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Introduction
This Special Instruction contains information for installing the Seat Belt Reminder Systems on all Cat® Products and non-Cat machines.
The system consists of an operator seat belt reminder or a trainer (passenger) seat belt reminder. Either or both systems can be installed in the same machine. Each system will transmit a separate warning if the associated seat belt is not buckled under the prescribed conditions.
Note: The newer generation of Cat cabs may have this feature in-built, so please check before installation.
Important Safety Information
Do not perform any procedure until you have completely read and understand the information in this Special Instruction. Procedures must be performed only by persons who have the necessary training, skills, and tools to perform the functions properly. 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 also should be observed.
Safety precautions and warnings are provided in this instruction and on the product. Disregarding these warnings can result in bodily injury or death 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 on the product are not all inclusive.
The following safety measures must be observed:
- Ensure that any tool, procedure, work method, and operating technique that you use is safe.
- Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
- Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions.
- Be alert to potential hazards. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions. |
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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
Applicability
The Seat Belt Reminder System and the Trainer (Passenger) Reminder System, can be retrofitted for many brands and types of mobile equipment and is offered as an after market attachment for both Cat and competitive brands, providing a fleet solution for equipment owners.
Operator Seat Belt Arrangement
The operator seat belt arrangement is intended for use on the operator seat.
Trainer Seat Belt Arrangement
The trainer, or passenger seat belt arrangement is intended for use on the trainer or passenger seat.
Note: The "Operator Seat Belt Arrangement" and "Trainer Seat Belt Arrangement", do not come packaged together. The arrangements must be ordered separately.
Required Documents
The reference documents are available on the Cat Service Information System (SIS) web site. The reference documents should be reviewed and required portions potentially printed for reference prior to installation.
Reference: Refer to Special Instruction, REHS0036, "Installation of Retractable Seat Belt", for more details.
Electrical Requirements
The system is designed to operate on 12 VDC or 24 VDC, negative ground. Current draw of the control package is less than 2 A. External solenoids, loads driven by the control relays and connection of Cat® Electronic Technician (Cat ET) Service Tool communications adapter will add to the current draw.
The system requires a switch to ground for detection of an applied parking brake.
The system includes an output for driving an optional relay beacon.
Features
There are different alarms and warnings associated with the Seat Belt Reminder System or the Trainer Seat Belt Reminder System installed on the machine. The system is integrated in the buckle which includes a red warning LED, and an audible alarm. The second alarm consists of a solid-state output for driving a customer-supplied relay, which can be used to control a beacon.
The following steps are the proper sequence of operations to begin machine operation.
- Operator inserts the seat belt tab into the buckle.
- Ignition switch is turned ON, and the engine is started.
- The parking brake is released.
If the seat belt tab is not inserted in the buckle when the parking brake is off, the alarm will sound and the red indicator warning light will illuminate. The alarms indicate that the machine is in an operable state and the operator is not wearing the seat belt.
Communication Options
Communication options are not available with the Seat Belt Reminder System or the Trainer Seat Belt Reminder System currently.
Preparing the Machine for Installation
- Move the machine to a smooth, level surface that will support the weight of the machine.
- Turn off the machine with the engine switch to the OFF position.
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Illustration 1 g03055081 - Use proper lockout and tag out procedures. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine. The warning tags (Special Instruction, SEHS7332) are available from your Cat Dealer.
Operator Seat Belt Reminder System Installation Group Part Numbers
Table 1 lists the group part numbers that comprise a seat belt reminder system kit. There are six individual configurations available to accommodate most machine configurations. The Installation group ordered, will depend on the configuration of the seat belt system that is being replaced. Some of the configurations are for the Comfort Ride System (CRS).
