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Installation of the Payload Monitoring System in Certain Wheel Loaders {7494} Caterpillar


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Installation of the Payload Monitoring System in Certain Wheel Loaders {7494} [REHS4512]
OPERATOR STATION
MONITOR GP
Installation of the Payload Monitoring System in Certain Wheel Loaders {7494}
1.1. Introduction
2.1. Safety
3.1. Required Parts
4.1. Machine Preparation
5.1. Installation Procedure
6.2. Installation of Payload Monitoring System on Machines with Payload Control System Already Installed
7.2. Installation of the Pressure Sensor
8.2. Installation of the Pressure Sensor on the 980H Machines
9.2. Software and Password
Wheel Loader
928G (S/N: DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)
938F (S/N: 1KM1-UP; 2RM1-UP; 8SM1-UP; 7SN1-UP)
938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)
938G Series II (S/N: RTB1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)
950E (S/N: 22Z1-UP)
950F (S/N: 7ZF1-UP; 6YG1-UP)
950F Series II (S/N: 4DJ1-UP; 5SK1-UP; 8TK1-UP; 2LM1-UP)
950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)
950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)
950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)
960F (S/N: 9ZJ1-UP; 4CL1-UP; 6XL1-UP; 1YM1-UP)
962G (S/N: 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)
962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)
962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)
966D (S/N: 99Y1-UP)
966F (S/N: 4YG1-UP; 3XJ1-UP)
966F Series II (S/N: 8BG1-UP; 9YJ1-UP; 1SL1-UP)
966G (S/N: AAH1-UP; 3ZS1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP; 8XW1-UP)
966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)
966H (S/N: A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP)
970F (S/N: 7SK1-UP; 9JK1-UP; 7PL1-UP)
972G (S/N: 7LS1-UP; AAW1-UP; 1EW1-UP; 4WW1-UP; 6AW1-UP; 9GW1-UP)
972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)
972H (S/N: A7D1-UP; A7G1-UP; A7J1-UP)
980C (S/N: 63X1-UP)
980F (S/N: 8CJ1-UP)
980F Series II (S/N: 8JN1-UP)
980G (S/N: 9CM1-UP; 2KR1-UP; 2SR1-UP)
980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)
980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)
980H Series 2 (S/N: MKP1-UP)
988B (S/N: 50W1-UP)
988F (S/N: 8YG1-UP)
988G (S/N: BNH1-UP; 2TW1-UP)
988H (S/N: BXY1-UP)
990 (S/N: 7HK1-UP)
990 Series II (S/N: BCR1-UP; 4FR1-UP)
990H (S/N: BWX1-UP)
992C (S/N: 42X1-UP; 49Z1-UP)
992D (S/N: 7MJ1-UP)
Revision History:

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Table 1
Revision  Summary of Changes 
08  Updated effectivity. 

Introduction

This service publication contains the installation information that is needed to install payload monitoring system on a field machine.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before you open any compartment or disassemble any component containing fluids.

Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids in AVSpare Machines.

Dispose of all fluids according to local regulations and mandates.

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NOTICE

Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

Safety

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

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.

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

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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

Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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 also 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 should 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 that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Required Parts

