Installation of the White Noise Back Up Alarms {7406} Caterpillar

Asphalt Paver

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Cold Planer

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Paving Compactor

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Pipelayer

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Track-Type Loader

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Track-Type Tractor

D3C - D5C Series III

Wheel Loader

950L (S/N: TNS1-UP; LXX1-UP)

950M (S/N: EMB1-UP; ENE1-UP; XCJ1-UP; FTR1-UP; LCR1-UP; J1S1-UP)

950M Z (S/N: HE81-UP)

962K (S/N: T6A1-UP; FLL1-UP)

962L (S/N: MTN1-UP; SXS1-UP)

962M (S/N: EJB1-UP; JYD1-UP; LSE1-UP; RCL1-UP; J2S1-UP; F2T1-UP)

962M Z (S/N: SA81-UP)

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

Introduction

The information that is contained in this Special Instruction guides the user in the installation of the White Noise Back Up Alarms

Do not perform any of the procedures until you have read the information in this publication.

Back Up alarms are designed to provide and audible warning to personnel and others in the area behind a reverse maneuvering vehicle or hazard area.

The White Noise Back Up alarms produce a “SHHH-SHHH” sound versus a typical tonal (“beep-beep”) back up alarm sound

Important Safety Information

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.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

Illustration 1	g00037860

Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be both feet and one hand or a single foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.

General Preparation

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

In addition to the normal safety precautions that are taken in the day to day operation of heavy machinery, the following steps are recommended:

1. Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Lower any implements to the ground.

4. Stop the engine.

5. Engage the parking brake.

6. When possible, maintain ownership of the machine keys.

Required Parts

Illustration 2	g03139558
389-2297 Alarm As and 385-7540 Alarm As

Illustration 3	g03139560
385-7539 Alarm As and 385-7541 Alarm As

Installing and Mounting the White Noise Back Up Alarm

Select a mounting position at the back of the vehicle which will enable your alarm to operate properly:

• For correct functioning, mount the alarm on a level surface facing directly rearwards in a position which allows unobstructed sound projection to the hazard area

• DO NOT mount the alarm facing upwards, downwards, or sideways

• DO NOT mount in a confined area or cover in any way

• Keep away from high temperature zones (engine or exhaust)

• Protect from impact, flying objects, and dirt

• Mount the alarm securely through fixing holes provided and ensure that the alarm will not shake loose

• DO NOT mount Auto-Adjusting alarms near noise source (ex. engine or exhaust) which may cause alarm not to function properly

• DO NOT install the Self-Adjusting (SA) alarm in confined spaces where an echo effect may interfere with the self-adjusting volume system

Wiring and Connections

Wiring the alarm to the machine may involve replacing an existing alarm or installing a new alarm or installing to a non-two-pin connector. Refer to the sections below for the appropriate install.

Replacing an Existing Alarm with the White Noise Alarm

These alarms are wired using a two-pin connector (pin 1 (+) Red, pin 2 (-) ground) which will be compatible to existing machines equipped with a similar connector allowing for easy installation.

Installs where the connections are not compatible, Refer to "New Install (No Existing Alarm) or Without Two Pin Connector" section for proper wire connections.

New Install (No Existing Alarm) or Without Two Pin Connector

If the machines are not equipped with a backup alarm or a non-compatible connector, refer to instructions below.

1. Before working on the electrical system, make sure to disconnect the battery cables to avoid electrical incidents.

2. The positive (+) and negative (-) wires on the alarm are identified as follows:

   • Positive (+): Red

   • Negative (-): Black

3. When installation is completed, reconnect the battery ground and test for operation. The alarm will operate for as long as the reverse gear is engaged.

Machine connections

1. Ensure that the alarm is wired to the fused, positive (+) reversing lamp circuit.

2. Observe correct polarity or the alarm may not work.

3. The ground connection (-) must be attached to a substantial , clean, unpainted metal body or chassis part to provide a dependable ground path.

After installing the alarm, confirm that the alarm is functioning. Place the vehicle in reverse mode and confirm the sound.

Perform Sound Assessment

On all new application installs, perform a sound assessment per ISO 9533:2010. If alarm does not meet this standard, the alarm cannot be used, install alarm that meets this standard per your application.

Alarm Sound

The White Noise Alarms produce a “Shhh-Shhh” sound. The sound will not produce a tonal “Beep-Beep” sound. Make sure that all personnel are aware of this White Noise sound

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Operating multiple machines with different backup alarms with different sounds in a work zone may lead to operator/bystander confusion which could result in personal injury or death. Caterpillar strongly recommends that only one type of backup alarm, either tonal or white noise BBS, be used in a work zone where multiple machines are operating. Ensure that all personnel are aware of the type of backup alarm and are familiar with the sound of the backup alarm that is being used in the work zone.

Procedure for Installation of White Noise Backup Alarm for machines with operational issues

Some machines may have operational issues when a White Noise Backup Alarm is installed. To resolve the issues on the machines listed, install the parts listed per the instructions below.

Other machines may exhibit operational issues with the White Noise Backup Alarm, and may need these additional components

Submit a DSN to determine the correct solution.

Functional Validation

To functionally validate installation on all machine

1. Start engine and disengage park brake.

2. Move gear shift to the Reverse position.

3. The alarm should sound.

4. Place gear shift back in Park position and reengage park brake.

   If the Backup Alarm does not pass functional validation after installation, perform the Electrical validation.

Electrical Validation:

To electrically validate installation on all machine

Using a DMM and Spoons and disconnect Solid-State Relay:

1. Measure between Key Switch-ECM and Backup Alarm-ECM, should measure open.

2. Measure between Backup Alarm-ECM and Solenoid Return-ECM, should measure 2.7k ohms.

3. Measure between Backup Alarm-ECM (positive probe), and Backup Alarm-Harness (negative probe), should measure <10M ohms.

4. Measure between Backup Alarm-ECM (negative probe) and Backup Alarm-Harness (positive probe), should measure 135k ohms.