| Operator Seat Belt Reminder System Kit | ||||
|---|---|---|---|---|
| Buckle Type | Webbing Size | System | Belt Type | Installation GP-Field
Part Number |
| CRS95 | 2 inch | 2 Point | Lap | 435-0224 Communication Installation Gp |
| CRS95 | 3 inch | 2 Point | Lap | 435-0225 Communication Installation Gp |
| Steel Strap | 2 inch | 2 Point | Lap | 435-0226 Communication Installation Gp |
| Steel Strap | 3 inch | 2 Point | Lap | 435-0227 Communication Installation Gp |
| CRS95 | 3 inch | 3 Point | LH Shoulder | 435-0228 Communication Installation Gp |
| CRS95 | 3 inch | 3 Point | RH Shoulder | 435-0229 Communication Installation Gp |
Trainer Seat Belt Reminder System Installation Group Part Numbers
Table 2 lists the group part numbers that comprise a seat belt reminder system kit with a trainer seat belt reminder system kit. There are four individual configurations available to accommodate most machine configurations. The Installation group ordered, will depend on the configuration of the seat belt system that is being replaced. Some of the configurations are for the Comfort Ride System (CRS).
| Operator Seat Belt Reminder System Kit with Trainer Seat Belt Reminder System Kit | ||||
|---|---|---|---|---|
| Buckle Type | Webbing Size | System | Belt Type | Installation GP-Field Part Number |
| CRS95 | 2 inch | 2 Point | Lap | 467-9241 Communication Installation Gp |
| CRS95 | 3 inch | 2 Point | Lap | 467-9242 Communication Installation Gp |
| Steel Strap | 2 inch | 2 Point | Lap | 467-9243 Communication Installation Gp |
| Steel Strap | 3 inch | 2 Point | Lap | 467-9244 Communication Installation Gp |
Retrofit Installation Process
The process for installing the Seat Belt Reminder System and the Trainer Seat Belt Reminder System is described briefly below.
- Removal of the old seat belt and harness.
- Mechanical installation.
- Seat belt buckle and harness connections.
- Seat Belt Reminder ECM.
- Electrical installation that includes the following.
- Wiring for detection of the parking brake.
- Buckle connector to ECM connections.
- Install "Trainer Seat Belt Reminder System" enable/disable switch.
- System power +12 V or +24 V and ground connections
- Installation of optional relay for driving a beacon.
- Validation of the installed system.
Removal Of The Old Seat Belt
Remove the old seat belt buckle and the mounting bolt.
Customer Supplied Components
The following items are supplied by the customer and required to assemble the harnessing for installation of the Seat Belt Reminder System or the Trainer Seat Belt Reminder System. The required items are not provided in the kit. Items from Table 3 are required for the Seat Belt Reminder System. Items from Table 4 are required for the Trainer Seat Belt Reminder System.
18 gauge wire will also be required. The length of the 18 gauge wire will be determined by the routing path.
| Additional Required Parts for the Seat Belt Reminder System | ||
|---|---|---|
| Qty | Part Number | Comments |
| 1 | 155-2274 Connecting Plug Kit | Deutsch, DT, plug, six positions, includes wedge |
| 4 | 9X-3402 Connector Socket | Socket, 14-18 AWG, Machined, Gold, No insulation grip for Deutsch DT connectors |
| Additional Required Parts for the Trainer Seat Belt Reminder System | ||
|---|---|---|
| Qty | Part Number | Comments |
| 1 | 155-2274 Connecting Plug Kit | Deutsch, DT, Plug, six positions, includes wedge |
| 1 | Switch-SPST, 2A Contact | Switch can be a toggle switch, key switch, or another preferred type by the customer (1) |
| 4 | 9X-3402 Connector Socket | Socket, 14-18AWG, Machined, Gold, No insulation grip, for Deutsch DT connectors |
| (1) | This switch type depends on the customer preference. |
Seat Belt Buckle and Harness
Install the new buckle at the same mounting point where the old buckle was attached. Use the appropriate bolt and washers that were provided in the kit.
Trainer Seat Belt Reminder Enable/Disable Switch Wiring
The enable/disable switch is set to enable when a person is using the "Trainer Seat". When no one is using the "Trainer Seat", the switch is set to disable.
