Installation of the Payload Monitoring System in Certain Wheel Loaders {7494} Caterpillar

Wheel Loader

928G (S/N: DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)

938F (S/N: 1KM1-UP; 2RM1-UP; 8SM1-UP; 7SN1-UP)

938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)

938G Series II (S/N: RTB1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)

950E (S/N: 22Z1-UP)

950F (S/N: 7ZF1-UP; 6YG1-UP)

950F Series II (S/N: 4DJ1-UP; 5SK1-UP; 8TK1-UP; 2LM1-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

960F (S/N: 9ZJ1-UP; 4CL1-UP; 6XL1-UP; 1YM1-UP)

962G (S/N: 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

966D (S/N: 99Y1-UP)

966F (S/N: 4YG1-UP; 3XJ1-UP)

966F Series II (S/N: 8BG1-UP; 9YJ1-UP; 1SL1-UP)

966G (S/N: AAH1-UP; 3ZS1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP; 8XW1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966H (S/N: A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP)

970F (S/N: 7SK1-UP; 9JK1-UP; 7PL1-UP)

972G (S/N: 7LS1-UP; AAW1-UP; 1EW1-UP; 4WW1-UP; 6AW1-UP; 9GW1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972H (S/N: A7D1-UP; A7G1-UP; A7J1-UP)

980C (S/N: 63X1-UP)

980F (S/N: 8CJ1-UP)

980F Series II (S/N: 8JN1-UP)

980G (S/N: 9CM1-UP; 2KR1-UP; 2SR1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)

980H Series 2 (S/N: MKP1-UP)

988B (S/N: 50W1-UP)

988F (S/N: 8YG1-UP)

988F Series II (S/N: 2ZR1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: BXY1-UP)

990 (S/N: 7HK1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990H (S/N: BWX1-UP)

992C (S/N: 42X1-UP; 49Z1-UP)

992D (S/N: 7MJ1-UP)

Introduction

This service publication contains the installation information that is needed to install payload monitoring system on a field machine.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

Safety

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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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 attachments have been lowered, 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.

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Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 should 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 that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Required Parts

Machine Preparation

1. Park the machine on a smooth, level surface.

2. Shift the transmission direction control switch to the NEUTRAL position.

3. Lower the bucket or the work tool to the ground.

4. Engage the parking brake.

5. Place blocks in front of the wheels and behind the wheels.

6. Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.

Installation Procedure

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Illustration 1	g03779991
(C) 173-2187 Cover As (D) 211-0667 Cover As

1. Remove the Cover As (C) and Cover As (D). Retain for reinstallation.
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   Illustration 2	g03781500
   (F) 9X-2043 Screw (G) 196-0052 Duct As

2. Remove four Screws (F) and the Duct As (G). Retain for reinstallation.
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   Illustration 3	g03781502
   (J) 173-2185 Cab Liner (K) 370-8332 Instrument Panel Gp

3. Remove the Instrument Panel Gp (K) and pull the Cab Liner (J) away from the roof. Retain for reinstallation.
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   Illustration 4	g03779198
   (A) 304-5687 Electronic Control Module (ECM) (B) 8T-6870 Bolt and 9N-0869 Hard Washer

4. Remove four Bolts and Hard Washers (B) securing the Electronic Control Module (A). Discard the bolts and washers.
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   Illustration 5	g03779202
   (17) 325-3347 Bracket As (34) 8T-3647 Bolt (43) 9N-0869 Hard Washer

5. Install four Bracket As (17) along with the Electronic Control Module (A). Use four Bolts (34) and four Hard Washers (43) to secure the brackets and the ECM.
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   Illustration 6	g03779199
   (4) 8T-9655 Isolation Mount (14) 304-5691 Electronic Control Module (ECM) (31) 6I-1418 Spacer

6. Assemble the Isolation Mounts (4) and the Spacers (31) to the Electronic Control Module (14). Use two mounts and one spacer per mounting location on the ECM. Assemble all four mounting locations on the ECM.
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   Illustration 7	g06290995
   (14) 304-5691 Electronic Control Module (ECM) (17) 325-3347 Bracket As (42) 8T-6912 Bolt (43) 9N-0869 Hard Washer (48) 288-1401 Bracket

7. Install the Electronic Control Module (14) to the Brackets (17). Secure the ECM with four Bolts and eight Hard Washers . Place the washers as indicated in Illustration 7.

