The Main Cab Harness Has Been Improved{1408, 1417, 1420} Caterpillar

The Main Cab Harness Has Been Improved{1408, 1417, 1420}

Usage:

Wheel Tractor-Scraper:: 613C Series II (S/N: 8LJ1-UP)

Introduction

The cab harness has been lengthened and panel assemblies have been altered in order to provide improved connections. This procedure will provide information regarding the inspection and repair of the specific machines.

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

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weight's in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not Caterpillar parts.

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Illustration 1	g00629745
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

Procedure to Remove the Wiring Harness for the Cab

Note: The installation of this harness is a procedure that consumes much time. The wiring harness for the cab should be replaced only if it is necessary. The wiring harness can also be replaced when the cab or the engine is being removed for another purpose.

Note: Machines that have a serial number range of S/N:8LJ1-3298 will require the engine harness to be replaced with the 304-4393 Engine Harness As also. Machines that have a serial number range of S/N:8LJ3299-UP do not require the engine harness to be replaced.

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Table 1
Required Parts
Item	Qty	Part Number	Description
9	1	310-6273	Circuit Breaker
10	1	248-3288	Circuit Breaker As
11	1	288-3687	Circuit Breaker As
53	1	305-8101	Wire As
51	1	305-8100	Cab Harness As
52 ⁽¹⁾	1	304-4393	Engine Harness As
54	2	8T-4896	Hard Washer

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^( 1 )

Change the engine harness if the serial number of your machine is S/N:8LJ1-3298.

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Table 2
Required Tools
Tool	Part Number	Description	Qty
A	1U-8162	Drill Bit	1
B	4C-4975	Bottom Tap	1
C	NA	Welding Equipment
D	1P-3047	Tap Wrench	1
E	NA	Grinder	1

Park the machine on a hard level surface. Lower the scraper bowl and engage the parking brake. Stop the engine and chock the wheels in order to prevent the machine from moving. Allow the exhaust system to cool.

Shut off the main disconnect

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Illustration 2	g01444721
View of the console

Remove cover (1), divider (2), and cover plate (3). Then loosen plate (4) in order to expose the wiring harness for the cab.

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Illustration 3	g01444745
View for the fuse panel

Remove the bolts that hold panel (5) and retain the bolts for reassembly. Then disconnect all clips, relays, fuses and breakers from the wiring harness.
Note: Label all connections in order to aid in the assembly of the new harness.

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Illustration 4	g01445214
A typical example of the circuit breakers

Remove 6T-3642 Circuit Breaker As (6), 3T-2662 Circuit Breaker As (7), and 6T-3644 Circuit Breaker As (8) from the fuse panel (5). Do not reuse the circuit breakers.

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Illustration 5	g01444957
View of the fuse panel with new circuit breakers

Install new 288-3687 Circuit Breaker As (11), 310-6273 Circuit Breaker (9), and 248-3288 Circuit Breaker As (10) onto the fuse panel (5) .

Disconnect the 8I-1496 Panel Harness As from the 8I-1494 Cab Harness As and disconnect the clips that hold the wiring harness.

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Illustration 6	g01446999
View of the rear of the switch panel

Remove the harness from the plate by removing clip (12) from boss (13) .

Select one of the two following options in order to secure the new harness to the switch plate.
- The existing boss can be reworked without being removed from the plate. Refer to Steps 10 and 11.
- The Existing boss can be removed and replaced by a new boss. Proceed to Step 12 through Step 14 for the procedure for this rework.

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Illustration 7	g01449444
View of the rear of the switch panel

Remove the necessary switches (14) in order to allow access to the boss (13) that is located on the 2T-3343 Plate As . Protect the remaining switches during machining of the boss.
Note: Label the connections in order to aid in the assembly of the new harness.

The rework of existing boss (13) can be performed by cutting the length to 30 mm ±1 long. Next drill a hole in the center of the boss. The dimensions of the drilled hole are 8.2 mm (0.32 inch) in diameter and a depth of 25 mm (0.98 inch). Do not drill through the switch plate. Thread the hole by using a 3/8-16-2B bottom tap to a minimum depth of 18 mm (0.71 inch).

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Illustration 8	g01449444
View of the rear of the switch panel

Remove the necessary switches (14) in order to allow access to the boss (13) that is located on the 2T-3343 Plate As . Protect the remaining switches from the grinding and welding operation.
Note: Label the connections in order to aid in the assembly of the new harness.

Boss (13) on the rear of the 2T-3343 Plate As can be removed by grinding the old boss off. then fabricate a new boss, and weld the new boss on the switch plate. Refer to Illustration 9 for information on the fabrication of the boss and refer to Illustration 10 for information regarding the assembly of the boss to the plate assembly.