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Table 2
Parts List for 345-2258 Payload Monitor Gp (KIT) 
Item  Qty  Part Number  Description 
1  1 dm  8T-2268  Trim 
2  1  5I-4376  Fitting 
3  2  7K-1181  Cable Strap 
4  8  8T-9655  Isolation Mount 
5  1  136-9699  Bracket As 
6  1  164-6871  Adapter As(1) 
7  1  168-1968  Tee As(2) 
8  1  261-3222  Display Mounting Gp (3) 
9  1  263-1493  Push-Button Switch 
10  1  265-2834  Block 
11  1  268-1708  Rocker Switch 
12  1  268-6497  Film 
13  1  301-0038  Box 
14  1  304-5691  Electronic Control Module 
15  1  308-3869  Electronic Control Module 
16  1  6V-0852  Dust Cap 
17  4  325-3347  Bracket As 
18  1  326-3092  Visor 
19  1  349-1178  Pressure Sensor 
20  1  351-4927  Hose As 
21  1  397-8226  Bracket As 
22  1  397-8228  Film 
23  1  130-5300  Clip 
24  1  148-8353  Elbow As (4) 
25  1  164-5567  Quick Disconnect Coupler As 
26  1  206-2423  Saddle 
27  1  221-3416  Pressure Sensor Gp 
28  1  3J-1907  O-Ring Seal 
29  4  4B-4274  Washer 
30  1  4P-7581  Clip 
31  4  6I-1418  Spacer 
32  1  6V-0852  Dust Cap 
33  4  8C-6438  Screw 
34  4  8T-3647  Bolt 
35  1  8T-4121  Hard Washer 
36  1  8T-4136  Bolt 
37  4  8T-4138  Bolt 
38  2  8T-4223  Hard Washer 
39  1  8T-4648  Bolt 
40  1  8T-4910  Bolt 
41  4  8T-5432  Bolt 
42  4  8T-6912  Bolt 
43  14  9N-0869  Hard Washer 
44  2  9X-2040  Screw 
45  4  9X-8256  Washer 
46  3  3S-2093  Cable Straps 
47  23  7K-1181  Cable Straps 
48  1  288-1401  Bracket 
49  1  317-5591  Chassis Harness As 
50  1  130-5300  Clip 
51  1  134-2540  Connection Resistor As 
52  1  205-7299  Clip 
53  1  205-4933  Film 
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(1) Refer to Table 3
(2) Refer to Table 4
(3) Refer to Table 5
(4) Refer to Table 6

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Table 3
164-6871 Adapter As (6) 
Item  Qty  Part Number  Description 
A  1  122-2222  Adapter 
B  1  6V-8397  O-Ring Seal 

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Table 4
168-1968 Tee As (7) 
Item  Qty  Part Number  Description 
A  1  126-6872  Tee 
B  1  3J-1907  O-Ring Seal 
C  1  6V-8397  O-Ring Seal 

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Table 5
261-3222 Display Mounting Gp (8) 
Item  Qty  Part Number  Description 
A  1  259-4397  Clamp 
B  2  259-4399  Base 

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Table 6
148-8353 Elbow As (24) 
Item  Qty  Part Number  Description 
A  1  6V-9001  Elbow 
B  1  3J-1907  O-Ring Seal 
C  1  6V-8397  O-Ring Seal 

Machine Preparation

  1. Park the machine on a smooth, level surface.

  2. Shift the transmission direction control switch to the NEUTRAL position.

  3. Lower the bucket or the work tool to the ground.

  4. Engage the parking brake.

  5. Place blocks in front of the wheels and behind the wheels.

  6. Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.

Installation Procedure

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    Illustration 1g03779991
    (C) 173-2187 Cover As
    (D) 211-0667 Cover As

  1. Remove the Cover As (C) and Cover As (D). Retain for reinstallation.
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    Illustration 2g03781500
    (F) 9X-2043 Screw
    (G) 196-0052 Duct As

  2. Remove four Screws (F) and the Duct As (G). Retain for reinstallation.
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    Illustration 3g03781502
    (J) 173-2185 Cab Liner
    (K) 370-8332 Instrument Panel Gp

  3. Remove the Instrument Panel Gp (K) and pull the Cab Liner (J) away from the roof. Retain for reinstallation.
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    Illustration 4g03779198
    (A) 304-5687 Electronic Control Module (ECM)
    (B) 8T-6870 Bolt and 9N-0869 Hard Washer

  4. Remove four Bolts and Hard Washers (B) securing the Electronic Control Module (A). Discard the bolts and washers.
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    Illustration 5g03779202
    (17) 325-3347 Bracket As
    (34) 8T-3647 Bolt
    (43) 9N-0869 Hard Washer

  5. Install four Bracket As (17) along with the Electronic Control Module (A). Use four Bolts (34) and four Hard Washers (43) to secure the brackets and the ECM.
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    Illustration 6g03779199
    (4) 8T-9655 Isolation Mount
    (14) 304-5691 Electronic Control Module (ECM)
    (31) 6I-1418 Spacer