   Incorporate the Bracket (48) into the lower mounting locations.

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   Illustration 8	g06290999
   (14) 304-5691 Electronic Control Module (47) 7K-1181 Cable Strap (48) 288-1401 Bracket (49) 317-5591 Chassis Harness As (51) 134-2540 Connection Resistor As (E) 372-4873 Cab Harness As (AE) PC-C1 connector. (Part of the Chassis Harness As (49) ( AF) PC-C2 connector. (Part of the Chassis Harness As (49)

8. Connect the PC-C1 connector (AE) to the right-hand port on the Electronic Control Module (14). Connect the PC-C2 connector (AF) to the left-hand port on the Electronic Control Module (14).

   Secure the Chassis Harness As (49) to the Bracket (48). Route the Chassis Harness As (49) along the Cab Harness As (E) and secure the two harnesses together. Use Cable Strap (47) to secure the harnesses. Refer to Illustration 8 for Cable Strap locations.

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   Illustration 9	g06291001
   (19) 317-5591 Chassis Harness As (47) 7K-1181 Cable Strap (E) 372-4873 Cab Harness As

9. Continue to route the Chassis Harness As (16) along the Cab Harness As (E) towards the right-hand side of the machine. Secure the harnesses together with Cable Straps (47).
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   Illustration 10	g06291047
   (47) 7K-1181 Cable Strap (49) 317-5591 Chassis Harness As (E) 372-4873 Cab Harness As

10. Continue to route the Chassis Harness As (49) along the Cab Harness As (E) up the center ROPS pillar. Secure the harnesses together with Cable Straps (47).
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    Illustration 11	g06291049
    Some components removed for clarity. (47) 7K-1181 Cable Strap (49) 317-5591 Chassis Harness As (E) 372-4873 Cab Harness As (J) 173-2185 Cab Liner (K) 370-8332 Instrument Panel Gp

11. Route the Chassis Harness As (49) along the Cab Harness As (E) under the Cab Liner (J) and the Instrument Panel Gp (K). Secure the harnesses together with Cable Straps (47).
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    Illustration 12	g03780104
    (8B) 259-4399 Base (21) 397-8226 Bracket As (23) 130-5300 Clip (37) 8T-4138 Bolt (44) 9X-2040 Screw (45) 9X-8256 Washer (AG) 091-1735 Block

12. Attach the Base (8B) to the Bracket As (21). Secure the base with four Bolts (37) and four Washers (45).

    Attach the Base and Bracket As to the Block (AG), on the left-front ROPS pillar. Secure the bracket with two Screws (44). Include the Clip (23) under the upper Screw (44).

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    Illustration 13	g03836992
    (11) 268-1708 Rocker Switch (13) 301-0038 Box (15) 308-3869 Electronic Control Module (18) 326-3092 Visor (33) 8C-6438 Screw

13. Assemble the Electronic Control Module (15) into the Box (13). Include the Visor (18) under the Electronic Control Module. Secure both with four Screws (33).

    Snap the Rocker Switch (11) into the proper location in the Box (13), next to the Electronic Control Module (15).

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    Illustration 14	g03836993
    (8B) 259-4399 Base (13) 301-0038 Box (15) 308-3869 Electronic Control Module (18) 326-3092 Visor (29) 4B-4274 Washer (41) 8T-5432 Bolt

14. Assemble the Base (8B) onto the Box (13). Secure the base with four Bolts (41) and four Washers (29).
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    Illustration 15	g03781503
    (8A) 259-4397 Clamp (8B) 259-4399 Base (13) 301-0038 Box (15) 308-3869 Electronic Control Module (18) 326-3092 Visor (29) 4B-4274 Washer (41) 8T-5432 Bolt

15. Attach the Clamp (8A) onto the Base (8B) that is mounted to the Box (13).

    Attach the open end of the Clamp (8A) to the Base (8B) that is mounted to the machine.

