Procedure To Install 3D Grade Control Harness On Certain Cold Planers {1408} Caterpillar

Cold Planer

PM620 (S/N: JB91-UP; LH91-UP)

PM622 (S/N: JFC1-UP)

Introduction

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

Safety Section

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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.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Torque Specifications

All fasteners are to be secured used standard torque unless otherwise noted.

English (SAE) Fasteners

The following table has the recommended standard torque values.

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Note: All fasteners are standard torque unless otherwise noted.

Required Parts

Illustration 1	g06276664
Breakdown of required parts. Some background components are made transparent for reference

Machine Modifications

Illustration 2	g06276637
Overview of harness to be installed on machine. Machine background geometry is transparent, and machine frame is shown as reference for harness routing.

A total of three machine panels need to be modified to accept the Control Harness

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Illustration 3	g06272960
(A) Horizontal Dimension - 84 mm (3.307 inch) (B) Vertical Dimension - 45 mm (1.771 inch)

1. Measure and drill 43.1 mm (1.696 inch) hole on right rear of machine for harness connector.
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   Illustration 4	g06271590
   (C) 100.3 mm (3.948 inch) (D) 186.75 mm (7.352 inch) (E) 86 mm (3.385 inch) (F) 215.4 mm (8.480 inch) (G) 67 mm (2.637 inch) (H) 60 mm (2.362 inch) (J) 274.2 mm (10.795 inch) (K) 407.2 mm (16.031 inch)

2. Measure for weld boss locations, and weld eight bosses (6) on rear corner of planer.
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   Illustration 5	g06272714

3. Modify two panels behind operators platform to accept two connector plugs from new harness. Image shows holes already cut and harness connectors installed as reference.
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   Illustration 6	g06276798
   Modify sheet metal cover to accept new wire harness (L) 87.2 mm (3.433 inch) (M) 72.3 mm (2.846 inch) (N) 47.2 mm (1.858 inch) (P) 37.2 mm (1.464 inch) (Q) 71.8 mm (2.827 inch) (R) 76.8 mm (3.023 inch) (T) 79 mm (3.110 inch) (U) 114.6 mm (4.511 inch) (V) 116.8 mm (4.598 inch) (W) 121.8 mm (4.795 inch)

4. Make D-shape cut-out to accept 3D harness connector plug using the dimensions provided.

5. Drill two 8.2 mm (0.323 inch) holes for the harness mounting hardware.
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   Illustration 7	g06280847
   (X) 426.9 mm (16.80 inch) (Y) 421.9 mm (16.61 inch) (Z) 419.9 mm (16.53 inch) (AA) 384 mm (15.11 inch) (BB) 381.9 mm (15.03 inch) (CC) 376.9 mm (14.83 inch) (DD) 292.9 mm (11.53 inch) (EE) 307.6 mm (12.11 inch) (FF) 332.9 mm (13.10 inch) (GG) 342.9 mm (13.50 inch)

6. Make D-shape cut out to accept 3D harness using the dimensions provided.

7. Drill two 8.2 mm (0.32 inch) holes for the harness mounting hardware.

Installation Procedure

Illustration 8	g06276637
Overview of harness to be installed on machine. Machine background geometry is transparent, and machine frame is shown as reference for harness routing. Route harness from right rear storage cabinet to rear side of operator platform.

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Illustration 9	g06277665

1. Start routing harness by installing the rear most harness plug into the rear storage cabinet on the right side using nut (8). Secure the harness to the existing wiring that is tied to the rear machine frame with tie straps (7) as needed.
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   Illustration 10	g06272727

2. Continue running the harness next to the existing wire harness as shown along the rear of the machine. Secure the harness to the existing wiring with tie straps (7) as needed.
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   Illustration 11	g06272754

3. Route harness around the left rear of machine. Plug connector end on the short harness end into electrical panel on rear left of machine as circled.
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   Illustration 12	g06272976

4. Continue routing harness around the left side of the main drive housing and under the drive pulley as shown. Secure the harness to the existing wiring with tie straps (7) as needed.
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   Illustration 13	g06277844

5. Route harness toward the operator panel. Secure harness connectors using clip (10) and cable straps (2). Secure the harness to the existing wiring with tie straps (7) as needed.
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   Illustration 14	g06277852

6. Continue routing the rest of the harness up to the panel behind the operator station. Install harness connection in panel and secure the harness to the existing wiring with tie straps (7) as needed.
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   Illustration 15	g06277443

7. Install bracket (12) using two bolts (4) and two washers (5).
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   Illustration 16	g06277469

8. Slide spring clip (9) over harness connector and mount to bracket using four screws (1).
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   Illustration 17	g06277472

9. Install dust cap (3).
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   Illustration 18	g06273086

10. Continue routing harness to the other panel behind the operator station. Install harness connection in panel and secure the harness to the existing wiring with tie straps (7) as needed.
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    Illustration 19	g06277480

11. Install bracket (12) using two bolts (4) and two washers (5).
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    Illustration 20	g06277489

12. Slide spring clip (9) over harness connector and mount to bracket using four screws (1).
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    Illustration 21	g06277609

13. Install dust cap (3).