  6. Assemble the Isolation Mounts (4) and the Spacers (31) to the Electronic Control Module (14). Use two mounts and one spacer per mounting location on the ECM. Assemble all four mounting locations on the ECM.
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    Illustration 7g06290995
    (14) 304-5691 Electronic Control Module (ECM)
    (17) 325-3347 Bracket As
    (42) 8T-6912 Bolt
    (43) 9N-0869 Hard Washer
    (48) 288-1401 Bracket

  7. Install the Electronic Control Module (14) to the Brackets (17). Secure the ECM with four Bolts and eight Hard Washers . Place the washers as indicated in Illustration 7.

    Incorporate the Bracket (48) into the lower mounting locations.

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    Illustration 8g06290999
    (14) 304-5691 Electronic Control Module
    (47) 7K-1181 Cable Strap
    (48) 288-1401 Bracket
    (49) 317-5591 Chassis Harness As
    (51) 134-2540 Connection Resistor As
    (E) 372-4873 Cab Harness As
    (AE) PC-C1 connector. (Part of the Chassis Harness As (49)
    ( AF) PC-C2 connector. (Part of the Chassis Harness As (49)

  8. Connect the PC-C1 connector (AE) to the right-hand port on the Electronic Control Module (14). Connect the PC-C2 connector (AF) to the left-hand port on the Electronic Control Module (14).

    Secure the Chassis Harness As (49) to the Bracket (48). Route the Chassis Harness As (49) along the Cab Harness As (E) and secure the two harnesses together. Use Cable Strap (47) to secure the harnesses. Refer to Illustration 8 for Cable Strap locations.

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    Illustration 9g06291001
    (19) 317-5591 Chassis Harness As
    (47) 7K-1181 Cable Strap
    (E) 372-4873 Cab Harness As

  9. Continue to route the Chassis Harness As (16) along the Cab Harness As (E) towards the right-hand side of the machine. Secure the harnesses together with Cable Straps (47).
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    Illustration 10g06291047
    (47) 7K-1181 Cable Strap
    (49) 317-5591 Chassis Harness As
    (E) 372-4873 Cab Harness As

  10. Continue to route the Chassis Harness As (49) along the Cab Harness As (E) up the center ROPS pillar. Secure the harnesses together with Cable Straps (47).
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    Illustration 11g06291049
    Some components removed for clarity.
    (47) 7K-1181 Cable Strap
    (49) 317-5591 Chassis Harness As
    (E) 372-4873 Cab Harness As
    (J) 173-2185 Cab Liner
    (K) 370-8332 Instrument Panel Gp

  11. Route the Chassis Harness As (49) along the Cab Harness As (E) under the Cab Liner (J) and the Instrument Panel Gp (K). Secure the harnesses together with Cable Straps (47).
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    Illustration 12g03780104
    (8B) 259-4399 Base
    (21) 397-8226 Bracket As
    (23) 130-5300 Clip
    (37) 8T-4138 Bolt
    (44) 9X-2040 Screw
    (45) 9X-8256 Washer
    (AG) 091-1735 Block

  12. Attach the Base (8B) to the Bracket As (21). Secure the base with four Bolts (37) and four Washers (45).

    Attach the Base and Bracket As to the Block (AG), on the left-front ROPS pillar. Secure the bracket with two Screws (44). Include the Clip (23) under the upper Screw (44).

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    Illustration 13g03836992
    (11) 268-1708 Rocker Switch
    (13) 301-0038 Box
    (15) 308-3869 Electronic Control Module
    (18) 326-3092 Visor
    (33) 8C-6438 Screw

  13. Assemble the Electronic Control Module (15) into the Box (13). Include the Visor (18) under the Electronic Control Module. Secure both with four Screws (33).

    Snap the Rocker Switch (11) into the proper location in the Box (13), next to the Electronic Control Module (15).

