Procedure to Install the Travel Alarm on 300.9D Mini Hydraulic Excavators{7429} Caterpillar

Mini Hydraulic Excavator:

300.9D (S/N: LJM1-UP)

Introduction

This special instruction outlines the basic procedures in order to install a travel alarm on a 300.9D Mini-Hydraulic Excavator.

The travel alarm available for installation on the 300.9D Mini-Hydraulic Excavator is 374-3437 Travel Alarm Group

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

Installation Procedure

Required Parts

Installation Instructions

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Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

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Illustration 1	g00354092
Park the machine. Lower any attachments and the blade to the ground.

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

2. Lower the attachments and the blade to the ground. Refer to Illustration 1.

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 2	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.

10. Remove the floor mat.

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Illustration 3	g00677074

11. Remove the floorplate (A) and plate assemblies (B) and (C). Refer to Illustration 3.

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Illustration 4	g00677121
(D) Retaining ring (E) Lever assemblies (F) Spacer

12. Remove the retaining ring (D) which secures the lever assemblies (E) to the frame of the excavator. Save the retaining ring (D) and any spacers (F) which are removed. Refer to Illustration 4.

13. Remove the lever assemblies from the shaft which holds the levers in place. Save the shaft.

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Illustration 5	g00677127
(E) Lever assemblies (H) Do not use this terminal connection. (J) Terminal connection which is normally open (K) Terminal connection (power) (L) G981-PU wire (M) 321-BR wire (1) 160-8125 Collar (2) 8T-9336 Socket Setscrew (3) 160-6464 Bracket (4) 5C-9553 Bolts (5) 8T-4205 Hard Washers (6) 6T-5925 Limit Switches (7) 169-5349 Harness (8) 147-1940 Screws (9) 5H-6555 Lockwashers

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Illustration 6	g03345317
Location to drill holes for attachment of brackets to (A) bracket of chassis.

Note: Temporarily assemble the switches and brackets for the location of the holes.

14. Drill two holes with a diameter of 3 mm (0.11 inch) into bracket "A". Tap each hole with a metric M4 X 0.7 tap. The holes will be used to attach brackets (1) and (2) during step 18 of the installation procedure. Refer to step 17 for attachment of brackets (1) and (2) .

15. Install a 373-9764 Crank (3) on each of the lever assemblies (E). Do not tighten the 373-9679 Setscrew (10). The setscrews will be tightened after the lever assemblies have been secured to the frame. Refer to Illustration 5.

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Illustration 7	g03345769
Completed assembly reference, before replacing floorplate.

16. Attach switch assemblies (15) to bracket (1) and bracket (2) with two screws (11) and two locknuts (9). Refer to Illustrations 7 and 8.

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Illustration 8	g03347350
(1) 373-9766 Bracket (2) 373-9765 Bracket (3) 373-9764 Crank (4) 8T-4138 Bolt (5) 372-1074 Washer (6) 129-3178 Locknut (7) 121-4405 Bolt (8) 381-6881 Cap (9) 8T-2658 Locknut (10) 373-9679 Setscrew (11) 373-9678 Screw (12) 381-2816 Horn (13) 373-9692 Special Washer (14) 373-9703 Washer (15) 375-7765 Switch (16) 372-7342 Plug (17) 375-7724 Terminal (18) 423-1726 Sleeve - Protect

17. Attach brackets (1) and (2) to bracket "A" using two 121-4405 Bolt (2), two 373-9692 Washer (13), and two 373-9703 Washer (14). Refer to illustrations 6 and 8.

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Illustration 9	g03347520
Wire harness connection.

18. Connect wire harness "X1.1" of main harness to wire harness "X1" of the travel alarm wire harness. Connect the travel alarm with the "X2" harness of the horn assembly. Crimp black wire from "X1.1" of main harness to the "X2" harness of the horn assembly. Crimp blue wire from "X1.1" to the dark green wire of "X1". Refer to Illustration 5 for the correct wire connections.

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Illustration 10	g03345151
Horn assembly mounted to frame of machine. (12) Horn As (B) location of bolts.

19. Drill two holes with a diameter of 5 mm (0.2 inch) to secure the Horn As (12) to the frame of the machine with two 8T-4138 Bolts (4), two 372-1074 Washers (5), two 129-3178 Locknut (6), and two 381-6881 Cap (8). Refer to Illustration 10.

20. Install the lever assemblies (E) to the frame with the parts which were removed in Steps 12 and 13.

21. Adjust the collars (1) while the lever assemblies (E) are in the NEUTRAL position. The rollers on the switches must be centered in the notches of the collars. Refer to Illustration 5.

22. Tighten the setscrews (2) .

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Illustration 11	g03348401
(16) 372-7342 Plug

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Illustration 12	g03348506
(16) 372-7342 Plug (12) 381-2816 Horn

23. Connect the 372-7342 Plug (16) to the chassis harness.

24. Route the harness (7) to the rear of the machine. Refer to Illustrations 12.

25. Connect the battery to the electrical system.

26. Test the alarm. Refer to the section ""Testing the Travel Alarm" " in this publication for the testing procedures.

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 13	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 (3) in order to ensure correct operation of the switches (6). 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.