Procedure to Install the Audio Visual Alarm on Off-Highway Trucks Equipped with Back Up Alarm {1408, 7400, 7402, 7407} Caterpillar

Off-Highway Truck/Tractor

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Introduction

This Special Instruction outlines the basic installation procedure for 521-6436 Alarm Gp (Audio Visual Alarm) on Cat^® machines equipped with back-up alarm.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Important Safety Information

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 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.

Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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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 and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Prepare the Machine

1. Park the machine on a hard level surface.

2. Apply parking brake.

3. Turn the engine key to the OFF position.

4. Isolate the electrical system by turning the battery disconnect switch to the OFF position.

5. Perform lock out tag out procedure to operator controls in the machine cab.

Required Parts

Required parts to install the audio visual alarm are listed in Table 1.

Rework Procedure

Use the following procedure to install the audio visual alarm:

Removal of Existing Back-Up Alarm

1. Disconnect the electrical connection to the existing back-up alarm.

2. Remove the existing back-up alarm assembled on the machine and retain the mounting hardware (8 washers, 4 bolts and 4 nuts).

Wiring Harness Assembly

Note: Wiring Harness (3) is required for audio visual alarm to function correctly as an integrated solution.

1. Prepare the alarm group (Audio visual alarm) (1) for installation on the machine.
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   Illustration 1	g06383110
   View of alarm assembly (A) 250-5780 Cover As (B) Bolt (C) Nut

2. Remove 250-5780 Cover As (A) from the alarm assembly (1a) in alarm group (1) and retain cover assembly and mounting hardware.
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   Illustration 2	g06383107
   (D) Inside area (E) Grommet (F) Cable strap (3) 297-2535 Wiring Harness

3. Install wiring harness (3) to inside area (D) of the 250-5569 Bracket As in alarm assembly (1a).

4. Route the 2–pin receptacle through the hole on the bottom. Connect the 130–6789 terminal to the flasher.

5. Connect the 3–pin receptacle to the 3–pin plug from the lamp and connect the 2–pin receptacle to the 2–pin plug from the alarm.

6. Tie the bundles together with one 3S-2093 Cable Strap (F).

7. Install one 8K-1433 Grommet (E) to the hole as shown in Illustration 2.

8. Again install 250-5780 Cover As to alarm group (1) using mounting hardware saved in Step 2.

Alarm Group (Audio Visual Alarm) Installation

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Illustration 3	g06383111
View of alarm assembly mounted on machine (1b) 5M-3062 Bolt (1c) 8T-4896 Hard Washer (2) 557-8803 Bracket

1. Mount the alarm assembly (1a) on the same plate on which the existing alarm was mounted using two bolts (1b) and two washers (1c).

   Note: 557-8803 Bracket (2) might be required for installing the alarm group in certain machine models.

2. Connect alarm assembly (1a) to the machine wiring harness and test for proper operation. If the audio visual alarm does not function, the machine harness connector may require reversing the connectors to gain the correct polarity.

   Note: Due to electrical differences on some older machines, the polarity of the machine harness connector may need to be reversed.

   Note: The alarm is sensitive to the polarity of the connection. Connecting the alarm with incorrect polarity will not damage the alarm. Validate the Alarm for polarity issues once it is installed. However, the alarm will not work if connected with incorrect polarity.

3. Mount the alarm group (1) preferably at the same location as the previous alarm was mounted.

   Note: If the machine does not have enough space to install the Audio Visual Alarm in one package, consider dismantling the lamp and back up alarm assembly and mounting them separately as per the instructions given below.

   1. Disassemble 213-9100 Alarm Assembly by removing four 5M-3062 Bolts and four 8T-4896 Hard Washers. Do not discard the hardware.

   2. Assemble the alarm assembly in the location where the existing backup alarm is mounted.

   3. Assembly the lamp assembly in a feasible location where it can be welded or mounted by drilling holes using the existing hardware.

   4. If the new location of the lamp assembly demands a longer harness, make a jumper harness with enough length to connect the lamp assembly and the alarm assembly using 16 AWG wires crimped into 180-9339 Pins to one 3E-3370 Connector Receptacle As at one end and the same wires crimped into 180-9340 Sockets into one 155-2267 Connector Plug As at the other end.

   5. Ensure that the location of the lamp is chosen in such a manner that it is visible and does not hinder with any safety requirements.