Seat Belt Reminder ECM
Given the wide range of machines on which the Seat Belt Reminder System or the Trainer Seat Belt Reminder System can be applied, a standardized mounting method is not possible. Some of the considerations to be made when selecting an ECM mounting location include:
- Within
1219 mm (48 inch) of the seat belt buckle - Access to +12 V or +24 V supplied by the ignition system
- Access to battery ground
- Access to the parking brake switch
- Wiring path for an optional beacon, and location for a relay
Note: One corner of the ECM includes a ground strap. The other end of the ground strap shall be placed flat against a conductive surface that is bonded to the chassis.
There are four mounting points on the ECM, one at each corner. Machine four holes that can accommodate a size M6 bolt. Each hole location must correspond to each ECM mounting point.
Use the fasteners that are provided to mount the ECM. Each M6 bolt requires two 1/4 inch flat washers, a 1/4 inch lock washer, and an M6 nut.
- Align the ECM with the mounting holes. Place a flat washer over the bolt and insert the bolt through the mounting hole.
- Put the second flat washer on the bolt then the lock washer. Install the nut on the bolt. Do not tighten yet.
- Repeat Steps 1 and 2 for the other three bolts to mount the ECM.
- Tighten the ECM mounting bolts and nuts.
Electrical Installation
Note: The wiring must be protected during installation in key locations. Key locations are any areas where the wiring could be nicked or cut and then come in contact with the chassis. Also, avoid installing wires where there could be excessive flexing, chafing, or cutting of the wires.
Parking Brake Wiring
The seat belt reminder detects when the seat belt should be in use. Detection is accomplished by monitoring a switched to ground input that is activated by application of the parking brake. The switch must be closed (connected to ground) when the parking brake is applied. This switch contact must be wired to pin 5 of connector "A-C5" of the seat belt reminder ECM. Refer to Illustration 5.
There are two scenarios for detecting when the parking brake is applied.
Scenario 1 - The parking brake lever has a switch that closes to ground when the lever is in the park position. An alternative to this scenario is an operator actuated parking brake switch that closes to ground. In both cases, pin 5 of connector "A-C5" must be connected to the contact that is switched to ground (2). The connection can be made at the ECM, at the switch contact (2), or by splicing into the wire (3) going from the switch to the ECM. Refer to Illustration 3.
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| Illustration 2 | g06001010 |
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Scenario 1 connections for pin 5, of the A-C5 connector | |
Scenario 2A - The position of the parking brake lever is determined by a position sensor (10). In "Scenario 2", there is no switched to ground contact. The park position is electronically encoded in a signal that is not usable by the Seat Belt Reminder ECM. When in park, the parking brake solenoid (11) is de-energized. Refer to Illustration 3.
The parking brake solenoid (11) is controlled by the machine ECM (12). Typically, the solenoid is de-energized to apply the parking brake.
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| Illustration 3 | g03883086 |
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Scenario 2A | |
Scenario 2B - A relay can be connected in parallel with the parking brake solenoid (11). In Illustration 3, the relay coil (15) has been wired in parallel with the parking brake solenoid (11). When the parking brake solenoid is de-energized, the relay is de-energized, allowing the relay contact (17) to close. The closed relay contact provides the input to the Seat Belt Reminder ECM.
When the parking brake is OFF, the solenoid, and relay are energized. When the parking brake is ON, the solenoid and relay are de-energized. Again, as shown in Illustration 4, the Normally Closed relay contact can be used to signal the seat belt reminder when the parking brake is applied. The Normally Closed side of the relay contact is wired to ground. The "common" contact is wired to pin 5 of connector "A-C5" of the seat belt reminder.