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    Illustration 14g03836993
    (8B) 259-4399 Base
    (13) 301-0038 Box
    (15) 308-3869 Electronic Control Module
    (18) 326-3092 Visor
    (29) 4B-4274 Washer
    (41) 8T-5432 Bolt

  14. Assemble the Base (8B) onto the Box (13). Secure the base with four Bolts (41) and four Washers (29).
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    Illustration 15g03781503
    (8A) 259-4397 Clamp
    (8B) 259-4399 Base
    (13) 301-0038 Box
    (15) 308-3869 Electronic Control Module
    (18) 326-3092 Visor
    (29) 4B-4274 Washer
    (41) 8T-5432 Bolt

  15. Attach the Clamp (8A) onto the Base (8B) that is mounted to the Box (13).

    Attach the open end of the Clamp (8A) to the Base (8B) that is mounted to the machine.

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    Illustration 16g06291064
    (49) 317-5591 Chassis Harness As
    (N) PC-C4 connector (Part of 49)
    (P) PC-C8 connector (Part of 49)

  16. Connect the PC-C4 connector (N) to the Rocker Switch (11). Connect the PC-C8 connector (P) to the Electronic Control Module (15).
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    Illustration 17g06291070
    (49) 317-5591 Chassis Harness As
    (23) 130-5300 Clip
    (R) PC-C7 connector (Part of 49)

  17. Attach the PC-C7 connector (R) to the Clip (23).
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    Illustration 18g06291074
    (49) 317-5591 Chassis Harness As
    (E) 372-4873 Cab Harness As
    (S) PC-C5 connector (Part of 49)

  18. Connect the PC-C5 connector (S) to the C-C40 connector (part of Cab Harness As (E).
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    Illustration 19g03837915
    (AB) 367-7475 Cover for the 2-Lever console
    (AB) 367-7476 Cover for the 3-Lever console
    (AC) 9X-2045 Screw
    (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

  19. Remove the Screws (AC) and the Cover (AB) from the Electrohydraulic Control and Mounting Gp (AH). Retain components for reinstallation.
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    Illustration 20g06291079
    (47) 7K-1181 Cable Strap
    (49) 317-5591 Chassis Harness As
    (L) 372-4845 Control Harness As
    (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

  20. Route the Chassis Harness As (49) along the Control Harness As (L) into the Electrohydraulic Control and Mounting Gp (AH). Secure the two harnesses together with two Cable Straps (47).
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    Illustration 21g06291085
    (47) 7K-1181 Cable Strap
    (49) 317-5591 Chassis Harness As
    (50) 130-5300 Clip
    (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

  21. Attach the Clip (50) to the Electrohydraulic Control and Mounting Gp (AH). Attach the PC-C3 connector on harness assembly (49) to the Clip (50). Secure the Chassis Harness As (49) to the Electrohydraulic Control and Mounting Gp (AH) with the Cable Strap (47).

  22. Machines equipped with 371-4487 Electrohydraulic Control and Mounting Gp, perform Steps 22a and 22b.

    Machines equipped with 371-4488 Electrohydraulic Control and Mounting Gp, perform Steps 22c and 22d .

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      Illustration 22g03831072
      (M) 8R-3695 Grommet
      (AH) 371-4487 Electrohydraulic Control and Mounting Gp

    1. Remove the Grommet (M) from the Electrohydraulic Control and Mounting Gp (AH). Refer to Illustration 22 for proper location.
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      Illustration 23g03832962
      (9) 263-1493 Push-Button Switch
      (12) 268-6497 Film
      (AH) 371-4487 Electrohydraulic Control and Mounting Gp

    2. Install the Push-Button Switch (9) into the open location in the Electrohydraulic Control and Mounting Gp (AH).

      Attach the Film (12) next to the Push-Button Switch (9). Refer to Illustration 23 for proper location.

