Installation Procedure for the TLV2 Seat Suspension Harness {1408, 7324} Caterpillar

Landfill Compactor

826K (S/N: 2321-6645; 2L31-UP; 2T61-UP; SET1-508)

836K (S/N: T6X1-UP; L6Z1-UP; TWZ1-581)

Off-Highway Truck/Tractor

770 (S/N: BZZ1-917)

770G (S/N: RMA1-100; TWA1-152; KDH1-322; ECM1-323; ECX1-113)

772 (S/N: RLB1-905)

772G (S/N: LTS1-397; KEX1-214; LTX1-209)

773F (S/N: EED1-1369; EXD1-145)

777F (S/N: JRP1-3340; JXP1-258)

777G (S/N: GT71-161; T5A1-123; TNM1-879; RDR1-378; T4Y1-209)

785G (S/N: RTL1-103)

789D (S/N: SPD1-704; SHH1-319; TWP1-109)

793F (S/N: SND1-133; SSP1-1160; SXP1-103; RBT1-179)

793F AC (S/N: EMD1-77)

794 AC (S/N: MN51-55; MT51-111)

795F AC (S/N: ERM1-296)

795FAC XQ (S/N: SNT1-101)

797F (S/N: LAJ1-609; WSP1-129; LTZ1-UP)

MT4400D AC (S/N: MH41-803; MT41-808)

OEM POWERTRAIN (S/N: DTE1-39020)

Quarry Truck

773G (S/N: MWH1-380; JWS1-334; T5S1-125; T5T1-105)

775F (S/N: EYG1-104; DLS1-76002)

775G (S/N: T5F1-102; RFM1-850; MJS1-529; T5W1-112)

Soil Compactor

825K (S/N: 2331-5016; 2L91-UP; 2T91-UP; SEE1-208)

Track-Type Loader

953D (S/N: LBP1-2045)

963D (S/N: LCS1-2494)

973D (S/N: LCP1-451)

Underground Articulated Truck

AD30 (S/N: DXR1-77012; GXR1-805)

AD45B (S/N: CXM1-576)

AD55 (S/N: DNW1-77019)

AD55B (S/N: JNW1-77002)

AD60 (S/N: KNW1-161)

Wheel Dozer

824K (S/N: 2T21-UP; 2L41-UP; 2341-4008; RWB1-121)

834K (S/N: TW41-UP; L4Y1-UP; LWY1-718; TWY1-706)

844K (S/N: MBE1-100; KLS1-405)

854K (S/N: H9K1-511; H8M1-511)

Wheel Loader

924K (S/N: ENC1-690; HJF1-592; PWR1-4403)

930K (S/N: DYB1-277; EYE1-789; RHN1-4152)

938K (S/N: SWL1-3925; XXT1-816; HFW1-437)

950M (S/N: EMB1-2230; FTR1-1089)

962M (S/N: EJB1-515; F2T1-562)

966K (S/N: PBG1-1246; TFS1-1450)

966K Series XE (S/N: NGX1-441)

966M (S/N: DYC1-1241; KJP1-1694)

966M Series XE (S/N: P6C1-1042)

972K (S/N: PEM1-947; Z4W1-771)

972M (S/N: A8P1-950; JPR1-909)

972M Series XE (S/N: EDW1-822)

980K (S/N: W7K1-2574; NEP1-114; GTZ1-891)

980M (S/N: KRS1-1279; N8T1-818)

982M (S/N: F9A1-401; K1Y1-632)

986K (S/N: MH81-UP; NL81-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-705; TWX1-970)

990K (S/N: DJK1-241; A9P1-333)

992K (S/N: 8801-632; ZMX1-642)

993K (S/N: Z4D1-504; Z8D1-UP; Z9K1-558; Z4Z1-515; Z8Z1-UP)

994H (S/N: DWC1-527)

994K (S/N: MM91-UP; MRK1-204)

Introduction

467-8080 Seat Wiring Gp installation instructions.