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| Illustration 4 | g03865060 |
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Scenario 2B | |
Wiring for Detection of the Parking Brake or Transmission in Park
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| Illustration 5 | g06000306 |
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(20) Seat belt tab
(21) Integrated buckle (22) Connector plug and resistor assembly (23) Connector plug and resistor assembly (24) Switch to Ground - Parking brake switch is closed when the parking brake is applied. (25) Optional relay and beacon | |
Refer to Illustration 5 and one of the following tables for connector information:
| A-C2 Connector |
|---|
| Part Number |
| 155-2271 Connecting Plug Kit |
| 9X-3402 Connector Socket |
| A-C3 Connector |
|---|
| Part Number |
| 102-8805 Receptacle Kit |
| 9x-3401 Connector Pin |
| A-C4 Connector |
|---|
| Part Number |
| 155-2271 Connecting Plug Kit |
| 9X-3402 Connector Socket |
| A-C6 Connector |
|---|
| Part Number |
| 8T-8735 Connector Plug |
| (22) Connector Plug and Resistor (1) |
|---|
| Part Number |
| 155-2267 Connector Plug As |
| 134-2540 Connection Resistor As (120 ohm) |
| (1) | Refer to Illustration 5. |
| (23) Connector Plug and Resistor (1) | |
|---|---|
| Part Number | |
| 155-2267 Connector Plug As | |
| 134-2540 Connection Resistor As |
| (1) | Refer to Illustration 5. |
Seat Belt Buckle Connector
The buckle connector "A-C4", that plugs into connector "A-C2" provides all the connections required for the buckle to function. No additional wiring is required. When installing the buckle connector, use the following guidelines:
- Select a location for the harness that is near the ECM
- Is accessible but is not in the path of the operator
- Not underfoot or where objects may be set on the harness
- The harness must be fastened out of the way of all traffic
System Power
The Seat Belt Reminder System will be operated from the ignition system switched "+Vbat". This source will be connected to pin 1 of connector "A-C5".
The Trainer Seat Belt Reminder System
The Trainer Seat Belt Reminder System will be operated from the ignition system switched "+V bat". This source will be connected to the enable/disable switch which is attached the "+V bat" pin 1 of A-C5 on the Trainer Seat Belts Reminder System harness.
Optional Relay for Driving a Beacon
The Seat Belt Reminder System or the Trainer Seat Belt Reminder System can drive a relay that could be used to operate an optional beacon. Refer to Illustration 5. One side of the relay coil would be connected to pin 6 of connector "A-C5" and the other side of the coil connected to ground. The relay coil should be diode suppressed to clamp voltage spikes when the ECM turns the power OFF to the coil.
Note: The relay is not to be used for any control applications. The relay is intended to activate an optional beacon only.
Items that are needed but are not provided in the kit for "Vbat+", ground, and parking brake switch-on connector "A-C5" listed in Table 11.
| Qty | Part Number |
|---|---|
| 3 | 9X-3402 Connector Socket |
Items for optional beacon are listed in Table 12.
| Qty | Part Number |
|---|---|
| 3 | 9X-3402 Connector Socket |
| 1 | 3E-5239 Relay As |
| 1 | 3E-5519 Connector Plug As |
| 4 | 9X-1056 Receptacle Terminal |
| 1 | 155-2270 Connecting Plug Kit |
| 1 | Beacon (blue or amber)(1) |
| (1) | Choose color from "Optional Beacon" listed in Table 13. A Beacon (blue or amber) must be ordered. If a color other than blue or amber is desired (red, green, or clear), that beacon lens must also be ordered. |
| Optional Beacon | |
|---|---|
| Qty | Part Number |
| 1 | 382-2746 Warning Beacon Lamp Gp - Blue |
| 1 | 371-2241 Warning Beacon Lamp Gp - Amber |
| 1 | 421-5584 Lens - Clear |
| 1 | 421-5585 Lens - Green |
| 1 | 421-5583 Lens - Red |
Validation of the Installed System
Buckle Reminder Validation - Electrical
Perform the below listed tests for validating the buckle reminder:
- Unplug connector "A-C1" from the ECM. Connect the DVM negative lead to pin 8 of connector "A-C1". With the parking brake set, measure the resistance to pin 9 of "A-C1". The resistance should be less than 10 ohms.
- Ensure that the machine will not roll, then release the parking brake. The resistance to pin 9 of "A-C1" should be greater than 10K ohms. Apply the parking brake.
