Replacement of the Seat Suspension Compressor on Certain Caterpillar Machines{7312, 731S, 7324} Caterpillar

Landfill Compactor:

826H (S/N: AWF1-UP)

836H (S/N: BXD1-UP)

Soil Compactor:

825H (S/N: AZW1-UP)

Motor Grader:

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

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

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

14M (S/N: B9J1-UP)

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

16M (S/N: B9H1-UP)

24M (S/N: B9K1-UP)

Off-Highway Truck/Tractor:

772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP)

773F (S/N: EED1-UP; EXD1-UP)

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

Quarry Truck:

775F (S/N: EYG1-UP; DLS1-UP)

Pipelayer:

PL61 (S/N: WGS1-UP)

Track-Type Loader:

953D (S/N: LBP1-UP)

963D (S/N: LCS1-UP)

973D (S/N: LCP1-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; 9TR1-UP; 7PZ1-UP)

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

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

D6K (S/N: DHA1-UP; NCF1-UP; HMG1-UP; FBH1-UP)

D6N (S/N: DJA1-UP; CBF1-UP; CCG1-UP; CBL1-UP; LJR1-UP; CCS1-UP; GHS1-UP; MLW1-UP; DJY1-UP)

D6R Series III (S/N: JEK1-UP; EXL1-UP; LFM1-UP; LGP1-UP; EXW1-UP)

D6R (S/N: 5LN1-UP; 9PN1-UP)

D6T (S/N: JHB1-UP; ZEB1-UP; SMC1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; LKJ1-UP; KJL1-UP; SKL1-UP; RLW1-UP; LAY1-UP; PEZ1-UP)

D7E (S/N: MDB1-UP; SCG1-UP)

D7R Series II (S/N: EEA1-UP; KNA1-UP; AEC1-UP; ABJ1-UP; BNM1-UP; BRM1-UP; AGN1-UP; BRP1-UP; BPT1-UP; BNX1-UP)

D7R (S/N: 2EN1-UP)

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

D8R (S/N: 9EM1-UP)

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

D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; WDM1-UP)

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

Wheel Dozer:

824H (S/N: ASX1-UP)

834H (S/N: BTX1-UP)

Wheel Loader:

938G Series II (S/N: PHN1-UP)

950H (S/N: N1A1-UP; JAD1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP)

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

972H (S/N: GTA1-UP; WLA1-UP; A7D1-UP; A7G1-UP; A7J1-UP)

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

988H (S/N: BXY1-UP)

993K (S/N: LWA1-UP; Z9K1-UP)

Wheel Skidder:

525C (S/N: 5251-UP)

535C (S/N: 5351-UP)

545C (S/N: 5451-UP)

Introduction

This Special Instruction will explain the rework for the field installation of a replacement seat suspension compressor. Do not perform any procedure that is not outlined in this publication. Do not order parts until the information that is contained in this document is understood.

Parts Needed for Replacement of Seat Suspension Compressor

1. Remove and retain the bolt and washer from the front of the seat and slide the seat upper off the suspension.

2. Remove and discard the four mounting bolts and four washers from the seat suspension, disconnect any harnesses, and remove the suspension from the machine.

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Illustration 1	g02166373

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

4. Remove and retain the suspension boot (2) .

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Illustration 2	g02166395

5. Loosen setscrew in the adjustment knob (1) and remove adjustment knob (1). Remove nut (3) and lock washer (3A). Remove plate (4) from air valve (8). Refer to Illustration 2.

6. Remove and retain shaft assemblies (5) .

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Illustration 3	g02166754

7. Remove cable strap (6) in order to disconnect harness assemblies (9) from upper housing assembly (7) .

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Illustration 4	g02166813
Top view

8. Lift upper housing assembly (7) and push air valve (8) away from upper housing assembly (7). Remove upper housing assembly (7) .

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Illustration 5	g02166814

9. Disconnect harness assembly (9) and hose assembly (10) from air valve (8) .

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Illustration 6	g02166816

10. Raise scissor assembly (11) and install block. This procedure will prevent scissor assembly (11) from falling.

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Illustration 7	g02167234

11. Remove and retain bolts (24) in order to remove compressor assembly (25) from scissor assembly (11) .

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Illustration 8	g02157653

12. Disconnect electrical harness and air lines and remove compressor assembly (25) from mount (26). Discard compressor assembly (25) .

    Note: Make note of the routing of the existing harness.

13. Remove existing harness. Discard harness

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Illustration 9	g02157659
(A) Fully seated on compressor

14. Install compressor assembly into mount (26). Ensure that mount is fully seated (no gap) on the compressor.

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Illustration 10	g02167237

15. Mount compressor assembly (16) to the scissor center plate assembly (11) with bolts (24) retained from Step 11.

16. Install harness assembly (15) in the following order:

    1. Route the harness assembly (15) up the center rear of the suspension.

    2. Route the harness assembly (15) over the lower rear scissor tube.

    3. Route the harness assembly (15) on top of the center plate at the air spring.

    4. Route the harness assembly (15) underneath the center plate at the bumper.

    5. Route the harness assembly (15) over the front lower toggle link.

17. Connect the black wire of harness assembly (15) with the black wire on compressor assembly (16). Ensure that the connector is fully plugged in.

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Illustration 11	g02157681
Side view

18. Connect the air lines to compressor assembly (16). The air line that goes to the air bag gets attached to the top compressor assembly fitting (B). The air line that goes to the air valve gets attached to the side compressor assembly fitting (C) .

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Illustration 12	g02157683
Rear view of air valve (8) (D) 60 Degrees

19. Check the angle of output of the existing air valve to ensure that the angle is 60 degrees (D). Refer to Illustration 12 and Illustration 13.

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Illustration 13	g02167313
Air valve

20. Connect orange wire (E) of the compressor assembly (16) and red wire (F) of the harness to air valve. Ensure that the wires are routed over the toggle link. Ensure air line (10) is routed under toggle link. Refer to Illustration 13.

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Illustration 14	g02157698

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Illustration 15	g02157703

21. Secure harness assembly (15) with four cable straps (18) and a p-clip (17) at the following locations:

    1. Measure down 127 mm (5 inch) from the end of the convoluted tubing for the air valve and install cable strap (18). The cable strap (18) must be tightened securely so that the cable strap (18) cannot move with respect to the center plate.

    2. Place three cable straps (18) at the location shown in Illustration 14, 15 and 16.

    3. Install the harness in clip (17) and use the air bag mounting bolt to secure the clip (17). Refer to Illustration 14.

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Illustration 16	g02157731
View of routing for harness

22. Install the upper housing assembly (7). Route the air valve through the hole in the front of the upper housing assembly.

23. Install the shaft assemblies (5) .

24. Reinstall the plate (4) to the upper housing assembly over the air valve. Install the lock washer (3A) and nut (3). Install the adjustment knob (1) with the setscrew. Refer to Illustration 2.

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Illustration 17	g02157739

25. Secure the harness assembly (15) to the upper housing assembly (7) with cable strap (18). Once tightened, push the head of the cable strap (18) below the mounting surface of the upper housing assembly (7). Refer to Illustration 17.

26. Reinstall suspension boot (2) that was removed in Step 4.

27. Install suspension in the machine with four new bolts (20) and four hard washers (19). Tighten the bolts to a torque value of 55 ± 10 N·m (40 ± 7 lb ft). Connect the harnesses assemblies.

28. Slide the seat upper onto the suspension and reinstall the bolt and washer in the front of the seat.