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Illustration 9	g01444500
Dimensions for the fabrication of the boss (A) 30 ± 1 mm (1.18 ± 0.04 inch) (B) 19 mm (0.75 inch) (C) 3/8-16-2B Through hole

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Illustration 10	g01444502
View of the back side of the plate Dimensions for adding the new boss to the plate assembly (D) 333 ± 3 mm (13.1 ± 0.1 inch) (E) 64 ± 3 mm (2.5 ± 0.1 inch)

Rework the switch plate (4) by adding the new boss per the Illustration 10.

Remove the hood assembly off the machine as shown in Disassembly and Assembly, SENR9158, "Hood - Remove and Install"

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Illustration 11	g01445087
The view of the wiring harness for the cab is shown prior to the removal of the fuse panel.

Remove the 8I-1494 Cab Harness As (15) from the cab by threading the cab harness out of the access hole into the cab.

If it is necessary to tilt the cab then refer to Steps 18 through Step 38. If it is not necessary to tilt the cab then proceed to Step 39.

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Illustration 12	g01447853
This is a view from a point below the rear of the cab.

Remove two bolts (16) from shield (17). Remove shield (17) from the cab.

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Illustration 13	g01447863
The view of the hoist and a suitable lifting device attached to the cab.

Use a hoist and a suitable lifting device to tilt cab (18) to relieve the load from the cab mounts. The weight of the cab (18) is approximately 835 kg (1840 lb).

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Illustration 14	g01451194
View of the underside of the cab

Disassemble linkage (19) for the steering valve at the spool end.

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Illustration 15	g01457108
View of the underside of the cab

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Illustration 16	g01451198
The view of the bottom side of the cab shows the steering valve from the left side of the cab.

Cut tie straps (20) from the hoses. This will allow slack when the cab is tilted.

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Illustration 17	g01451211
View of the bottom of the cab from the left side of the engine

Remove clips (21) and (22) for the cab harness in order to allow slack when the cab is tilted.

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Illustration 18	g01451215
View of the throttle linkage

Disassemble nuts (23) and pins (24) from the throttle linkage.

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Illustration 19	g01451310
View from the right hand platform toward the inside of the right hand fender

Disconnect two cables (25) from the valve. Loosen the locknuts on cables (26) and slide the cables out of the bracket. Then remove the tie straps (20) that secure the cables.

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Illustration 20	g01451220
View down forward of the inside of the left hand fender

Disassemble linkage (27) for the elevator from the valve.

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Illustration 21	g01451933
View of the rear of the tractor transmission

Remove harness assembly (28) from the clip. Disconnect harness assembly (28) and put aside. Remove bolts (29) and light (30) from the transmission. Remove cover (31) from the transmission.

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Illustration 22	g01451935
View of the rear of the tractor transmission

Remove bolt (32) from transmission selector valve (33) .

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Illustration 23	g01451936
View of the rear of the tractor transmission

Remove yoke rod end (36) from transmission selector valve (33). Remove nut (34) and cable (35) from the transmission.

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Illustration 24	g01451228
View forward from behind the transmission.

Cut all cable ties (20) from the transmission forward to the first clip. The remaining tie straps beyond the clip do not need to be cut.

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Illustration 25	g01451229
View forward from behind the transmission.

Disassemble clips (37) .

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Illustration 26	g01451230
View of the bottom of the tractor that is seen from the front

Disassemble clips (38) that hold the heater line to the front of the crossmember that supports the engine.

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Illustration 27	g01451231
View of the left frame rail from below the front bumper

Cut tie straps (20) .

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Illustration 28	g01457733
View of the air conditioner cover

Remove air conditioner cover (39) .

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Illustration 29	g01447857
View of the right front cab mount from below the cab

Remove the nut, the lockwasher, and the bolt (40) from the mount assembly.

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Illustration 30	g01451242
Front view of the right hand side of the cab

Adjust hoses (41) in order to provide sufficient slack for tilting the cab.

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Illustration 31	g01447861
View of the right rear cab mount beside the hitch

Remove the nut, the lockwasher and the bolt (42) from the mount assembly.

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Illustration 32	g01451118
View of the left front cab bolt

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Illustration 33	g01451115
view of the left rear cab bolt

Loosen bolts (43), and bolts (44) that secure the left side of the cab and tilt the cab away from the engine.

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Illustration 34	g01451241
View from below the inside of the left hand platform in front of the cab

Support the cab in the tilted position by using the 2T-1535 Tilt Brace Assembly (45) at the right front cab mount.

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Illustration 35	g01447084
View of the wiring harness and the point of entry into the cab

Remove grommet (46) and plate (47) in order to provide clearance for the cab harness.

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Illustration 36	g01445185
View of the connector for the engine wiring harness and the wiring harness for the cab

Remove 8I-1494 Cab Harness As (48) from the cab. Do not reuse the old wiring harness for reassembly. Disconnect 8I-1494 Cab Harness As (48) from 8I-1495 Engine Harness As (49) at location (50) .

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Illustration 37	g01447433
View of the connector for the engine wiring harness and the wiring harness for the cab

Replace the 8I-1495 Engine Harness As (49) with new 304-4393 Engine Harness As (52) if it is necessary. Do not reuse the old wiring harness for reassembly.

