- Motor Grader
- 120H (S/N: CAF1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-UP; 9FN1-UP; 3GR1-UP; 9YR1-UP)
- 12H (S/N: XZJ1-UP; CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP)
- 135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 8WN1-UP; AMX1-UP)
- 140H (S/N: CCA1-UP; XZH1-UP; 2ZK1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3FR1-UP; 3AS1-UP)
- 143H (S/N: 1AL1-UP; APN1-UP)
- 160H (S/N: ASD1-UP; 9EJ1-UP; XZK1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-UP; 3HR1-UP; 2HS1-UP)
- 163H (S/N: 5AK1-UP; ARL1-UP)
- 24H (S/N: 7KK1-UP)
- 12H (S/N: XZJ1-UP; CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This Special instruction provides instructions to determine if a system power circuit needs to be installed for the initial machine installation of the 452-9831 Transmission Control (Transmission Gear Select Switch) on certain early model H Series Motor Graders. The Transmission Gear Select Switch requires an unswitched system power supply for proper operation. The prior model Transmission Gear Switch did not require a system power circuit for operation.
Important Safety Information
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. 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.
After power is removed, wait for five minutes before the UPS is opened. This action allows the capacitors to discharge. Ensure that the capacitors are at a zero energy level before performing work.
Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing maintenance on the UPS.
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Working with electrical circuits is hazardous and exposes personnel to electrical potential. To ensure safe operation, personnel must be trained in proper operating procedures. Bodily contact with electrical potential will cause serious personal injury or death. |
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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures. |
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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on. |
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Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE". |
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| Illustration 1 | g00104545 |
Prevent the machine from movement. Park the machine on a level surface.
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags are available from your Caterpillar dealer. Attach the warning tags to the system and to each operator control station.
Machine Preparation
Follow the below procedure to prepare the machine for installation:
- Park the machine on a level surface.
- Switch off the engine and leave the key in the "OFF" position.
- Engage the Parking Brake.
- Turn the Key Start Switch to the OFF position.
- Open the Battery Disconnect Switch and lock out the Battery Disconnect Switch.
Required Parts
The required parts for the installation of power circuit are listed in Table 1.
| System Power Connection Parts List | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | 207-3814 | Wire As |
| 2 | 102-8802 | Receptacle Kit |
| 2 | 155-2270 | Connecting Plug Kit |
| 4 | 8T-8737 | Seal Plug |
| 1 | 9X-3402 | Connector Socket |
| 1 | 9X-3401 | Connector Pin |
| 10 | 7K-1181 | Cable Strap |
| |
5P-0659 | Electrical Wire |
| - | - | Alphanumeric Wire Labels |
Note: Normal connector circuit removal tools and circuit termination tools will be used for this procedure.
Checking for the Availability of Power Circuit
The Transmission Gear Select Switch requires an unswitched system power supply for proper operation. The prior model Transmission Gear Switch did not require a system power circuit for operation.
Machine models released later will have a system power circuit in the harness connector for the switch that was not used. Some early models do not have a required unswitched system power circuit in the harness connector for the Gear Switch.
If the part to be replaced is already a 452-9831 Transmission Control (Transmission Gear Select Switch) that has worked as expected in the past, then this procedure does not need to be performed.
Note: If the part to be replaced is not a Transmission Gear Select Switch then the Section "Power Circuit Installation Procedure" must be performed to install the power circuit.
The Transmission Gear Select Switch that is being replaced would have already had a system power connection or the component would not have worked when initially installed. If you still have doubts, perform the procedure below to check whether there is an unswitched system power supply already installed before initially installing the 452-9831 Transmission Control (Transmission Gear Select Switch).
- Remove the covers on the right-hand console to access the cab harness connector for the transmission gear switch.
- Disconnect the 24-pin harness connector for the transmission gear switch.
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Illustration 2 g06221719 Harness side view of the cab harness connector pin out for the transmission gear switch.
(1) Connector location 15 - Check the connector location 15 (1) as noted in Illustration 2.
- If there is a circuit wire in connector location 15 (1), this procedure does not need to be performed.
- Any circuit in location 15 (1) would be a system power circuit. If there is no circuit wire in connector location 15 (1), the Power Circuit Installation procedure needs to be performed.
- Proceed to the Section "Power Circuit Installation Procedure" to connect an unswitched system power circuit to the harness connector for the switch.
