Procedure to Install the Travel Alarm on 302.7D Mini-Hydraulic Excavators{7429} Caterpillar

Mini Hydraulic Excavator:

302.7D (S/N: LJL1-UP)

Introduction

This special instruction outlines the basic procedures in order to install a travel alarm on a 302.7D Mini-Hydraulic Excavator.

The Travel alarm for the 302.7D Mini-Hydraulic Excavator is 386-0852 Travel Alarm Kit .

Read this publication before you install any parts. Also refer to the Service Manual and the Parts Manual for additional references.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Avoid errors during assembly: Always bear in mind the correct order of assembly.

Note: Avoid damaging parts during assembly: Always refer to the last pages of these instructions with the tightening torques for the screws and screw connections.

Required Parts

Illustration 1	g03357109

Machine Preparation

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Illustration 2	g00354092
Park the machine. Lower any attachments and the blade to the ground.

1. Park the machine on a level surface. Refer to Illustration 2.

2. Lower the attachments and the blade to the ground. Refer to Illustration 2.

3. Move the governor control lever to the LOW IDLE position and operate the engine at low idle for 5 minutes in order to allow the engine to cool down.

4. Turn the engine start switch to the OFF position.

5. When the engine has stopped, turn the engine start switch key to the ON position.

6. Move the hydraulic control levers back and forth in order to relieve hydraulic pressure.

   Note: The hydraulic control console must be lowered in order for the hydraulic circuit to be activated.

7. Turn the engine start switch to the OFF position and remove the key.

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Illustration 3	g00492157
Move the hydraulic control console to the RAISED position.

8. Place the left and / or the right hydraulic control console in the RAISED position.

9. Disconnect the battery from the electrical system.

Installing the Vacuum pump

Note: Use of a vacuum pump is recommended to minimize the loss of hydraulic oil when removing hydraulic hoses and components.

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Illustration 4	g03355277

1. Remove cap (A) .

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Illustration 5	g02723419
Breather

2. Open the engine door and remove the rear access cover.

3. Relieve the internal pressure in the hydraulic tank by slowly loosening the breather.

Replacing the Pilot valve

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Illustration 6	g03354883
(A) Rubber mat

1. Remove rubber mat (A) .

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Illustration 7	g03370649
(B) Base plate

2. Remove base plate (B) .

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Illustration 8	g03370655
(C) Screws (D) Drive levers

3. Remove screws (C) and both drive levers (D). Save screws and drive levers for installation.

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Illustration 9	g03370826
Pilot valve (E) Screws (F) Pilot valve

4. Loosen screws (E) on pilot valve (F) .

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Illustration 10	g03370829
Hydraulic hose connections on side of pilot valve

Note: Mark all hydraulic hoses and connections at the pilot valve before removal. Use the marked hydraulic lines for reference during installation of the new pilot valve. Refer to illustration 11.

5. Remove the hydraulic hoses connected on the sides of the pilot valve.

6. Remove the pilot valve.

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Illustration 11	g03370830
Pilot valve with hydraulic hoses marked

7. Remove the hydraulic hoses from the bottom of the valve.

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Illustration 12	g03370836

Note: Clean the screw connections prior to mounting the new pilot valve to prevent dirt from entering the hydraulic system. Remove all residues, particles, and contaminants.

8. Remove fittings (J) from old pilot valve (H) and install on new pilot valve (1). Reinstall the screw connections with suitable tools and to the specific torque value.

9. Transfer the markings of the connections of removed pilot valve (H) to new pilot valve (1) .

10. Install seal (3) and pressure switch (2) on new pilot valve.

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Illustration 13	g03370843
(1) Pilot valve (2) Pressure switch

Note: Clean new pilot valve (1) thoroughly to prevent dirt from entering the hydraulic system. Remove all residues, particles, and contaminants.

11. Mount the new pilot valve.

12. Install all removed hydraulic hoses to the side and bottom of new pilot valve. Use the marked hydraulic hoses and markings on new pilot valve for reference during installation.

13. Install the new pilot valve to the floor using the screws (E) removed during step 3

Installing the Travel Alarm Assembly

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Illustration 14	g03370845

1. Remove cover (K) .

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Illustration 15	g03370847

2. Fasten 381-2816 Alarm (Travel) to the cover, using the screws, washers, and nuts.

Note: Loosely install the shrink tubing on the wires prior to crimping the connectors.

3. Crimp flat connectors (10) on the wire and install the shrink tubing.

4. Install connectors (10) in connector housing (11)

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Illustration 16	g03370848
Ground lead (15) Ground lead (13) Connector (14) Cable lug

5. Crimp connector (13) and cable lug (14) to ground lead (15) .

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Illustration 17	g03370850
(15) Ground lead (L) Screw

6. Attach the cable lug (14) of the ground lead (15) to the screw (L) .

   Note: Check the ground connection for good contact.

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Illustration 18	g03370853
Mounted cover and travel alarm

7. Reinstall cover (K) .

8. Route connector (X4) of the alarm harness assembly to the travel alarm.

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Illustration 19	g03370855

9. Connect terminal (13) of the ground lead and (X4) of the alarm harness to flat connector housing (12) and connect with the travel alarm.

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Illustration 20	g03370857
(4) Alarm Harness As

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Illustration 21	g03370858
Wiring harness routed through base plate

10. Route alarm harness assembly (4) to the front of the machine. Route the harness to the area of the removed base plate.

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Illustration 22	g03485159

11. Connect (X3) from the alarm harness to pressure switch (2) and install the rubber boot over the connection.

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Illustration 23	g03485220

12. Connect (X2) from the alarm harness to (S21.1) connector.

Note: Reinstall all components removed from the machine that are necessary for operation.

13. Reinstall drive levers (D) with screws (C) .

14. Reinstall floor plate (B) and rubber mat (A) .

Testing the Travel Alarm

1. Start the engine. Move the left and right hydraulic control consoles to the LOWERED position.

2. Raise the attachments. Make sure that there is adequate overhead clearance.

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Illustration 24	g00363053
Travel levers

3. Use the travel levers to move the machine forward. The travel alarm should sound.

4. Release the travel levers in order to stop the machine.

5. Use the travel levers to move the machine backward. The travel alarm should sound.

6. If the alarm does not sound, adjust the height of the bracket in order to ensure correct operation of the switches. The alarm must sound when the lever assemblies are moved forward and backward.

7. Slowly release the travel levers in order to stop the machine. Lower the attachments to the ground. Move the right hydraulic control console and/or the left hydraulic control console to the RAISED position. Stop the engine.