- Using pin 8 of connector "A-C1" as reference, the resistance of pin 5, pin 10, pin 11, and pin 12 should be greater than 1M ohm.
- If the optional relay has been installed, measure the resistance of pin 6 of connector "A-C1". The resistance should be greater than 15 ohms (The resistance should be the resistance of the relay coil plus up to 10% more).
- Turn the ignition ON but do not start the engine. Measure the voltage on pin 7 of connector "A-C1". The voltage should be "+Vbat".
Note: If any of the foregoing observations were incorrect, the problem should be determined and corrected before proceeding.
Note: So that the seat belt reminder will be fully effective, make sure that there is nothing covering the seat belt buckle, such as loose clothing. Covering the seat belt buckle will obscure the led indicator and muffle the warning alarm.
Note: Make sure that the cab door is closed so that exterior noise will not obscure the warning alarm.
Buckle Reminder Validation - Functional
If the optional relay and beacon have been installed, the beacon will be turned ON whenever the buckle sounder is turned ON for each of the following tests.
- When the sounder is enabled, a pattern of two 0.1 second beeps, 0.3 seconds in between, repeated four times with 2 seconds between sets will occur. The sequence will take 10 seconds to perform. A delay of 50 seconds occurs before the prior sequence is repeated. This entire sequence is repeated five times over a period of 5 minutes.
- Plug connector "A-C1" into the ECM. Leave the ignition OFF. The LED and the sounder in the buckle should be turned OFF.
- Set the parking brake. Turn ON the ignition but do not start the engine. The red LED in the buckle should be lit and the sounder should be turned OFF.
- Plug the harness tab into the buckle, then the LED and the sounder should be turned OFF.
- Remove the tab from the buckle, the LED should be turned ON. Release the parking brake, then the sounder should be ON. Plug the tab back into the buckle, then the LED and the sounder should be OFF.
- Set the parking brake, turn the ignition OFF, and plug the tab into the buckle. Again turn the ignition ON but do not start the engine. The LED should be turned OFF and the sounder OFF.
Note: If any of the foregoing tests did not pass, resolve the issue before proceeding the Belt Reminder into service.
- Set the parking brake, turn the ignition OFF, and remove the tab from the seat belt buckle.
J1939 Specifics
The suspect parameter number and failure mode identification (SPN-FMI) combination will check if the parking brake (SPN 70) is disengaged. If the seat belt is not buckled, the system will report a "1856-14 Diagnostic".
| Suspect Parameter Number (SPN) | Failure Mode Identification (FMI) | Description |
|---|---|---|
| 1856 | 31 | Operator Seat Belt Not Buckled |
| 1856 | 14 | Seat Belt Not Buckled with Parking Brake disengaged |
Event and Diagnostic Data Transfer (EDDT) Events
The retrofit kit has the capability of reporting two events. Both diagnostics will be reported as "Warning Category Indicators" (WCI 1).
| Event Identifier (EID) | Warning Category Indicators (WCI) | Description |
|---|---|---|
| 1403 | 1 | Seat belt unfastened with parking brake disengaged |
| 1434 | 1 | Operator seat belt unfastened |
Troubleshooting
The Seat Belt Reminder System can function as a stand-alone system or can be connected to the main data link of the machine.
For a stand-alone system, a hard wired parking brake switch connection to the ECM will be necessary.
If the parking brake switch status is available to the A5M8 ECM over the main J1939 data link as SPN 70, the seat belt system will communicate over the J1939 data link as a first priority.
If the parking brake switch status is not available to the A5M8 ECM over the main J1939 data link as SPN 70 from another source, a hard wire from the parking brake switch to the A5M8 ECM must be installed.
