Installation of Wheel Loader Payload Measurement System{7494} Caterpillar

Installation of Wheel Loader Payload Measurement System{7494}

Usage:

992C (49Z0001-Up)

Introduction

This instruction provides the necessary information needed to install a Payload Measurement System on the 992C Wheel Loader.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Reference: See Special Instruction SEHS9307 Operating Manual-Wheel Loader Payload Measurement System for operation and troubleshooting information.

See Special Instruction SEHS9273 Caterpillar Wheel Loader Payload Measurement System for quick reference information on operation and calibration.

Necessary Parts

Installation Procedure

1. Install 6D3025 Bearing (1), 2L6726 Snap Ring (2), 6D3025 Bearing (1) and 2L6726 Snap Ring (2) into 4E2250 Housing (3).

NOTE: The 2L6726 Snap Ring (2) between the two 6D3025 Bearings (1) serves as a spacer. The 4E2250 Housing (3) does not have a groove for it to set in.

2. Slide 4E2453 Shaft (4) in from the front of 4E2250 Housing (3), through the two bearings (1).

3. Install 2H3429 Snap Ring (5) on 4E2453 Shaft (4) as shown.

4. Install one 8C5608 Spacer (6) and two 8C5607 Mounts (7) in each of the three holes on 4E2250 Housing (3).

5. Install 9X9100 Position Sensor (8) to the back of housing (3) with two 6V2313 Bolts (9) and two 4B4274 Washers (10).

6. Remove left side collet bolt. Using a 100-7421 Rod Assembly (11) and two existing 4K0684 Washers and one existing 3K9770 Nut, install 9U3298 Guard Assembly (12) to collet pin. Torque bolt to 1800 ± 200 N·m (1332 ± 148 lb ft).

7. Using three 7X7888 Bolts (13), six 9X6165 Washers (14), and three 9U3300 Spacers (15), install housing (3) to guard assembly (12).

NOTE: One or two additional sets of three washers (14) may be required to provide clearance between position sensor (8) and rod assembly (11). Install additional washer sets between 9U3300 Spacers (15) and 8C5607 Mounts (7).

8. Secure wire from sensor (8) to guard assembly (12) using one 8M2771 Clip (16), 5C9553 Bolt (17) and 9X8256 Washer (18).

Lift Arm.

9. Center 3T3812 Block (19) side to side and using a fillet weld along the long side only, weld to left lift arm.

10. Using two 5S7382 Bolts (20) and 8T4896 Washers (21), secure 100-7420 Bail Arm (22) to block (19).

11. Remove 8R1939 Tube Assembly and install 100-7423 Tube Assembly (66).

12. Place the lift arms in the lowest possible position with the bucket tilted fully back. Install 6S4868 Lever (23) on 4E2453 Shaft (4) with an 8T2502 Bolt (24) and 8T4896 Washer (21).

NOTE: Do not tighten 8T2502 Bolt (24) on 6S4868 Lever (23) at this time.

13. Assemble one 4F2294 Nut (25) and one 8K1253 Rod End (26) on each end of 3N9311 Rod (27) to a length of 149 mm (5.9 in), then lengthen rod (27) by eight turns of rod end (26).

NOTE: The eight turns of rod (27) should be four on each end.

14. Connect rod (27) and 8T4224 Washer (28) to bail arm (22). Connect the other end to 6S4868 Lever (23) with 8T4224 Washer (28) and 3D8752 Locknut (29).

15. Tighten 8T2502 Bolt (24) on lever (23) at this time.

16. Once rod (27) is in place, disconnect it from bail arm (22) and shorten by eight turns.

NOTE: Shortening rod (27), positions lever (23) so that it protects sensor from bottoming out.

17. Connect rod (27) back to bail arm (22) and tighten nuts (25) to rod ends (26).

18. Using three 4M5281 Bolts (30) and 5P4115 Washers (31), install 9U4474 Plate (32) to guard assembly (12).

Control Group (Hydraulic pressure sensor) (33).

NOTE: Tilt bucket forward so it rests flat on the ground to release the lift arm pressure and minimize hydraulic fluid loss.

19. Using the dimensions shown, locate and weld 4E2448 Bracket (36). Use vertical weld along side only.

20. Locate and weld 3W3895 Boss (37) as shown.

21. Attach 6V8636 Connector (34), with a 3J1907 O-ring Seal (35), to the port on the bottom of the 103-2040 Hydraulic Pressure Sensor (33).

22. Secure the control group (Hydraulic Pressure Sensor) (33) to Bracket (36) with two screws (C), included with sensor.

23. Connect 9R2152 Hose Assembly (38), with one 6V8397 Seal (39), to the 6V8636 Connector (34) on the control group (33) as follows.

* Connect the 90° end of the 9R2152 Hose Assembly (38) to the connector on the hydraulic pressure sensor (33).

Lift Cylinder Pressure Line.

24. Using 3J1907 Seal (35), connect 6V8724 Connector (61) to head end of pressure implement valve. Using one 6V8397 Seal (39), connect 9R2152 Hose Assembly (38), straight end, to connector (61).

Installation of Electronic Control Group (Controller)

25. Route 100-7424 Harness Assembly (42) through loader frame. Install one 6V3341 Grommet (67). Using one 5M3062 Bolt (40), 8T4896 Washer (21) and 4D7794 Clip (41), mount harness assembly (42). Connect harness assembly (42) to switch (D). Install one 7K1181 Strap (43) to secure sensor breakout (pigtail) to sensor (33).

