Installation Instruction for 212-7779 Shock Absorber Kit , 192-7848 Shock Absorber Kit , and 213-5170 Indicator Kit on Toggle Link Vertical (TLV) Seat Suspensions {7324} Caterpillar

Articulated Truck:

725 (S/N: B1L1-UP; AFX1-UP)

730 (S/N: AGF1-UP; B1M1-UP)

735 (S/N: B1N1-UP; AWR1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: AZZ1-UP)

D250E Series II (S/N: 4PS1-UP)

D300E Series II (S/N: 5KS1-UP)

D350E Series II (S/N: 2XW1-UP)

D400E Series II (S/N: APF1-UP; 8PS1-UP)

Landfill Compactor:

816F Series 2 (S/N: BZR1-UP)

826G Series II (S/N: AYH1-UP)

826G (S/N: 7LN1-UP)

826H (S/N: AWF1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

836H (S/N: BXD1-UP)

836K (S/N: TWZ1-UP)

Soil Compactor:

815F Series 2 (S/N: BYN1-UP)

825G Series II (S/N: AXB1-UP)

825G (S/N: 6RN1-UP)

825H (S/N: AZW1-UP)

Integrated Toolcarrier:

IT14G (S/N: FWL1-UP; 8ZM1-UP; KZN1-UP; 1WN1-UP)

IT28G (S/N: WAC1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)

IT38G Series II (S/N: JAN1-UP; CSX1-UP)

IT38G (S/N: 7BS1-UP; 1CW1-UP)

IT38H (S/N: JNJ1-UP)

IT62G Series II (S/N: AYA1-UP)

IT62G (S/N: AKP1-UP; 6PS1-UP)

IT62H (S/N: M5G1-UP)

Mini Hydraulic Excavator:

303.5 (S/N: AFW1-UP)

Motor Grader:

120M Series 2 (S/N: M9C1-UP; M9H1-UP; R9N1-UP; R9W1-UP)

120M Series 3 (S/N: N9C1-UP; N9H1-UP; N9N1-UP; N9W1-UP)

120M (S/N: R9A1-UP; B9C1-UP; R9C1-UP; B9N1-UP; B9W1-UP; D9W1-UP)

12M Series 2 (S/N: F9M1-UP; R9P1-UP; R9S1-UP)

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

12M (S/N: R9B1-UP; B9F1-UP; B9R1-UP; B921-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)

14M (S/N: B9J1-UP; R9J1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

16M (S/N: B9H1-UP; R9H1-UP)

24M (S/N: B9K1-UP; B931-UP)

Off-Highway Truck/Tractor:

769D (S/N: BBB1-UP; 5SS1-UP)

770 (S/N: BZZ1-UP)

772 (S/N: RLB1-UP)

773D (S/N: BGL1-UP; 7CS1-UP)

773E (S/N: BDA1-UP)

773F (S/N: EED1-UP)

776D (S/N: AFS1-UP)

777D (S/N: AGC1-UP; AGY1-UP)

777F (S/N: JRP1-UP)

784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP)

Quarry Truck:

771D (S/N: BCA1-UP; 6YS1-UP)

775D (S/N: 8AS1-UP)

775E (S/N: BEC1-UP)

775F (S/N: DLS1-UP)

Track-Type Tractor:

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D10T2 (S/N: RAB1-UP; JJW1-UP)

D11R (S/N: AAF1-UP; 7PZ1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; DDD1-UP; MDG1-UP; JEL1-UP; RAL1-UP; JNS1-UP)

D5N (S/N: AKD1-UP; AGG1-UP; CFH1-UP; CKT1-UP)

D5R (S/N: D5X1-UP)

D6H Series II (S/N: 4RC1-UP; 6FC1-UP; 3ZF1-UP; 3YG1-UP; 8ZJ1-UP; 9KJ1-UP; 5KK1-UP; 6CK1-UP)

D6N (S/N: DJA1-UP; PBA1-UP; CBF1-UP; CCG1-UP; ALH1-UP; JAH1-UP; CCK1-UP; CBL1-UP; AKM1-UP; ALR1-UP; LJR1-UP; PER1-UP; CCS1-UP; GHS1-UP; MLW1-UP; ALY1-UP; DJY1-UP)

D6R Series II (S/N: BNC1-UP; AFD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6R (S/N: A6M1-UP; EMM1-UP; JEN1-UP; 2YN1-UP; 3ZN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 9PN1-UP; DMP1-UP; S6T1-UP; S6X1-UP; S6Y1-UP; C6Z1-UP)