Power Circuit Installation Procedure
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| Illustration 3 | g06221722 |
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Typical cab harness connections in the right-hand console for the Transmission Gear Select Switch before rework | |
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| Illustration 4 | g06221723 |
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Typical cab harness connections in the right-hand console for the Transmission Gear Select Switch after the rework has been completed. Dashed lines indicate reworked wiring and connector additions. | |
Note: Harness and connector configuration of the machine may not match the typical schematic, but the connections to the Service Connector and the Transmission Gear Select Switch will be the same. Refer to Illustration 3 and 4.
Follow the below steps to install the Power Circuit:
- Label each wire segment of the 207-3814 Wire As (three-way splice harness) as a "308" circuit, using the wire labels.
- On each of the two segments that has the socket terminated, install the wire and socket in a 155-2269 Connector Plug As (two-pin plug connector) that is part of the 155-2270 Connecting Plug Kit at pin location 2. Ensure that the sockets are fully inserted and locked in place. Install the wedge in each plug.
- Install an 8T-8737 Seal Plug in each plug connector at the unused pin location 1. Set the splice harness aside.
- At the right-hand console, remove the covers to the console to access the cab harness connector and the connection side of the Service Connector.
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Illustration 5 g06221721 Pin out of the Service Connector as viewed from the rear connection side - At the rear connection side of the Service Connector, use a terminal removal tool to remove the yellow wire and pin at location (A). This circuit is the "308-YL" unswitched system power circuit. Refer to the service connector pinout Illustration 5.
Removing the connector from the mount may provide greater access if needed.
- Install the "308-YL" wire and pin in a 3E-3364 Receptacle (two-pin receptacle connector) that is part of the 102-8802 Receptacle Kit at pin location 2. Ensure that the pin is fully inserted and locked in place.
- Install the wedge in the two-pin receptacle connector. Install an 8T-8737 Seal Plug in the receptacle connector at the unused pin location 1. Connect the two-pin receptacle connector to one of the two-pin plug connectors on the three-way splice harness. Ensure that the connectors are in the locked position.
- Insert the wire segment of the three-way splice harness that has the pin installed in the service connector at the vacant location (A). Verify that the pin and wire are locked in the service connector. If the service connector was removed from the mount, remount the service connector on the mount.
- With the 5P-0659 Electrical Wire
609.6 mm (2.00 ft) section of yellow wire, properly crimp a 9X-3401 Connector Pin on the end of the wire. Label the wire end as a "308" circuit. - Insert the wire and pin in a 3E-3364 Receptacle (two-pin receptacle connector) at pin location 2. Verify that the pin and wire are locked in the receptacle connector.
- Install the wedge in the two-pin receptacle connector. Install an 8T-8737 Seal Plug in the receptacle connector at the unused pin location 1.
- Connect the two-pin receptacle connector to the other segment of the three-way slice harness that has the two-pin plug connector open. Ensure that the connectors are in the locked position.
- Cut the yellow wire segment to a length that will allow connection to the cab harness connector for the Transmission Gear Select Switch and allow for proper routing of the wire along the cab harness.
- Properly crimp a 9X-3402 Connector Socket on the end of the cut end of the yellow wire. Label the wire as a "308" circuit. If the cab harness connector for the transmission gear switch is not disconnected, disconnect the harness connector and remove the transmission gear switch that will be replaced from the mount.
- Insert the wire and socket into the cab harness connector for the transmission gear switch at connector location 15 (1). Verify that the wire and socket are locked in the connector body. Refer to Illustration 2.
- Use the 7K-1181 Cable Strap to secure the new wiring to the existing harness in the console. Ensure that the wires are secured and protected from any locations where the wires could rub on a hard surface.
- Mount the new 452-9831 Transmission Control (Transmission Gear Select Switch) on the mount. Connect the cab harness connector to the transmission gear select switch connector.
- Before replacing the covers on the console, close the disconnect switch. Turn the key start switch to the ON position.
- Check to see if any diagnostic codes have been activated. If diagnostic codes are active for the transmission gear select switch, verify that all the wiring is correct according to Illustration 4. Verify that all the connections are fully inserted and the connectors are locked together.
- If no diagnostic codes are active for the transmission gear select switch, reinstall the covers for the right-hand console. Start the engine and verify that the operation of the transmission gear select switch is correct before returning the machine to service.