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    Illustration 16	g06291064
    (49) 317-5591 Chassis Harness As (N) PC-C4 connector (Part of 49) (P) PC-C8 connector (Part of 49)

16. Connect the PC-C4 connector (N) to the Rocker Switch (11). Connect the PC-C8 connector (P) to the Electronic Control Module (15).
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    Illustration 17	g06291070
    (49) 317-5591 Chassis Harness As (23) 130-5300 Clip (R) PC-C7 connector (Part of 49)

17. Attach the PC-C7 connector (R) to the Clip (23).
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    Illustration 18	g06291074
    (49) 317-5591 Chassis Harness As (E) 372-4873 Cab Harness As (S) PC-C5 connector (Part of 49)

18. Connect the PC-C5 connector (S) to the C-C40 connector (part of Cab Harness As (E).
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    Illustration 19	g03837915
    (AB) 367-7475 Cover for the 2-Lever console (AB) 367-7476 Cover for the 3-Lever console (AC) 9X-2045 Screw (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

19. Remove the Screws (AC) and the Cover (AB) from the Electrohydraulic Control and Mounting Gp (AH). Retain components for reinstallation.
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    Illustration 20	g06291079
    (47) 7K-1181 Cable Strap (49) 317-5591 Chassis Harness As (L) 372-4845 Control Harness As (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

20. Route the Chassis Harness As (49) along the Control Harness As (L) into the Electrohydraulic Control and Mounting Gp (AH). Secure the two harnesses together with two Cable Straps (47).
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    Illustration 21	g06291085
    (47) 7K-1181 Cable Strap (49) 317-5591 Chassis Harness As (50) 130-5300 Clip (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

21. Attach the Clip (50) to the Electrohydraulic Control and Mounting Gp (AH). Attach the PC-C3 connector on harness assembly (49) to the Clip (50). Secure the Chassis Harness As (49) to the Electrohydraulic Control and Mounting Gp (AH) with the Cable Strap (47).

22. Machines equipped with 371-4487 Electrohydraulic Control and Mounting Gp, perform Steps 22.a and 22.b.

    Machines equipped with 371-4488 Electrohydraulic Control and Mounting Gp, perform Steps 22.c and 22.d .

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    Illustration 22	g03831072
    (M) 8R-3695 Grommet (AH) 371-4487 Electrohydraulic Control and Mounting Gp

    1. Remove the Grommet (M) from the Electrohydraulic Control and Mounting Gp (AH). Refer to Illustration 22 for proper location.
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       Illustration 23	g03832962
       (9) 263-1493 Push-Button Switch (12) 268-6497 Film (AH) 371-4487 Electrohydraulic Control and Mounting Gp

    2. Install the Push-Button Switch (9) into the open location in the Electrohydraulic Control and Mounting Gp (AH).

       Attach the Film (12) next to the Push-Button Switch (9). Refer to Illustration 23 for proper location.

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       Illustration 24	g03832964
       (M) 8R-3695 Grommet (AH) 371-4488 Electrohydraulic Control and Mounting Gp

    3. Remove the Grommet (M) from the Electrohydraulic Control and Mounting Gp (AH). Refer to Illustration 24 for proper location.
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       Illustration 25	g03832965
       (12) 268-6497 Film

    4. Install the Push-Button Switch (9) into the open location in the Electrohydraulic Control and Mounting Gp (AH).

       Attach the Film (12) next to the Push-Button Switch (9). Refer to Illustration 25 for proper location.