Optional Dashboard Light and Alarm
This optional kit is for installing an extra light in the dashboard of the machine and an extra alarm to the "Seat Belt Reminder System".
| 500-8869 Controls Installation Gp | |
|---|---|
| Qty | Part Number |
| |
500-8870 Cable As |
| 1 | 500-8871 Receptacle As |
| 1 | 232-1792 Horn |
| 5 | 136-4877 Wire Splice |
| 2 | 5P-4571 Blade Terminal |
| 1 | 155-2274 Connecting Plug Kit |
| 1 | 155-2270 Connecting Plug Kit |
| 5 | 9X-3402 Connector Socket |
| 1 | 442-1341 Indicator Lamp Gp |
Installation Instructions
The process for installing the Optional Dashboard Light and Alarm is described below.
- Choose a location for the LED. Drill a
20 mm (0.79 inch) hole and remove all burrs. Insert LED harness into hole and seat the grommet firmly into the hole. - Choose a location for the alarm. Drill a
27.5 mm (1.1 inch) hole and remove all burrs. Remove the retaining ring from the alarm and insert alarm into the hole from the back of the panel. - Cut 500-8870 Cable As into two equal lengths.
- Using half of the cable, you will cut a
76.2 mm (3 inch) piece. From the76.2 mm (3 inch) piece, pull out the black wire and discard the rest. This piece will be used as a jumper between 155-2274 Connecting Plug Kit and 155-2270 Connecting Plug Kit . Install 9X-3402 Connector Socket on each end.Show/hide table
Illustration 6 g06156534 - Remove
38.1mm (1.5 inch) of the cable jacket. Cut off drain line and shielding. Install 9X-3402 Connector Socket onto the ends of the Red, Black, and White wires. Install the Black wire into position 4 of 155-2274 Connecting Plug Kit. Install the White wire into position 6 of 155-2274 Connecting Plug Kit. Install previously made Jumper wire into position 3 of 155-2274 Connecting Plug Kit. Install Red wire into position 1 of 155-2274 Connecting Plug Kit. Install remaining end of Jumper wire into position 2 of 155-2274 Connecting Plug Kit. Refer to Illustration 6. - Connect LED harness to 155-2270 Connecting Plug Kit. Connect 500-8871 Receptacle As to 155-2274 Connecting Plug Kit. Route harness back to the Seat Belt Reminder ECM.
- Remove
38.1mm (1.5 inch) of the cable jacket of the remaining cable. Cut off White wire, drain line and shielding. Install 5P-4571 Blade Terminal connectors onto the Red and Black wires.Show/hide table
Illustration 7 g06156515 - Connect Alarm harness to 232-1792 Horn. The horn is polarity sensitive. Route harness back to the Seat Belt Reminder ECM. Refer to Illustration 7
- Remove
38.1mm (1.5 inch) of the cable jacket from both Dashboard Light and Alarm harness. Once the harnesses are routed back to the Seat Belt Reminder ECM. Remove the shielding and cut the drain wire from the harness for the Dashboard Light. Remove the shielding and cut the White wire and the drain line from the harness for the Alarm. - Remove connector A-C1 from Seatbelt Reminder ECM.
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Illustration 8 g06156516 - Pull the wire from position 1. Cut the wire
76.2 mm (3 inch) behind the socket. Using 136-4877 Wire Splice, splice the Red wire from the LED harness into this wire and insert socket back into the connector. Refer to Illustration 8.Show/hide table
Illustration 9 g06156518 - Pull the wire from position 2. Cut the wire
76.2 mm (3 inch) behind the socket. Using 136-4877 Wire Splice, splice the Black wires from the LED harness and Alarm harness into this wire and insert socket back into the connector. Refer to Illustration 9.Show/hide table
Illustration 10 g06156523 - Pull the wire from position 3. Cut the wire
76.2 mm (3 inch) behind the socket. Using 136-4877 Wire Splice, splice the White wire from the LED harness into this wire and insert socket back into the connector. Refer to Illustration 10.Show/hide table
Illustration 11 g06156525 - Pull the wire from position 6. Cut the wire
76.2 mm (3 inch) behind the socket. Using 136-4877 Wire Splice, splice the Red wire from the Alarm harness into this wire and insert socket back into the connector. Refer to Illustration 11.Show/hide table
Illustration 12 g06156530 - Completed connection to connector on harness. Refer to Illustration 12.
