Rework Procedure for Cat® Fleet Onboard Installations on Certain 793F, 795F, and 797F Off-Highway Trucks{1408} Caterpillar

Machine Control and Guidance Products:

CAT DETECT (S/N: DTK1-UP)

MINESTAR ONBRD (S/N: DNG1-UP)

Off-Highway Truck/Tractor:

793F Series AC (S/N: EMD77-UP)

793F (S/N: SSP509-UP; RBT1-165)

795F Series AC (S/N: ERM214-UP)

797F (S/N: LAJ316-UP; WSP113-UP)

Introduction

ReferenceSpecial Instruction, REHS7413, "Installation Guide for Cat® Fleet Onboard System"

ReferenceSchematic, UENR3608, "MineStar Fleet and Proximity Awareness On-Board Electrical System 382-1517"

The Special Instruction provides the necessary information on rework procedure for Cat^® Fleet Onboard Installations on certain machines that are listed above. The rework procedure for Fleet Onboard Installations prevents the following:

• Power Back Feed - There is a splice in the 379-9514 Cab Harness As (wire (130-RD)) that will cause the Fleet Onboard back up battery to feed power to the truck when the trucks battery power is isolated with the master shut off if the battery is connected to the connector "CN-C5" of the 379-9514 Cab Harness As .

• Incorrect Ethernet Wiring - Connector "CN-C3" for Fleet Onboard Ethernet connection has "Rx+" and "Rx-" pinned to positions 3 and 4. The Onboard hardware will connect to the receptacle has "Rx+" and "Rx-" and positions 6 and 5. The customer cannot connect Fleet Onboard to an Ethernet switch in this state and renders the system inoperable. The 379-9514 Cab Harness As connector "CN-C3" will need to have the "Rx+" and "Rx-" wires moved to the correct positions.

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

Important Safety Information

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. Caterpillar 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 any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Illustration 1	g00037860

Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be both feet and one hand or a single foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.

ReferenceFor more information on welding practices and procedures refer to Special Instruction, REHS1841, "General Welding Procedures"

General Preparation

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

In addition to the normal safety precautions that are taken in the day to day operation of heavy machinery, the following steps are recommended:

1. Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Stop the engine.

4. Engage the machine brake.

5. When possible, maintain ownership of the machine keys.

Rework Procedure

When installing Fleet Onboard hardware and harnessing in the cabs of the F series Large Mining Trucks with the above serial numbers, perform the task listed below:

Note: These trucks came with a cab display harness that contains a connector that was mislabeled on early schematics as the connector for the backup battery. This connector should be used for the powering of the MS952 Mid Precision GPS (MPGPS) receiver only. The backup battery should never be connected to this connection.

Display Ethernet Wiring Rework

Parts to connect a reworked connector to a Cat 5 cable are listed in Table 1.

Illustration 2	g03404384
(1) Location of display harness connectors "CN-C3", "CN-C5", and "CN-C7"

Illustration 3	g03404377
(2) Connector "CN-C3" (3) Connector "MC-C3"

For the Object Detection cab harness ( 379-9514 Cab Harness As ), when used with Fleet Onboard, the connector "CN-C3" (2) will need to have two wires moved in order to match up with the 419-5974 Adapter .

Perform the following procedure for display Ethernet wiring rework:

1. Disconnect the receptacle "CN-C3" (2) from cab harness connector "MC-C3" (3) .

2. Remove the wire (1406-BR) from position 3 of connector "CN-C3" (2) .

3. Install the wire (1406-BR) into position 6 of connector "CN-C3" (2) .

4. Remove the wire (1407-BU) from position 4 of connector "CN-C3" (2) .

5. Install the wire (1407-BU) into position 5 of connector "CN-C3" (2) .

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Illustration 4	g03404379
Connector "CN-C3" after rework

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Illustration 5	g03404391
382-0995 Network Cable As and 419-5974 Adapter connected to connector "CN-C3"

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Illustration 6	g03404392
(4) 419-5974 Adapter (5) 435-9854 Connector Adapter

6. Install the 382-0995 Network Cable As and the 419-5974 Adapter (4) to the reworked connector. The Cat 5 Ethernet cable from the customer supplier Ethernet switch will be connected to the 419-5974 Adapter (4) .The 435-9854 Connector Adapter (5) can be applied as needed to the Cat 5 cable.

   Note: Connector "MC-C3" (3) will not be used when connecting to a customer supplier Ethernet switch

Installation of the 440-2318 Lighting Harness As for Backup Battery Connections

Illustration 7	g03405737
440-2318 Lighting Harness As (6) Receptacle "M-C1" connects to connector "MC-C108" (7) "M-C3" Power from backup battery (8) "M-T1" Ground (9) "M-C4" Power to backup battery (10) Plug "M-C2" connects to machine "CN-C7"

The parts required for Installation of the 440-2318 Lighting Harness As for backup battery connections are listed in Table 2.

Perform the following procedure for Installation of the 440-2318 Lighting Harness As for backup battery connections:

1. Using the 343-8455 Battery Mounting Gp , mount the 167-8984 Battery Gp .

   Note: Caterpillar recommends that the battery should be mounted in an area easily accessible as the battery should be replaced every 6 months to prevent display flash corruptions. Possible locations include the rear cab tray or a location behind the seat.