Introduction

This Special Instruction provides an improved routing procedure to install a replacement 485-5423 Seat Wiring Group on the machines listed above. The 485-5423 Seat Wiring Group is compatible with the following “TLV2” seat suspension groups:

• 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

• 436-8490 Seat Suspension Gp

The improved wiring harness routing location and installation procedure will extend the service life 475-0258 Wiring Harness . The 485-5423 Wiring Group will replace 467-8080 Kit-Wire Harness on all “TLV2” suspensions.

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 101-0003 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 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 the hole pictured in Illustration 3 through Illustration 5 is not present on the suspension top plate, proceed to with this section. If the hole is present, proceed to Step 2.

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Illustration 3	g06127513
Orientation view of the seat suspension group and location of the reference hole indicated by arrow

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Illustration 4	g06125139
View of dimensions for new hole (D) 35 ± 5 mm (1.4 ± 0.19 inch)

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Illustration 5	g06125134
View of dimensions for new hole (E) 12 ± 5 mm (0.5 ± 0.19 inch)

1. Drill hole for push clip (fir tree) on the new wiring harness.

   Use existing hole under seat tracks as reference.

   Note: The push clip (fir tree) requires hole to be 4.9 mm (0.19 inch) to 5.1 mm (0.2 inch).

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   Illustration 6	g06125200
   (1) 475-0258 Wiring Harness (2) 479-1744 Bracket

2. Install harness (1) to bracket (2) with harness push clips.
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   Illustration 7	g06125215
   (1) 475-0258 Wiring Harness (2) 479-1744 Bracket (3) 3S-2093 Cable Strap

3. Continue installing wiring harness (1) to bracket (2). Secure wiring harness (1) in place using three cable straps (3).
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   Illustration 8	g06125225

4. Disconnect and remove the seat air compressor.

   Note: Retain hardware to reinstall.

5. Assemble harness (1) and bracket (2) to the seat air compressor as shown in Illustration 8. Plug wire harness terminals on the sear air compressor at the locations shown above.

   Note: The orange wire connects to the terminal on the ride side of the compressor. The black wire connects to the terminal on the left side of the compressor.

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   Illustration 9	g06125233
   (1) 475-0258 Wiring Harness (2) 479-1744 Bracket (3) 3S-2093 Cable Strap

6. Secure the black wire to bracket (2) using one cable strap (3) as shown above.

7. Reinstall seat air compressor to the center plate using the hardware removed in Step 4.

8. Torque the screws to 2.8 N·m (25 lb in).
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   Illustration 10	g06125249
   Proper spacing between the points indicated

9. Adjust the position of the seat air compressor to avoid contact to the metal casting. Contact with the metal casting may cause vibration during seat inflation.
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   Illustration 11	g06125276
   Tie strap locations (1) 475-0258 Wiring Harness (3) 3S-2093 Cable Strap

10. Secure wiring harness (1) by installing two tie straps (3) to the center casting.
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    Illustration 12	g06125283
    (1) 475-0258 Wiring Harness (3) 3S-2093 Cable Strap

11. Route wiring harness (1) to the back of the center casting. Secure wiring harness (1) in place using one cable strap (3).
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    Illustration 13	g06125288
    (F) Seat Air Switch

12. Locate seat air switch (F).

13. Pull the wires to seat air switch (F) as shown in Illustration 13.
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    Illustration 14	g06125307
    (3) 3S-2093 Cable Strap

14. Secure the wiring harness to the upper housing with a push clip (fir tree).

15. Secure the airline and wiring harness together using one cable strap (3).

16. Connect red wire (G) to the angled switch contact on right-hand side of the switch.

17. Connect the orange wire (H) to straight contact on left-hand side of the switch.
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    Illustration 15	g06125316

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    Illustration 16	g06125345
    (3) 3S-2093 Cable Strap

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

19. The harness should be routed as shown in Illustration 15 and Illustration 16

    Note: The harness should not rub on other components as shown in Illustration 15.

Seat Suspension Boot and Components Installation

1. Ensure Harness Assembly and Seat Suspension functions properly.
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   Illustration 17	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.