Installation Procedure for the 467-8080 TLV2 Seat Suspension Harness Kit{1408, 7312, 7324} Caterpillar

Landfill Compactor:

826K (S/N: SET1-UP; 2321-UP)

Soil Compactor:

825K (S/N: SEE1-UP; 2331-UP)

Off-Highway Truck/Tractor:

770 (S/N: BZZ1-UP)

770G (S/N: RMA1-UP; TWA1-UP; KDH1-UP; ECM1-UP; ECX1-UP)

772 (S/N: RLB1-UP)

772G (S/N: LTS1-UP; KEX1-UP; LTX1-UP)

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

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

777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP; GT71-UP)

785G (S/N: RTL1-UP)

789D (S/N: SPD1-UP; SHH1-UP; TWP1-UP)

793F Series AC (S/N: EMD1-UP)

793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; RBT1-UP)

795F Series AC (S/N: ERM1-UP)

795F (S/N: SNT1-UP)

797F (S/N: LAJ1-UP; WSP1-UP)

CAT MT4400D AC (S/N: MH41-UP; MT41-UP)

CAT MT5300D AC (S/N: MN51-UP; MT51-UP)

OEM POWERTRAIN (S/N: DTE1-UP)

Quarry Truck:

773G (S/N: MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)

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

775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Track-Type Loader:

953D (S/N: LBP1-UP)

963D (S/N: LCS1-UP)

Underground Articulated Truck:

AD30 (S/N: DXR1-UP; GXR1-UP)

AD45B (S/N: CXM1-UP)

AD55 (S/N: DNW1-UP)

AD55B (S/N: JNW1-UP)

AD60 (S/N: KNW1-UP)

Wheel Dozer:

824K (S/N: RWB1-UP; 2341-UP)

834K (S/N: LWY1-UP; TWY1-UP)

844K (S/N: KLS1-UP)

854K (S/N: H9K1-UP; H8M1-UP)

Wheel Loader:

924K (S/N: ENC1-UP; HJF1-UP; PWR1-UP)

930K (S/N: DYB1-UP; EYE1-UP; RHN1-UP)

938K (S/N: SWL1-UP; XXT1-UP; HFW1-UP)

950M (S/N: EMB1-UP; FTR1-UP)

962M (S/N: EJB1-UP; F2T1-UP)

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

966M Series XE (S/N: P6C1-UP)

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

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

972M Series XE (S/N: EDW1-UP)

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

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

980M (S/N: KRS1-UP; N8T1-UP)

982M (S/N: F9A1-UP; K1Y1-UP)

988K (S/N: LWX1-UP; TWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP)

992K (S/N: ZMX1-UP; 8801-UP)

993K (S/N: Z4D1-UP; Z9K1-UP; Z4Z1-UP)

994H (S/N: DWC1-UP)

994K (S/N: MRK1-UP)

Introduction

467-8080 Seat Wiring Gp installation instructions.

Introduction

This Special Instruction provides an improved routing procedure to install a replacement 467-8080 Kit-Wire Harness . The 467-8080 Kit-Wire Harness is for "TLV2" 348-2373 Seat Suspension Gp , 348-2409 Seat Suspension Gp , 355-6681 Seat Suspension Gp , 373-8745 Seat Suspension Gp , 399-1560 Seat Suspension Gp , 421-1223 Seat Suspension Gp , and 436-8490 Seat Suspension Gp in operator cabs on certain machines. The improved wiring harness routing location and installation procedure will extend the service life of the 467-8080 Kit-Wire Harness . The 467-8080 Kit-Wire Harness will replace 370-8069 Kit-Wire Harness on all "TLV2" suspensions.