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Illustration 8	g03404399
Connectors (11) Ground terminals (12) Connector "CN-C7" (13) Connector "MC-C108"

2. Locate the connector "CN-C7" (12) of the display harness and disconnect from the connector "MC-C108" (13) of the cab harness.

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Illustration 9	g03404403
View from rear of cab with backup battery mounting in rear cab tray (14) 265-8147 Wiring Harness (15) 167-8984 Battery Gp (16) 440-2318 Lighting Harness As (17) Ring terminal "M-T1" to Ground

3. Connect the plug "M-C2" of the 440-2318 Lighting Harness As (16) into the receptacle "CN-C7" of the display harness. Connect the plug "MC-108" into the receptacle "MC-C1" of the 440-2318 Lighting Harness As (16). Connect the ring terminal "M-T1" to the machine ground.

4. Connect the plug "M-C4" of the 440-2318 Lighting Harness As (16) to the input of the 167-8984 Battery Gp (15). The output of the 167-8984 Battery Gp (15) will be connected to the 265-8147 Wiring Harness (14). Connect the output of 265-8147 Wiring Harness (14) to the receptacle "M-C3" of the 440-2318 Lighting Harness As (16) .

MPGPS Installation

Illustration 10	g03405756
388-2414 Wiring Harness (18) "TM-C2" VIMS 3G CAN (19) "TN-C6" service port (20) Resistor (21) "TM-C1" connection to MPGPS module (22) "TM-C4" Power In (23) "TM-C5" Power Out

The parts required for MS952 GPS receiver installation are listed in Table 3.

Perform the following procedure for MS952 GPS receiver installation:

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Illustration 11	g03404428
View from rear of cab (24) 395-1067 Satellite Receiver (GPS) (25) Antenna coax cable (26) Plug "TM-C1" (27) CAN Resister (28) Cable tie (29) Pass through to cab interior (30) Main cab harness

1. Mount the 395-1067 Satellite Receiver (GPS) (24) in the rear cab compartment as shown in Illustration 11. The 318-7412 Bracket As will mount with the 8T-4121 Hard Washer and 8T-4137 Bolt . The 395-1067 Satellite Receiver (GPS) (24) will then mount to the 318-7412 Bracket As with the 8T-4138 Bolt and 9X-8256 Washer .

2. Connect the 343-8448 Cable As to the receiver and route as needed to the 372-4806 Antenna .

3. Connect the plug "TM-C1" (26) to the MS952 MPGPS Receiver.

4. Route the 388-2414 Wiring Harness starting with the connector "TM-C1" from the receiver through the electronics bay (e-bay) and to the center console.

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Illustration 12	g03404439
(31) Connector "TM-C2" (32) Connector "MA-C2" (33) Connector "MC-C62" (34) Cable tie (35) 388-2414 Wiring Harness

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Illustration 13	g03404445
(36) Location for connecting the C2 end of the 388-2414 Wiring Harness

5. At the center console, remove the CAN resistor (27) from the connector "MA-C2" (32). Install the CAN resistor (27) in the connector "TM-C3" of the 388-2414 Wiring Harness (35) .

6. Connect the connector "TM-C2" (31) of the 388-2414 Wiring Harness (35) to the connector "MA-C2" (32) of the machine harness.

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Illustration 14	g03404476
(37) Install the plug "CN-C9" into connector "TM-C4" (38) Connector "TM-C4" connecting to connector "CN-C5" with the plug "CN-C9" removed

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Illustration 15	g03404822
(39) "TM-C6" service port (40) Cover As (41) Fuse block harness

7. To make the power connection, locate the connector "CN-C5". Remove the plug "CN-C9" and connect the connector "TM-C5". Install the plug "CN-C9" into the receptacle "CN-C4".

8. The "TM-C6" connection will be installed in a 25.4 mm (1 inch) diameter hole drilled between the VIMS and machine service connector if desired. This is a service port for the GPS module and may also be run to the module location and secured with wire ties.

LPGPS Installation

The parts required for installation of 304-3928 Satellite Receiver Gp (LPGPS module) are listed in Table 4.

Perform the following procedure for installation of 304-3928 Satellite Receiver Gp (LPGPS module):

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Illustration 16	g03404463
(42) LPGPS mounting location

1. Mount the 304-3928 Satellite Receiver Gp in the rear cab compartment as shown in Illustration 16. The 318-7412 Bracket As will mount with the 8T-4121 Hard Washer and 8T-4137 Bolt . The 304-3928 Satellite Receiver Gp will then mount to the 318-7412 Bracket As with the 8T-4138 Bolt and 9X-8256 Washer .

2. Connect the plug "CD-C2" of 357-7170 Wiring Harness to connector "MC-C35" (Product Link Connection) of the machines harness.

3. Connect the plug "CD-C1" of the 357-7170 Wiring Harness to the LPGPS receiver.

4. Connect one end of the antenna cable to the receiver and the other end to the antenna.

VIMS Connection

1. For the VIMS Ethernet connection, use a 305-5528 Wiring Harness . Connect the plug "RJ45" to the customers switch and the service port end to the machines service port.

   Note: For schematics, refer to Schematic, UENR3608, "MineStar Fleet and Proximity Awareness On-Board Electrical System 382-1517", and Schematic, UENR2573, "793F Off-Highway Truck Electrical System (For Serial Numbers SSP509-Up) All Other Serial Numbers 1-UP)". Refer to Special Instruction, REHS7413, "Installation Guide for Cat® Fleet Onboard System" Fleet Onboard installations.