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      Illustration 24g03832964
      (M) 8R-3695 Grommet
      (AH) 371-4488 Electrohydraulic Control and Mounting Gp

    3. Remove the Grommet (M) from the Electrohydraulic Control and Mounting Gp (AH). Refer to Illustration 24 for proper location.
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      Illustration 25g03832965
      (12) 268-6497 Film

    4. Install the Push-Button Switch (9) into the open location in the Electrohydraulic Control and Mounting Gp (AH).

      Attach the Film (12) next to the Push-Button Switch (9). Refer to Illustration 25 for proper location.

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    Illustration 26g06291088
    (9) 263-1493 Push-Button Switch
    (49) 317-5591 Chassis Harness As

  23. Connect the Push-Button Switch (9) to the PC-C3 connector on harness assembly (49).
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    Illustration 27g03837915
    (AB) 367-7475 Cover for the 2-Lever console
    (AB) 367-7476 Cover for the 3-Lever console
    (AC) 9X-2045 Screw
    (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

  24. Reinstall the Screws (AC) and the Cover (AB) onto the Electrohydraulic Control and Mounting Gp (AH). Use the original components.

Installation of Payload Monitoring System on Machines with Payload Control System Already Installed

  1. Remove the existing payload monitor.

  2. Disconnect and remove the harnesses connected to the monitor.

  3. Install 304-5691 Electronic Control Module (14). Refer to "Machine Preparation", Steps 3 through 7.
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    Illustration 28g06279772
    View showing dimensions to weld bosses to the back of the cab
    (D1) 325 mm (12.8 inch)
    (D2) 168 mm (6.6 inch)

  4. If provision is not in the cab, using the dimensions in Illustration 28, weld four 9R-2160 Bosses to the back of the cab.

    Install the ECM on the bosses. Refer to "Machine Preparation" Steps 12 through 16.

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    Table 7
    WIRE NAME  POSITION 
    138PC5  1 
      2 
    251-PC41  3 
      4 
    C529-PC23  5 
    C530-PC24  6 
    614-PC42  7 
    944-PC1  8 
    945-PC40  9 
    E416-PC22  10 
      11 
      12 

  5. When connecting the 317-5591 Chassis Harness As to the cab harness in the machine, ensure that the cab harness connector has pinouts in Table 7. If the pinouts do not match, rework the connector. Remove the wires and reconnect in the positions mentioned in Table 7. Extra wires, if any, can be connected to positions 2, 4, 11 and 12.

  6. Install the display. Refer to "Machine Preparation" Steps 12 through 16.

  7. Keep the existing sensors as such and connect the sensor harnesses to the 317-5591 Chassis Harness As.

Installation of the Pressure Sensor

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    Illustration 29g03836975
    (W) 6V-9829 Cap As
    (Z) 6V-8781 Tee and 6V-8397 O-Ring Seal

  1. Remove the Cap As (W) from the Tee (Z).
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    Illustration 30g03836973
    (2) 5I-4376 Fitting
    (AA) 6V-8397 O-Ring Seal

  2. Replace the Cap As (W) removed in Step 1 with the Fitting (2). Seal the connection with one O-Ring Seal (AA).
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    Illustration 31g03836802
    (X) 155-2267 Connector Plug As (Part of 393-6513 Front Harness As)
    (Y) AG-C2 connector (Part of 393-6513 Front Harness As)
    (AD) 112-1817 Ball Valve

  3. Remove the Connector Plug As (X) from the AG-C2 connector (Y) and discard.
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    Illustration 32g03836990
    (27) 221-3416 Pressure Sensor Gp
    (Y) AG-C2 connector (Part of 393-6513 Front Harness As)
    (AA) 3J-1907 O-Ring Seal

  4. Connect the Pressure Sensor Gp (27) to the Fitting (2). Seal the connection with one O-Ring Seal (AA).

    Connect the sensor connector to the AG-C2 connector (Y).

Installation of the Pressure Sensor on the 980H Machines

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    Illustration 33g03836296
    (5) 136-9699 Bracket As
    (10) 265-2834 Block
    (38) 8T-4223 Hard Washer
    (39) 8T-4648 Bolt
    (40) 8T-4910 Bolt
    (AJ) 9C-7863 Block

  1. Attach the Block (10) to the Block (AJ). Secure the block with one Bolt (40) and one Hard Washer (38) for the left-hand location.

