Installation Procedure for the 192-7805 Seat Compressor Harness{1408, 7312, 7324} Caterpillar

Articulated Truck:

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

725C (S/N: LFB1-UP; TFB1-UP)

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

730C (S/N: LFF1-UP; TFF1-UP)

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

735B (S/N: L4D1-UP; T4P1-UP)

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

740 EJECTOR (S/N: AZZ1-UP)

740B (S/N: L4E1-UP; GLH1-UP; T4R1-UP; E4S1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

Backhoe Loader:

416E (S/N: SHA1-UP; CBD1-UP; MFG1-UP)

422E (S/N: HBE1-UP; DSK1-UP; MAW1-UP)

422F (S/N: LRH1-UP)

428E (S/N: DXC1-UP; DPH1-UP; SNL1-UP)

428F (S/N: LBH1-UP; SJW1-UP)

432E (S/N: JBA1-UP; BXE1-UP; RXS1-UP)

432F (S/N: SEJ1-UP; LNR1-UP)

434E (S/N: SXB1-UP; SEF1-UP; FSH1-UP; SJL1-UP)

434F (S/N: LDH1-UP; FLY1-UP)

442E (S/N: EME1-UP; PCR1-UP; GKZ1-UP)

444E (S/N: NBA1-UP; HXB1-UP; LBE1-UP)

444F (S/N: LJJ1-UP; FBN1-UP)

Landfill Compactor:

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

816F (S/N: BMR1-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)

815F (S/N: BKL1-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; KZN1-UP; 1WN1-UP)

IT28G (S/N: WAC1-UP; DBT1-UP)

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

IT38G (S/N: 7BS1-UP)

IT38H (S/N: JNJ1-UP)

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

Motor Grader:

120M Series 2 (S/N: M9C1-UP; M9H1-UP; R9N1-UP; M9W1-UP; R9W1-UP)

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

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

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

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-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 (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

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

24H (S/N: 7KK1-UP)

24M (S/N: B9K1-UP)

Off-Highway Truck/Tractor:

797F (S/N: LAJ1-UP)

Pipelayer:

PL61 (S/N: WGS1-UP)

Track-Type Loader:

953C (S/N: 2ZN1-UP)

953D (S/N: LBP1-UP)

963C (S/N: 2DS1-UP)

963D (S/N: LCS1-UP)

973 (S/N: 86G1-UP)

973C (S/N: 3RZ1-UP)

973D (S/N: LCP1-UP)

Track-Type Tractor:

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

D10T (S/N: RJG1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

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

D3G (S/N: JMH1-UP; ZDN1-UP; BYR1-UP; CXT1-UP)

D3K Series 2 (S/N: GAE1-UP; KFF1-UP; KLL1-UP)

D3K (S/N: JTD1-UP; FFF1-UP; LLL1-UP)

D4G (S/N: HYD1-UP; TLX1-UP)

D4K Series 2 (S/N: KMM1-UP; KRR1-UP)

D4K (S/N: MMM1-UP; RRR1-UP)

D5G (S/N: WGB1-UP; RSC1-UP; RKG1-UP; DKT1-UP)

D5K Series 2 (S/N: TRF1-UP; KWW1-UP; KYY1-UP)

D5K (S/N: JLF1-UP; WWW1-UP; YYY1-UP)

D5M (S/N: 6GN1-UP; 3CR1-UP; 4JS1-UP; 5ES1-UP; 5FS1-UP)

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

D5R (S/N: D5X1-UP)

D6K Series 2 (S/N: WMR1-UP; RST1-UP)

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

D6M (S/N: 9ZM1-UP; 3WN1-UP; 4JN1-UP)

D6N (S/N: DJA1-UP; PBA1-UP; CBF1-UP; CCG1-UP; ALH1-UP; CBL1-UP; AKM1-UP; ALR1-UP; LJR1-UP; PER1-UP; CCS1-UP; GHS1-UP; MLW1-UP; ALY1-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; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; MRT1-UP; EXW1-UP)

D6R (S/N: A6M1-UP; 5LN1-UP; 9PN1-UP; S6T1-UP; S6X1-UP; S6Y1-UP; C6Z1-UP)

D6T (S/N: JHB1-UP; KSB1-UP; ZJB1-UP; SMC1-UP; DTD1-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; WLM1-UP; GCT1-UP; JRW1-UP; RCW1-UP; LAY1-UP; PEZ1-UP)

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

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

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

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

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

D8R (S/N: RJM1-UP; 7XM1-UP; 9EM1-UP)

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

D9R (S/N: HWH1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

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

Wheel Dozer:

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

814F (S/N: BGF1-UP)

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

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

824H (S/N: ASX1-UP)

834G (S/N: BPC1-UP)

834H (S/N: BTX1-UP)

844 (S/N: BBN1-UP; 2KZ1-UP)

844H (S/N: BTW1-UP)

854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)

854K (S/N: 2211-UP)

Compact Wheel Loader:

914G (S/N: PDF1-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)

924GZ (S/N: RTA1-UP; AAB1-UP; WGX1-UP; DFZ1-UP)

924H (S/N: HXC1-UP; JTM1-UP; KLN1-UP)

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

928G (S/N: DJD1-UP; WLG1-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)

950F Series II (S/N: 5SK1-UP)

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

950G (S/N: 5MW1-UP; 8JW1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP; MXL1-UP; JLX1-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: 5RS1-UP; 6HW1-UP)