26. Route harness assembly (42) along existing pilot lines and secure harness assembly to pilot lines with five 7K1181 Straps (43).

27. Weld 3W3895 Boss (37) to left inside loader frame. Boss will be in approximately the same location as the standard wiring boss located on the right inside loader frame.

Route harness assembly (42) along existing floodlight wiring with five 4D7794 Clips (41) and four 3S2093 Straps (58).

Connect harness assembly (42) to 9X9100 Control Group switch wiring (8).

28. Route 100-7425 Harness Assembly (68) and secure it with two 7N3718 Clips (44) using existing hardware.

NOTE: Gather excess harness (68) between clips (44) and secure it with straps (58) as shown.

Connect gray wiring connectors of harness assembly (68) to 100-7424 Harness Assembly (42).

Secure harness assembly (42) to standard front harness with straps (58).

29. Remove right side cover (door).

30. Remove 4V3752 Sheet (E) from cab.

31. Drill four 10.5 mm (.41 in) diameter holes as shown in sheet (E).

32. Using four 5M3062 Bolts (40) and 8T4896 Washers (21) mount 3E9292 Electronic Control Group (45) to sheet (E). Install sheet (E) with electronic control group (45) mounted to it in cab.

33. Fold back the existing window seal and drill two 6.8 mm (.27 in) diameter holes in right cab post as shown. Tap both holes 5/16-18 thread.

NOTE: For open ROPS machines, install 103-1763 Plate (73). Plate may be fabricated from 10 mm (.39 in) plate as shown.

Weld plate to handhold.

Weld all around lower edge of plate (73) to channel.

NOTE: Some weld at tube may have to be removed to allow flush mounting of plate to handrail assembly.

34. Using two 5P7923 Screws (46) install 9U4477 Bracket (63) to cab post or to (103-1763 Plate for open ROPS machine).

35. Remove two existing dash screws (F). Using two 4V6981 Screws (47), install 9U4480 Bracket (48).

36. Remove one existing screw (G). Use this screw and install 8V9332 Bracket (49).

37. Route 9U4472 Harness Assembly (50) from 8V9332 Bracket (49).

38. Secure harness assembly (50) to bracket (49) with 4M5281 Bolt (30), 8T4205 Washer (64), 6V8185 Nut (65) and 6V4369 Clip (52).

38A. (Open ROPS only), drill two 7.5 mm (.30 in) holes in dash cover assembly, as shown. Use two 4M5281 Bolts (69), 6V3185 Nuts (71) and four 8T4205 Washers (70) to secure harness (50) with two 8J1256 Clips (51) to existing dash cover assembly.

39. Route harness assembly (50) along bottom of window and secure with 8J1256 Clips (51) and existing screws.

(Open ROPS only). Install two 9M8406 Clips (72) using existing hardware.

40. Use clip (52) and five 3S2093 Straps (58) to secure harness assembly to existing wiring.

41. Remove fuse panel and install harness assembly (50) to hour meter fuse holder. (The existing white wire-123 will have to be removed from the fuse panel and reconnected to harness assembly). Secure fuse panel to dash.

42. Secure the large 20 pin connector from harness assembly (50) to the electronic control group (45).

43. Remove collar (H) off two 9X9688 Switch Assemblies (53). Install switches (53) into 9U4478 Cover (54) and reinstall collars (H) onto switch assemblies (53).

44. Connect the two, two-pin DT connectors from 9U4472 Harness Assembly (50) to the switch assemblies (53) and install 5P8441 Grommet (55) in the 9U4478 Cover (54).

NOTE: The longer lead of harness assembly (50) will be connected to the top switch.

45. Using three 6V3884 Screws (56), secure cover (54) to bracket assembly (48).

46. Install 9X8861 Film (57) on face of cover (54) between switches (53).

47. Drill 25 mm (1 in) diameter hole in floor plate. Drill 10.5 mm (.41 in) diameter hole on existing vertical panel as shown.

48. Route 9U4472 Harness Assembly (50) down along existing panel through floor plate. Connect harness assembly (50) to harness (68) under the cab.

49. Connect breakout (pigtail) ground wire from harness assembly (50) to existing cab ground.

50. Using one 5M3062 Bolt (40), 8T4896 Washer (21), 6V8801 Nut (59), and 4D7794 Clip (41), secure harness assembly (50) to existing panel.

51. Install 7G7053 Grommet (60) into floor plate. Install cover plate (door).

52. Weld 3W3895 Boss (37) to cab support channel. Using one 5M3062 Bolt (40), 8T4896 Washer (21), and 4D7794 Clip (41), secure harness assembly (50) to boss (37).

53. Connect two connectors from harness assembly (50) to 3E8945 Electronic Control Group (Display Monitor) (62). Using two 5M3062 Bolts (40) and 8T4896 Washers (21), mount control group (62) to bracket (48).

54. Articulate the machine fully right and left. Then, lift the bucket up and down fully to make sure all harness wires and hoses have proper clearances and no restrictions.

55. Refer to the Operation and Maintenance Manual for type and quantity and fill the hydraulic tank to its proper level.

56. During the installation process, inadvertent faults can be recorded (unplugged connector, unhooked position sensor linkage). At this time, clear out the faults that have been recorded using the procedure in the Operating Manual. Any faults that appear after this, should be considered actual faults that need to be addressed, according to the troubleshooting portion of the Operating Manual.

System Setup

These steps setup the system after everything has been properly installed and connected. Run these procedures before any other activity (i.e., calibration) takes place.