- Motor Grader:
- 120K (S/N: SZN1-1405; JAP1-1777)
- 12K (S/N: JJA1-452; SZP1-302)
- 140K Series 2 (S/N: SZW1-158)
- 140K (S/N: JPA1-1587; SZL1-1596)
- 160K (S/N: SZM1-441; JBP1-152)
- 12K (S/N: JJA1-452; SZP1-302)
Introduction
This special instruction provides information on how to update the front light wiring harness assembly on certain Motor Graders. Read through the entire special instruction and ensure comprehension before ordering parts or performing service.
Important Safety Information
Do not perform any procedure in this special instruction until you have read this special instruction 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. Work safely, most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazards warnings are not heeded, bodily injury or death could occur to you or to others persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
 |
Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
 |
|
Electrical shock can result in severe personal injury or death. Operation of the circuit breaker and service of the circuit breaker should only be performed by qualified personnel that are familiar with the circuit breaker and familiar with the switchgear. |
|
Required Parts
| Item | Qty | Part Number | Description |
| 1 | 1 | 385-5215 | Console Harness As |
| 2 | 1 | 385-5216 | Console Harness As (1) |
| 3 | 2 | 3E-6477 | Relay As |
| 4 | 1 | 3E-8772 | Rocker Switch |
| 5 | 1 | 3E-8766 | Switch (1) |
| ( 1 ) | Indian Roading Arrangement |
Installation Procedure
- Disconnect the 338-8423 Console Harness As under the cab platform.
 | |
| Illustration 1 | g03202720 |
338-8423 Console Harness As disconnected and clips removed. | |
- Remove the clips that hold the harness under the platform left-hand and right-hand sides.
- Remove the cover on top of the steering column.
 | |
| Illustration 2 | g03202800 |
Top cover on the steering column | |
 | |
| Illustration 3 | g03202801 |
Top cover of the steering column removed | |
- Remove the side plates on the steering column left and right sides.
 | |
| Illustration 4 | g03202802 |
Side plate to be removed | |
- Disconnect the harness from the switches and fuse box.
 | |
| Illustration 5 | g03202804 |
Wiring harness disconnected from the switches. | |
 | |
| Illustration 6 | g03202805 |
Wiring harness disconnected from the fuse box. | |
- Remove the instrument front panel group in order to have access to the brake and modulation pedal switches.
 | |
| Illustration 7 | g03202806 |
Instrument front panel to be removed. | |
- Disconnect the wires from the pedal switches.
 | |
| Illustration 8 | g03202808 |
Wires disconnected from the pedal switches | |
- At the cab platform there is an opening for the hoses and lines to pass through. The opening is lined with foam to protect against rubbing and dust entering the cab. Push the old harness through the hole.
Note: Removing the harness may be easier, if the connector is removed before pushing the harness though.
 | |
| Illustration 9 | g03202809 |
Foam lined opening for lines | |
 | |
| Illustration 10 | g03202810 |
Old harness being pushed through the foam hole. | |
 | |
| Illustration 11 | g03202811 |
Connectors removed from harness | |
 | |
| Illustration 12 | g03202812 |
Removed harness with points where the connectors have been removed. | |
- In order to install 385-5215 Console Harness As (1) or 385-5216 Console Harness As (2), removing the connectors may be necessary. However, be careful removing the connectors as the connectors will have to be reinstalled. If the connectors are removed, protect the end of the wires from being damaged when pushed through the opening.
 | |
| Illustration 13 | g03202813 |
Console Harness As (1) or (2) being prepared for installation. | |
 | |
| Illustration 14 | g03202814 |
Installing the Console Harness As (1) or (2) . | |
- When installing the harness, be sure to use the same clip locations to prevent interfering with steering column movement.
 | |
| Illustration 15 | g03202815 |
New harness clipped in same locations. | |
- Install the harness in the fuse box and put the harness back on the steering column.
 | |
| Illustration 16 | g03202816 |
Fuse box | |
- Install the two new 3E-6477 Relay As (3) inside the steering column.
 | |
| Illustration 17 | g03202817 |
- Connect the harness to the pedal switches.
 | |
| Illustration 18 | g03202818 |
Pedal switches | |
- Pass the harness from the steering column through the cab platform.
- Reinstall the connectors on the wire ends being careful to get each wire in the correct pin location.
 | |
| Illustration 19 | g03202819 |
Wire harness ready for connectors | |
- Connect the harness under the platform and clip back in the same locations.
 | |
| Illustration 20 | g03202820 |
Wire harness reconnected | |
- Replace the existing 3E-8772 Rocker Switch (4) or 3E-8766 Switch (5) with a new one of the same part number.
- Test all the lights in order to ensure that the lights are properly functioning.
- Reinstall both side plates and top cover on the steering column and the instrument front panel.
 | |
| Illustration 21 | g03202821 |
Side plates and cover | |