D6T (S/N: JHB1-UP; KSB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; KJL1-UP; SKL1-UP; TSM1-UP; GCT1-UP; JRW1-UP; RCW1-UP; LAY1-UP; HTZ1-UP; PEZ1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; MDB1-UP; SCG1-UP; SSH1-UP; TAN1-UP)

D7H Series II (S/N: 5BF1-UP; 4FG1-UP; 79Z1-UP; 80Z1-UP)

D7R Series II (S/N: EEA1-UP; AEC1-UP; AFG1-UP; ABJ1-UP; BPK1-UP; BNM1-UP; BRM1-UP; AGN1-UP; BRP1-UP; ACS1-UP; BPT1-UP; ADW1-UP; BNX1-UP)

D7R (S/N: DSH1-UP; 9HM1-UP; DLN1-UP; 2EN1-UP; 3DN1-UP; DJR1-UP; 2HR1-UP)

D8R Series II (S/N: AKA1-UP; 6YZ1-UP)

D8R (S/N: 7XM1-UP; 9EM1-UP; T5X1-UP)

D8T (S/N: J8B1-UP; MLN1-UP; FCT1-UP; KPZ1-UP)

D9R (S/N: HWH1-UP; ABK1-UP; ACL1-UP; WDM1-UP)

D9T (S/N: TWG1-UP; RJS1-UP; REX1-UP)

Wheel Dozer:

814F Series 2 (S/N: BXG1-UP)

824G Series II (S/N: AWW1-UP)

824G (S/N: 4SN1-UP)

824H (S/N: ASX1-UP)

834G (S/N: BPC1-UP; 6GZ1-UP)

834H (S/N: BTX1-UP)

844 (S/N: 2KZ1-UP)

844H (S/N: BTW1-UP)

854G (S/N: AMP1-UP; A4W1-UP)

854K (S/N: 2211-UP)

Compact Wheel Loader:

914G (S/N: PDF1-UP; 7ZM1-UP; 9WM1-UP)

914G2 (S/N: KNP1-UP)

IT14G2 (S/N: ERP1-UP)

Wheel Loader:

924G (S/N: DDA1-UP; RBB1-UP; WMB1-UP; AAN1-UP; 9SW1-UP; 3PZ1-UP)

924GZ (S/N: RTA1-UP; AAB1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)

924H (S/N: HXC1-UP; KLN1-UP)

924HZ (S/N: WLB1-UP; PED1-UP; JZZ1-UP)

928G (S/N: DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)

928HZ (S/N: BYD1-UP; CXK1-UP)

930G (S/N: TWR1-UP; TFW1-UP)

930H (S/N: DHC1-UP; FTD1-UP)

938G Series II (S/N: RTB1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)

938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)

938H (S/N: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966G (S/N: AAH1-UP; 3ZS1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP; 8XW1-UP)

966H (S/N: A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP; TAL1-UP)

966K (S/N: PBG1-UP; TFS1-UP; NGX1-UP)

966M (S/N: DYC1-UP; KJP1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972G (S/N: 7LS1-UP; AAW1-UP; 1EW1-UP; 4WW1-UP; 6AW1-UP; 9GW1-UP)

972H (S/N: GTA1-UP; LCC1-UP; A7D1-UP; A7G1-UP; A7J1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

972M (S/N: A8P1-UP; JPR1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980G (S/N: BGC1-UP; 9CM1-UP; 2KR1-UP; 2SR1-UP)

980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

980M (S/N: KRS1-UP)

982M (S/N: K1Y1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: BXY1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990H (S/N: BWX1-UP)

992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)

992K (S/N: H4C1-UP)

994F (S/N: 4421-UP)

Wheel Skidder:

525B (S/N: 3KZ230-UP)

535B (S/N: AAE452-UP)

545 (S/N: 2FZ305-UP)

Introduction

This Special Instruction provides directions for installing the following parts: 192-7848 Shock Absorber Kit , 212-7779 Shock Absorber Kit and 213-5170 Indicator Kit . Install these parts as needed if the operating conditions do not allow proper operation of the seat suspension assembly. Also, these parts are recommended if the weight of the operator exceeds 136 kg (300 lb).

Note: These instructions apply to the above machines with the seat suspensions that are listed below. When you are adding a second shock to the 191-2933 Seat Suspension Group , use the 212-7779 Shock Absorber Kit . When you are adding a second shock to the 199-5725 199-5727 256-8768 Seat Suspension Groups , use the 192-7848 Shock Absorber Kit .