962H (S/N: N4A1-UP; SSA1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP; PCW1-UP)

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

966F Series II (S/N: 9YJ1-UP; 1SL1-UP)

966F (S/N: 4YG1-UP)

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

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

966H (S/N: A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP; TAL1-UP; BJ61-UP)

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

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

972G (S/N: AAW1-UP; 4WW1-UP; 9GW1-UP)

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

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

980F (S/N: 3HK1-UP)

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

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

980H Series 2 (S/N: MKP1-UP)

980H (S/N: P8B1-UP; MHG1-UP; A8J1-UP; KZL1-UP; JMS1-UP)

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

988F Series II (S/N: 2ZR1-UP)

988F (S/N: 8YG1-UP)

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

988H (S/N: A7A1-UP; BXY1-UP)

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

990 (S/N: 7HK1-UP)

990H (S/N: BWX1-UP)

992D (S/N: 7MJ1-UP)

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

992K (S/N: H4C1-UP)

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

994 (S/N: 9YF1-UP)

994D (S/N: 3TZ1-UP)

994F (S/N: 4421-UP)

Wheel Skidder:

525B (S/N: 3KZ1-UP)

525C (S/N: 5251-UP)

535B (S/N: AAE1-UP)

535C (S/N: 5351-UP)

545 (S/N: 2FZ1-UP)

545C (S/N: 5451-UP)

Introduction

This Special Instruction provides an improved routing procedure to install a replacement 192-7805 Harness As . The 192-7805 Harness As is for "TLV1" 366-5830 Seat Suspension Gp , 191-2933 Seat Suspension Gp , 199-5725 Seat Suspension Gp , 199-5740 Seat Suspension Gp , 191-4508 Seat Suspension Gp , 256-8768 Seat Suspension Gp , and 303-9405 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 192-7805 Harness As .

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.

Parts List

Harness Assembly Replacement Procedure

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

Remove Existing 192-7805 Harness As from Seat Suspension

1. Remove 101-0003 Fastener and the 192-7795 Boot from the outside of the seat suspension. Retain the removed components in order to install after the harness assembly has been replaced.

2. Remove existing tie straps from 192-7805 Harness As and remove existing harness from seat suspension.

Install New 192-7805 Harness As in Seat Suspension

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Illustration 1	g03350381

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Illustration 2	g03350383

1. Route harness along scissor arm behind optional shock mounting location. Refer to Illustrations 1 and 2.

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Illustration 3	g03350385

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Illustration 4	g03350386

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Illustration 5	g03350388

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Illustration 6	g03350389

2. Attach harness to the inner scissor arm using a 3S-2093 Cable Strap . Locate the head of the cable strap towards the inside of the suspension to avoid interference with the outer scissor arm. This strap should be routed through the hole at the bottom where the scissor arm is welded to the center plate. Positioning the harness in this manor to avoid having a sharp bend in the harness.

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Illustration 7	g03350390

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Illustration 8	g03350392

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Illustration 9	g03350393

3. If the seat suspension is equipped with an optional shock on the left side of the suspension, ensure that the harness is strapped to the inside (right) of the upper shock mounting location. It is imperative that the harness is installed exactly as instructed. Refer to Illustrations 7 and 8. If no optional shock is present attach harness with 3S-2093 Cable Strap directly to the upper shock mounting bolt. Refer to Illustration 9.

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Illustration 10	g03350397

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Illustration 11	g03350398

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Illustration 12	g03350400
Attach black wire from harness to the black jumper wire from the compressor.

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Illustration 13	g03350401

4. Route red wire from harness above the air line going to the top of the air spring above the center plate. Secure red wire and airline to center plate using a 3S-2093 Cable Strap and existing hole in the center plate as shown in Illustrations 10 through 13. Attach black wire from harness to the black jumper wire from the compressor as shown in illustration 12.

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Illustration 14	g03350610

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Illustration 15	g03350643

5. Route the red wire from the harness and the orange jumper wire from the compressor to the switch. Attach the wires with a loose 3S-2093 Cable Strap . Refer to Illustrations 13 and 14. The loose cable strap is attached to the hole located in the front center of the center plate. Refer to Illustrations 14 and 15.

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Illustration 16	g03350658

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Illustration 17	g03350660

6. Route both the red and orange wires above the pivot bar. Attach wires to the seat switch at the front of the seat suspension. Attach wires to top plate cutouts with a 3S-2093 Cable Strap . Refer to Illustration 16. Ensure that the head of the cable strap is located under or inside of the top steel plate on the seat suspension. Refer to Illustration 17.

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Illustration 18	g03350667

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Illustration 19	g03350673

7. Check harness routing in Step 3 and ensure that harness is in the correct location prior to completing the assembly process. If equipped with a secondary optional shock, it is critical to ensure that the harness is attached to the inner side of the shock. If no secondary shock is installed, then strap directly to the shock mounting bolt. Refer to Illustrations 18 and 19.

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Illustration 20	g03354599

8. The harness should be routed as is represented in Illustration 20. Illustration 20 is of the top view looking through the top plate of the suspension. The view shows the five clipping locations and routing path for the harness.

9. Be sure that all tie straps are properly tightened to avoid any rubbing between the harness and metal.

10. Pull any excess wire length out of the suspension at the rear of the seat in order to avoid pinching.

Install Seat Suspension Boot and Components

1. Ensure harness assembly and seat suspension functions properly.

2. Install boot and fasteners.

3. remove lockout from machine.