    Use 1 Bolt (39) and one Hard Washer (38) for the right-hand location. Include one Bracket As (5) on the right-hand location.

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    Illustration 34g03836297
    (7) 168-1968 Tee As
    (7B) 3J-1907 O-Ring Seal
    (7C) 6V-8397 O-Ring Seal
    (10) 265-2834 Block
    (25) 164-5567 Quick Disconnect Coupler As
    (32) 6V-0852 Dust Cap

  2. Install the Tee As (7) into the lower port on the Block (10). Seal the connection with one O-Ring Seal (7B).

    Install the Quick Disconnect Coupler As (25) into the lower port on the Tee As (7). Seal the connection with one O-Ring Seal (7C). Install the Dust Cap (32) onto the Quick Disconnect Coupler As.

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    Illustration 35g03836300
    (10) 265-2834 Block
    (19) 349-1178 Pressure Sensor
    (28) 3J-1907 O-Ring Seal

  3. Install the Pressure Sensor (19) into the remaining open port on the Block (10). Seal the connection with one O-Ring Seal (28).
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    Illustration 36g03836302
    (5) 136-9699 Bracket As
    (30) 4P-7581 Clip
    (35) 8T-4121 Hard Washer
    (36) 8T-4136 Bolt

  4. Attach the Clip (30) to the Bracket As (5). Secure the clip with one Bolt (36) and one Hard Washer (35).
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    Illustration 37g03836304
    (7) 168-1968 Tee As
    (7B) 3J-1907 O-Ring Seal
    (20) 351-4927 Hose As

  5. Connect the Hose As (20) to the side port on the Tee As (7). Seal the connection with one O-Ring Seal (7B).
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    Illustration 38g03836798
    (3) 7K-1181 Cable Strap
    (19) 349-1178 Pressure Sensor
    (30) 4P-7581 Clip
    (T) AK-C2 connector (Part of 422-0639 Sensor Harness As

  6. Connect the AK-C2 connector (T) to the Pressure Sensor (19).

    Secure the wiring harness to the Clip (30) with one Cable Strap (3).

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    Illustration 39g03836801
    (U) 226-7659 Tube As
    (V) 9S-4191 Plug and 3J-1907 O-Ring Seal

  7. Remove the Plug and O-Ring Seal (V) from the Tube As (U).
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    Illustration 40g03836799
    (6) 164-6871 Adapter As
    (24) 148-8353 Elbow As
    (24-B) 3J-1907 O-Ring Seal
    (24-C) 6V-8397 O-Ring Seal
    (U) 226-7659 Tube As

  8. Replace the Plug and O-Ring Seal (V) removed in Step 8 with the Elbow As (24). Seal the connection with one O-Ring Seal (24-B).

    Connect the Adapter As (6) to the Elbow As (24). Seal the connection with one O-Ring Seal (24-C).

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    Illustration 41g03836800
    (6) 164-6871 Adapter As
    (6-B) 6V-8397 O-Ring Seal
    (20) 351-4927 Hose As
    (U) 226-7659 Tube As

  9. Connect the Hose As (20) to the Adapter As (6). Seal the connection with one O-Ring Seal (6-B).

Software and Password

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

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

    https://fps.cat.com

    Enter the required information to obtain the factory passwords.

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

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

  3. New software will need to be installed. Flash 289-2217 Monitor Software Gp (PCS) and 326-4287 Monitor Software Gp (Message Display).

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

  4. Navigate to the configuration screen for the payload control system.
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    Illustration 42g01948864

  5. Select "ECM Identification Parameters".

  6. Select "Product ID" and enter the machine serial number. Then select "OK".
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    Illustration 43g01948861

  7. Select "System Settings".

  8. Select "Machine Payload Control Systems Installation Status".
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    Illustration 44g01948866

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

  10. Press "OK".
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    Illustration 45g01948893

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

  12. Press "OK".

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

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

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