the parking brake.

Stop the engine and remove the key.

Block the wheels and install the steering frame lock.

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

Installation of PCS Switch for Machines that Are Equipped with Levers




    Illustration 1g01955500

    Top view of right hand console

  1. Remove the plug from the right hand console. Install the 268-1708 Rocker Switch (4) .

  1. Remove the plug and install the 263-1493 Push Button Switch (3). Tighten the 263-1493 Push Button Switch (3) to 5 ± 1 N·m (3.69 ± 0.74 lb ft).

  1. Install 268-6497 Film (5) .

    Note: Clean surface before applying film

Installation of PCS Switch for Machines that Are Equipped with a Joystick




Illustration 2g01945976

  1. Remove 8R-3695 Grommet .

  1. Install 263-1493 Push Button Switch (4). Torque to 5 ± 1 N·m (3.7 ± 0.7 lb ft)

    Note: Place a 16.5 mm (0.65 inch) hole in this location for machines that are not equipped with the hole and a grommet.

  1. Install 268-6497 Film (5) .

    Note: Clean the surface before applying the film.

Install the Wiring Group for the Payload Control System




    Illustration 3g01894639

    View of rear wall of enclosed ROPS cab




    Illustration 4g01894641

    View of rear wall of open ROPS cab




    Illustration 5g01894642

    View of section "A-A" from Illustration 3

  1. Use the following hardware and install the two 280-7285 Bracket As (5) onto the rear of the cab:

    • Four 5C-9553 Bolts (14)

    • Four 5P-4115 Hard Washers (15)

  1. Use the following hardware and install the 252-2422 Electronic Control Module (11) onto the 280-7285 Bracket As (5) :

    • Four 6I-1418 Spacers (2)

    • Four 7X-0818 Bolts (17)

    • Eight 8T-9655 Mounts (20)

    • Four 9N-0869 Hard Washers (21)

  1. Connect the 281-9481 Control Harness As (6) onto the 252-2422 Electronic Control Module (11) .

  1. Connect the 134-2540 Receptacle As (10) to the 281-9481 Control Harness As (6).

  1. Connect the 281-9481 Control Harness As (6) to the printer for the payload control system.

  1. Connect the 281-9481 Control Harness As (6) onto the main cab harness.

  1. Secure the 134-2540 Receptacle As (10) onto the 281-9481 Control Harness As (6) with a 3S-2093 Cable Strap (1) .



    Illustration 6g01894977

    Inside view of front frame




    Illustration 7g01894979

    View "D-D" from Illustration 6

  1. Install the 2M-3432 Grommet (12) into the front frame.

  1. Connect the 305-4377 Control Harness As (7) onto the lift position sensor.

  1. Refer to Illustration 6 and Illustration 7 for routing. Install the 305-4377 Control Harness As (7) .

  1. Connect the 305-4377 Control Harness As (7) to the front harness.

  1. Connect the 305-4377 Control Harness As (7) to the front harness.

  1. Use the following and secure the 305-4377 Control Harness As (7) :

    • Five 3S-2093 Cable Straps (1)

    • One 130-5300 Clip (8)

    • Two 132-5789 Clips (9)

    • One 4P-7581 Clip (13)

    • One 5P-9297 Clip (16)

    • Four 8T-4121 Hard Washers (18)

    • Four 8T-4137 Bolts (19)

Installation of the Pressure Sensor and Mounting Gp for the Lift Cylinder Oil




    Illustration 8g01959834

    Partial top view of front frame

    (A) Fitting

  1. Remove cap assembly from fitting (A) .

  1. Install a 164-6871 Adapter As (3) in place of the cap assembly.

  1. Install a 5I-4376 Fitting (1) onto the 164-6871 Adapter As (3) .

  1. Install a 164-5567 Fitting As (5) into the 5I-4376 Fitting (1) .

  1. Install a 6V-0852 Dust Cap (2) onto the 164-5567 Fitting As (5) .

  1. Use a 3J-1907 O-Ring Seal (6) and install a 221-3416 Pressure Sensor Gp (4) onto the 5I-4376 Fitting (1) .

Installation of the Position Sensor




    Illustration 9g01949573

  1. Install one 6D-3025 Ball Bearing (37) into the 4E-2250 Housing (21) .

  1. Install one 2L-6726 Retaining Ring (39) into the 4E-2250 Housing (21) .

    Note: This 2L-6726 Retaining Ring (39) serves as a spacer. The 4E-2250 Housing (21) does not have a groove for the 2L-6726 Retaining Ring (39) .

  1. Install the other 6D-3025 Ball Bearing (37) into the 4E-2250 Housing (21) .

  1. Install the other 2L-6726 Retaining Ring (39) into the groove in the 4E-2250 Housing (21) .

  1. Slide the 4E-2453 Shaft (38) into the front of the 4E-2250 Housing (21), and then through the two 6D-3025 Ball Bearings (37) .