The 212-7779 Shock Absorber Kit can replace the existing nonadjustable shock or the 212-7779 Shock Absorber Kit can be added with the existing nonadjustable shock absorber. Adding the adjustable shock with the nonadjustable shock will help to prevent undesired contact with the stops for the suspension.

Note: When two shocks are used, the adjustable 212-7779 Shock Absorber Kit is always on the right-hand side of the suspension and the control is on the left-hand side.

Required Parts

Installation Procedure

Show/hide table

The air spring of the air suspension is filled with air pressure. Prior to disassembly, release the air pressure in the air spring. Failure to do so could result in personal injury.

Note: When you are operating the machine in good conditions on good haul roads, the 212-7779 Shock Absorber Kit that is added to the existing nonadjustable shock absorber may provide a ride that is too firm for operators under 68 kg (150 lb). The 213-5170 Indicator Kit can be installed to aid in proper adjustment of the height of the suspension for the weight of the operator. The boot is removed from the suspension and the indicator kit is installed.

Show/hide table



Illustration 1	g00871915
(1) Knob (2) Boot

1. Pull adjustment knob (1) in order to release the air from the seat.

2. Remove boot (2) .

   Note: Some components are not shown in Illustration 2 in order to provide a better view of the shock absorber.

Show/hide table



Illustration 2	g01198620
(3) Scissor Assembly (4) Bolts (5) Shock Absorber (6) Housing Assembly

3. Raise scissor assembly (3) and install blocking in order to prevent the scissor assembly (3) from falling.

4. Remove bolts (4) in order to remove shock absorber (5) from scissor assembly (3) and housing assembly (6) .

Show/hide table



Illustration 3	g01198625
Existing Shock

5. Remove bearings (7B) from shock absorber (8) .

   Note: Illustration 3 shows the location of lockwasher (7A), bearings (7B), washers (7C), nut (7D), and locknut (7E).

6. Repeat Steps 4 and 5 if the seat is equipped with a shock absorber on the opposite side.

Show/hide table



Illustration 4	g01198627
212-7779 Shock Absorber Kit (9) 192-7812 Shoulder Bolt (10) 212-7780 Shock Absorber (11) 3J-4818 Lockwasher (12) 163-1137 Bearing (13) 192-7811 Washer (14) Nut (15) 2K-4973 Locknut

7. Install bearings (12) to shock absorber (10) .

Show/hide table



Illustration 5	g01198644
(16) Clamp (17) Bolt (18) Cable Assembly (19) Bracket (20) Shock Absorber

8. If this shock absorber kit is disconnected, then replace this shock absorber kit.

Show/hide table



Illustration 6	g01198661
(21) Scissor Assembly (22) Bolts (23) Shock Absorber (24) Housing Assembly

9. Install bolts (22) in order to attach shock absorber (23) to scissor assembly (21) and housing assembly (24). Remove the blocking.

   Note: Illustration 4 shows the location of lockwasher (11), bearings (12), washers (13), nut (14), and locknut (15).

10. Repeat Steps 7 and 9 in order to attach the nonadjustable shock absorber on the opposite side.

    Note: Invert the location of the following components: lockwasher (7A), bearings (7B), washers (7C), nut (7D) and locknut (7E). See Illustration 3.

    Note: Perform Step 10 only if the adjustable shock absorber is being installed in addition to the existing nonadjustable shock.

Show/hide table



Illustration 7	g01198677
(25) Bolts (26) Bracket (27) Cable Assembly (28) Bolt (29) Bolt (30) Lever

11. Install bolts (25) in order to attach bracket (26) .

12. Install bolt (29) in order to attach lever (30) to bracket (26) .

13. Install bolt (28) in order to attach cable assembly (27) to lever (30) .

Installing the Ride Indicator

Illustration 8	g01198545
213-5170 Indicator Kit (31) Locknut (32) Rod (33) Indicator Arm (34) Nut (Self-Locking) (35) Housing (36) Bolt (Hex 10-24)

Illustration 9	g01198690
(37) Link (38) Rod (39) Indicator Arm

1. Install the rod (38) and nuts on link (37) .

Note: Orient the rod (38) in the curvature toward the top of the suspension. Do not bend the rod.

2. Install indicator arm (39) onto rod (38) .

Show/hide table



Illustration 10	g01198699
(40) Bolts (41) Indicator

3. Install bolts (40) in order to attach indicator (41) to the seat.

Show/hide table



Illustration 11	g01198706
(42) Boot

4. Install boot (42) to the suspension.