Refer to the necessary parts list.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

Safety

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Required Parts

Machine Preparation

1. Move the machine to a smooth, level surface that will support the weight of the machine.

2. Lower all attachments to ground level.

3. Ensure that the engine of the machine is OFF and the machine is locked out.

Existing Harness Removal

1. Remove fasteners from mounting locations and remove seat and seat suspension from the machine.

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Illustration 1	g03862007
View of seat suspension boot removal (A) 192-7795 Boot

2. Remove boot (A) from the seat suspension.

3. Retain the removed components in order to install after the harness assembly has been replaced.

4. Remove existing tie straps from 192-7805 Harness As .

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Illustration 2	g03862012
View of harness routing (B) Bolt (C) P-Clip

5. Remove bolt (B) and p-clip (C) securing harness to center plate.

   Note: Do not move or tip suspension on its side after bolt is removed or air spring will fall out of place.

6. Remove existing harness from seat suspension.

Harness Installation

Note: If hole pictured in Illustration 3 is not present on suspension top plate, proceed to step 1. If hole is present, proceed to step 2.

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Illustration 3	g03862016
View of dimensions for new hole (D) 35 ± 5 mm (1.4 ± 0.19 inch)

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Illustration 4	g03862018
View of dimensions for new hole (E) 12 ± 5 mm (0.5 ± 0.19 inch)

1. Drill hole for new cable tie mounting (1) .

   Use existing hole under seat tracks as reference.

   Note: cable tie mounting (1) requires hole to be 4.9 mm (0.19 inch) to 5.1 mm (0.2 inch).

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Illustration 5	g03862032
View of conduit installation (2) 211-5358 Flexible Conduit

2. Place 150 mm (6 inch) of conduit (2) on harness and orange jumper wire routed to switch. Conduit should start at heat shrink of red wire.

3. Connect the red wire to angled switch contact on right-hand side of the switch. Connect the orange wire to straight switch contact on left-hand side of the switch.

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Illustration 6	g03862047
View of fir tree installation (1) 467-8173 Cable Tie Mounting

4. Secure cable tie mounting (1) to harness and install in hole.

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Illustration 7	g03862062
View of conduit installation (2) 211-5358 Flexible Conduit (3) 3S-2093 Cable Strap

5. Secure end of conduit (2) near compressor using cable strap (3) .

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Illustration 8	g03862064
View of harness installation (F) Orange Wire (G) Black Wire

6. Connect the orange wire terminal (F) to compressor contact on the right. Wire should be routed downwards, as shown in Illustration 8.

   Connect the black wire terminal (G) to compressor contact on the left. Wire should be routed upwards and loop around, as shown in Illustration 8.

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Illustration 9	g03862066
View of harness routing (3) 3S-2093 Cable Strap

7. use cable strap (3) to secure orange and black jumper wires to compressor housing.

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Illustration 10	g03862072
View of wiring harness routing

Note: Conduit routed down center plate should be positioned behind airline conduit to ensure that wires do not rub on airline conduit.

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Illustration 11	g03862073
View of wiring harness routing

8. Tie strap harness and airline to center casting.

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Illustration 12	g03862099
View of p-clip installation (B) Bolt (C) P-Clip (2) 211-5358 Flexible Conduit

9. Install existing p-clip (C) on to harness and secure bolt (B) to casting. Torque bolt (B) to 5 ± 0.5 N·m (44 ± 4 lb in).

   Note: Conduit (2) should extend 114 mm (4.5 inch) past the center of p-clip (C) .

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Illustration 13	g03862106
View of harness routing (3) 3S-2093 Cable Strap

10. Tie strap harness to back of casting, using cable strap (3) .

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Illustration 14	g03862115
View of suspension at the top of the cycle

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Illustration 15	g03862116
View of suspension going through the mid-range cycle

11. While the suspension is at the top of the cycle and going through its mid-range cycle, the harness should not rub on other components.

12. Check harness routing in Step 3 and ensure that harness is in the correct location prior to completing the assembly process.

13. The harness should be routed as is represented in Illustrations 5 and 7.

Seat Suspension Boot and Components Installation

1. Ensure Harness Assembly and Seat Suspension functions properly.

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Illustration 16	g03862121
View of harness routing

2. Reinstall Boot and fasteners. Ensure that harness has been routed through hole in suspension boot. The rest of the harness will exit the boot.

3. Reinstall Seat and Seat Suspension in the machine.

4. Remove lock out from machine.