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    Illustration 26	g06291088
    (9) 263-1493 Push-Button Switch (49) 317-5591 Chassis Harness As

23. Connect the Push-Button Switch (9) to the PC-C3 connector on harness assembly (49).
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    Illustration 27	g03837915
    (AB) 367-7475 Cover for the 2-Lever console (AB) 367-7476 Cover for the 3-Lever console (AC) 9X-2045 Screw (AH) 371-4487 Electrohydraulic Control and Mounting Gp or 371-4488 Electrohydraulic Control and Mounting Gp

24. Reinstall the Screws (AC) and the Cover (AB) onto the Electrohydraulic Control and Mounting Gp (AH). Use the original components.

Installation of Payload Monitoring System on Machines with Payload Control System Already Installed

1. Remove the existing payload monitor.

2. Disconnect and remove the harnesses connected to the monitor.

3. Install 304-5691 Electronic Control Module (14). Refer to "Machine Preparation", Steps 3 through 7.
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   Illustration 28	g06279772
   View showing dimensions to weld bosses to the back of the cab (D1) 325 mm (12.8 inch) (D2) 168 mm (6.6 inch)

4. If provision is not in the cab, using the dimensions in Illustration 28, weld four 9R-2160 Bosses to the back of the cab.

   Install the ECM on the bosses. Refer to "Machine Preparation" Steps 12 through 16.

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   Table 6

   WIRE NAME	POSITION
   138PC5	1
   	2
   251-PC41	3
   	4
   C529-PC23	5
   C530-PC24	6
   614-PC42	7
   944-PC1	8
   945-PC40	9
   E416-PC22	10
   	11
   	12

5. When connecting the 317-5591 Chassis Harness As to the cab harness in the machine, ensure that the cab harness connector has pinouts in Table 6. If the pinouts do not match, rework the connector. Remove the wires and reconnect in the positions mentioned in Table 6. Extra wires, if any, can be connected to positions 2, 4, 11 and 12.

6. Install the display. Refer to "Machine Preparation" Steps 12 through 16.

7. Keep the existing sensors as such and connect the sensor harnesses to the 317-5591 Chassis Harness As.

Installation of the Pressure Sensor

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Illustration 29	g03836975
(W) 6V-9829 Cap As (Z) 6V-8781 Tee and 6V-8397 O-Ring Seal

1. Remove the Cap As (W) from the Tee (Z).
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   Illustration 30	g03836973
   (2) 5I-4376 Fitting (AA) 6V-8397 O-Ring Seal

2. Replace the Cap As (W) removed in Step 1 with the Fitting (2). Seal the connection with one O-Ring Seal (AA).
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   Illustration 31	g03836802
   (X) 155-2267 Connector Plug As (Part of 393-6513 Front Harness As) (Y) AG-C2 connector (Part of 393-6513 Front Harness As) (AD) 112-1817 Ball Valve

3. Remove the Connector Plug As (X) from the AG-C2 connector (Y) and discard.
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   Illustration 32	g03836990
   (27) 221-3416 Pressure Sensor Gp (Y) AG-C2 connector (Part of 393-6513 Front Harness As) (AA) 3J-1907 O-Ring Seal

4. Connect the Pressure Sensor Gp (27) to the Fitting (2). Seal the connection with one O-Ring Seal (AA).

   Connect the sensor connector to the AG-C2 connector (Y).

Installation of the Pressure Sensor on the 980H Machines

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Illustration 33	g03836296
(5) 136-9699 Bracket As (10) 265-2834 Block (38) 8T-4223 Hard Washer (39) 8T-4648 Bolt (40) 8T-4910 Bolt (AJ) 9C-7863 Block

1. Attach the Block (10) to the Block (AJ). Secure the block with one Bolt (40) and one Hard Washer (38) for the left-hand location.

   Use 1 Bolt (39) and one Hard Washer (38) for the right-hand location. Include one Bracket As (5) on the right-hand location.

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   Illustration 34	g03836297
   (7) 168-1968 Tee As (7B) 3J-1907 O-Ring Seal (7C) 6V-8397 O-Ring Seal (10) 265-2834 Block (25) 164-5567 Quick Disconnect Coupler As (32) 6V-0852 Dust Cap

2. Install the Tee As (7) into the lower port on the Block (10). Seal the connection with one O-Ring Seal (7B).

   Install the Quick Disconnect Coupler As (25) into the lower port on the Tee As (7). Seal the connection with one O-Ring Seal (7C). Install the Dust Cap (32) onto the Quick Disconnect Coupler As.

