- Backhoe Loader
- 415F2 (S/N: HWA1-UP)
- 416F2 (S/N: LYA1-UP; HWB1-UP; LBF1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Some operators of mechanically operated machines may request a switch to operate the machine forward horn while facing the rear of the machine.
This procedure will instruct you how to install an electrical switch on the right-hand side console, which when pressed will operate the front horn.
| |
| Illustration 1 | g06264458 |
|
Location of horn button | |
Note: Before starting any work on the electrical system, make sure that the battery isolator switch is turned off, and for Tier 4 engine machines, that the amber DEF warning lamp next to the isolator key is extinguished.
Reference Section
Reference: Schematic, UENR5450, "415F2 and 427F2 Backhoe Loader and 415F2 Industrial Loader Electrical System (Interactive) 417-4231"
Reference: Schematic, UENR8036, "415F2, 427F2 Backhoe Loader and 415F2 Industrial Loader, Electrical System, (Preliminary), 417-4231-01"
Reference: Schematic, UENR8038, "Backhoe Loader,416F2, 422F2, 428F2 and 434F2 Electrical System, (PRELIMINARY), 417-4233-01"
Reference: Schematic, UENR3750, "416F2, 422F2, 428F2 and 434F2 Backhoe Loader Electrical System (Interactive) 417-4233"
Reference: Schematic, UENR5151, "416F2, 428F2 and 434F2 Backhoe Loader, Electrical System, (Interactive), HWN1-451, HWR1-202, HWB1-820, 417-4228-00"
Reference: Schematic, UENR3748, "416F2 Backhoe Loader Hydraulic System (Interactive) 447-0400-01"
Safety Section
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. Caterpillar 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 Caterpillar. If used, ensure the safety of the operating personnel and others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
Operation and maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and are understood.
 |
|
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. |
Required Parts
| Item | Qty | Part | ||
|---|---|---|---|---|
| 1 | |
16 AWG Wire (Orange Color) | ||
| 2 | 2a | |
16 AWG Wire (Black Color) | |
| 2b | |
16 AWG Wire (Black Color) | ||
| 3 | |
16 AWG Wire (Purple Color) | ||
| 4 | 3 | 104-1995 Blade Terminal (2 Wires) | ||
| 5 | 3 | 122-4401 Terminal (Single Wire) | ||
| 6 | 1 | 387-6549 Rocker Switch (Horn) | ||
| 7 | 1 | 350-3483 Terminal (Fuse Box) | ||
| 8 | 1 | 228-5856 Connector | ||
Required Tooling:
| Tool | Qty | Part |
|---|---|---|
| T1 | 1 | 6V-3001 Crimp Tool |
| T2 | 1 | Manufacturing part number: 1-1579007-4 TE Amp Connector Extraction Tool |
Installation Procedure
Installation requires installing crimps onto existing wires. Ensure that no bare wires are left exposed after performing the splice.
Note: Use 1mm2 (16AWG). This ensures that the cable is of sufficient size for the 15 amp fuse rating. Smaller size wires may overheat and melt.
Note: When crimping connectors onto wires, use a suitable crimp tool (such as Crimp Tool (T1)). Ensure that both the conductor crimp and insulation crimp are secure.
- Take the
750 mm (29.5 inch) orange wire and crimp a Terminal (5) onto one end. Push the terminal into position 3 of the Connector (8). - Take the
400 mm (15.7 inch) purple wire and crimp a Terminal (5) onto one end. Push the connector into position 7 of the Connector (8).Show/hide table
Illustration 2 g06264883 Show/hide table
Illustration 3 g06264889 Correct wire positions on the rear of the new horn connector - Cut
100 mm (3.9 inch) off the black wire and crimp a Terminal (5) onto one end. At the other end of the wire crimp both this wire, and the remaining black wire into a Blade Terminal (4) (2 wires into 1 terminal). Push one terminal into position 8 of the switch receptacle and the other into position 2.Show/hide table
Illustration 4 g06264920 Gauge cluster removed from side console - Carefully remove the gauge cluster from the right-hand console. Use a blunt tool to pry the console from the switch housing. This will give you access to the rear of the switches.
- Remove the switch blank from the location for the horn switch as shown in Illustration 1.
Show/hide table
Illustration 5 g06264959 New horn connector and wires in location on side console - Take the switch connector and the previously fabricated wires and push the new orange, black, and purple wires through the opening in the rear of the side console.
Show/hide table
Illustration 6 g06264962 Front work light switch removed from side console - Carefully pry out the front lighting switch in the console and locate the following wires on the rear connector:
- 202-RH15 Black
- 614–RH63 Purple
Show/hide table
Illustration 7 g06265004 Wires removed from front work light switch connector - Use a small screwdriver to release the tabs on the electrical terminals. Remove the 614 Purple and 202 Black from the switch connector block.
- Cut the original terminals off the 2 wires.
Show/hide table
Illustration 8 g06265032 New purple and black wires crimped to work light switch wires - Pass the purple and black wires on the new horn connector from behind the console to the light switch location. Carefully crimp the two black wires together with a Blade Terminal (4) and the two purple wires together with another Blade Terminal (4).
- Reinsert the wires back into the light switch connector. Black goes into position 7, purple goes into position 8.
- Reinsert the light switch into the harness connector and push the switch back into the console.
Show/hide table
Illustration 9 g06265040 - Insert the new horn switch onto its new connector and push the switch into the console.
- Do not reinstall the gauge cluster at this time.
- Remove the fuse panel cover and unscrew the 6 screws that retain the fuse panel to the right-hand console. Carefully pull the fuse panel forward.
Show/hide table
Illustration 10 g06265268 Fuse panel unscrewed and new orange wire visible - Locate the switch panel. Push the other end of the orange wire down towards the rear of the fuse panel.
Show/hide table
Illustration 11 g06265296 Show/hide table
Illustration 12 g06265305 Show/hide table
Illustration 13 g06265308 Location of pin 17 in connector X14 and secondary locking tab - Locate wire 320-PM128 Orange. The wire will be in pin 17 on the X14 connector (purple connector) on the rear of the fuse panel.
- Remove pin 17 electrical terminal from the connector by sliding the secondary locking tab on the side of the connector (see Illustration 13)
Show/hide table
Illustration 14 g06265314 TE Amp connector extraction tool - Release the locking tab on the rear of the terminal using an Amp Connector Extraction Tool (see Illustration 14), and cut the terminal from the wire.
Show/hide table
Illustration 15 g06265319 Both orange wires installed into the new terminal - Crimp both the new orange wire and 320-PM128 Orange wire into a Terminal (7), and push firmly back into location 17 of the X14 connector. Slide the secondary locking tab back into place.
- Reconnect the plug into the fuse panel and reinstall back into the side console.
Show/hide table
Illustration 16 g06265323 New wire installed into connector X14 - Turn on the electrical power and test the operation of the switch. When depressed, the front horn should sound. If the horn does not sound, check your electrical connections for any errors.
- Reinstall the gauge cluster.