  1. Install the 2H-3429 Retaining Ring (31) onto the 4E-2453 Governor Control Shaft (38) .

  1. Install one 8C-5608 Spacer (35) and two 8C-5607 Mounts (34) in each of the three holes in the 4E-2250 Housing (21) .

  1. Use the following hardware to install the 266-1484 Position Sensor (28) to the back of 4E-2250 Housing (21) :

    • Two 6V-2313 Bolts (29)

    • Two 4B-4274 Washers (30)

  1. Use the following hardware to install the 129-6792 Bail Arm (25) onto lift arm:

    • Two 8T-4186 Bolts (41)

    • Two 8T-2561 Hard Washers (40)

  1. Use the following hardware to install the 4E-2250 Housing (21) onto the 7I-3236 Support (23) :

    • Three 9X-2480 Bolts (32)

    • Six 9X-6165 Washers (33)

    • Three 5C-2890 Nuts (36)

  1. Use the following hardware to install the 7I-3236 Support Bracket (23) onto the studs on the frame:

    • Three 8T-4244 Nuts (1)

    • Three 8T-4223 Hard Washers (2)

  1. Place lift arm in the lowest possible position. Place the bucket in the fully racked back position.

  1. Use the following hardware to install the 6S-4868 Lever (22) onto the 4E-2453 Governor Control Shaft (38) :

    • One 9B-7237 Bolt (19)

    • One 8T-4896 Hard Washer (20)

    Note: Do not tighten the 9B-7237 Bolt (19) on the 4E-2453 Governor Control Shaft (38) at this time.

  1. Assemble one 6V-8186 Full Nut (27) and 8K-1253 Rod End (26) completely onto one end of 129-6791 Rod (24) .

  1. Assemble one 8L-4496 Jam Nut (16) and 5P-9683 Rod End (15) completely onto the other end of 129-6791 Rod (24) .

  1. Set the length between the centerlines of the rod ends to 284 mm (11.1811 inch) by turning the 129-6791 Rod (24) .

  1. Use a 8T-4224 Hard Washer (18) and connect 8K-1253 Rod End (26) to 129-6792 Bail Arm (25) .

  1. Use the following hardware to connect the other rod end to the 6S-4868 Lever (22) .

    • Two 8T-4224 Hard Washers (18)

    • One 3D-8752 Locknut (17)

  1. Press the "Arrow Down" button on the message center display until "Service" is displayed. Select "OK". Press the "Arrow Down" button until "System Parameters" is displayed. Select "OK". Press the "Arrow Down" button until "Payload Control" is displayed.

  1. Rotate the 4E-2453 Shaft (38) in order to achieve a display reading between 15% and 20% for the duty cycle for the lift cylinder position sensor. Tighten 9B-7237 Bolt (19) in order to secure the lever to the 4E-2453 Shaft (38) at this time.

  1. Raise the lift arms slowly. Observe the duty cycle reading. The duty cycle reading for the lift cylinder position sensor should be between 66% and 90% at full lift. If the value exceeds 90%, rotate rod until the range is achieved. Then tighten nuts.

Software and Password

  1. This kit will require a password to complete installation. Refer to Information Release Memo, PELJ0138, "Software Enabled Attachments".

    The factory passwords can be found at the following web site:

    https://fps.cat.com

    Enter the required information in order to obtain the factory passwords.

    Note: A charge for obtaining factory passwords will be incurred by the dealership.

  1. Connect to the machine with AVSpare Electronic Technician (ET).

  1. New software will need to be installed. Flash 289-2217 Monitor Software Gp (PCS). The software group for the messenger may need to be updated. Verify that the monitor software is 333-3207 Monitor Software Gp (Messenger) or that the software is greater. This software supports English, French, and Spanish. Determine the proper version of the monitor software for the messenger for the languages that are required on the machine.

    Note: All flash files are available on SIS Web. Use the latest software that is available.

  1. Navigate to the configuration screen for the payload control system.



    Illustration 10g01948864

  1. Select "ECM Identification Parameters".

  1. Select "Product ID" and enter the machine serial number. Then select "OK".



    Illustration 11g01948861

  1. Select "System Settings".

  1. Select "Machine Payload Control Systems Installation Status".



    Illustration 12g01948866

  1. Change the value from "Not Installed" to "Installed".

  1. Press "OK".



    Illustration 13g01948893

  1. Enter the required information in the factory password web site. Enter the Passwords in ET.

  1. Press "OK".

  1. After the passwords have been accepted and the status is installed, cycle the power in order to activate the payload control system.

    Note: The payload control system must be calibrated before proper operation can begin. Refer to Testing and Adjusting, RENR6293, "Medium Wheel Loaders Payload Control System" for the calibration procedure.

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