Connect new 304-4393 Engine Harness As (52) to 305-8100 Cab Harness As (51) and reconnect all connections for the cab harness and all clips that hold the cab harness. Then replace the grommet and the plate in the access hole into the cab.

Lower the cab if it was necessary to raise the cab for the removal or the harness. Refer to Steps 44 through 65. If it was not necessary to raise the cab then refer to Step 66.

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Illustration 38	g01447863
The view of the hoist and a suitable lifting device attached to the cab.

Use a hoist and a suitable lifting device to tilt cab (18) back into the proper place.

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Illustration 39	g01451241
View from below the inside of the left hand platform in front of the cab

Remove 2T-1535 Tilt Brace Assembly (45) from the right front cab mount and place the tilt brace assembly in the storage position.

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Illustration 40	g01447861
View of the right rear cab mount beside the hitch

Reinstall the bolt, the lockwasher, and the nut (42) into the mount assembly.

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Illustration 41	g01447857
This is a view of the right front cab mount from below the cab.

Reinstall the bolt, the lockwasher, and the nut (40) into the mount assembly.

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Illustration 42	g01451118
View of the front cab bolt

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Illustration 43	g01451115
view of the rear cab bolt

Tighten bolts (43) and bolts (44) that secure the left side of the cab.

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Illustration 44	g01451242
Front view of the right hand side of the cab

Make sure that hoses (41) are back in the proper positions.

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Illustration 45	g01457733
View of the air conditioner cover

Reinstall air conditioner cover (39) .

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Illustration 46	g01451231
View of the left frame rail from below the front bumper

Tie the hoses in the proper position with new tie straps (20) and reinstall the air conditioner cover that is not shown.

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Illustration 47	g01451230
View of the bottom of the tractor that is seen from the front

Reassemble clips (28) that hold the heater line to the front of the crossmember that supports the engine.

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Illustration 48	g01451229
View forward from behind the transmission.

Reassemble clips (37) .

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Illustration 49	g01451228
View forward from behind the transmission.

Replace all cable ties from the transmission forward to the first clip.

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Illustration 50	g01451936
View of the rear of the tractor transmission

Install cable (35) and nut (34) to the transmission. Install yoke rod end (36) to transmission selector valve (33) .

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Illustration 51	g01451935
View of the rear of the tractor transmission

Install bolt (32) to transmission selector valve (33). Adjust the transmission selector valve (33). Refer to Testing and Adjusting, SENR5624, "Transmission Hydraulic Control Linkage - Adjust"

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Illustration 52	g01451933
View of the rear of the tractor transmission

Install cover (31) to the transmission. Install light (30) and bolts (29) to the transmission. Connect harness assembly (28). Install harness assembly (28) to the clip.

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Illustration 53	g01451220
View down forward of the inside of the left hand fender

Reassemble nut (27) to the linkage for the elevator to the valve.

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Illustration 54	g01451310
View from the right hand platform toward the inside of the right hand fender

Reinstall the cables (25) and cables (26) and replace the tie straps (20) that secure the cables.

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Illustration 55	g01451215
View of the throttle linkage

Reassemble the pin (24) and nut (23) to the throttle linkage and install new tie straps.

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Illustration 56	g01451211
View of the bottom of the cab from the left side of the engine

Reinstall clip (21) and clip (22) for the cab harness.

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Illustration 57	g01457108
View of the underside of the cab

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Illustration 58	g01451198
The view of the bottom side of the cab shows the steering valve from the left side of the cab.

Reinstall tie straps (20) onto the hoses.

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Illustration 59	g01451194
View of the underside of the cab

Reassemble the linkage (19) for the steering valve at the spool end.

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Illustration 60	g01447863
The view of the hoist and a suitable lifting device attached to the cab.

Remove the hoist and the suitable lifting device from the cab (18) .

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Illustration 61	g01447853
This is a view from a point below the rear of the cab.

Reinstall shield (17) onto the cab by using two bolts (16) .

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Illustration 62	g01447926
View of the back side of the fuse panel

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Illustration 63	g01444947
New circuit breakers and jumper wire

Connect the 288-3687 Circuit Breaker As (11) to 310-6273 Circuit Breaker (9) by using 305-8101 Wire As (53) prior to connecting the 305-8100 Cab Harness As (51) to the harness of the fuse panel.

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Illustration 64	g01447100
View of the connection of the panel harness to the cab harness which is located behind the Switch panel

Reconnect the 8I-1496 Panel Harness As to the 305-8100 Cab Harness As (51) .

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Illustration 65	g01444960
View of the fuse panel with the added spacers

Install the fuse panel to the cab and install two 8T-4896 Hard Washers (54) behind the panel.

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Illustration 66	g01445097
View of the fuse panel

Reconnect all breakouts and clip points.

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Illustration 67	g01444961
View of the rear of the switch panel

Reinstall the switches (14) in the switch panel (4) and connect the switch harness to the switches (14). Then clip the harness (12) to the switch panel.