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   Illustration 35	g03836300
   (10) 265-2834 Block (19) 349-1178 Pressure Sensor (28) 3J-1907 O-Ring Seal

3. Install the Pressure Sensor (19) into the remaining open port on the Block (10). Seal the connection with one O-Ring Seal (28).
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   Illustration 36	g03836302
   (5) 136-9699 Bracket As (30) 4P-7581 Clip (35) 8T-4121 Hard Washer (36) 8T-4136 Bolt

4. Attach the Clip (30) to the Bracket As (5). Secure the clip with one Bolt (36) and one Hard Washer (35).
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   Illustration 37	g03836304
   (7) 168-1968 Tee As (7B) 3J-1907 O-Ring Seal (20) 351-4927 Hose As

5. Connect the Hose As (20) to the side port on the Tee As (7). Seal the connection with one O-Ring Seal (7B).
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   Illustration 38	g03836798
   (3) 7K-1181 Cable Strap (19) 349-1178 Pressure Sensor (30) 4P-7581 Clip (T) AK-C2 connector (Part of 422-0639 Sensor Harness As

6. Connect the AK-C2 connector (T) to the Pressure Sensor (19).

   Secure the wiring harness to the Clip (30) with one Cable Strap (3).

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   Illustration 39	g03836801
   (U) 226-7659 Tube As (V) 9S-4191 Plug and 3J-1907 O-Ring Seal

7. Remove the Plug and O-Ring Seal (V) from the Tube As (U).
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   Illustration 40	g03836799
   (6) 164-6871 Adapter As (24) 148-8353 Elbow As (24-B) 3J-1907 O-Ring Seal (24-C) 6V-8397 O-Ring Seal (U) 226-7659 Tube As

8. Replace the Plug and O-Ring Seal (V) removed in Step 8 with the Elbow As (24). Seal the connection with one O-Ring Seal (24-B).

   Connect the Adapter As (6) to the Elbow As (24). Seal the connection with one O-Ring Seal (24-C).

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   Illustration 41	g03836800
   (6) 164-6871 Adapter As (6-B) 6V-8397 O-Ring Seal (20) 351-4927 Hose As (U) 226-7659 Tube As

9. Connect the Hose As (20) to the Adapter As (6). Seal the connection with one O-Ring Seal (6-B).

Software and Password

1. This kit will require a password to complete installation. Refer to Information Release Memo, PELJ0138, "Software Enable Attachments".

   The factory passwords can be found at the following web site:

   https://fps.cat.com
   

   Enter the required information to obtain the factory passwords.

   Note: A charge for obtaining factory passwords will be incurred by the dealership.

2. Connect to the machine with Caterpillar Electronic Technician (ET).

3. New software will need to be installed. Flash 289-2217 Monitor Software Gp (PCS) and 326-4287 Monitor Software Gp (Message Display).

   Note: All flash files are available on SIS Web. Use the latest software that is available.

4. Navigate to the configuration screen for the payload control system.
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   Illustration 42	g01948864

5. Select "ECM Identification Parameters".

6. Select "Product ID" and enter the machine serial number. Then select "OK".
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   Illustration 43	g01948861

7. Select "System Settings".

8. Select "Machine Payload Control Systems Installation Status".
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   Illustration 44	g01948866

9. Change the value from "Not Installed" to "Installed".

10. Press "OK".
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    Illustration 45	g01948893

11. Enter the required information in the factory password web site. Enter the Passwords in ET.

12. Press "OK".

13. After the passwords have been accepted and the status is installed, cycle the power to activate the payload control system.

    Note: The payload control system must be calibrated before proper operation can begin. Refer to Testing and Adjusting, "Medium Wheel Loaders Payload Control System" for the calibration procedure applicable to your machine.