Installation of Aftermarket Seatbelt Alert kit on Caterpillar<SUB>&reg;</SUB> 773D and 777D Off-Highway Trucks {1408, 7327, 7400} Caterpillar

Off-Highway Truck/Tractor

773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

Introduction

Illustration 1	g06376526
Overview Diagram

The information that is contained in this Special Instruction guides the user in the installation of the "LCV Seat Belt Kit". Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

The "LCV Seat Belt Kit" is offered as an aftermarket attachment for use on Caterpillar _® 773D and 777D Off Highway trucks, providing a fleet solution for equipment owners.

This kit provides an audio alert in form of buzzer, visual alert in form of dashboard indicator lamp, and a beacon for site superiors, when the seat belt is not worn by the operator during operation.

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.

Required Parts

This system is designed to operate in 24V DC, negative ground. Current draw of the control package is less than 1A.

Installation Procedure

Perform the following procedure to mount the timer and relay assembly:

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Illustration 2	g06376547
(1) 6.6 mm (0.25 inch) Holes (2) Clearance Holes for Timer Relay

1. Drill four 6.6 mm (0.25 inch) diameter holes for mounting 453-9924 Relay As.

2. Drill two clearance holes for mounting 115-7942 Timer. Refer to Illustration 2

3. Mount 453-9924 Relay As with one 5C-9553 Bolt, two 9X-8256 Washer, and one 5C-2890 Nut for each relay.
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   Illustration 3	g06376548

4. Set the timer relay setting to 3 mins. Refer to Illustration 3.

   Note: Knob position in pin numbers 5, 6, and 8 should be in closed position

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   Illustration 4	g06376530
   Relay and Timer Mounted

5. Mount 115-7942 Timer with two 030-8838 Screw, and two 6V-8368 Nut.

Perform the following procedure to mount the alarm assembly:

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Illustration 5	g06394105
(3) 232-1792 Horn (ALARM) (4) 123-9694 Horn

1. Drill 28.4 mm (1.19 inch) diameter hole in 379-3159 Plate As to mount 123-9694 Horn. Refer to Illustration 5.

2. Drill two 2.38 mm (0.09 inch) diameter holes in 379-3159 Plate As as indicated in the illustration to mount 232-1792 Horn (ALARM).

3. Unscrew the mounting part of 123-9694 Horn, fix in the hole and screw with horn base.

4. Unscrew the mounting part of 232-1792 Horn (ALARM) place in the hole and secure by screwing together with alarm base.

Perform the following procedure for mounting the belt assembly:

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Illustration 6	g06394466
(5) Mechanical Latch (6) Seat Belt

1. Remove the existing mechanical latch (5) by removing the M12 bolt.

2. Assemble electrical latch of 381-4539 Seat Belt Gp (RETRACTABLE, 2-IN) in place of the removed mechanical latch with M12 bolt and washer.

3. Assemble belt portion of 381-4539 Seat Belt Gp (RETRACTABLE, 2-IN) on the left side of operator seat with M12 bolt, washers, and spacer as indicated in Illustration 6.
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   Illustration 7	g06394498
   Film and Indicator Light Plate (7) 450-9786 Plate As (8) 163-1876 LED Lamp (9) 452-5798 Film

4. Mount 450-9786 Plate As with two 9X-2045 Screw refer to Illustration 7.

5. Snap 163-1876 LED Lamp (8) into the 450-9786 Plate As (7).

6. Apply 452-5798 Film next to the indicator.

Perform the following procedure for the harness assembly installation:

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Illustration 8	g06394631
Relay Connectors (10) C11 Connectors (11) C9 Connectors (12) C5 Connectors (13) C4 Connectors (14) T1 Connectors (15) T4 and T5 Connectors

1. Connect the C11, C9, C5, and C4 connectors to relay from 571-0803 Harness as indicated in Illustration 8 according to length.

   Connect terminal T4 and T5 to 115-7942 Timer.

2. Unbolt the cab ground point as indicated in the above illustration and add terminal T1 of seat belt harness and bolt.

3. Route the other end of harness with connector C6 though the hole behind tower along with the other harnesses.
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   Illustration 9	g06394664
   Harness Routing Under Cab

4. Route the harness underneath to cab, to the dash board as indicated in the below illustration

5. Connect C6 connector to 163-1876 LED Lamp.

6. Route the harness with Terminal T2, T3 for alarm 1 and T7, T8 for alarm 2 though the grommet behind the co-operator seat.

7. Connect T2 and T3 to 123-9694 Horn and T7 and T8 to 232-1792 Horn (ALARM).

Functional Testing After Installation