Test and Repair for Excessive Current Draw{1401, 1408} Caterpillar

Integrated Toolcarrier:

IT62H (S/N: M5G1-346)

Wheel Loader:

950H (S/N: N1A1-1751; M1G1-1064; J5J1-587; K5K1-1673)

962H (S/N: N4A1-681; M3G1-334; J6J1-239; K6K1-323)

966H (S/N: A6D1-1303; A6G1-2296; A6J1-799)

972H (S/N: A7D1-558; A7G1-769; A7J1-261)

Introduction

This Special Instruction provides a procedure to install a retrofit harness in order to reduce the current draw of the batteries.

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 should also have the necessary training, skills, and tools in order 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. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

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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.

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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.

Required Parts

Procedure

Refer to Electrical Schematic, RENR8882, "950H, 962H, and IT62H Wheel Loader Electrical System" and Electrical Schematic, RENR6332, "966H and 972H Wheel Loader Electrical System 237-5751-01".

1. Turn the key start switch to the OFF position.

2. Turn the battery disconnect switch to the ON position.

3. Remove fuse 25 for the "ECAP/Center Dash Indicator Panel".

4. Measure the current through fuse 25.

   If the current is below 20 milliampere, no action is required at this time.

   If the current is above 20 milliampere, proceed with Step 5.

5. Turn the battery disconnect switch to the OFF position.

6. Use T20 and T15 Torx wrenches in order to remove the upper dash panel. Refer to Illustration 1.

7. Loosen the lower dash panel. Refer to Illustration 1.

   Note: It may be difficult to remove the lower dash panel due to the connection of the parking brake. The connectors that are applicable for this procedure can be assessed without completely removing the lower panel.

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Illustration 1	g01382976
(1) Upper panel (2) Lower panel

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Illustration 2	g01382977
The four connectors in Illustration 2 will need to be accessed in order to install the jumper harness. The connector designations are the same designations that are used on the schematic for the machine. (3) C-C73 Connector (4) C-C93 Connector (5) C-C44 Connector (6) C-C25 Connector

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Illustration 3	g01382996
View of connectors from above the dash (3) C-C73 Connector (4) C-C93 Connector (5) C-C44 Connector (6) C-C25 Connector

8. Locate the C-C73 connector (3). The C-C73 connector is plugged into the left hand LED display. The C-C73 is a 12-pin plug with a 147-RD wire in pin 1.

9. Disconnect the C-C73 connector (3) from the left hand LED display.

10. Plug the C-C73 connector (3) into the C4 connector of the jumper harness.

11. Plug the C3 connector of the jumper harness into the receptacle for the left hand LED display.

    Note: The receptacle for the left hand LED display was mated previously to the C-C73 connector (3) .

12. Locate the C-C25 connector. The C-C25 is an 8-pin plug with a 104-YL wire in pin 1.

    If the Machine security System (MSS) is installed on the machine, the connector will be connected to the key reader for MSS. If MSS is not installed on the machine, a cap plug will be installed on the connector.

13. If the C-C25 connector (6) is connected to the key reader for MSS, disconnect the C-C25 connector. If there is a cap plug on the C-C25 connector, remove the cap plug. Secure the cap plug for later use.

14. Plug the C-C25 connector (6) into the C2 connector of the jumper harness.

15. Plug the C1 connector of the jumper harness into the key reader for MSS, if installed, or cap off the C1 connector with the cap plug that was mated to the C-C25 connector (6) .

16. Locate the C-C93 connector (4). The C-C93 connector is a 6-pin plug with a 147-RD wire in pin 1. The C-C93 is plugged into the center LED display, if the center LED display is installed. If the center LED display is not installed the C-C93 connector will have a cap plug installed and the connector will be located behind the instrument cluster.

17. Disconnect the C-C93 connector (4) from the center LED display.

    If the C-C93 connector has a cap plug installed, remove the cap plug.

18. Plug the C-C93 connector (4) into the C8 connector of the jumper harness.

19. If the center LED display is installed, plug the C7 connector of the jumper harness into the center LED display. If the center LED display is not installed, then install a cap end on the C7 connector that was previously mated to the C-C93 connector (4) .

20. Locate the C-C44 connector (5), which is plugged into the right hand LED display. The C-C44 connector is a 12-pin plug with a 147-RD in pin 1.

21. Disconnect the C-C44 connector (5) from the right hand LED display and plug the C-C44 connector into the C6 connector of the jumper harness.

22. Plug the C5 connector of the jumper harness into the right hand receptacle on the LED display.

    This connector was previously connected to the C-C44 connector.

23. Locate the C-C79 plug for the hazard switch (7). Refer to Illustration 4.

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Illustration 4	g01383015
(7) C-C79 plug for the hazard switch

24. Disconnect the C-C79 plug (7) from the Hazard Switch.

    Note: Remove the switch from the panel for easier removal of the plug.

25. Locate the 518-OR wire. The 518-OR wire is in pin 6 of the C-C79 connector (7) .

26. Cut the 518-OR approximately 2 inches away from the C-C79 connector (7). Strip the insulation from each end of the cut wire.

27. Crimp a socket on the end closer to the C-C79 connector (7), and crimp a pin on the end farther from the C-C79 connector.

28. Install the pin into position 1 of a new 2-pin 102-8802 Receptacle Kit . Install a white 8T-8737 Seal Plug plug into position 2 of the receptacle.

29. Install the socket into position 1 of a new 2-pin 155-2270 Connecting Plug Kit . Install a white 8T-8737 Seal Plug plug into position 2 of the plug.

30. Route the C11 connector and the C13 connector of the jumper harness behind the dash.

31. Pull the C11 connector and pull the C13 connector next to the new plug and the new receptacle.

32. Mate the new 2 pin plug with the C13 connector of the jumper harness.

33. Mate the new 2-pin receptacle with the C11 connector of the jumper harness.

34. Reinstall the hazard switch and reconnect the C-C79 connector (7) to the hazard switch.

    All connections are now complete for the jumper harness.

35. Use 247-0762 Tie Straps in order to assemble all of the loose wires of the jumper harness into one bundle.

36. Turn the disconnect switch to the ON position.

37. Test the hazard indicators.

    Ensure that the hazard indicators on the LED display are activated when the hazard switch is turned to the ON position with the key start switch in the OFF position.

38. Test the LED displays.

    Ensure that the LED displays are activated with the key start switch turned to the ON position and the hazard switch turned to the OFF position.

39. Test the LED displays.

    Ensure that the LED displays are activated when the hazard switch and the key start switch are both turned to the ON position simultaneously.

40. Reinstall the upper dash panel and the lower dash panel.